Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
INDEX Item A
Description
Page
Technical Procedures 1. Introduction
4-6
2. References
6-8
3. Responsibilities
8-9
4. Coating system requirements
9-15
5. Inspection / Testing
15-19
6. Handling Transportation and storage 7. Laboratory quality control testing on incoming raw
19 19-20
material 8. Documentation
20-36
Document No: Revision No: Revision Date:
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
QP 07-2 0 25th Nov13
PO Number
PROCESS FLOW DIAGRAM
Transportation of Bare Pipe from Stockpile to Coating Pl ant
1
2
Hot Water Preheat
Incoming Racks & Foam Plu Insertion
4
Blast Cleaning
3
I
I
5
Inspection Racks & Internal Blow-Out Station
Acid Wash/ Pressure
8
13
I
I
Adhesive Application
Holiday Detection and Coating Inspection
FBE Application
Induction Heating
6
I
9
7
Water Wash
Polypropylene 11 Application
10
14
Cutback Cleaning
15
Sinter Application (If applicable )
Pipe Identification marks shall be confirmed.
12
Water Quench
16
Transportation to Internal Plant or Stockpile
Pipe No Length
I
KEY:
Process
I Direction of Flow
?
Activity Number
I
Ins ection Point
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
1.0
INTRODUCTION
1.1
SCOPE
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
This Quality Procedure defines the application, inspection, repair, handling and storage requirements of factory applied external three layer Polypropylene coatings for the anti-corrosion protection of steel line pipe. The coating system can be applied to longitudinal welded, spiral welded and to seamless pipe for the construction of buried or submerged pipelines. This procedure is written with the intention of being a working instruction for BSMEL personnel by detailing the standard of workmanship and acceptance criteria throughout each phase of t he process. 1.2
DEFINITIONS BSMEL
-
Bredero Shaw Middle East Limited
CUSTOMER
-
The Company awarding the purchase order/contract to BSMEL
TPI
-
Third Party Inspector, representing the Customer
CS PIPE
-
Carbon Steel Pipes
CRA PIPE
-
Corrosion Resistant Alloy (CRA) Cladded Pipe. The CRA Pipe shall be mentioned through-out the document as Pipe.
FBE COATING
-
Fusion bonded epoxy coating
PP
-
Polypropylene
3-LPP
-
Three Layer Polypropylene coating consisting of a primer layer, adhesive layer and outer pol ypropylene layer.
DFT
-
Dry film thickness
DMP
-
Daily management process
QC INSPECTOR
-
A representative of the Quality Control department whose function is to witness, verify and document one or more aspects of the process and to ensure that the minimum specified requirements are complied with. The term QC Inspector throughout this document shall be understood to mean ‘Quality Control Inspector’.
DESIGNEE
-
Designee is a person who is designated to carry out the assignment on behalf of the responsible person. The designee shall be a trained and competent person, who shall be able to carry out the assigned task.
OPERATIVES
-
Personnel charged with responsibility to complete tasks.
CUSTOMER SUPPLIED
-
CS Pipes, Bends and Anodes (if required) provided by the Customer for the purpose of application or installation of coating or any other service as may be provided by BSMEL and throughout this document; shall be known as pipes except specific reference is made to Bends and Anodes.
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
1.3
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
MANUFACTURER
-
Manufacturer of raw materials associated with the coating process.
SUPPLIER
-
The Party, which manufactures and/or supplies material, equipment and services to perform the duties as specified in the scope of supply.
ISO
-
International Organization for Standardization
TG
-
Glass Transition Temperature
API
-
American Petroleum Institute
DNV
-
Det Norske Veritas
PQT
-
Production-qualification Test
QP
-
Quality Plan / Procedure
ITP
-
Inspection and Test plan
SMS
-
ShawCor Manufacturing System
ACID WASH
-
A method by which contaminants are removed from the pipe surface by washing the pipe with Oakite or Company approved equivalent phosphoric acid shall be used.
RO water
-
Reverse Osmosis water
pH
-
The negative log to the base 10 of the hydrogen ion concentration. i.e being either acidic or alkaline in nature.
PRE-HEATING
-
Applying heat to the pipe before a necessary process step, when increased pipe temperature will serve a useful purpose.
HOLIDAY
-
A coating defect penetrating through the coating, to the steel pipe surface of such as dimensions that it is detectable using a high voltage search electrode
UNIT OF PRODUCTION
-
A unit of production is a set of pipes coated in one production run on the same coating line, using the same coating technique, having the same nominal pipe diameter and wall thickness and coated with the same coating products. Breaks in production caused by equipment or plant breakdown, factory shut down or any break in production exceeding three days shall be the end of a production run. Subsequent start-up constitutes a new unit of production
Rz
-
Surface roughness value
REVISION STATUS
-
Clause revision shall be identified by the symbol the margin column of the document
COATING SYSTEM DESCRIPTION
in
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
The coating system described in this document shall be manufactured using FBE, Adhesive and Polypropylene as the coating material, using suitable surface preparation and application techniques to obtain the coating properties required for its intended installation and operating conditions. 1.4
APPROVED MATERIAL Approved coating raw material shall be used. The FBE , Adhesive and Polypropylene coating material shall be used as per clause 16 and Appendix – A of ADCO Doc. No. 30.99.37.0017.1 Rev.0.
