A== cnr. oor vwr- BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 REV. A PAGE 1 OF 30 SPECIFICATION FOR INDUCTION BEND FBE INTERNAL COATED PIPELINE AND A ISSUED FOR APPROVAL 11.23.2021 uuc CHEN L3. FAN X.H,/CHI H. REVD DONG L. REV. DESCRIPTION CHK'DBASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 2 OF 30 CONTENT 1.0 GENERAL 1.4 Scope 12 Definitions 2.0 CODES AND STANDARD. 3.0 ABBREVIATIONS... 4.0 DEVIATIONS. 5.0 COATING REQUIREMENTS 5.1 General No oe eR eR 2.2 Coating System Kequirements.. 6.0 MATERIALS. 6.1 Steel Pipes and Bends 6.2 Coating Material: 63 Repair Materials 7.0 QUALIFICATION OF COATING MATERIALS. 7A Qualification by Manufacturer 7.2 Qualification by Applicator 8.0 COATING SYSTEM APPLICATION.... 81 Cleaning and Surface Preparation 82 Primer Application. 8.3 Heating before FBE Application... 84 FBE Powder Application 8.5 Cut Back.. 8.6 FBE Pipe. 8.7 Field Joint CoatingINSPECTION AND TESTING . 9.1 General 92 Visual Inspection 9.3. Thickness Tes! 9.4 Adhesion Test 9.5 Holiday Test 9.6 — Flexibility/Bend Test. 9.7 Thermal Analysis of Epoxy Powder and Cured Coating Film .. 9.8 Porosity of the coating. 9.9 Surface Dust Contamination 9.10 Production Test Ring 10.0 REPAIRS. 11.0 MARKING. 11.1 General 11.2 Required Marking .. 12.0 HANDLING AND STORAGE 13.0 DOCUMENTATION. APPENDIX A PROJECT CONDITION & BASIC DATA... AA Projects Condition 2 Project Basic Data APPENDIX B AUTOCLAVE TESTS (CHEMICAL RESISTANCE) APPENDIX C COATING QUALIFICATION. APPENDIX D SURFACE PREPARATION-PRODUCTION AND PLANT QUALIFICATION28 APPENDIX E INSPECTION AND TEST FOR PRODUCTION & PLANT QUALIFICATION30BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 4 OF 30 1.0 GENERAL 1.1 Scope This document provides the minimum requirements for shop-applied primed fusion bonded ‘epoxy (FBE) powder coating systems used for corrosion protection of internal surface of carbon steel pipes, fittings and induction bends under continuous sour crude oil/gas/water flowlines and trunklines with operation temperature 95°C and design temperature 110°C. It specifies the requirements for coating materials, surface preparation, coating application, inspection and testing, repair, handling and storage, and gives procedures for the qualification ‘of coating materials and coating applicators. This specification covers shop applied internal FBE coating and shop applied repairs. This specification is not applicable to field cold bends. 1.2 Definitions WORD MEANING COMPANY PetroChina International Iraq FZE Iraq Branch ‘The organization selected and entrusted by COMPANY to perform the CONTRACTOR Engineering, Procurement, Construction, Start-up, pre-Commissioning and Commissioning of the Project. ‘The party who is in charge of awarding agreement on behalf of PURCHASER COMPANY / CONTRACTOR for the supply of goods and services in connection with the work “The party to the contract and/or purchase order which has undertaken SUBCONTRACTOR | the obligation o supply the goods andior services which are ordered and specified herein. APPLICATOR ‘The manufacture applying the intemal FBE coating to the pipeifitting Shall Indicates a mandatory requirement ‘Should Indicates a strong recommendation to comply with the requirements of | this document 2.0 CODES AND STANDARD SUPPLIER shall meet or exceed the requirements of the latest edition of the following codes, regulations and standards, except as superseded herein. In cases where more than one code, regulation or standard apply to the same condition, the most stringent shall be followed. In the event of a conflict between this specification and other specifications or correspondence, the Company shall be consulted and a ruling, in writing, shall be obtained before any work is started, Site Testing of Protective Coatings Determination of Residual AS 9894.6 Contaminants ASTMD714 Standard Test Method for Evaluating Degree of Blistering of PaintsBASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 5 OF 30 Standard Test Method for Conductimetric Analysis of Water AST Daeg Soluble lonic Contamination of Blast Cleaning Abrasives (CSA245.20 External Fusion Bond Epoxy Coating for Steel Pipe Preparation of steel substrates before application of paints and related products - Visual assessment of surface Iso 8501-1 Cleanliness - Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings Preparation of steel substrates before application of paints and related products - Tests for the assessment of surface Cleanliness - Part 3: Assessment of dust on steel surfaces prepared for painting (pressure-sensitive tape method) Preparation of steel substrates before application of paints 180 8802-6 and related products - Tests for the assessment of surface cleanliness - Part 