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 2017

ECCN EAR99

DESIGN AND ENGINEERING PRACTICE

© 2017 Shell Group of companies

All rights reserved. No part of this document 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. Part 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. Part 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 typically 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) 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.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3) 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. INTRODUCTION ........................................................................................................ 4
1.1 SCOPE ....................................................................................................................... 4
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 4
1.3 DEFINITIONS ............................................................................................................. 4
1.4 CROSS-REFERENCES ............................................................................................. 6
1.5 SUMMARY OF MAIN CHANGES ............................................................................... 6
1.6 COMMENTS ON THIS DEP ....................................................................................... 7
1.7 DUAL UNITS............................................................................................................... 7
1.8 NON NORMATIVE TEXT (COMMENTARY) .............................................................. 7
2. GENERAL INFORMATION ........................................................................................ 8
2.1 GENERAL ................................................................................................................... 8
2.2 SAFETY ...................................................................................................................... 8
2.3 PRE-JOB MEETING ................................................................................................... 8
2.4 APPLICATOR’S TECHNICAL REPRESENTATIVE ................................................... 9
2.5 INFORMATION TO BE SUBMITTED BY THE CONTRACTOR ................................ 9
3. COATING SYSTEM REQUIREMENTS ..................................................................... 9
3.1 GENERAL ................................................................................................................... 9
3.2 FINISHED COATING SYSTEM REQUIREMENTS.................................................... 9
4. MATERIALS ............................................................................................................. 11
4.1 GENERAL ................................................................................................................. 11
4.2 POWDER TESTING ................................................................................................. 11
5. COATING SYSTEM APPLICATION ........................................................................ 12
5.1 SURFACE PREPARATION ...................................................................................... 12
5.2 COATING APPLICATION ......................................................................................... 14
5.3 QUALITY CONTROL ................................................................................................ 15
5.4 QUALITY PLAN, INSPECTION AND TEST PLAN, MANUFACTURING PLAN ...... 22
6. DOCUMENTATION .................................................................................................. 22
7. STORAGE AND HANDLING ................................................................................... 23
8. REFERENCES ......................................................................................................... 24

APPENDICES
APPENDIX A APPLICATOR QUALIFICATION .................................................................... 25
APPENDIXB COATING SYSTEM QUALIFICATION .................................................................... 29
APPENDIX C DATASHEET ................................................................................................... 30

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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 February 2012; 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.
1. The word shall indicates a requirement.
2. The word should indicates a recommendation.
The word may indicates a permitted option.

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1.3.2 Specific definitions

Term Definition

Ambient Environmental conditions in the immediate area of coating application

work and upon surfaces being coated.

Applicator The Applicator is the party that applies the coating.

Batch The amount of materials produced within one uninterrupted production

run of maximum 12 hours under constant production conditions.

Chemical Treatment of the blast cleaned pipe surface with a chemical solution
Pre-Treatment before application of the primer or adhesive to improve adhesion of the
first coating layer (phosphate, chromate).

Holiday A defect penetrating through the coating to the steel pipe surface, of
such dimensions that it is detectable by means of the specified
procedures.

Mil 1/1000 inch

Primer A thin film liquid coating applied prior to application of the FBE

Shift 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.

Water The injection of deoxygenated, chemically treated seawater to aid

Injection (or recovery of hydrocarbon.
Waterflood)

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1.3.3 Abbreviations

Term Definition

AFC Approved for Construction

AUT Automated Ultrasonic Testing

FBE Fusion Bonded Epoxy

ID Internal Diameter

ITP Inspection and Test Plan

MP Manufacturing Plan

OD Outside Diameter

PQT Pre-Qualification Trial

QC Quality Control

QP Quality Plan

RH Relative humidity

SCR Steel Catenary Riser

TLPE 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 revision of the DEP of the same number dated February 2012, which was a
conversion of DEP 31.40.30.39-DWP dated October 2006 into DEP 31.40.30.39-Gen. The
changes followed a requirements quality review and were not a full technical update. The
following are the main, non-editorial changes

Section/Clause Change
All Restructured and clarified requirements, enforced use of shall /
should / may for normative statements.