1.5
PRE-INSPECTION MEETING Pre-inspection meeting shall be held with all r elevant parties prior to commencement of Pre-qualification test as clause 4.5 of ADCO Doc. No. 30.99.37.0017.1 Rev.0.
2.0
REFERENCES
The Customer Specification ADCO No. 30.99.37.0017.1 Rev.0 ADCO Doc. No.11.99.23.1604 Rev.1
ADCO Doc: Technical Specification for External Pipeline Coatings Material Specification for External Three Layer Polypropylene Coating for Line pipe
Shell DEP Standards DEP31.40.30.31
Technical specification or external polypropylene and polyethylene coating for line pipe
American Standards ASTM D792 ASTM D1505 technique ASTM D 3418 ASTM D3895 ASTM D4138 ASTM D4940 ASTM G 14 weight test) SSPC-AB2 SSPC-AB3 SSPC-SP1 SSPC-PA2 (1991) SSPC-SP10 SSPC Publication 91-12
Standard test methods for density and specific gravity (relative density) of plastics by displacement Standard test method for density of plastics by the density-gradient Standard test method for Transition Temperatures of polymers by differential scanning calorimetry Test method for oxidative-induction time of polyolefins by differential scanning calorimetry Standard practice for measurement of dry film thickness of protective coating systems by destructive, cross-sectioning means. Standard Test Method for Conductimetric Analysis of Water Soluble Ionic Contamination of Blasting Abrasives Standard test method for impact resistance of pipeline coatings (falling SSPC-AB1 Mineral and slag abrasives Cleanliness of recycled ferrous metallic abrasives Ferrous Metallic Abrasive Solvent Cleaning Measurement of dry paint thickness with magnetic gauges Near-white metal blast cleaning Coating & lining inspection manual (1991)
International Standard’s ISO 9001:2008 ISO 9004 ISO 306
Quality Management System – Requirements Quality Management Systems - Guidelines for Performance Improvement Plastics — Thermoplastic materials —Determination of Vicat softening temperature (VST)
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
ISO 527-2 ISO 527-3 ISO 1133 ISO 1183 ISO 1872-2 ISO 1873-2 ISO 2808 ISO 2811 ISO 3251 ISO 8501-1
ISO 8502-2
ISO 8502-3
ISO 8502-9
ISO 8503-1
ISO 8503-2
ISO 8503-3
ISO 8503-4
ISO 8503-5
ISO 11124
ISO 11126
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Plastics—Determination of tensile properties — Part 2: Test conditions for moulding and extrusion plastics Plastics—Determination of tensile properties — Part 3: Test conditions for films and sheets Plastics - Determination of the melt mass flow rate (MFR) and the melt volume flow rate (MVR) of thermoplastics Plastics— Methods for determining the density of non-cellular plastics Plastics— Polyethylene (PE) moulding and extrusion materials — Part 2: specimens and determination of properties Plastics— Polypropylene (PP) moulding and extrusion materials — Part 2: Preparation of test specimens and determination of properties Paints and Varnishes - Determination of film thickness Paint and varnishes — Determination of density Paints, varnishes and plastics — Determination of non-volatile matter content Preparation of steel substrates before application of paints and related products - visual assessment of surface cleanliness - Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings Preparation of steel substrates before application of paints & related products - tests for assessment of surface cleanliness – Part 2: Laboratory determination of chloride on cleaned surfaces 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 (pressuresensitive tape method) Preparation of steel substrates before application of paints and related products — Tests for the assessment of surface cleanliness — P art 9: Field method for the conductometric determination of water-soluble salts Preparation of steel substrates before application of paints and related products - surface roughness characteristics of blast cleaned steel substrates. Part 1: Specifications and definitions for IS O surface profile comparators for the assessment of abrasive blast cleaned surfaces Preparation of steel substrates before application of paints and related products - surface roughness characteristics of blast cleaned steel substrates. Part 2: Method for the grading of surface profile of abrasive blast-cleaned steel - comparator procedure Preparation of steel substrates before application of paints and related products - surface roughness characteristics of blast cleaned steel substrates. Part 3: Methods for the calibration of I SO surface profile comparators and for the determination of surface profile - focusing microscope procedure Preparation of steel substrates before application of paints and related products – surface roughness characteristics of blast cleaned steel substrates. Part 4: Methods for the calibration of I SO surface profile comparators and for the determination of surface profile - st ylus instrument Procedure Preparation of steel substrates before application of paints and related products— Surface roughness characteristics of blast-cleaned steel substrates — Part 5: Replica tape method for the determination of the surface profile Preparation of steel substrates before application of paints and related products—Specifications for metallic blast-cleaning abrasives Preparation of steel substrates before application of paints and related products —Specifications for non-metallic blast-cleaning abrasives
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
ISO 11127-6
ISO 15512 ISO 21809-1
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Preparation of steel substrates before application of paints and related products — Test methods for non–metallic blast cleaning abrasives — Part 6: Determination of water-soluble contaminant by conductivity measurement Plastics— Determination of water content Petroleum and natural gas industries – external coatings for buried or submerged pipelines used in pipeline transportation systems –Part 1: Polyolefin coatings (3-layer PE and 3-layerPP)
Canadian Standards Associations: CAN/CSA Z245.20
External Fusion Bonded Epoxy Coating for Steel Pipe.