6: Extraction of soluble contaminants for analysis — The Bresle method Preparation of steel substrates before application of paints and related products Tests for the assessment of surface cleanliness - Part 9: Field method for the conduct metric determination of water soluble salts ISO 8502-3 ISO 8502-9 Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of ISO 8503-4 blast-cleaned steel substrates - Part 4: Method for the calibration of ISO surface profile comparators and for the determination of surface profile - Stylus instrument procedure Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of 1S0 8503-5 blast-cleaned steel substrates - Part 5: Replica tape method for the determination of the surface profile Petroleum and natural gas industries - External coatings for 1S0 21809-2 buried or submerged pipelines used in pipeline transportation systems Part 2: Single layer fusion-bonded epoxy coatings SSPC-SP1 Solvent Cleaning Coating Application Standard No. 2 Procedure for SSPC-PA2 Determining Conformance to Dry Coating Thickness Requirements Petroleum, Petrochemical, and Natural Gas industries — NAGE MR O175/ISO Materials for Use in H2S-containing Environments in Oil and Gas Production Application, Performance, and Quality Control of Plant- NACE SP0394 Applied Single Layer Fusion-Bonded Epoxy Extemal Pipe CoatingBASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 6 OF 30 Evaluation of Internal Plastic Coating for Corrosion Control of NACE TM0185 Tubular Goods by Autoclave Test Holiday Detection of Internal Tubular Coatings of Less Than NACE TM0384° 501m Dry-Film Thickness Standard Test Method for Pull-off Strength of Coating Using ASTM D4541 Portable Adhesion Testers ASTM D6677 Standard Test Method for Evaluating Adhesion by Knife ASTMD714 Standard Test Method for Evaluation Degree of bisterng of Standard Test Method for Indicating Ol or Water in ASTM 04285 Compressed Air 3.0 ABBREVIATIONS APS Application Procedure Specification ASME ‘American Society of Mechanical Engineers ASTM. ASTM Internatonal FRE Fusion Bonded Epoxy 1D Internal Diameter Iso International Standards Organization iP Inspection and Test Plan MP Manufacturing Plan NACE National Association of Corrosion Engineers Pat Procedure Qualification Trial a Quality Pian ped Per pipe diameter RH Relative Humidity Ta Glass Transition Temperature 4.0 DEVIATIONS The internal coating FBE shall strictly comply with the requirements of this Specification, standards, codes and any other effective documents of this Specification and the appendixes thereof, Any deviation to the required documents, relevant standards and this Specification shall be noted in the Deviation Form of the Tender. If no deviation from this Specification is stated in the Offer of the Supplier, COMPANY shall deem this offer in full conformance with this Specification.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 7 OF 30 5A 52 6.0 61 COATING REQUIREMENTS General The APPLICATOR shall confirm at the bidding stage the grade and tradename of FBE proposed for this project and submit their track record for the materials in pipeline projects with operating temperatures 95°C and design temperature 110°C, or higher, and the selected the FBE power properties shall be suitable for service condition, as shown in the APPENDIX A ‘The APPLICATOR shall ensure that incividual pipes are fully traceable during and after the coating process. If the serial number of the pipe as given in the pipe mill is removed or obliterated, it shall be reapplied. The APPLICATOR's own serial number shall be indicated on the pipe and records shall be kept identifying the sequence and time of coating and the batch of materials used for each pipe. Internal FBE coating shall be applied before the external coating The APPLICATOR shall provide the guideline for site installation and construction of internal coating pipe. ‘The Third Party Inspection Agency shall be nominated for whole coating process in factory. The ITP (inspection test plan) shall be prepared and get approval from COMPANY prior to starting all activities. Coating System Requirements ‘The proposed FBE coating shall have been pre-qualified as a lining material for pipes operating at 95°C or higher, by other major Oil Companies and pre-qualification data from these projects shall be submitted at the bidding stage. All materials shall be subject to COMPANY approval. The coating system shall comply with all Sections of this specification, and related other requirement not specified in this specification shall refer to specific clauses in ISO 21809-2 A primer is recommended to enhance chemical resistance of the coating. The primer shall be applied as per the recommendation of the MANUFACTURER, and