quality procedure for dual fbe coating rev.01

8/10/2019 Quality Procedure for Dual FBE Coating Rev.01

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ABU DHABI GASDEVELOPMENT COMPANY LIMITED

SHAH GAS DEVELOPMENT(SGD)PROGRAM

Contract Description: Tie in of 12 wells to the Gas GatheringSystem Agreement No: 13526801

Company Document Number: Company Rev.: 01 Page 1 of 2

PM00-DM-FRM-0022_Rev02_ SUPPLIER DOCUMENT TEMPLATE

SUPPLIER/VENDOR DOCUMENTATIONPurchase Order Number: GG1213022

Equipment Description: FUSION BOND EPOXY COATING

Vendor/Supplier Name: BREDERO SHAW SDRL Code H02

Document Title: Quality Procedure for Dual FBE Coating Rev.0Vendor/Supplier DocNumber: GG1213022-1200-H02000003

Vendor/SupplierRevision: 01

Tag/Item Number(s): DUAL LAYER FBE COATING OF PIPES

Unit: Vendor/Supplier Prepared By

Initials / SignatureVendor/Supplier Checked

ByInitials / Signature

Vendor/Supplier ApprovedBy

Initials / Signature

Vend/SuppRevision Date

P.D A.G S.K 18-Nov-14

Status of Submission (tick applicable box before submission)

For Review/Info: Certified Final : As-Built: Purchaser signature below does not indicate responsibility or liability for accuracy or completeness of this

document, nor does it alter any contractual terms or conditions or relieve the Supplier/Vendor of hiscontractual obligations.

CONTRACTOR AREA BELOW

Contract Namer : Consolidated ContractingEngineering & Procurement S.A.L. Offshore (CCC) Contractor Doc. No : N/A(If applicable)

Review Code and Status ContractorInitials/SignatureDate

signed

Code 1REJECTED - Vendor to revise and Resubmit.Work cannot proceed

Code 2Comments As Noted - Work May proceed,subject to compliance with and incorporationof comments

Code 3 No Comments - Work may proceed.

Code 4 Information only -Review not required.

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ABU DHABI GASDEVELOPMENT COMPANY LIMITED

SHAH GAS DEVELOPMENT(SGD)PROGRAM

Contract Description: Tie in of 12 wells to the Gas GatheringSystem Agreement No: 13526801

Company Document Number: Company Rev.: 01 Page 2 of 2

PM00-DM-FRM-0022_Rev02_ SUPPLIER DOCUMENT TEMPLATE

REVISION RECORD:

RevisionNo.

Reason for RevisionDate Remarks

01 Issued for Approval 18-Nov-14

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Quality Procedure forDLFBE Coating

Document No: BSIBV QP 05-1

Revision No: 0

Revision Date: 18 th Nov 2014

Customer Project BSIBV Project No:

CCEP / AL HOSN GAS GG12 - Tie - In of 12 Wells tothe Gas Gathering System

INDEXItem Description Page

A Technical Procedures

1. Introduction

2. References

3. Responsibilities

4. Coating system requirements5. Inspection / Testing

6. Handling Transportation and storage

7. Laboratory quality control testing on incoming

raw material

8. Documents

4-5

5-7

7-8

8-1313-17

17-18

18

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1.0 INTRODUCTION

SCOPE This Quality Plan /Procedure was prepared for the smooth run of Coating Process with usage of Dual FBECoating system using Duponts NapGard 2514 /2504 Dual Layer FBE material. It defines the application,inspection, repair, handling and storage requirements of factory applied external Fusion Bonded Epoxypowder based coatings for the anti-corrosion protection of steel line pipe. The coating system can be appliedto longitudinal welded, spiral welded and to seamless pipe for the construction of buried or submergedpipelines.

The initial coating plan shall be prepared on the basis of all the following documentation such as Standards,Test methods, Manufacturing Specifications and Control plans. Quality Plan shall be prepared according tothe entire requirement of production. The NapGard Dual Layer FBE coating shall be used to protect the pipelines as an anti-corrosion protection. Application and usage are given in following clauses.

1.1 DEFINITIONS

BSIBV - B REDERO S HAW INTERNATIONAL B.V.

TR / CONTRACTOR - CONSOLIDATED CONTRACTING ENGINEERING & P ROCUREMENT S.A.L. - OFFSHORE (CCEP)

AH / COMPANY - AL HOSN GAS

CUSTOMER - CCEP / AL HOSN GAS

TPI - Third Party Inspector, representing the Customer

CRA P IPE - Corrosion Resistant Alloy (CRA) Cladded Pipe. The CRA Pipe shallbe mentioned through-out the document as Pipe.

DLFBE / 2LFBE COATING - Dual-Layer Fusion Bonded Epoxy Coating

SMS - ShawCor Management System

DMP - Daily Management Process

QC I NSPECTOR - A representative of the Quality Control department whosefunction it is to witness, verify and document one or moreaspects of the process and to ensure that the minimumspecified requirements are complied with. The term QC Inspector

throughout this document shall be understood to mean QualityControl Inspector.

OPERATIVES - Personnel charged with the responsibility to complete specific tasks.

MANUFACTURER - Manufacturer or Supplier of raw materials associated with thecoating process.