DEUTSCHES INSTITUT FUR NORMUNG (DIN): DIN 30678 (1992) DIN 53455
Polypropylene coatings for steel pipes Standard for Tensile Test - Elongation
Bredero’s Global Product Specification & Regional Product Specification GPS 3LPP Regional Product Specification BSMEL AD QP 07-2 BSMEL ITP 07-2 Material Data Sheet
Global Product Specification, proprietary to CR&D or Divisional Quality Bredero Shaw Bredero’s Regional Product Specification for 3LPP coating Repair Procedure for 3 Layer Polypropylene (3LPP) Addendum to BSMEL QP 07-2 Inspection Test Plan for 3 LPP Coating Akzo Nobel - Resicoat® R-556 Material Data Sheet & Other approved material.
3.0
RESPONSIBILITIES
3.1
Plant Manager is responsible for ensuring that production activities are carried out on time to the required specification, at the required level of quality and for ensuring that all relevant Managers / Dept. heads are implemented 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 related materials are available for the successful and timely completion of the project. The Project Manager shall also communicate to Customer; act as BSMEL interface with the Customer throughout the duration of the Project.
3.3
The QA/QC Manager shall supervise and undertake technical responsibility, develop recommend and implement Quality Plans to ensure that manufactured products are of acceptable quality and produced in accordance with specifications and company quality standards. Shall develop initial plan and preparation of QP & ITP of the PQT, the same shall be submitted for review and approval. In addition the QA/QC Manager has 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 and when required. He supervises and undertakes technical responsibility, develop recommend and implement the Quality department to ensure that manufactured products are process as per the specifications and company quality standards.
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
3.5
The Production 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 product meets the requirements specified herein.
3.6
HSE Manager shall be responsible to ensure that all workers are versed in safety procedures and all equipment is visually checked, colour coding is used for hooks and slings, workers are provided with all required PPE.
3.7
SMS Coordinator shall make sure the Standard Operating Procedure (SOP), Process Failure Mode Evaluation Analysis report (PFMEA), Control Plan (CP) prior to start of the PQT. The set parameters shall be recorded and kept for further reference.
3.8
QA/QC Supervisor is responsible for organizing the QC Inspectors and coordinating their activities in conjunction with production and contract requirements. Ensure t hat the QC Inspectors inspect and control the quality of the product in accordance with this document. Also perform inspection equipment calibration on a Daily basis at the QP/ITP Requirement. Carry out necessary liaison between the Production/Quality Control Department and Customers site representative.
3.9
Project Engineer shall ensure that all services and coating related materials are available for the successful and timely completion of the project. The Project Engineer shall also act as BSMEL interface (in the absence of the Project Manager) with the material manufacturer throughout the duration of the PQT project.
3.10
QC Supervisor shall be responsible for all inspections and documentation required to ensure each pipe processed complies with specified contract/purchase order requirements. In addition, he shall train QC Inspectors to be responsible for inspection, documentation and marking required ensuring full traceability of each pipe.
3.11
Tally Coordinator shall be responsible for all matters relating to the arrangements of bare pipes, efficient identification and data input of pipes received, coated and loaded out. The tally coordinator shall also be responsible for tracking data related to production and quality control for records and invoicing purpose of pipes, and other related products applicable. The tally coordinator will also take the responsibility of tracking the entire process data reports and shall ensure that the same are filed and documented in a proper manner.
3.12
Laboratory Supervisor shall ensure all laboratory tests are performed in accordance with BSMEL procedures and customer specifications. Ensure incoming raw materials meet specification. Test daily production samples to ensure quality according to BSMEL and relevant standards as per the PQT document.
3.13
Field Supervisor shall be responsible for the correct storage and handling of all pipes and the execution of pipe movement from load in receipt, within the yard, and for dispatch. He shall also be responsible for the maintenance and upkeep of the storage areas.
4.0
COATING SYSTEM REQUIREMENTS
4.1
Manufacturer’s blasting and coating material data sheets shall be submitted to the customer prior to Prequalification testing. Pre-qualification testing will not commence until the proposed coating materials are approved by the customer. Each new batch of material certificate shall be submitted to Customer’s representative prior to release the material for Production. The materials used will be as; FBE powderAkzo Nobel - Resicoat® R-556 or ADCO approved FBE Coating Material or other ADCO approved FBE material., Copolymer adhesive - Borealis BB 127E, Polypropylene - Borealis BB108E-1199 granules. The material each batch of FBE Primer, Adhesive and PP Materials’ certificate of analysis shall be DIN EN 10204-3.1/ISO 10474 3.1B.