its suitability is qualified as complete system with the proposed FBE coating ‘The dry film thickness (DFT) of the finished coating shall be 375-625microns, and no Individual thickness reading shall be below 375m. The glass transition temperature (Tg) of the coating shall be 240°C above the maximum pipeline temperature. It is considered tht the max. service temperature is 95°C and the risk of ‘temperature excursions assessed, so that the Tg shall be not less than 135°C and temperature of qualification testing of the proposed coating can be selected accordingly. MATERIALS Steel Pipes and Bends The pipes and bends materials shall comply with the related project specification. For sour service condition, the mother pipe shall follow NACE MRO175/1SO 15156.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 8 OF 30 The girth weld pipe is not permitted to use as base pipe of internal coating pipes or bends. 6.2 Coating Materials The APPLICATOR shall obtain from the coating MANUFACTURER, copies of their most recent technical data sheets describing the product, its general performance, and application requirements. The APPLICATOR shall obtain from the MANUFACTURER, certification for each batch or lot ‘of powder used to coat the line pipes. A batch will be defined by the coating MANUFACTURER but shall not exceed the quantity of powder produced by the coating MANUFACTURER in an eight-hour pericd from one production line. As a minimum, each batch of epoxy powder shall be tested by the MANUFACTURER. ‘The certification shall include the following information: 1) Certified by the MANUFACTURER to be in accordance with the requirements of ISO 21809-2, Section 7.1.2 and 8.1, and compatible with the requirements of ISO 21809-2 Section 9.2, 9.3 and 9.4. 2) Powder coating materials supplied to the APPI ICATOR shall be certified by Manufacturer with the following information, which must meet initially, approved material: = The Manufacturer's name ™ Product description; = Mass of material = The material identification number @ The batch number Product temperature range (maximum and minimum) = Date of manufacture = Location of manufacturing = Temperature required for transportation and storage The she life (or expiration date) 3) Handled, transported, and stored in accordance with the %MANUFACTURER's recommendations. 4) Product quality control test results in accordance with ISO 21809-2, Table 1. All coating materials used in any one system shall originate from one MANUFACTURER, and only qualified coating can be used to coat pipes for the Project and approval for COMPANY. Any changes or deviation from the description, composition and physical properties of approved coating materials shall be resubmitted COMPANY for approval. Qualified coating materials accepted for use shall be as follows:63 In MANUFACTURER original, unopened containers; ™ Stored in a dry, clean location, controlled at or below the MANUFACTURER recommended maximum temperature; = Clearly marked with the batch number and date of manufacture; = Applied six months or less from the date of manufacture. Epoxy powder shall be stored in a dry, clean location, and handled in accordance with the ‘epoxy powder MANUFACTURER's recommendations. Each batch of epoxy powder received by APPLICATOR shall be retested. Reclaimed powders shall not be used as internal coating. Repair Materials ‘The APPLICATOR shall use repair materials that are certified by the MANUFACTURER to be ‘compatible with the epoxy powder before starting the qualification process, and the repair materials shall be suitable for service condition and the properties shall be not lower than FBE properties. Repair material batches shall be Identified by the product MANUFACTURER with the following: The Manufacturer's name Product description: Mass of material ‘The material identification number The batch number Product temperature range (maximum and minimum) Date of manufacture Location of manufacturing Temperature required for transportation and storage The she life (or expiration date) Repair materials shall be handled, transported, and stored in accordance with the material MANUFACTURER's recommendations. The repair coatings shall have a track record at the maximum operating temperature of 95°C, and submit COMPANY for approval. Proposed repair system shall be confirmed at the bidding stage.