DESIGNEE - Designee is a person who is designated to carry out theassignment on behalf of the responsible person. The designee shallbe trained and competent person, who shall be able to carry out theassigned task.

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CUSTOMER SUPPLIED - CRA Pipes, provided by the Customer for the purpose ofapplication or installation of coating or any other service as may beprovided by BSIBV and throughout this document;

ACID WASH - A method by which contaminants are removed from thePipes surface by washing the pipe with phosphoric or other acids.

pH - The negative log to the base 10 of the hydrogen ion concentration. i.ebeing either acidic or alkaline in nature.

P RE -HEATING - Applying heat to the pipe before a necessary process step, whenincreased pipe temperature will serve a useful purpose.

HOLIDAY - A coating defect penetrating through the coating to the steel pipesurface of such as dimensions that it is detectable using a highvoltage search electrode.

ITP - Inspection and Testing Plan, the document is outline the extent ofwitness inspection and its reporting. The minimum requirement of theactivities for quality control and inspection of the coating process

UNIT OF PRODUCTION - A unit of production is a set of pipes coated in one production run onthe same coating line, using the same coating technique, having thesame nominal pipe diameter and wall thickness and coated with thesame coating products. Breaks in production caused by equipment orplant breakdown, factory shut down or any break in productionexceeding three days shall be the end of a production run.

Subsequent start-up constitutes a new unit of production

REVISION S TATUS - Clause revision shall be identified by the symbol in the margincolumn of the document

1.2 COATING SYSTEM DESCRIPTION

The coating system described in this document shall be coating application using Fusion Bonded EpoxyPowder as the main coating material, using suitable surface preparation and application techniques to obtainthe coating properties required for its intended installation and operating conditions.

2.0 REFERENCESAmerican Society for Testing and Materials (ASTM):ASTM D570 Standard Test Method for Water Absorption of Plastics.

ASTM B490 09 Standard Practice for Micrometer Bend Test for Ductility ofElectrodepositsASTM D2240 Standard Test Method for Rubber Property Durometer Hardness.ASTM D3417 Standard Test Method for Enthalpies of Fusion and Crystallization of

Polymers by Differential Scanning Calorimetry (DSC).ASTM D3418 Standard Test Method for Transition Temperatures of Polymers by

Differential Scanning Calorimetry.ASTM F372 Standard Test Method for Water Vapour Transmission Rate of

Flexible Barrier Materials Using an Infrared Detection Technique.ASTM G14 Standard Test Method for Impact Resistance of Pipeline Coatings

(Falling Weight Test).ASTM G17 Standard Test Method for Penetration Resistance of Pipeline

Coatings (Blunt Rod).

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ASTM G95 Test Method for Cathodic Disbonding of Pipeline Coatings (AttachedCells Method)

ASTM E-29 Using significant digits in test data to determine conformance withspecifications.

Canadian Standards Association:CAN/CSA Z245.20 External Fusion Bonded Epoxy Coating for Steel Pipe.

Deutsches Institut fr Normung (DIN):DIN EN 10204 Metallic products - Types of Inspection Documents.

International Standards Organization (ISO):ISO 9001:2008 Quality Management System RequirementsISO 9004 Quality Management Systems - Guidelines for Performance

Improvement.ISO 10474 Steel and Steel Products Inspection Documents.ISO 2808 Paint and varnishes Determination of film thickness.ISO 4624 Paint and varnishes Pull off test for adhesion.ISO 129447 Execution and supervision.ISO-8501-1 Preparation of steel substrates before application of paints and

related products Visual assessment of surface cleanliness Part 1:Rust grades and preparation grades of uncoated steel substrates andsteel substrates after overall removal of previous coatings.

ISO 8503-1 Preparation of steel substrates before application of paints andrelated products- Surface roughness characteristics of blast cleanedsteel substrates.

ISO 8503-4 Preparation of steel substrates before application of paints or relatedproducts surface roughness characteristics of blast cleaned

substrates part 4: Methods for the calibration of ISO surface profilecomparators and for the determination of surface profile stylusinstrument procedure.

ISO 21809-2, 2007 Rev1 Petroleum and natural gas industries External coatings for buriedor submerged pipelines used in pipeline transportation systems Part 2: Fusion Bonded Epoxy Coatings.

National Association of Corrosion Engineers (NACE International):NACE SP0394 Application, Performance, and Quality Control of Plant- Applied,

Fusion-Bonded Epoxy External Pipe Coating.NACE SP0490 Holiday Detection of FBE External Pipeline Coatings of 250 to 760

micrometers (10 to 30 mil). SHELL DEP Specification:

DEP 31.40.30.32-Gen. External FBE Power Coating for Line Pipe (2003)The Society for Protective Coatings (SSPC):SSPC-SP1 Solvent Cleaning.SSPC-PA2 (1991) Measurement of dry paint thickness with magnetic gauges.SSPC-SP5 White metal blast cleaning.SSPC-SP10 Near-white metal blast cleaningSSPC-AB1 Mineral and Slag Abrasives.SSPC-AB2 Cleanliness of Recycled Ferrous Metallic Abrasives.SSPC-AB3 Ferrous Metallic Abrasive.SSPC Publication 91-12 (1991) Coating & lining inspection manual.