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
4.2
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
PRE-QUALIFICATION TRIAL (PQT) Prequalification test shall be carried out as per Table 8, 9 and 10 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. The test criteria, frequency and requirements are mentioned BSMEL ITP 07-2. After completion of all PQT tests the production will be commenced.
4.3
INCOMING RACKS – PIPE RECEIPT Pipes have been previously accepted by the load-in inspector in accordance with BSMEL QP 01 Procedure for Receipt and Dispatch shall be transported from the storage area by means of a front-end loader or by flat bed truck or pole trailer unit, and off loaded by front-end loader onto the incoming racks. All pipes shall be visually inspected 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 shall be identified, cleaned, or removed as per SSPC SP 1, from the racks when necessary. All the lifting equipments are certified by third party and detailed risk assessment and job procedure for all pipe handling activities are in place. The Pre-inspection pipe numbers are recorded QF 001 Pipe incoming Pre-inspection report (Appendix 1). 4.3.1 Hot water preheat The pipes shall be transferred to the hot water preheat station where dirt deposits and soluble surface salts shall be removed prior to blasting. The final preheat temperature of the pipe is controlled by the water temperature and duration of hot water immersion. After completion of washing, the pipe shall be kept in one end up and blow off the water. The process shall be such as to ensure steel temperature shall be simultaneously higher than 5°C of ambient temperature and more than 3°C above dew point. Process shall be stopped if relative humidity > 85%, for t he remainder of surface preparation stages. 4.3.2 End Plugs End plugs (sponge) shall be placed inside both ends of the pipe after hot water bath to prevent the ingress of abrasive material during the blast cleaning process. These shall be removed immediately after blasting, at which time any dust or abrasive accumulating inside the bore of the pipe shall be removed by clean dry compressed air.
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 such as oil or grease. Self-inspecting operatives shall ensure that the contaminants/propriety solvent is completely removed prior to abrasive blasting.
4.4.2 In the event of inclement weather, the preheat system shall be used to ensure that the minimum pipe steel temperature shall be simultaneously higher than 5°C of ambient temperature and more than 3°C above dew point. Pre-heat if required; relative humidity > 85% the coating shall be stopped. The temperature shall be monitored by use of a calibrated infra-red Temperature gauge or touch type Pyrometer. 4.4.3 Abrasive shall be such that the specified degree of cleanliness and a clean angular surface profile are achieved. The abrasive material shall not contain more than 100-ppm sulfates and 100-ppm chlorides. Surface chlorides shall be measure by use of an Elcometer 130 SCM 400 salt meter; Surface residual 2. chlorides shall be < 20 mg/m The Conductivity of blast material shall be < 50µS/cm. BSMEL shall submit material Manufacturers’ certificate of conformance and /or independent laboratory certificate 4.4.4 Blast Cleaning
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Rotating pipe shall be conveyed into the centrifugal blaster(s) where it is blast cleaned using dry abrasive techniques. The blast media/abrasive is continually fed through the system. All fines and debris from the pipe surface and system shall be removed by the extraction system into the dust collector. The blaster shall be frequently topped up with small additions of fresh abrasive to maintain the desired surface profile and visual finish. 4.4.5 When the pipe has exited the blast cabinet, residual abrasive/dust shall be removed from the pipe surface by means of an air knife, wire brush or other suitable means. Using clean dry compressed air an operator shall blow out residue which has accumulated on the internal surface. 4.4.6 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 metal defects the operator shall rotate the pipe to blow out any abrasive material from inside the pipe with clean 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 a detrimental 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 have excessive metal defects, the inspector shall direct the pipe be dispatched from the incoming rack and the pipe shall be re-blasted or set aside for the customer’s evaluation. 4.5.4 When the pipe has been accepted it shall be transferred to the coupling installation station. 4.5.5 Operatives shall install a coupling into one end of the pipe, ensuring that it is clean and free of oils and lubricants.
4.6
PHOSPHORIC ACID AND WATER WASH TREATMENT 4.6.1 On exit from the abrasive blast inspection station, pipes are conveyed, in-line through the acid wash station 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 in the following table. Relative humidity (%) Max. Elapsed time (Hours) >85 0.5 80 1.0 70 1.5 60 1.75 50 2.0 < 85 % RH Process shall be stopped or pre-heated. Any pipe showing signs of flash rusting shall be re-blasted even if the above conditions have not been exceeded. 4.6.3 Pipes are conveyed through the acid wash station where they are treated with a phosphoric acid wash. Phosphoric acid is directed at the pipe surface and applied through spray tips ensuring full coverage. After the appropriate dwell time, the operator shall activate the fresh water pumps to rinse of the residual acid. The rinse water shall be high pressure at 500 to 1000 psi. 4.6.4 Air knives, which are used to dry the pipe prior to heating, are situated immediately after the water rinse booth and both the angle of the air knives and air pressure shall be adjusted so that the maximum drying effect is achieved.