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1.6 COMMENTS ON THIS DEP

Comments on this DEP may be submitted to the Administrator using one of the following
options:

Shell DEPs Online Enter the Shell DEPs Online system at

https://www.shelldeps.com
(Users with access to
Select a DEP and then go to the details screen for
Shell DEPs Online)
that DEP.
Click on the “Give feedback” link, fill in the online
form and submit.

DEP Feedback System Enter comments directly in the DEP Feedback

System which is accessible from the Technical
(Users with access to
Standards Portal http://sww.shell.com/standards.
Shell Wide Web)
Select “Submit DEP Feedback”, fill in the online form
and submit.

DEP Standard Form Use DEP Standard Form 00.00.05.80-Gen. to record

feedback and email the form to the Administrator at
(other users)
standards@shell.com.

Feedback that has been registered in the DEP Feedback System by using one of the above
options will be reviewed by the DEP Custodian for potential improvements to the DEP.

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.

1.8 NON NORMATIVE TEXT (COMMENTARY)

Text shown in italic style in this DEP indicates text that is non-normative and is provided as
explanation or background information only.
Non-normative text is normally indented slightly to the right of the relevant DEP clause.

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2. GENERAL INFORMATION

2.1 GENERAL
FBE 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.
1. The Contractor shall furnish at his cost, all labour, supervision, equipment, materials,
and testing necessary to complete coating work.
2. Unless specifically stated as the Principal’s responsibility, the requirements of this
DEP shall be the responsibility of the Contractor.
3. This DEP may 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.
a. Qualification and approval may not be related to a specific project.
4. Selection of the Applicator to this DEP shall be subject to the approval of the Principal,
prior to production of any pipe coating.
5. For specific projects, the qualification shall be for the line pipe diameter and wall
thickness as detailed in the contract documents, AFC drawings or pipe coating
datasheet.
6. The coating system shall consist of a primer and FBE of a type subject to approval by
the Principal.
7. The Principal shall specify in the requisition a suitable temperature class for the
coating system, based on the maximum operating temperature or design temperature
of the pipeline.
8. The suitability of the coating system shall be demonstrated by performing qualification
tests given in this DEP.
a. 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.
1. Safety concerns regarding personnel and the environment shall be identified and
included in the detailed coating procedure, and pre-job discussions.
2. Adequate exhaust/ventilation equipment shall be used for removal of over-spray and
other spray by-products to acceptable air quality standards, and to provide for operator
personal protection.
3. Coating work pieces shall be electrically grounded, as required, to eliminate static
charges associated with surface preparation and coating operations.

2.3 PRE-JOB MEETING

1. The Applicator shall schedule a pre-job meeting to ensure that job requirements are
fully understood, roles and responsibilities are clear (e.g., when the Principal will deal
directly with the Applicator).

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2.4 APPLICATOR’S TECHNICAL REPRESENTATIVE

1. The Applicator shall designate a Technical Representative who is fully conversant with
the coating material and application techniques, and able to:
a. attend the pre-job meeting and other similar meetings;
b. serve as the primary liaison between the Principal and the Applicator;
c. provide the Principal Representative with copies of all documents and reports
required by this specification.

2.5 INFORMATION TO BE SUBMITTED BY THE CONTRACTOR

1. The Contractor shall submit information to the Principal on the coating system to be
used, including 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.

3. COATING SYSTEM REQUIREMENTS

3.1 GENERAL
1. 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).
a. Any modification of the application shall require re-qualification.
2. 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

3.2.1 Visual appearance
1. The coating shall be free from blisters, pinholes, scratches or any other irregularities
detrimental to coating performance, and have a uniform colour and gloss when
inspected from each end.
a. All other irregularities shall be brought to the attention of the Principal
Representative who will advise on the disposition of the pipe.
3.2.2 Degree of cure
1. The degree of cure shall be determined by differential scanning calorimetry, refer to
with ISO 21809-2, Section A.8.4.
a. The ∆Tg value shall be between +3 °C (37 °F) and -1.5 °C (29 °F).
3.2.3 Microscopic examination
1. The coating interface shall have no more than 10% contamination by foreign matter.
2. Foaming shall not be present in either through-film or across-film.
3. Any occasional voids in the cross-section or at the interface shall not exceed a number
1 rating in accordance with NACE RP0394-2002, Appendix G; Figure G2.