The Customer Specification:GG01-0100-95-SPE-0019 Rev.2 Single and Dual Layer FBE Pipeline Coatings

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Quality Plan & Inspection Test Plan BSIBV RAK Site Specific:BSIBV QP 01 Quality Plan for Handling, Receipt and Dispatch of pipes.BSIBV ITP 05-1 Inspection Test Plan for External Dual Layer Fusion Bonded Epoxy CoatingMaterial Data Sheet NapGard 2514 /2504 Dual Layer FBE Material Data Sheet

3.0 RESPONSIBILITIES

3.1 Plant Manager is responsible for ensuring that production activities are carried out on time to the requiredspecification, at the required level of quality and for ensuring that all relevant Managers / Dept. heads areimplemented company policy and procedures at all times.

3.2 Project Manager has overall responsibility of the Project. He shall ensure that all services and coating relatedmaterials are available for the successful and timely completion of the project. The Project Manager shall alsocommunicate to Customer; act as BSIBV interface with the Customer throughout the duration of the Project.

3.3 The QA/QC Manager shall supervise and undertake technical responsibility, develop recommend andimplement Quality Plans to ensure that manufactured products are of acceptable quality and produced inaccordance with specifications and company quality standards. Shall develop initial plan and preparation ofQP & ITP of the Project, the same shall be submitted for review and approval. In addition the QA/QC Managerhas the authority to halt production if products have been identified non-conforming as per this quality Plan.

3.4 The Regional Quality / Technical Manager shall provide general technical support to the projects as andwhen required. He supervises and undertakes technical responsibility, develop recommend and implementthe Quality department to ensure that manufactured products are process as per the specifications andcompany quality standards.

3.5 The Operations Manager shall be responsible for all workforce and equipment necessary for the required

operation. He shall also ensure that the operations are performed in a safe manner and that the productmeets the requirements specified herein.

3.6 HSE Manager shall responsible to ensure that all workers are versed in safety procedures and, colour codingis used for lifting tackles such as hooks and slings. And he shall make sure that all workers are provided withall required PPE.

3.7 The Facility Maintenance Manager shall ensure all the Plant machineries/equipments, Rolling Stock includingcranes and front end loaders used for pipe handling and storage are regularly maintained and kept in a safecondition at all times.

3.8 SMS Coordinator shall make sure the Standard Operating Procedure (SOP), Process Failure ModeEvaluation Analysis report (PFMEA), Control Plan (CP) prior to start of the Project. The set parameters shallbe recorded and kept for further reference.

3.9 QA/QC Supervisor is responsible for organizing the QC Inspectors and coordinating their activities inconjunction with production and contract requirements. Ensure that the QC Inspectors inspect and control thequality of the product in accordance with this document. Also perform inspection equipment calibration on aDaily basis at the QP/ITP Requirement. Carry out necessary liaison between the Production/Quality ControlDepartment and Customers site representative.

3.10 Project Engineer shall ensure that all services and coating related materials are available for the successfuland timely completion of the project. The Project Engineer shall also act as BSIBV interface (in the absence ofthe Project Manager) with the material manufacturer throughout the duration of the project.

3.11 QC Supervisor shall be responsible for all inspections and documentation required to ensure each pipeprocessed complies with specified contract/purchase order requirements. In addition, he shall train QC

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Inspectors to be responsible for inspection, documentation and marking required ensuring full traceability ofeach pipe.

3.12 QA Engineer shall assist QA/QC Manager in preparation and implementation of all relevant QualityAssurance documentation necessary to maintain the certification of ISO 9001-2008. He shall monitor InternalQuality Audit Schedule, Quality Objectives and Corrective Actions.

3.13 Tally Coordinator shall be responsible for all matters relating to the arrangements of bare pipes, efficientidentification and data input of pipes received, coated and loaded out. The tally coordinator shall also beresponsible for tracking data related to production and quality control for records and invoicing purpose ofpipes, and other related products applicable. The tally coordinator will also take the responsibility of trackingthe entire process data reports and shall ensure that the same are filed and documented in a proper manner.

3.14 Laboratory Supervisor shall ensure all laboratory tests are performed in accordance with BSIBV proceduresand customer specifications. Ensure incoming raw materials meet specification. Test daily production samplesto ensure quality according to BSIBV and relevant standards as per the Project document.

3.15 Field Supervisor shall be responsible for the correct storage and handling of all pipes and the execution ofpipe movement from load in receipt, within the yard, and for dispatch. He shall also be responsible for themaintenance and upkeep of the storage areas.

4.0 COATING SYSTEM REQUIREMENTS

4.1 Manufacturers blasting and coating material data sheets shall be submitted to the customer prior to start ofProduction. Production will not commence until the proposed coating materials are approved by the customer.Each new batch of material certificate shall be submitted to Customers representative prior to the release of

the material for Production. The materials used will be FBE powder - Dual FBE DuPont's NapGard Gold -7-2514 / 7-2504 Material.

4.2 PRE-QUALIFICATION TRIAL (PQT)

Previous record of Prequalification test results shall be submitted if required.