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
4.7
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
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 the application temperature recommended by the manufacturer. The temperature of pipe shall not exceed o 275 C. 4.7.2 The first pipe on the conveyor line shall be used to establish the surface temperature of the pipe for coating application, which shall be in accordance with the manufacturer’s recommendations. 4.7.3 The surface temperature of the first pipe shall be determined by the plant operator or designee using calibrated surface Pyrometer. The results shall be recorded manually every 30 minutes. The temperature shall be confirmed by using tempilstick every hour. The pre-heating temperature shall be between as mentioned in the BSMEL ITP 07-2. 4.7.4 The operator shall continue to monitor the surface temperature throughout the coating process. The application temperature shall be as per material Manufacture recommendation. 4.7.5 The operator shall ensure the line travel speed of the pipe is in accordance with parameters as determined by pipe size and required coating thickness.
4.8
POWDER APPLICATION AND RECLAIM SYSTEM 4.8.1 Powder room operatives will check the manufacturing date of each box of powder, and ensure the batch or lot number has been approved by the laboratory before introducing the powder into the system. 4.8.2 Virgin powder (Resicoat R-556.) will be transferred through a screening system into the application system fluidizing bed. Powder is then transferred through a set of magnets to remove any foreign particles, to the application guns, which are electro statically charged to facilitate the application of the powder. As the heated pipe enters the spraying booth, application guns will be activated and electro statically charged FBE powder will be sprayed evenly over the rotating pipe surface to the required thickness, the coated surface shall be smooth and even finish. The operator shall feed FBE powder to application system and powder application shall be carried as per the requirement. The application temperature shall be in accordance with the Powder Manufacture’s recommendations. 4.8.3 Over spray powder is continually extracted into a reclaim system, transferred through a cyclone/dust collector and a screening system. Screened powder is then transferred into a portioning hopper and reclaimed material separately applied. The usage of reclaim material; 10% reclaim coating material shall be used in coating process.
4.9
ADHESIVE (INTERMEDIATE COAT) APPLICATION 4.9.1 When adhesive material (Borealis BB 127E) to be used is supplied in powder form this shall be applied by spray method using a fluidizing bed and powder guns. Copolymer adhesive shall be spray applied evenly over the rotating pipe surface. 4.9.2 Application of adhesive will be timed to occur before the FBE powder has cured so that maximum adhesion is achieved between powder and subsequent intermediate coat. Application temperature mentioned on clause in 4.7.3 4.9.3 Intermediate coat thickness will be confirmed on the first partially coated pipe. Thickness of FBE and Adhesive mentioned on clause 5.3.4
4.10
POLYPROPYLENE (TOP-COAT) APPLICATION
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
4.10.1 Virgin Polypropylene (Borealis BB108E-1199 granules) extruded sheet is spirally wound in multiple layers so that a homogeneous layer of Polypropylene is formed. To eliminate air entrapment between layers of Polypropylene a soft pliable pressure roller is applied to the coating in conjunction with the Polypropylene application. The temperature of the PP extruded material shall be continuously monitored and recorded every 30 minutes. Thickness of total coating system shall be as per clause 5.3.4. 4.10.2 Throughout the course of production the operator shall continuously monitor the extruder operation to ensure consistency of coating quality. The extrusion material temperature shall be recorded every 1 hour. 4.10.3 An even coating will be produced that is f ree of bubbles, tears and voids. In the event that that a coating is produced which is not even and is not free of bubbles tears and voids, the operator shall cut through the coating with a sharp tool circumferentially. 4.11
QUENCH STATION On completion of the coating process, the coating shall be quenched with potable water for cooling and the method of quenching shall be such that the coating will not sustain mechanical damage as the pipe travels along the conveyor. Potable water may be injected into the internal surface of the pipe to assist pipe cooling. The coating shall be cooled to below 70 Degree C.
4.12
CUTBACK BRUSHING
4.12.1 Cut back of the three-layer Polypropylene coating shall be performed using power wire brush Machines to provide a cut back. The cut back shall be 150mm ± 20mm from the bevel ends. Cut back bevel angle shall be maximum 30 °, FBE toe shall be protruded minimum 2-5 mm from the cut back area. The requirement shall be as per clause 8.3 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. 4.12.2 In the event that all the Polypropylene has not been removed by the end cut back cleaning machines the pipe shall be transferred (on completion of holiday testing and thickness check) to another inspection rack where the end cut back area will be heated by the use of blow torch/s on the internal surface/ heating coil and the softened Pol ypropylene shall be removed by use of scrapers/ or manually grind off the PP Coating until required cut back obtained. The additional cleaning occurred, when the residue of PP material observed on the cut back area and end of the coating. The operator shall make sure the heating process does not damage t he parent coating. 4.12.3 Residual FBE remaining on the surface profile after wire brush cleaning is acceptable. 50mm from the pipe bevel shall have no residual FBE in the surface profile to facilitate field welding. 4.13
COOLING AND INSPECTION RACKS Coated pipe is rolled and set on cooling racks. Electrical test (holiday detection) will be carried out at a travel speed of approximately 30cm/second. All detected holidays shall be clearly marked by use of a wax type/permanent marker and ensure the marks are approximately 50mm away from the defect. Visual inspection and coating thickness checks shall also be performed. The travel speed of the Holiday detector is electrically controlled to maintain constant speed throughout the holiday process.