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3.2.4 Total coating thickness

1. The coating thickness shall be measured in accordance with (5.3.8).
2. The average thickness of the total coating system shall be between 177 µm (8 mils)
and 305 µm (12 mils).
a. No individual thickness reading shall be below 6 mils (150 µm) or greater than
14 mils (350 µm).
b. The dry film thickness of the EP10 primer component shall be between 6.4 – 4.5
µm (0.25 mil-1.0 mil).
3.2.5 Holidays
1. Holiday detection shall be used to monitor consistency of coating applications, refer to
(5.3.9).
3.2.6 Adhesion
1. Pull-off adhesion when tested in accordance with ASTM 4541-02 shall exceed 20 MPa
(3000 psi), with the failure mode being cohesive for more than 75% of surface area.
3.2.7 Flexibility
1. 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°/OD minimum, total strain (arc matching), refer also to (A.2).
3.2.8 Hot water resistance
1. 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.
2. When tested in accordance with ASTM 4541-02, the pull-off adhesion shall exceed 20
MPa (3000 psi), with the failure mode being cohesive for more than 75% of surface
area.

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4. MATERIALS

4.1 GENERAL
1. The Applicator shall obtain the following from the Manufacturer/Supplier:
a. copies of the most recent technical data sheets describing the product, its
general performance, and application requirements;
b. certification for each batch or lot of powder used to coat the Principal line pipe.
2. A batch will be defined by the Manufacturer/Supplier, but shall not exceed the quantity
of powder produced by the Manufacturer/Supplier in an eight-hour period from one
production line.
3. The batch certification shall include:
a. product name, designation and batch number;
b. product quality control test results in accordance with (4.2).
4. A statement shall be issued by 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.
a. When advised of any such changes, the Principal shall promptly review and/or
test the product for re-approval.
5. 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

1. The Applicator shall test each batch of powder prior to production coating, with
reference 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
1. 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.
2. Oil, grease and other contaminants shall be removed before blast cleaning by
a suitable solvent, detergent, fresh water, or combination of these.
a. 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.
3. Chemical cleaning agents and remaining detergents shall be washed off by means of
deionized water.
4. Salt contamination shall be measured using an instrument that has been subject to the
approval of the Principal.
If salt contamination is greater than 1.5 µg/cm the pipe ID shall be blast cleaned
2
a.
followed by a high-pressure wash with deionized water [20.7 MPa (3000 psi)].
b. 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 may be waived.
5. The pipe surface shall be dried before the final blast cleaning and surface preparation.
5.1.2 Cleanliness and profile
1. 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.
2. 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.
3. Each pipe shall be subjected to a minimum of two (2) complete blasting passes, one
into and one out of the pipe.
4. 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, refer to ISO 8501-1, or SSPC-SP 10 (NACE No. 2, near
white cleanliness).
5. The anchor profile shall be 50 µm – 100 µm (2 mils – 4 mils) refer to ISO 8503-2 and
ISO 8503-5.
6. The cleanliness and anchor profile shall be monitored and recorded.
7. The abrasive used for the final blast cleaning shall be metallic grit, with new abrasive
being added in small quantities as required to replenish consumed abrasive.
a. Infrequent large additions of new abrasive shall be avoided.

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8. During coating operations, conductivity of the abrasive material extracts shall be

monitored.
a. 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.
9. Grit samples shall be taken and examined through a microscope to establish the
presence of new angular grit.
10. 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
1. 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
1. 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.
2. Blast cleaning shall not be carried out when the pipe surface to be blasted is wet.
3. The ambient Relative Humidity (RH) shall be monitored and recorded.
a. Below 85% RH, up to four hours may be allowed after blasting and prior to
coating.
b. Above 85% RH, one hour is allowed.
c. Pipe that exceeds these limits shall be re-blasted.
d. Any pipe with visible rusting, or which has not been coated within the specified
time above, shall be re-blasted.
5.1.5 Contamination
1. 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.
a. 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/cm .
2
2.
5.1.6 Pipe damage
1. 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.