4.3 INCOMING RACKS PIPE RECEIPT

Pipes have been previously accepted by the load-in inspector in accordance with BSIBV QP 01 Procedure forReceipt and Dispatch shall be transported from the storage area by means of a front-end loader or by flatbedtruck or pole trailer unit, and off loaded by front-end loader onto the incoming racks. Bevel protectors if fittedshall be removed prior to coating and shall be reinserted once coating is completed. All pipes shall be visuallyinspected by QC/ Tally Inspector and incoming rack operatives for surface contamination by oil, grease and

bevel damages etc. and they shall remove any debris from inside the pipe. Pipe with such contamination shallbe identified, cleaned, or removed as per SSPC SP 1, from the racks when necessary. All the liftingequipments are certified by third party and detailed risk assessment and job procedure for all pipe handlingactivities are in place. The Pre-inspection pipe numbers are recorded QF 001 Pipe incoming Pre-inspectionreport (Appendix 1). The pipe identity shall be maintained throughout the process using various inspectionreport form on each inspection area. The pipe traceability records shall be kept in Tally documentation by hardand soft copies. The same shall be handover to customer once the entire project handed over. A water breaktest shall be performed on the surface of the pipe. Clean water poured on a metal surface should form a thin,unbroken film. Formation of droplets shall be considered evidence of contamination.

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4.3.1 END PLUGSEnd plugs shall be placed inside both ends of the pipe to prevent the ingress of abrasive material duringthe blast cleaning process. These shall be removed immediately after blasting, at which time any dust orabrasive accumulating inside the bore of the pipe shall be removed by clean dry compressed air.While inserting end-plugs, operator shall ensure that the CRA surface is not damaged.

Attached are examples of the type of end plugs used:

4.4 SURFACE PREPARATION

4.4.1 Solvent Cleaning (If required)

Solvent washing in accordance with the method described in SSPC SP-1 shall remove contaminants suchas oil or grease. Self-inspecting operatives shall ensure that the contaminants/propriety solvent iscompletely removed prior to abrasive blasting.

4.4.2 Hot Water bathThe pipes shall be immersed in the hot water preheat station where dirt deposits and soluble surface saltsshall be removed prior to blasting. The final preheat temperature of the pipe is controlled by the watertemperature and duration of hot water washing. The process shall be such as to ensure that the surfacetemperature shall maintain a minimum of 3C above dew point, for the remainder of surface preparationstages.

4.4.3 Pipe PreheatThe inspector shall determine the suitability of the climatic conditions prior to the commencement ofabrasive blast cleaning.

4.4.4 In the event of inclement weather, the preheat system shall be used to ensure the pipe surfacetemperature is within the specified range 40C to 70C.The temperature shall be monitored by use of aninfra-red temperature gauge/pyrometer.

4.4.5 Abrasive shall be such that the specified degree of cleanliness and a clean angular surface profile areachieved. The abrasive shall be capable to attain the required surface profile on the blast cleaned surface.BSIBV shall submit material Manufacturers Data Sheet to the customers representative.

4.4.6 Blast CleaningRotating pipe shall be conveyed into the centrifugal blaster(s) where it is blast cleaned using dry abrasivetechniques. The blast media/abrasive is continually fed through the system. All fines and debris from thepipe surface and system shall be removed by the extraction system into the dust collector. The blaster

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shall be frequently topped up with small additions of fresh abrasive to maintain the desired surface profileand visual finish.

4.4.7 When the pipe has exited the blast cabinet, residual abrasive/dust shall be removed from the pipe surfaceby means of an air knife, wire brush or other suitable means.

4.4.8 The operator shall transfer the pipe to the inspection/grinding station.

4.5 INSPECTION AND DRESSING OF METAL DEFECTS

4.5.1 When the pipe is situated on the inspection station pipe rotation wheels to facilitate the dressing of metaldefects the operator shall rotate the pipe to blow out any abrasive material from inside the pipe with cleandry compressed air and to facilitate the dressing of metal defects.

4.5.2 Metal defects such as surface slivers, laminations, scabs, burrs or other defects likely to have adetrimental effect on the coating shall be removed by manual cosmetic grinding or fil ing.

4.5.3 In the event that the pipe has not achieved the specified degree of surface cleanliness, or found to haveexcessive metal defects, the inspector shall direct the pipe be dispatched from the incoming rack and thepipe shall be re-blasted or set aside for the customers evaluation.

4.5.4 When the pipe has been accepted, high temperature tape shall be applied on the cut back area of theblast cleaned pipe for easy removal of coating at outbound. The pipe shall then be transferred to thecoupling installation station to install couplings.

4.5.5 Operatives shall install a coupling into one end of the pipe, ensuring that it is clean and free of oils andlubricants. While inserting couplings, operator shall ensure that the CRA surface is not damaged.

4.6 PHOSPHORIC ACID PRETREATMENT

4.6.1 On exit from the abrasive blast inspection station, pipes are conveyed, in-line through the acid washstation where they are treated with phosphoric acid.

4.6.2 The elapsed time between blast cleaning and phosphoric acid wash shall not exceed the limits listed inthe following table.

Relative humidity (%) Max. Elapsed time (Hours)>85

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4.6.4 Air knives, which are used to dry the pipe prior to heating, are situated immediately after the water rinsebooth and both the angle of the air knives and air pressure shall be adjusted so that the maximum dryingeffect is achieved.

4.7 INDUCTION HEATING SYSTEM

4.7.1 Prepared pipe are then conveyed through the induction coil(s) that are pre-set to heat the pipes to theapplication temperature recommended by the Manufacturer.