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 10 OF 30 7.0 QUALIFICATION OF COATING MATERIALS 7.1 Qualification by Manufacturer Where existing prequalification is considered insufficient by the COMPANY the FBE Internal Coating and proposed repair material shall be qualified in accordance with ISO 21809-2, Section 8.1 and this specification, Appendix C. Coatings for the project shall be subject to the additional testing for coatings for continuous service above 95°C as required by ISO 21809-2 Section 8.1.1.1 with the addition that all hot- water adhesion testing shall be carried out at 95°C or above. Tests for prequalification shall be those listed in ISO 21809-2, Table2 with the following amendments: '™ Hot water adhesion testing and hardness testing shall be carried out at 95°C or above. = Animmersion testis to be added to the list of tests in ISO 21809-2, Table 2 Specimens (3 No.) This test shall be tested in synthetic corrosive media as APPENDIX A for 90 days at 95°C. None of the coated test specimens shall show evidence of loss of adhesion, ‘swelling and discoloration. Blistering shall be no worse than “few blisters” of size 8 or greater, as determined and defined by ASTM D714. 7.2 Qualification by Applicator ‘The Applicator shall produce an APS (Application Procedure Specification) in accordance with ISO 21809-2 Section 8.2.3, which shall be approved by the COMPNAY prior to the start of production and qualification. A project specific PQT to verify the APS, shall be carried out in accordance with ISO 21809-2, Section 8.2 and this specification, Appendix D & E. In addition to the requirements of ISO 21809-2 Section 8.2 a PQT shall be carried out for each wall thickness and diameter combination of pipe. Qualification for bends shall be carried out on the first bend of each walll thickness, bends radius and diameter combination. Tests for qualification shall be those listed in ISO 21809-2, Table 3 & 4 with the following amendments: ™ Visual inspection of blasted surface should be Sa 3.0. = When measuring the thermal characteristics of the coating the Tg shall be at least 40°C above the operating temperature and not less than 135°C for fully cured material '™ Hot water adhesion testing and hardness testing shall be carried out at 95°C. = Pull-off adhesion shall be added in test list. '™ When measuring the Degree of Cure of the coating the acceptance criteria shall be ATg s se. The detailed requirements and frequency for inspection of qualification by applicator are ‘shown in Appendix D and E.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 11 OF 30 8.0 COATING SYSTEM APPLICATION 8.1 Cleaning and Surface Preparation Prior to abrasive cleaning, all oil, grease and other deleterious materials shall be removed by solvent cleaning in accordance with SSPC SP 1 or by detergent washing or steam cleaning. No residue that will affect adhesion shall be left on the surface. Surface Preparation and Coating Applications shall comply with all paragraphs of ISO 21809- 2, Section 9 with the following additional requirements: ™ Environmental conditions; ambient temperature, relative humidity and dew point temperature, shall be monitored and recorded every 4 hours during production. = The maximum residual chloride level on the blast-cleaned surface shall be 20 mg/m? when evaluated by a salt contamination meter. ™ Visual assessment of surface cleanliness shall meet to ISO 8501-1 Sa3. ™ The dust level on the blast-cleaned surface shall be Class 2 when evaluated in accordance with ISO 8502-3. ™= Compressed alr 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, Before and after blasting, pipes or fittings surface temperature shall be at least 3°C above the dew point. If preheating is used, it shall be carried out in a uniform manner to avoid distortion. = The ambient Relative Humidity (RH) shall be monitored and recorded. Below 85% RH, up to four hours may be allowed after blasting and prior to coating. Above 85% RH, one hour is allowed. Pipe that exceeds these limits shall be re-blasted. Any pipe with visible rusting, ‘or which has not been coated within the specified time above, shall be re blasted. ™ The coating cutback shall be 50~75mm unless otherwise stated. The detailed requirements for inspection of surface preparation-production and plant qualification are shown in Appendix D, Table D.1 8.2 Primer Application A primer is required to enhance chemical resistance of the coating. The primer shall be applied as per the recommendation of the MANUFACTURER, The dry film thickness of the primer layer shall be approximately 15 to 25m, ‘The FBE and its primer coating material shall be applied according to the raw material MANUFACTURER application procedure/data sheet, which incorporates the epoxy powder MANUFACTURER'S recommendations. The APPLICATOR shall submit his application procedure to review by COMPANY or COMPANY’s Representative Application of primer prior to the application of FBE shall not be controlled manually, and the primer shall be uniformly applied to the pipe surface. A machine shall be used to ensure that the travel of application is constant and that the DFT shall be between 15~25um in all areas to just wetting the blasted surface and keeps the surface profile peaks exposed to allow optimum adhesion for the FBE coating. This low thickness cannot be measured by the conventional DFT gauges. Therefore, APPLICATOR should describe in the coating application procedure.