4.14
REPAIR PROCEDURE
4.14.1 Repairs shall be traceable using the following methods. The defect area shall not exceed 10 cm2 and the total number of defects being repaired shall not exceed one defect per meter length of pipe unless otherwise specified. If the size or number of defects exceeds these limits the affected pipe shall be stripped and recoated as per clause 10 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. Note: Coating damage caused by quality control testing is permitted if area does not exceed 10 cm². Borouge Sinter Powder.
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
•
•
•
• • •
•
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
The damage/repair area shall be ground or filed to smooth, loose coating shall be removed. The dust or residue coating material shall be cleaned. The repair area shall be heated using a hot air gun/gas torch or required device until the Polypropylene coating is softened. Fill the area with Polypropylene Borealis or Sinter Powder and continuously apply the heat on the area to soften repair material and parent coating using an electrical heater/gas tourch. Smooth the repair after filling the damaged area and remove excess material with a scraper. The test voltage shall be 10 kV for each 1 mm of coating thickness with a maximum of 25 kV. DFT check of the repaired area shall be performed to ensure the thickness complies with the customer’s specification. The inspector shall visually inspect the repair to ensure the repair is smooth and even.
4.14.2 If the repairs are carried out immediately on completion of holiday detection the repairs shall be recorded on report form QF 07-3(Appendix1). It the repairs are carried out at a location away from the holiday detection station, repairs shall be recorded on form QF 07-9 (Appendix1). 4.15
CALIBRATION
4.15.1 The QC Inspector or designee at the twice (AM/PM) per shift during production shall calibrate all dry film thickness gauges used by the inspector in accordance with SSPC, The Society for Protective Coatings Paint Application Standard No. 2. The result shall be recorded on form QF 500-1 (Appendix1). 4.15.2 The QC Inspector shall calibrate the holiday detector twice (AM/PM) per shift by use of a calibrated voltmeter. The test voltage shall be 10 kV for each 1 mm of coating thickness with a maximum of 25 kV. The result shall be recorded on form QF 500-1 4.15.3 The QC Inspector shall calibrate the micrometer used to check the surface profile once per shift, by use of a calibrated thickness shim at the mid range of the surface profile range. The result shall be recorded on form QF 500-1. 4.15.4 The QC Inspector shall calibrate the Digital Contact Thermometer once in a week with the master Thermometer or boiling water. The result shall be recorded on form QF 500-1. 4.16
MARKINGS
4.16.1 After completion of PP coating the Pipe Number, length shall be confirmed on the internal surface of the pipe. All such markings shall be within 2 meter of the pipe end. The pipe number shall be traced through Tally track system. After completion of coating, the pipe tracking records shall be passed to the customer along with entire process documents. Any disputed pipe shall be on hold until clear the proper identification of same. 4.17
STORAGE AND HANDLING
4.17.1 The storage and handling of coated pipe shall be performed as per BSMEL QP 01 Procedure. The finished coated pipe shall then be transported by crane and truck and/ or by forklift with padded types to a designated area for storage, and stacked on Polypropylene covered sand berms, which shall be a minimum of 150mm high from the ground to prevent surface water entering during the storage period. 4.17.2 All other storage, handling, and load out requirement shall be as per BSMEL Quality Plan QP-01. 4.17.3 The number of tiers in the pipe stack shall be limited to a safe working height of 4 meters.
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
4.18
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
STRIPPING OF REJECT PIPE
4.18.1 Prior to stripping the QC inspector shall ensure the pipe has been rejected and shall mark the pipe number on the internal surface of the pipe. The 3LPP coated pipe shall be subject to heating using LPG gas or diesel or similar method which shall be safe and appropriate to use. The heating shall be done through internal surface using blow torch, the pipe and hose used for same shall be approximately half inch. The 3LPP coated pipe shall be heated to 170°C-210°C and make sure the coating is soft enough to scrape of the coating. Once the require temperature obtained the Polypropylene Coating shall be stripped off. Once the entire top coat is stripped-off the pipe shall be subject to Blast station to blast off the remaining FBE coating. After completion of blast cleaning, coating residues may observe on the side of weld seam or any isolated area shall be grind off using abrasive paper grinder. These pipes shall be re-blasted to achieve required cleanliness.