Air knives, steel brush and /or vacuum system (dust removal) shall clean the pipe prior to the coatingbooth. The recommended coating application temperature of pipes is 232 to 239 0C. Pipe temperatureshall not be allowed to exceed 275 0C

4.7.2 The first pipe on the conveyor line shall be used to establish the surface temperature of the pipe forcoating application, which shall be in accordance with the material manufacturers recommendations.

4.7.3 The surface temperature of the first pipe shall be determined by the plant operator using surfacepyrometer, infra-red gun or melt sticks that may be applied anywhere on the pipes surface.

4.7.4 The operator shall continue to monitor the surface temperature throughout the coating process usingsurface pyrometers and/or infra-red guns, which continually monitor the pipe surface temperature

4.7.5 The operator shall ensure the line travel speed of the pipe is in accordance with parameters asdetermined by pipe size and required coating thickness.

4.8 QUENCH STATION

Coated pipe shall then be conveyed to quenching station where pipe is cooled by a drenching flood ofcooling water to allow further handling. Pipe shall not be directly quenched before 180 seconds after thepowder application. The cooling (quenching) requirement shall be altered in accordance with FBEManufactures recommendations for proper curing of FBE coating. Pipe temperature on exit from quenchshall not exceed 80 C.

Air will be blown inside the pipes to remove excessive water from inside the pipes. The pipe is then liftedonto inspection racks .

4.9 COOLING AND INSPECTION RACKS

As coated pipe is rolled and set on cooling racks, cutback ends will be cleaned of all excess coating material.

Electrical test (holiday detection) will be carried out at a travel speed of no more than 0.3 m/sec and

inspection voltage shall be as set and calibrated at a frequency as dictated by the Inspection and Test planbelow. All detected holidays shall be clearly marked and the number of holidays detected on each pipe shallbe written at the end of the pipe.

Immediately after holiday detection, pipes shall be inspected for dry film thickness, uniform finish,adhesion...etc., as required in the Inspection and Test plan. At the same time Stencil marking shall be appliedin accordance to the contractual requirement. If Stencil marking required, marking will be appliedapproximately foot away from the pipe end.

4.10 CUTBACK BRUSHING

The high temperature tape applied on both ends of the cut back area of blast cleaned pipe shall beremoved at outgoing rack. The pipes applied with tapes at cut back area from mid rack is conveyed

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through acid treatment, pre-heating, coating application process until pipes are kicked off from coatingconveyor to Outgoing rack.

4.13 CALIBRATION

4.13.1 The QC Inspector at the start of the shift and thereafter every four hours during production shall calibrateall dry film thickness gauges used by the inspector in accordance with SSPC, The Society for ProtectiveCoatings Paint Application Standard No. 2. The result shall be recorded on form QF 500-1 (Appendix1).

4.13.2 The QC Inspector shall calibrate the holiday detector at the start of the shift by use of a calibratedvoltmeter and thereafter every four hours. Maximum Holiday detector voltage shall be 1750 volts. TheHoliday detector shall be set to 5 V for each micro meter of nominal coating thickness. The detector shallbe calibrated at least once every working shift (to a maximum of 12 h). By referring to the relevantspecification, the inspector shall ensure that specific requirements such as test voltage 4.0 Kv (Avg DFT810 m, 5V per m). The holiday detection shall be as per Table 1 of NACE RP 0490 - Holiday Detectionof Fusion Bonded Epoxy External Pipeline Coatings or clause 10.2.3.6 of ISO/DIS 21809-2 Standard; theresult shall be recorded on form QF 500-1.

4.13.3 The QC Supervisor or designee shall calibrate the micrometer used to check the surface profile twice pershift, by use of a calibrated thickness standard of the surface profile range. The result shall be recordedon form QF 500-1.

4.13.4 The QC Supervisor or designee shall calibrate the Digital Contact Thermometer with calibrated DigitalMaster Thermometer.

4.14 REPAIRS

4.14.1 The maximum number of holidays allowed to be repaired shall be as per ITP.

The holiday acceptance criteria shall be as per clause 15.9 Table 8 of Doc. No. GG01-0100-95-SPE-0019. Areas less than 625mm shall be repaired with the FBE Manufacturers recommended or therecommended repair material as mentioned in ITP. The maximum total surface area per pipe that may berepaired is 40 cm .

Each repaired area shall be holiday tested in accordance with Section 15.8 of Doc. No. GG01-0100-95-SPE-0019. If the FBE coated pipes affected with repair area exceeds 625mm, excessive holidays thanmentioned above and the maximum total surface area per pipe exceeds 40 cm. Such pipes shall bestripped and recoated.

4.14.2 All holidays or coating damage shall be appropriately marked (with ink marker). Slivers, scabs or otherloose materials shall be removed by scraper, file or pencil grinder. This area shall then be cleaned and

roughened by sandpaper or file. Cleaning solvent may be used when necessary. All edges of preparedarea shall be smooth and chamfered. The surface shall be cleaned to St 3 or equivalent. Patchingcompound shall be mixed and applied as per the Manufacturers instruction.