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5.2 COATING APPLICATION

5.2.1 Primer application
1. During primer application, the pipe surface temperature shall be as recommended by
the Manufacturer/Supplier and, as a minimum, simultaneously higher than 5 °C (41 °F)
and more than 3 °C (5 °F) above the ambient dew point.
2. The ambient RH shall be monitored and recorded.
a. Below 85% RH, up to 4 hours may be allowed after blasting and prior to coating.
b. Above 85% RH, one hour is allowed.
c. Pipe that exceeds these limits shall be re-blasted.
d. Any pipe with visible rusting, or which has not been coated within the specified
time above, shall be re-blasted.
3. The primer shall be uniformly applied to the pipe surface, according to parameters set
prior to application of the primer to production pipe.
4. The primer thickness shall be in accordance with (3.2.4).
5. The coating cutback should be 20 cm (8 in) unless otherwise stated.
5.2.2 Heating for FBE application
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.
1. Heating parameters shall be set prior to coating production pipe.
2. Pipe shall be uniformly heated so the internal temperature immediately prior to coating
application is between 199 °C and 216 °C (390 °F to 420 °F).
a. External and internal pipe temperature shall not exceed 260 °C (500 °F).
3. Uniform heat on the external pipe surface and internal surface at the pipe ends shall
be verified and recorded.
4. Pipe heated to application temperature and not coated shall be reblasted after cooling
to ambient temperature.
5. Pipe temperature shall be monitored just before coating application and recorded.

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5.2.3 FBE powder application

1. The coating shall be uniformly applied to the internal pipe surface.
2. The coating lance and its movement mechanism shall not damage or scratch the
internal surface.
3. Powder delivery to the pipe surface shall take place via a coating lance as the lance is
being removed from the pipe.
4. The lance shall move at a continuous uniform speed until it is completely removed
from the pipe.
5. The internal pipe surface temperature shall be continually monitored, with the
temperature, once coated, remaining above 193 °C (380 °F) and below 216 °C
(420 °F) for a minimum of 15 minutes.
6. The pipe shall 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.
a. Heating parameters shall be set prior to coating production pipe.
7. The internal coating shall be fully cured within 2 hours of the application.
a. 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
1. 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.
5.3.2 Identification of materials
1. The Applicator shall ensure that all materials supplied for the coating operation have
been marked in accordance with (4.0).
2. Material that is not marked shall be removed from the site.
5.3.3 Ambient conditions
1. The Applicator shall measure the ambient conditions at regular intervals during
blasting and coating and keep records of prevailing temperature, humidity and dew
point.
a. 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
1. Before surface preparation starts, each pipe shall be visually examined for dents, laps,
defective bevels and any other defects to avoid coating unusable pipes.
a. Defective pipes shall be removed from the coating line for repair or, if repair is not
possible, rejection.
2. The internal pipe surface shall be visually checked for contamination with salts, oil or
grease.
a. Contaminated pipes shall be cleaned by a solvent or detergent washing
procedure proposed by the Contractor and approved by the Principal.
3. Salt contamination shall be evaluated by the use of a Principal-approved instrument.

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5.3.5 Inspection after blasting