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 of production and thereafter every four hours. The inspector shall ensure the steel surface temperature is remains 3°C above the dew point during, and after abrasive blast cleaning. The ambient temperature shall be greater than 5°C and the relative humidity shall be < 85% unless the pipe is pre-heated. The coating process shall be stopped if relative humidity is greater than 85%. The result shall be recorded on form QF 07-2B (Appendix1). 5.1.2 The QC Supervisor or designee shall perform a contamination test in accordance with ASTM D4940 once per shift on the re-circulated abrasive used in the blast cleaning machines Result shall be recorded on form QF 07-1 (Appendix 1). 5.1.3 In event that the material is contaminated the material shall be removed form the closed blast system and replaced. The inspector shall check the surface of first 3 pipes and after every hour which comes first in accordance with ISO 8502-3 for dust contamination at one location on the pipe. The dust level on the blast cleaned pipe shall be < class 2 in accordance with ISO 8502-3. The test shall be carried as per clause 8.1.2/8.1.3 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. The inspector shall record the result on report form QF 07-1. The Inspector shall attach the clear tape test strips to form QF 07-7 (Appendix 1) 5.1.4 Twice per shift the QC Supervisor or designee shall test the compressed air supply for the presence of oil or water in accordance with ASTM D 4285-83. In the event that oil or water is detected the inspector shall inform the plant Supervisor who shall stop the operation and ensure remedial action is taken. Result shall be recorded on form QF 021 (Appendix1). 5.1.5 The inspector shall ensure the degree of surface cleanliness is a near white metal finish equal to Sa2½ as per ISO 8501-1/SIS SS 05 59 00 (1988) SA 2½ or SSPC-SP10/NACE No.2. as per clause 8.1.2 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. 5.1.6 The inspector shall use Digital Profile Gauge shall be used by the inspector on the first five pipes thereafter every 2 hours/50 pipes whichever comes first to determine the surface profile (anchor pattern) of the blast cleaned surface in accordance with Digital Profile Gauge as per ISO 8503-4 or ASTM D4415, Method C. Surface profile shall be 50-100 micrometers. The surface profile/roughness results shall be recorded on form QF 07-2b. The test shall be carried as per clause 8.1.2 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. 5.1.7 In the event that a pipe has not achieved the specified degree of surface cleaning and /or profile, the inspector shall direct that the pipe be dispatched from the inspection / grinding station and returned to the incoming rack for evaluation and /or re-blasting.
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
5.1.8 On completion of abrasive cleaning the surface shall be inspected for metal defects. The repair of any defects which can be repaired by filing or grinding, and for restoring the anchor pattern at the location of such defect or repair size greater than 10cm2 per meter of the pipe length or 0.5% of the pipe surface area shall be re-blasted as per clause 8.1.2 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. 5.1.9 Pipe with serious defects such as laminations, excessive slivers etc. shall be set aside for the customer’s evaluation. If subsequent grinding is performed, as per Customer requirement or as per Specification for ISO 3183-3 seamless line pipe for critical service. In case any pipe does not satisfy the above requirement, a non-conformance report, RF 002 (Appendix1) shall be raised and submitted to the customer’s representative. 5.1.10 Pipe shall be tested one of 100 pipes and immediately pipes and following each change of Blastcleaning material. For the presence of residual chlorides by use of an Elcometer 130 SCM 400 salt 2 meter and/or bresel test method; Surface residual chlorides shall be < 20 mg/m . The requirement shall be as per clause 8.1.4 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. Result shall be recorded on form QF 07-1. In the event of a failure the pipe shall be retested; if the test fails all pipes that were blast cleaned after the 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 coated before the failed test shall be acceptable. If the contamination of the surface occurs, the quality of the blast cleaning material and process shall be examined. Result shall be recorded on form QF07-1. Once per shift, the bare pipe shall be tested for residual chlorides by using Elcometer SCM 400 salt meter. The test shall be used for information purpose only. The result shall be recorded on QF 01-3 (Appendix I) 5.1.11 Conductivity of the blasting media shall be checked once per shift for conformance, also if the contamination of the surface occurs. If the conductivity of the blasting material is greater than 50µS/cm, the blasting materials shall be replaced. The conductivity test shall be carried out in laboratory and result shall be recorded on QF 01-3 (Appendix 1). 5.2
PHOSPHORIC ACID TREATMENT AND WATER RINSE 5.2.1 The acid mixture shall have a pH of ≤ 2. The pH level shall be checked with pH indicating paper. The pH of the residual acid shall be checked on the first three pipes coated and every one hour thereafter. Phosphoric acid contact time shall be > 20 seconds at a pipe temperature of 43°C to 65°C. For every degree centigrade below 43°C the acid contact time shall be increased by one (1) second. Result shall be recorded on form QF 023. The Acid pH shall be tested once per day in laboratory and result shall be recorded on QF 01-3(Appendix 1). 5.2.2 The pH of the high-pressure potable rinse water shall be > 6. The pH level shall be checked with pH indicating paper. The pH of the residual rinse water shall be checked on the first three pipes coated and every hour thereafter. The water must be potable with less than 200 ppm total dissolved solids and 50 ppm chlorides. The water pH shall be tested once per day in laboratory and result shall be recorded on QF 01-3(Appendix 1).Result shall be recorded on form QF 023.