Repair material shall cover the surrounding chamfered coating. Tape may be used to mask the sides ofthe area when repairing large or difficult areas to achieve a neat finish. The area to be repaired shall beprepared by filing and /or grinding or a combination of both ensuring the parent coating is abraded for aminimum distance of 25mm.

4.14.3 The repair material shall be mixed and applied as per the Manufacturer instructions.

4.14.4 On completion of cure the repair area shall be holiday detected as per clause 5.3.11, the repair shall beholiday free.

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4.15 MARKINGS

4.15.1 Each pipe shall have identification marking on the internal surface of both ends of pipes. Stencil shall beapplied on one end of accepted 2LFBE coated pipes only, within two meters from the open end. Thestencil marking may rub off while transporting or handling the coating pipe, the coater shall not beresponsible for such issues. The marking matter shall be approved by the Customer.

4.15.2 After completion of marking, the end-caps supplied with the bare pipes shall then be reapplied to thecoated pipes to protect the CRA surface.

4.16 STORAGE AND HANDLING

4.16.1 Rope separators are put on finished coated pipes at three equidistant location (one on either ends andone in the middle)

4.16.2 The finished coated pipe shall then be transported by crane and truck and / or by forklift/front loader withpadded forks to a designated area for storage, and stacked on sand berms covered with polyethylenesheet, which shall be a minimum of 150mm high from the ground to prevent surface water entering duringthe storage period. The End Cap shall be reinstalled after the pipes are inspected and prior to thetransportation to the storage yard.

4.16.3 All other storage, handling, and load out requirement shall be as per BSIBV Quality Procedure QP-01.

4.16.4 The number of tiers in the pipe stack shall be limited to a safe working height of 4.0 meters.

4.17 STRIPPING OF REJECT PIPE

4.17.1 Prior to stripping the QC inspector shall ensure the pipe has been rejected, and shall mark the pipenumber on the external surface of the pipe. The FBE coated reject pipe shall be transported to strippingarea. The rejected FBE coated pipe shall be subject to heating using LPG or similar method which shallbe safe and appropriate to use.

The heating shall be done through external surface using blow torch, the pipe and hose used for sameshall be approximately half inch. The FBE coated pipe shall be heated to approximately 220C and makesure the coating is soft enough to scrape-off the coating. Ensure the temperature shall not exceed 275Cas per Doc No. GG01-0100-95-SPE-0019.

The heated reject coating shall be removed by a scraper. Once the require temperature obtained the FBEcoating shall be stripped off. The residue FBE coated material shall be removed in blast cleaning process.Stripped and re-blasted pipes surface shall be checked with magnifying glass (X30) to conform noresidues of FBE remain in the anchor pattern valleys. All pipes to be recoated shall be subject to all of theprocesses starting at the incoming inspection rack. The process shall be recorded on QF01-3 form.

5.0 INSPECTION/TESTING

5.1 ABRASIVE BLAST

5.1.1 The inspector shall determine the suitability of the climatic conditions prior to the commencement ofproduction and thereafter every two hours. Pipe temperature shall be 3C above the dew point. Theprocess shall be stopped if relative humidity greater than 85% and pipe temperature is less than 3Cabove dew point. Pre-heat if pipe temperature is less than the required level. The result shall berecorded on form QF 05-2B (Appendix1). The surface chloride test shall be carried-out in the incomingrack as per ITP. A water break test shall be performed on the surface of the pipe. Clean water poured on

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a metal surface should form a thin, unbroken film. Formation of droplets shall be considered evidence ofcontamination QF 01-3 (Appendix1).

5.1.2 The QC Supervisor or designee shall perform a contamination test in accordance with procedure 7.3 ofSSPC Publication 91-12 on the re-circulated abrasive used in the blast cleaning machines. Result shall berecorded on form QF 05-1 (Appendix 1).

5.1.3 Start of the normal production, the QC Supervisor or designee shall test the compressed air supply for thepresence of oil or water in accordance with ASTM D 4285-83. In the event that oil or water is detected theinspector shall inform the plant Supervisor who shall stop the operation and ensure remedial action istaken. Result shall be recorded on form QF 021 (Appendix1)

5.1.4 The inspector shall check the surface of pipes, in the normal production first 3 pipes and after every hourin accordance with ISO 8502-3 for dust contamination at one location on the pipe. The dust level on theblast cleaned pipe shall be < class 2 in accordance with ISO 8502-3. The inspector shall record the resulton report form QF 05-1. The Inspector shall attach the clear tape test strips to form QF 05-10 (Appendix 1)from the tested pipe.

5.1.5 The inspector shall ensure the degree of is a near white metal finish equal to Sa2 as per ISO 8501-1/SIS SS05-5900 (1988) or SSPC-SP10/ NACE No.2. Result shall be recorded on form QF 05-1.

5.1.6 Surface profile shall be as per ITP. Digital Profile gauge (calibrated) shall be used by the inspector toobtain the surface profile of blast cleaned pipe. The test shall be carried out in accordance with ISO 8503-4 or 8503-5. For regular production, measurement shall be made on the first 3 pipes at the start of theshift during production and thereafter one pipe every two hours to determine the surface profile (anchorpattern) of the blast cleaned surface. The surface profile/roughness results shall be recorded on form QF05-2B

5.1.7 In the event that a pipe has not achieved the specified degree of surface cleaning and /or profile, theinspector shall direct that the pipe be dispatched from the inspection7 / grinding station and returned tothe incoming rack for evaluation and /or re-blasting.