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 12 OF 30 It shall ensure that the primer is applied in a uniform and layer of primer does not fill the profile. 8.3. Heating before FBE Application The pipe or bend shall be play in the fumace until the surface temperature reaches the recommended powder application temperatures. The internal surface of primer coated pipes shall not be contaminated when transporting the pipe or bend to the oven. The external pipe surface shall be verified and recorded during the uniform heating. ‘Temperature of internal surface at the end of ends shall be verified and recorded. After property heating, the pipes shall be taken out of the furnace. It shall be sure the internal surface temperature of the pipe is at the suitable range of FBE coating, which is recommended by the powder MANUFACTURER. If the temperature is within the range, powder shall be applied by spray to the surface of the pipes. 84 FBE Powder Application ‘The FBE powder shall be uniformly applied to the internal surface of the pipe. Powder delivery to the pipe surface shall take place via a coating lance as the lance is being removed from the pipe. The coating lance and Its movement mechanism shall not damage or scratch the Internal surface. The lance shall move at a continuous and uniform speed until it is completely removed from the pipe. The dry film thickness of the finished coating shall be range from 375-625 microns The internal pipe surface temperature shall be monitored. FBE powder shall be applied at temperature as recommended by MANUFACTURER and not exceed 275°C. The coated pipes and bends shall be post-cured. The optimum post cure time and temperature depends on the wall thickness and diameter.it shall be reminded by powder manufacture Complete cure shall be confirmed by DSC analysis. The internal coating system should be fully cured prior to any heating for an external FBE application, i.e., cured immediately folowing application and allowed to cool to ambient temperature prior to heating for the external coating. 8.5 CutBack After the coating, while the powder is a gel, the pipe shall be placed on rollers and rotated. The coating from the cut back area shall be removed using a spatula or other protected measures to the required width 50~75 mm for pipes or bends. This area shall be wire brush cleaned after post cure, 86 FBE Pipe 8.6.1. Out of Roundness The roundness of the pipe shall comply with the vendor recommendation. 8.6.2 Ending Protection It shall be secured by fitting and caps at the end of pipe to prevent the internal coating damaged and water/ debris aggressive.Field Joint Coating ‘The internal weld field joint surfaces shall be coated at site. APPLICATOR shall provide a suitable field joints type or coating system proposal to COMPANY for review and approval. For flowlines (6" and below), the weldable sleeve should be considered and recommended to use for installation of internal FBE coating pipes, which consists basically of a cylindrical case made of carbon steel fitted with grooves and upsets for installation of O-rings, heat wrap and backing ring, as shown in Figure 8.7-1. MG tp Figure 8.7-1: Schematic drawing of sleeve The sleeve shall meet to the following technical requirements, as follows: The sleeves shall be compatible with FBE coating and applied for size of 6” flowline and bends. The sleeves shall be integrally coated and 100% holiday free. The plain internal surface as well as the nose up to the O-ring groove is coated with high performance coating material. Sleeve tabs establish the recommended distance between pipe ends and blend into the weld bead. The tabs ensure longitudinal stability of installed sieeve. APPLICATOR shall recommend number of tabs according the pipe size The two layers heat shield consisting of high heat resistant ceramic wrap and a wide steel backing ring prevents coating damage on internal diameter of insert sleeve during welding. ™ Two O-rings shall be replaced on each sleeve end to perform as an addition barrier and as support elements during sleeve installation. These O-rings shall be made of high performance fluoropolymers, which shall have high UV-resistant, which keep the material performance during storage and handle especially in high temperature climate. In addition, O-rings shall ensure that field-applied mastic