1. Each pipe shall be inspected for surface cleanliness.
a. Pipes that do not comply with the requirements in (5.1.2) and (5.1.5) shall be
reblasted.
2. 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.
a. If the surface roughness is outside the specified limits, the blasting material shall
be checked and replaced as necessary.
b. The Principal Representative shall advise on the disposition of the rejected pipe.
3. The conductivity of the blasting material shall be checked at a frequency of four (4)
times per shift.
a. If the blasting material conductivity is greater than 50 µS/cm then the blasting
material shall be replaced.
4. The internal surface of one pipe per shift shall be checked for chloride contamination.
5.3.6 Application temperatures
1. The temperature of the pipe surface shall be monitored and recorded by means of
suitable instruments (e.g., infrared sensors, contact thermometers, thermocouples).
2. The monitoring instrument shall be calibrated prior to each unit of production and
independent of the temperature control equipment.
3. Any deviation from the recommended application temperature range shall be rectified.
a. If immediate rectification is not possible, the production shall be stopped until the
cause of the deviation has been eliminated.
4. 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).
5. Pipes that do not comply with the quality control requirements shall be rejected,
cleaned and recoated.
5.3.7 Coating appearance
1. Immediately following FBE coating application, each coated pipe shall be visually
checked for imperfections and irregularities of the coating (3.2.1).
a. Pipes that do not comply with the requirements shall be marked and removed
from the coating line for repair or recoating.
b. If subsequent pipes do not comply with the requirements, the coating process
shall be checked or stopped to eliminate the cause of the problem.

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5.3.8 Coating thickness

1. Total dry film thickness for the coating system shall be measured using a calibrated
digital gage approved by the Principal.
2. 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.
a. The plate thickness shall be a minimum of 6.35 mm (¼ in).
b. 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.
c. For gauges that allow only one shim for calibration, the shim thickness shall be
±20% of the nominal thickness of the coating system.
3. For quality control purposes the coating thickness shall be measured at each end of
the pipe.
4. At each location, the thickness shall be measured at four positions, equally spaced
around the internal circumference of the pipe.
5.3.9 Holiday detection
1. A holiday test should 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 and supported so that it
maintains constant contact with the full circumference of the pipe.
a. Alternatively holiday detection may be carried out using a high voltage detector
with an internal conductive rubber electrode, using an inspection voltage of 5
V/mm (125 V/mil).
2. Excessive holidays shall require the Applicator to review the application process.
Excessive holidays in this context are defined as more than five (5) per pipe joint.
3. The earth connection shall be made directly on the pipe.
4. The test voltage shall be checked at least once per shift.
5. When the holiday test is carried out the internal pipe surface shall be free of moisture.
6. During testing, the electrode shall be moved over the entire pipe surface at a speed of
not more than 0.3 m/s (1 ft/s).
5.3.10 Destructive testing
1. At predetermined intervals, one pipe shall be selected for destructive testing of the
coating.
a. 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 number of tests and frequency will be determined during clarification
discussion.
2. Destructive tests shall commence as soon as possible after coating to allow
readjustment of the coating process if required.
3. 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).
a. The pipe end bevel shall be re-machined to the original pipe specification.
b. Alternatively a test ring may be attached to a dedicated host joint, subject to
Principal approval.

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5.3.11 Degree of cure of FBE

1. The degree of cure shall be determined by differential scanning calorimetry in
accordance with ISO 21809-2 Section A.8.4, using a ∆Tg value between +3 °C (37 °F)
and -1.5 °C (29 °F).
5.3.12 Flexibility
1. For flexibility requirements, refer to ISO 21809-2, (A.12).
a. The test straps shall be cooled to 0 °C (32 °F) by immersing in an ice/water bath
for a minimum of 30 minutes.
b. Final examination of the test straps shall take place 24 hours following the
bending, refer to (3.2.8).
2. Edges of straps 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).
This is because the strap will be ID coated, so there will be stress at the edge of the
strap.
5.3.13 Microscopic examination
1. Surface contamination shall be evaluated in accordance with ISO 21809-2,
Section A.10, and the maximum acceptable level is stated in (3.2.3).
2. 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 helping the
Applicator adjust the surface preparation procedures to minimize the amount of
surface contamination.
3. Porosity shall be evaluated in accordance with NACE RP0394-2002 Appendix G, refer
to (3.2.3).
4. The thru-film porosity evaluation shall be made on the edges of coating chips that
were fractured during low-temperature bending, with the interfacial porosity always
being 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