5.1.8 On completion of abrasive cleaning the surface shall be inspected for metal defects. The repair of defects,which can be repaired by filing or grinding, and the location of such repairs when the size is 625mm andif it is more the pipe shall be reblasted.

5.1.9 Pipe with serious defects such as laminations, excessive slivers etc. shall be set aside for the customersevaluation. Grinding shall only be used for minor defects and. Should a defect be found wheresubsequent grinding might infringe minimum pipe wall thickness as per API 5L the pipe shall be passedthrough the system uncoated and shall be quarantined. A non-conformance report, RF 002 (Appendix1)shall be raised and submitted to the customers representative.

5.1.10 The pipe shall be tested for the presence of residual chlorides by use of an Elcometer 130 SCM 400 saltmeter, such test method as recommended by ISO 8502-2. Result shall be recorded on form QF 05-1.Residual external surface chlorides of the bare pipes prior to washing shall be checked and resultsrecorded. Result shall be recorded on form QF 05-1.

5.1.11 In the event of a failure the pipe shall be retested; if the test fails all pipes that were blast cleaned afterthe contaminated pipe shall be tested until three (3) in a row pass the test. As the pipes are subsequently,phosphoric acid washed prior to coating application to remove all surface contaminants, all pipes coatedbefore the failed test shall be acceptable. The abrasive material shall be tested for conductivity by use of acalibrated conductivity meter. Result shall be recorded on form QF01-3.

5.1.12 Conductivity of the blasting media shall be checked for conformance and also if the contamination of the

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5.3.8 In the event that the cut back is not in accordance with the relevant specification or the coating is notuniform, and has coating defects, the inspector shall direct that the pipe be placed on hold in a quarantinearea for evaluation or rework and inform the production supervisor.

5.3.9 The inspector shall record the result of the visual inspection on report form QF 05-3. In the event that thepipe is rejected, the reason for the rejection shall be noted in the comments column of the report form.

5.3.10 The inspector shall measure the total thickness of the coating (all pipes) in accordance with ISO 2808.The total coating thickness shall be based on the two layers of FBE combined and Measurements shall bemade at 12 points uniformly spaced over the length of pipe, that is, three each at the 12, 3, 6 and 9oclock positions with 12 oclock being taken as the longitudinal weld. At least 3 points shall be measuredon longitudinal welds. The coating thickness shall be mentioned in ITP. Individual readings less than therequirement shall be cause for the pipe to be rejected. The inspector shall record the results on reportform QF 05-3.

5.3.11 The inspector shall ensure that the holiday detection is carried out at a speed of approximately 30 cm/secwith a spring electrode and/or conductive rubber electrode. For inspection, the direct current potential ofthe Holiday detector shall be set to 5 V for each micrometre of nominal coating thickness. The detectorshall be calibrated at least once every working shift (to a maximum of 12 h). By referring to the relevantspecification, the inspector shall ensure that specific requirements such as test voltage as per ITP. Theholiday detection shall be carried out as per Table 1 of NACE RP 0490 - Holiday Detection of FusionBonded Epoxy External Pipeline Coatings or clause 10.2.3.6 of ISO/DIS 21809-2 Standard, "Externalcoating for buried or submerged pipelines used in pipeline transportation systems - Part 2: Fusion BondedEpoxy Coatings". Coated pipe having holidays shall be repaired in accordance with the requirements of11.2 of ISO/DIS 21809-2 Standard and clause 4.13 of the mentioned procedure.

5.3.12 The maximum number of holidays allowed to be repaired shall be mentioned in ITP. The holidayacceptance criteria shall be as per 15.9 Table of Doc. No. GG01-0100-95-SPE-0019. The maximum totalsurface area per pipe shall be less than 40 cm. The repair material shall be Duponts 7-1854 two partputty epoxy patch compound or equivalent approved by company. Any pipe observes more than thementioned requirement shall be stripped and recoated. Results of the holiday detection process shall berecorded on form QF 05-3, and in the event that the recorded results are not in accordance with thespecified requirements, the inspector shall direct that the coated pipe be placed on hold for repairs and/orrejected.

5.3.13 The frequency and acceptance criteria for the Cathodic Disbondment test shall be as per the agreed ITP.The voltage shall be -1.5 volts. The sample shall be 125 mm x 125 mm (5 inch x 5 inch) or larger panel iscut from the production coated ring sample. A 6 mm holiday is drilled through the coating to the steel. Theresult shall be recorded on report form QF 05-6 (Appendix 1) Note: the pipe requires to be cut to performthe test. The test sample shall be free of holidays and blisters. The testing shall be carried out as per

clause 15.9 and Appendix 3 of Doc. No. GG01-0100-95-SPE-0019.5.3.14 The Impact test shall be performed as per ASTM G 14, and the test shall be carried out as per ITP. The

pipe sample shall be cut and kept inside to attain the required test temperatures.

5.3.15 Foaming level shall be tested on one pipe at start of the project; FBE sample shall be examined for Cross-section Porosity and Interface Porosity examination of the coating under a 40 X-power magnification shallbe as per ISO 21809-2. The test shall be carried as per Appendix 2 of of Doc. No. GG01-0100-95-SPE-0019 but with the acceptance criteria based on ISO 21809-2.