was wiped to sleeve ends. For trunklines (above 6"), the remotely controlled robotic is preferred and recommended to use for the on-site cleaning, coating application, inspection and repair for the internal weld field joint surfaces. The related technical requirement shall be as follows:BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 14 OF 30 9.0 91 9.2 9.3 ™ The dry film thickness (DFT) for joints should be in the range of 400 to 800m unless otherwise agreed upon in writing by COMPANY. The overlap of the field joint coating on the FBE layer shall be no less than 50mm. It shall be at least with the same preformation of the internal field joint coating than main pipe's coating (FBE), but the coating type (liquid of FBE) will be recommend by APPLICATOR. INSPECTION AND TESTING General A Quality Plan (QP) consisting of an Inspection and Test Plan (ITP) and the Application Procedure Specification (APS) shall be developed specifically for all aspects of work and shall be approved prior to commencement of manufacturing operations. The QP shall clearly define the sequence of operations and process controls to be implemented at each operation. Qualification shall be achieved by successful evaluation of pipe coated samples using the specified coating line and the coating qualification test results shall be reported in accordance with the requirements of this specification. The minimum requirements for plant qualification and production are shown in Appendix D & E. Production test and inspection shall comply with all paragraphs of ISO 21809-2, Section 10 ‘except specified in this specification, the inspection requirements and inspection frequency are indicated in Appendix D & E. Visual Inspection The coating shall be free from blisters, pinholes, scratches or any other irregularities detrimental to coating performance and shall be with uniform colour and gloss when inspected from each pipe end. The internal surfaces being coated shall be inspected visually at each stage of the operation, using suitable illumination and inspection tools with sufficient frequency to ensure full ‘compliance with the requirements of this specification. Thickness Test Each pipe and bend shall be checked and recorded the dry film thickness at different position using a non-destructive type of thickness gauge as per the requirements of SSPC-PA2. The ry film thickness (DFT) shall be in the range of 375 to 625m, ‘The coating thickness shall be measured at three random locations along each pipe length using @ coating thickness gauge that is calibrated at least once every working shift (to a maximum of 12 h) against a thickness standard that is within the range of coating thickness specified in the purchase order. Such measured thickness values shall be recorded. For a specified minimum thickness of 375 ym. if one of individual measured thickness values is outside of the requirements, the coating thickness of the affected pipes shall be measured along the pipe length at intervals not exceeding 1 m. The average of such measured values for each pipe shall be at least 375 im and no individual value shall be less than 375 um.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 15 OF 30 94 9.4.4 9.4.2 95 95.1 If the coated pipe does not meet the requirements of this sub-clause, it shall be stripped and recoated in accordance with the requirements of Section 10. Adhesion Test Hot water adhesion of the coating For each test, use fresh tap water that has been heated to 95°C + 3°C prior to immersion of the test specimens. Place the test specimens in the slow cooker or water bath and submerge them fully in such preheated water. Submerge the test specimens for a minimum of 24 h at a water temperature of 95°C 3°C, and then remove them from the slow cooker or water bath. While the test specimen is still warm, use the utility knife to scribe an approximately 30 mm x 15 mm rectangle through the coating to the substrate, then air cool the test specimen to 20°C £3 °C. Within 1 h after removal from heat, insert the tip of the utility knife under the coating at ‘a comer of the scribed rectangle. Use a levering action to remove the coating. Continue inserting the tip of the knife and levering it under the coating until either all of the coating in the rectangle is removed or the coating demonstrates a definite resistance to the levering action. Pull-off adhesion Pulloff adhesion shall be tested in accordance with ASTM D4541.It shall be exceeded ZOMPa (3000psig) and the failure mode shall be cohesive for more than 75% of surface area. Holiday Test Test requirement 100% of the internally coated surface area of the pipe shall be tested with a hot spark, pulse- type DC holiday detector employing an