1. 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 marked for further testing.
a. The Applicator shall propose and agree with the Principal a test program to trace
any of the suspect pipes affected by the same failure.
b. Further testing shall involve inspection and examination similar to that carried out
on the original rejected test pipe(s).
c. Based on the test results, the final acceptance or rejection of the suspect pipes
shall be made by the Principal.
2. No pipes shall be dispatched from the coating yard before the Principal has approved
the quality control results.
3. 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.
a. In addition, the Applicator may be required to stop production and carry out a full
investigation into the source of the problem; submitting the results to the Principal
before receiving permission from the Principal to recommence production.
5.3.15 Traceability of pipes and coating
1. The Applicator shall ensure that individual pipes are fully traceable during and after the
coating process.
2. If the serial number of the pipe as given in the pipe mill is removed or obliterated, it
shall be reapplied.
3. The Applicator's own serial number shall be indicated on the pipe and records 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 Receipt of materials

Property DEP Section Test Frequency

Identification of Materials (4.0) All Materials
Initial Visual Inspection (5.1.1) All pipe
Salt contamination prior to
(5.1.1) 10% of pipe
blasting

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Table 2 Surface preparation

Property DEP Section Test Frequency

Two (2) per shift and after
Conditions during blasting (5.5.3) obvious changes in weather
conditions
Cleanliness of compressed After every compressor
(5.1.3)
air start-up and every 10 pipes
Four (4) per shift and after
Pipe temperature during
(5.1.4) change in environment
blasting
conditions
Surface cleanliness (5.1.2) All pipe
First five (5) pipes after
Surface profile (5.1.2), (5.3.5) every start-up and every
10 pipes
Dust contamination (5.1.5) Every 10 pipes
Four (4) per shift or every
Conductivity of blast media (5.1.2), (5.3.5)
10 pipes
Salt contamination following
(5.3.5) Every 10 pipes
blasting
Pipe damage (5.1.6) All pipe

Table 3 Primer application

Property DEP Section Test Frequency

Two (2) per shift and after
Conditions during primer
(5.5.3) obvious changes in weather
application
conditions
Pipe temperature during
(5.2.1) All pipe
primer application
First five (5) pipes at start-up
Primer thickness (3.2.4) then every five (5) pipes
(coupons or direct)
Cut-back (5.2.1) All pipe

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Table 4 FBE application

Property DEP Section Test Frequency

Two (2) per shift and after
Conditions during FBE
(5.3.3) obvious changes in weather
application
conditions
Pipe temperature prior to
(5.2.2), (5.3.6) All pipe
FBE application
Lance operation At start-up
Pipe temperature during FBE
(5.2.3), (5.3.6) All pipe
application
Pipe temperature during FBE
(5.2.3), (5.3.6) All pipe
cure

Table 5 Non-destructive testing

Property DEP Section Test Frequency

Conditions appearance (3.2.1), (5.3.7) All pipe
Coating thickness (3.2.4), (5.3.8) All pipe
Holiday detection (5.3.9) All pipe

Table 6 Destructive testing

Property DEP Section Test Frequency

Degree of cure (5.3.11) Two (2) per shift
Flexibility (5.3.12) Two (2) per shift
Hot water soak (3.2.9) Two (2) per shift
Adhesion (3.2.6) Two (2) per shift
Microscopic examination (3.2.3), (5.3.13) Two (2) per shift
NOTE Destructive testing frequency may be reduced to one (1) per shift after 10 consecutive ring samples
that meet the requirements of this DEP.

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5.4 QUALITY PLAN, INSPECTION AND TEST PLAN, MANUFACTURING PLAN

1. The Contractor shall develop and implement a quality system (e.g., ISO 9001 or
ISO 9002) or approved equivalent.
2. 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 be approved prior to
commencement of manufacturing operations.
a. Alternatively, one combined document consisting of an ITP and MP is acceptable
provided the guidelines stated above are followed.
3. The ITP shall provide columns or spaces for the Principal to indicate the Principal’s
and the Principal’s third-party-inspector inspection activity (e.g., the monitor, witness,
hold points), for the operations to be undertaken.
4. The MP shall clearly define the sequence of operations and process controls to be
implemented at each operation.