5.3.16 The Flexibility test (bend test) shall be performed on 6 Specimens. The test shall be carried out at roomtemperature (23 +/-2C) > =3PDL strain shall be induced in the coating of the sample. The samplecoupons shall be 200mm x 25mm x WT mm shall be cut from the coated pipe in the longitudinal directionof the pipe. The sample shall be free of holidays at the respective voltage. The samples shall be bending

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by means of a mandrel; the completing the bending with 30 seconds. On completion of bending the bendtest coupons shall be visually inspected for cracks, tears in the coating, and disbonding of the coatingafter the specimens have warmed to room temperature. The presence of such defect within 2.5 mm of thestrap edge or with 12 mm of support pin does not constitute a failure. The presence of strain marks alonedoes not constitute a failure. The Flexibility test method as per CAN CSA Z 245 20 Standard, NACE RP0394 or ISO/DIS 21809-2.

The test shall be carried as per Appendix 1 of of Doc. No. GG01-0100-95-SPE-0019.

5.3.17 Each pipe should be tied with minimum 3 nylon rope or similar rope rings.

5.3.18 The inspector shall ensure that repairs carried out by repair personnel are in accordance with the relevantspecification, and to manufacturer recommendations.

5.3.19 In the event of a test failure, BSIBV shall propose and agree with the customer a test programme toidentify suspect pipe. Further testing shall involve inspection and testing similar to the original failed test.

5.3.20 In such occasions that a pipe has been rejected, the inspector shall ensure that the rejected pipe ismarked R on the external coated surface and/ red colour band sprayed around the pipe, removed to aquarantine area and is not stacked with accepted pipes.

5.3.21 Inspection release Note shall be issued for accepted pipes and signed by all parties for release of coatedpipes for shipment. Final Documentation shall be submitted to TPI, by BSIBV once all the testings arecompleted.

6.0 HANDLING, TRANSPORTATION & STORAGE

6.1 MATERIAL Material used for production coating shall be checked upon receiving. Packaging secure, marking containingbatch number and expiry date shall be legible.

Coating material shall be stored in dry room, protected from UV light, with temperature below 30C or asmanufacturer recommendation.

Shelf life of material shall be controlled; the first in first out order shall be applied. Any deterioration shall bereported.

6.2 HANDLING After coating, pipes shall be rolled on padded racks for inspection/repair. Pipe shall be transferred fromoutgoing racks to trucks by means of crane with belts or loader fitted with suitable padding.

6.3 TRANSPORTATIONFlatbed trucks or pole trailers with suitably padded supports to prevent damage to the coating shall transportcoated pipes. Front-end fork loaders may also be used providing the lifting cradle is lined with soft rubber orfoam.

6.4 STORAGECoated pipe shall be stored on sand berms comprising of two baulks of sand, 50 cm high with a bearingsurface 1m wide, each approximately 6m apart. Sand berms shall be inspected for suitability prior to use.Sand berms shall be covered with polythene sheeting, to ensure no pipe contact with the Berm.

All pipes shall be stored in stacks segregating the pipe by source, grade, diameter, and wall thickness, coatingtype. Pipes shall be positioned clear of the ground. Pipe interiors shall be kept clean and free from mud

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splashing or dirt deposits during storage. Pipe will be stacked with due consideration to impact effects.Separation between coated pipe joints in a stack shall be provided by use of PE, Nylon or other plastic ropesecured sufficiently to prevent slippage. The rope separators shall be placed within 1.5m of each pipe end andat 3m spacing along the pipe length. The diameter of the rope separator shall not be less than 19mm for pipeof diameter up to and including 324mm and 25mm for larger diameter pipe.

7.0 LABORATORY QUALITY CONTROL TESTING ON INCOMING RAW MATERIALS

Laboratory testing on incoming raw materials is controlled by BSIBV form TRNM 001Test Requirement Notification Memorandum for Incoming Raw Materials.

Each batch of FBE powder shall be tested for: Moisture content Gel Time Thermal Analysis (DSC)

Raw materials shall be stored as per the manufacturers recommendations.Raw material batches or lots shall not be used until released by the laboratory and the manufacturerscertificate of conformance is received.

8.0 DOCUMENTS

RF 033 Material Received & Inspection ReportsTF 001 Load In Tally ReportQF 001 Pipe incoming Pre-inspection reportQF01-3 General Report Form

QF 05-1 Surface Preparation ReportRF 002 Non Conformances / Concession Request ReportQF 05-2b Environment & Profile ReportQF 021 Compressed Air Blotter Test ReportQF 05-7 Dust Contamination Test Sample Retention ReportQF 023 Phosphoric Acid Treatment ReportQF 028 Pipe Pre-coat Temperature Report FormQF 05-3 Final Inspection ReportTF 005 FBE/DLFBE Coating Tally ReportQF 024 Differentials Scanning Calorimetric ReportQF 05-6 Laboratory Test ReportQF 05-4 FBE Coating Impact Test ReportQF 05-9 FBE Coating Repair ReportQF 026 Stripping Report

QF 500-1 Daily Instrument Calibration reportQF 032 Residual Magnetic Intensity Report form

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