audible signalling device. The electrode used for locating holidays shall be designed to ensure direct contact with the coating (with no visible gaps). Travel rate of the detector electrode shall not exceed 75 cm/sec. The electrode shall not be allowed to remain stationary while the power is on. The earth connection shall be made directly on the pipe. The holiday test voltage of the hot spark detector shall be 125V DC per 25 micrometres of maximum coating thickness. However, to eliminate the need for continual adjustment during shop production, a maximum voltage of 2200450V shall be used for coating thickness in the range from 375 to 625 um, The test voltage shall be checked at least once per shift by means of a voltage meter. ‘When the holiday test is carried out the internal pipe surface shall be free of moisture. Holiday detection shall take place when the temperature of the coating is less than 100°C or ‘as agreed on the ITP. The temperature of the pipe shall be confirmed at 3 locations evenly spaced along the length of the pipe, before holiday detection begins, The holiday detection method proposed by the APPLICATOR shall be approved by the COMPANY before use.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 16 OF 30 9.5.2 Acceptance Criteria All holidays in pipe coated above 24” diameter shall be repaired. The maximum number allowed for repair is 10 holidays. They shall be holiday free when re-tested after repair in accordance with Section 10. If the number is more than 10 holidays, the pipe/bend shall be rejected. The number of holidays in a pipe joint with diameters up to 20” shall be permitted a maximum of 3 holidays per 12m length. Repair if these holidays are accessible; otherwise, leave them unrepaired and inform the Buyer's representative and log it in the quality control document. 9.6 Flexibility/Bend Test The flexibility of the FBE shall be no cracks and disbondment when tested at 2.5° ppd for 0°C, 2'ppd for 30°C and design temperature. 9.7 Thermal Analysis of Epoxy Powder and Cured Coating Film ‘Thermal analysis is used to characterize the uncured epoxy powder and the cured coating film. The method that shall be used is differential scanning calorimetry (DSC). The general procedure and definitions are given In ISO 11357-1. General handling and calibration shall be performed as in ISO 11357-1, unless otherwise stated in this part of ISO 21809. 9.8 Porosity of the coating The test should be conducted in accordance with ISO 21809-2, Clause A12. The acceptance criteria for both cross-section porosity and interface porosity shall be as per Figure A.11 and Figure A.12 in ISO 21809-2. 9.9 Surface Dust Contamination The dust level shall be measured in accordance with ISO 8502-3. The in process inspection ‘and acceptance requirements shall be in accordance with ISO 21809-2, Table 3. The maximum allowable level shall be Class 2 (for both size and quantity). 9.10 Production Test Ring The applicator shall have facilities availeble for the preparation, testing and evaluation of test ring samples for the tests required. ‘Test rings shall be obtained from locations at least 300 mm from the pipe end and shall be of sufficient size to provide the mandatory tests as described in APPENDIX E. Heat affected or cold-hardened zones shall be excluded when preparing test specimens. ‘The minimum test frequency, for each production line, shall be one test ring per pipe diameter and specified wall thickness every working shift (toa maximum of 12 h). For pipe that is stripped and recoated, at least one test ring of the stripped and recoated pipe shall be taken for each order item. if specified in the purchase order, additional test rings shall be taken. For each test ring, the tests conducted, the number of test specimens used, the test method used and the acceptance criteria shall be as shown in APPENDIX E.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 17 OF 30 10.0 REPAIRS ‘The repair of holidays shall conform to the manufacturer's recommended procedures and the following requirements: Pipelines shall not be repaired with hot melt patch stick; @ Pinholes and areas of 2 mm in diameter or smaller shall be repaired with the manufacturer recommended two-part coating or the purchaser-approved equivalent. ™ Areas greater than 2 mm in diameter and less than 250 cm? in area shall be repaired with the manufacturer recommended liquid coating, or the purchaser-approved equivalent; The minimum thickness of the repaired coating shall be in accordance with clause 9.3; All repairs shall be holiday-tested in accordance with clause 9.5; The number of repairs per length of pipe shall be recorded. 