6. DOCUMENTATION
1. The Contractor shall keep accurate records of all relevant data of the coating process,
consisting, as a minimum, of the following:
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.
2. 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

1. Coated pipe shall be stored and handled in such a manner as to prevent damage to
the pipe, pipe ends, bevels and applied coating.
2. All pipe shall be stored in a manner to provide for safe stacking and unstacking
operations.
3. 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.
a. 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.
4. All pipe shall be stored at an angle to allow water to drain from the interior.
a. Exposure of the internally coated pipe to water should be minimized where
possible.
5. For handling requirements for externally coated pipe, refer to DEP 37.81.41.30-Gen.
6. 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 DEP 31.40.30.31-Gen.
(amendments/supplements to ISO/DIS 21809-1:2009)
External fusion-bonded epoxy powder coating for line pipe DEP 31.40.30.32-Gen.
(amendments/supplements to ISO 21809-2:2007)

AMERICAN STANDARDS

Standard Test Method for Indicating Oil or Water in Compressed Air ASTM D4285
Standard Practice for the Preparation of Substitute Ocean Water ASTM D1141
Standard Test Method for Pull-Off Strength of Coatings Using Portable ASTM 4541
Adhesion Testers
Application, Performance, and Quality Control of Plant-Applied, NACE RP0394-2002
Fusion-Bonded Epoxy External Pipe Coating - Item No. 21064
Near White Metal Blast Cleaning SSPC-SP10 (NACE No. 2)

INTERNATIONAL STANDARDS

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

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 ISO 8502-3
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 ISO 8503-2
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 ISO 8503-5
Quality Management Systems - Requirements ISO 9001
Quality Management Systems – Model for Quality Assurance in for ISO 9002
Quality Assurance in Production, Installation and Servicing
Petroleum and Natural Gas Industries - External Coatings for Buried ISO 21809-2
or Submerged Pipelines Used in Pipeline Transportation
Systems -Part 2: Fusion-Bonded Epoxy Coatings
Quality Management Systems – Guidelines for Quality Plans ISO 10005

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APPENDIX A APPLICATOR QUALIFICATION

A.1 GENERAL
1. Before production application of a coating system may commence, the Applicator shall
be qualified to apply the coating system.
a. Applicator qualification shall take place on the production equipment with an
approved coating.
b. The qualification shall be carried out according to the procedures detailed in this
Appendix (A.2 to A.5)

A.2 COATING PROCESS AND APPLICATOR SELECTION

1. The Contractor shall submit to the Principal information on the required coating
process and recommended applicators, including, but not limited to:
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.

A.3 COATING PLANT

1. 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.

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A.4 QUALIFICATION
1. After approval of the process and plant details (A.2), (A.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).
2. The Applicator shall coat at least two (2) pipes with the coating system and subject
samples from these pipes to the tests given in (5.3.16).
a. The quality control tests may be carried out in the Applicator's own laboratory, or
by an independent laboratory.
b. The Principal shall witness the application and the tests.
c. The results of the tests shall be reported to the Principal, signed by the head of
the laboratory and the witness.
3. Additional testing, given in (A.5), shall be carried out by the Principal.
4. 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.

A.5 TESTING REQUIREMENTS

A.5.1 Quality control testing to be completed by the Contractor
All test in accordance with (5.3).
A.5.2 Additional testing to be completed by the Principal
A.5.2.1 Autoclave Test
1. 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.
2. The temperature shall be 65.5°C (150°F), pressure 62.05 MPa (9,000 psi), and the
test duration 7 days.
3. The sample dimensions shall be 25 mm wide x minimum 127 mm long (1 in wide x
minimum of 5 in long).
4. Release of pressure at the end of the test shall be completed in less than 30 minutes
and as quickly as safely possible.
5. Samples exhibiting blistering or cracking when removed from the autoclave and over a
24-hour period following removal at the end of the test shall be considered as having
failed the test.
A.5.2.2 Adhesion after Long Water Soak
1. 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.
a. Sample dimensions are a minimum of 100 mm x 100 mm (4 in x 4 in).
b. Following removal, the adhesion shall be evaluated in accordance with (3.2.6).
2. Adhesion values shall be greater than 17.2 MPa (2500 psi) or at least 75% of their
original adhesion values (before immersion).

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A.5.2.3 Resistance to Flow

1. 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.
a. Sample dimensions shall be 25 mm wide x minimum 127 mm long (1 in wide x
minimum of 5 in long).
b. The sample surfaces shall be exposed to the synthetic seawater moving at 3.65
m/s (12 ft/sec).
c. Velocity of seawater shall be a project requirement.
2. 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.
3. At the end of the test, the samples shall be removed and observed for deterioration at
the gouge.
4. Two parallel cuts shall be made perpendicular to the original gouge and 6 mm (¼ in)
apart.
5. An attempt shall be made to lift the coating, inside the two (2) cuts, with the point of a
knife, starting at the edge of the original gouge.
6. Any sample showing disbonding, uplifting, cracking or peeling on either side of the cut
shall be considered to have failed the test.
7. The knife test shall not remove more than 2 mm length of a coating chip.
A.5.2.4 Flexibility
1. Triplicate samples from both qualification pipes shall be tested in accordance with
(5.3.12).
A.5.3 Samples for testing
1. Samples for qualification testing by the Principal shall be prepared from the two
qualification joints by cold cutting the pipe at the locations shown in Figure A1.1/A1.2.
Figure A1.1 Location for qualification test samples

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Figure A1.2 Removal of stress risers for flexibility

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APPENDIXB COATING SYSTEM QUALIFICATION

B.1 GENERAL
1. The Contractor shall seek Principal approval for the use of any coating system not
already qualified to this DEP.
2. The Contractor shall supply all relevant datasheets and written confirmation that the
Manufacturer recommends the coating system for the intended service.
3. 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, refer to (3).
4. Testing of the proposed coating shall be carried out by the Principal in accordance
with (A.5).
5. If the proposed coating is accepted for use, the Contractor/Applicator shall be required
to qualify the application in accordance with (Appendix A).
a. If the proposed coating is not accepted for use, the Contractor/Applicator shall be
required to qualify the application of an approved coating system in accordance
with (Appendix A).
6. Applicator qualification shall take place on the production equipment with an approved
coating.
a. Unless stated by the Principal, a coating qualification and applicator qualification
shall not take place using the same pipe.
b. Application of a coating for coating qualification may be completed using pilot
equipment rather than the equipment that would be used during production.

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APPENDIX C DATASHEET

PROJECT: SPECIFICATION:
Internal Fusion-Bonded Epoxy Powder Coating for Water
Injection Line Pipe DEP 31.40.30.39-Gen.

PIPE USED FOR: PREPARED BY: DATE PREPARED:

INQUIRY/P.O. NO.: ITEM NO.:

GENERAL SCHEDULE

QUANTITY____________________________________ PIPE ARRIVAL DATE____________________________

JOINT LENGTH/TOLERANCE_____________________ TRANSPORTATION MEANS______________________

PIPE SIZE/WALL THICKNESS_____________________ REQ. COATING COMPLETION DATE_______________

PIPE MANUFACTURER__________________________ ADDITIONAL

INFORMATION_________________________________
______________________________________________
______________________________________________
______________________________________________
COATING THICKNESS

¡ AS SPECIFIED (Total coating thickness 7-11 mils)
¡ OTHER
______________________________________________
______________________________________________
______________________________________________
ADDITIONAL REQUIREMENTS
¡ QUALIFICATION REQUIRED
¡ OTHER
______________________________________________
______________________________________________
______________________________________________

COATING CUTBACK
ADDITIONAL SERVICES

+/-
External FBE (DEP 31.40.30.32-Gen.)
¡ NOT REQUIRED
¡ REQUIRED
COLOR CODING

External TLPE (DEP 31.40.30.31-Gen.)

¡ NOT REQUIRED
¡ REQUIRED

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Shell venkateswara.swamy@shell.com 23/11/2020 12:40:17