11.0 MARKING 41.1 General Coated pipe shall be marked in accordance with 8.2 and with any additional markings specified in the purchase order. Additional markings by the applicator shall be by agreement. 14.2 Required Marking The following markings shall be placed on the coating: Applicator’s name or mark; Reference to this part of ISO 21809 and year of publication, i.e. ISO 21809-2:2014; Coating MANUFACTURER, product name; Product temperature range (minimum and maximum); Markings required by the applicable pipe specification or standard; Date of coating application; = Pipe MANUFACTURER, pipe number, pipe OD and wall thickness. Marking shall be carried out using a method such as stencil painting or printing, to ensure legible and indelible identification. 12.0 HANDLING AND STORAGE Handling and storage of internally/externally coated pipe shall comply with all sections of with ISO 21809-2 Section 13 with the following additional requirements. ™ All pipes shall be stored in a manner to provide for safe stacking and unstacking operations.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 [ Reva | PAGE 18 OF 30 = Pipe without an external coating shall be stacked off the ground on berms covered with a plastic sheeting material, or on timbers with a minimum 15 cm (6 in) wide bearing surface. The berms or timbers shall be of sufficient height to prevent the pipe ends from coming into contact with the ground and to keep the pipe clear of any localized surface water. All pipes shall be stored at an angle to allow water to drain from the interior. Exposure of the internally coated pipe to water should be minimized where possible. Internally coated pipe shall be stored so that debris, oil or other contamination detrimental to the intemal pipe coating does not come in contact with the internal surface. Pipes shall be provided with secure iting end caps to prevent ingress of debris and water. 13.0 DOCUMENTATION Test Reports and Inspection Documents shall comply with all sections of with ISO 21809-2 Section 14 with the following additional requirements. ‘The APPLICATOR shall keep accurate records of all relevant data of the coating process. This documentation shall, as a minimum, consist of 1) Copies of the coating system information; 2) Copies of qualification information and test data; 3) Copies of, or reference to, all procedures for coating of the pipes; 4) MANUFACTURER's technical date sheets, material analysis certificate and material laboratory test certificates for the coating systems used. 5) Serial numbers of alll pipes as given by the Pipe MANUFACTURER (eg., by copies of the pipe mill data sheets); 6) Serial numbers as given by the Coating Applicator (if applicable) correlated with the MANUFACTURER'S serial numbers; 7) The order of coating, the day and shift of coating of each pipe; 8) The batch numbers of the coating materials, the day and time of loading of each batch; 9) Serial numbers of rejected pipes and the reason for rejection; 10) Specific repair proposal 11) The results of all quality control testing 12) 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, 13) Names and signatures of the responsible persons for the coating process and quality control 14) Internal field joint coating technical proposal 15) Intemal field joint coating procedure; 16) Vendor guarantee of FBE internal coating: 17) Vendor guarantee of internal field joint coating:BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 PAGE 19 OF 30 This documentation shall be submitted to COMPANY after completion of the coating work, together with the testing and inspection instruments’ calibration certificates.BASIC DESIGN DOC. NO.: GEN-PPL-SPC-0025 PAGE 20 OF 30 APPENDIX A PROJECT CONDITION & BASIC DATA A1 Projects Condition Internal FEE coating systems for line pipe and bend shall be qualified to ensure that the coating system properties meet the service condition as shown in Table A.1~A.4, Table A.1 Service Condition of Flowing Conditions 5 5 Water, BWPD Production il/Condensate, BOPD* (Water Cut 50%) GOR 12° Trunkline 11200 11200 180-1200 16" Trunkline 15800 15800 540-780 20" Trunkline 35000 35000 540-780 Note: The above oil flowrate is calculated by the following condition: 1) The length of trunkline is Skm; 2) The flowline for each well is 6", 2.5km: 3) The backpressure of the well not more than 2,0MPag, Table A.2 Corrosive Aggressive €O,, mol% HS, mol% TDS, mg/L Cr, mg/L, 3.85 08 185,340 129,575 Table A.3 Pipe and Connection Data Temp. °C Pressure, MPa Pipe type (Design/oPT) | _(Design/OPT) Trunkine 100185 40/1120 | AsperMTO Size & Length Table A.4 Formation Water Property HFS HF.3 HF-3 Formation Mishrif Nahr Umr Mishrif caz+mgn) 8,000 11,600 9,200 Mg2+(mgil) 1,944 1,458 2,430 cl(mgi) 1144875 129,575 129,575 ‘TDS(ppm) 166,840 185,340 192,450