5.3 FINAL INSPECTION 5.3.1
Prior to the start of inspection, the inspector shall ensure the pipe temperature < 70°C, the holiday detector being used is in accordance with the relevant specification and that the electrode covers 100% of the pipe surface.
5.3.2 The Q.A/Q.C Supervisor or designee shall ensure that all dry film thickness gauges to be used by the inspector during the shift are in accordance with the rel evant specification. 5.3.3 Type 2 dry film thickness gauges (electronic) will be used as defined by ISO 2808 the QC Supervisor or designee shall carry out the calibration of the gauges.
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
5.3.4
The thickness of FBE and Adhesive shall be measured at least daily at every production start and further more at each interruption (any interruption/break down more than two hours,) of the production process. The results shall be recorded on form QF 07-3. FBE thickness & adhesive thickness shall be as mentioned in BSMEL ITP 07-2.
5.3.5
A coating sample for DSC analysis shall be taken from the FBE primer layer, the test frequency shall 0 be as per BSMEL ITP 07-2. The DSC analysis shall be in the range of - 2°C to +3 C; the analysis shall be performed in accordance with CAN CSA Z 245 20 Standard. Result shall be recorded on form QF 024 (Appendix 1). The requirement shall be as per clause 14.9 of ADCO Doc. No. 30.99.37.0017.1 Rev.0.
5.3.6
The inspector shall check the FBE adhesion on the starter pipe in production. Test Procedure: With a sharp knife, two incisions (approximately 13mm long) shall be made in the form of an X through to the metal substrate. At the intersection of the X an attempt shall be made to force the coating from the steel substrate with the knife point. Refusal of the coating to disbond from the substrate shall be recorded as a pass. A pass shall also be recorded where the coating fails cohesively. Result shall be recorded on form QF 07-3.
5.3.7
The inspector shall measure the cut-back distance of the 3-layer coating to ensure that the end cutback is in accordance with customer specification, the requirement shall be mentioned in BSMEL BSMEL ITP 07-2 and a bevel angle of up to maximum 30º, result shall be recorded on form QF 07-3. The FBE toe shall be protruded as per BSMEL ITP 07-2. The requirement shall be as per clause 8.3 of ADCO Doc. No. 30.99.37.0017.1 Rev.0.
5.3.8
When the pipe is positioned on the final inspection bench, the inspector shall visually inspect to ensure that the coating is uniform, free of voids, blisters, and mechanical damages. The Cosmetic water marks on the PP surface are acceptable. The inspector shall ensure minimum thickness requirement are met as mentioned in Clause 5.4.11 of QP-07-2.
5.3.9
In the event that the cut back is not in accordance with the relevant specification or the coating is not uniform, and has coating defects, the inspector shall direct that the pipe be placed on hold in a quarantine area for evaluation or rework and inform the production supervisor.
5.3.10 The inspector shall record the result of the visual inspection on report form QF 07-3. In the event that the pipe is rejected, the reason for the rejections shall be noted in the comment column of the report form. 5.3.11 The inspector shall measure the thickness of the coating (all pipes) in accordance with ISO 2808, method 6A at three (3) locations, equally spaced along the length of the pipe. At each location the coating thickness shall be measured at four (4) positions equally spaced around the circumference of the pipe. Thickness requirement shall be as per clause 14.1 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. The minimum total coating thickness shall be as mentioned in BSMEL ITP 07-2. The results shall be recorded by the inspector on form QF 07-3. 5.3.12
The inspector shall ensure that the holiday detection is carried out at a speed of approximately 30 cm/sec with a spring electrode and/or conductive rubber electrode. If any holiday/repair observed shall be marked using proper marking pen.
5.3.13 The holiday detection requirement shall be as per clause 14.2 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. The test criteria and requirement shall be as per BSMEL IT P 07-2. The total number of defects being repaired shall not exceed one defect per meter length of pipe unless otherwise specified. If the size or number of defects exceeds these limits the affected pipe shall be stripped and recoated as per clause 10 of ADCO Doc. No. 30.99.37.0017.1 Rev.0.
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
5.3.14 Results of the holiday detection process shall be recorded on form QF 07-3, and in the event that the recorded results are not in accordance with the specified requirements, the inspector shall direct that the coated pipe be placed on hold for repairs and/or rejected. 5.3.15 Peel test criteria and requirement as per BSMEL ITP 07-2. The adhesion of the three layer coating shall be determined on the cut back area of the pipe using apparatus mentioned as per clause 14.3 & Table 8 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. The Peel test adhesion of the coating system shall be carried out at ambient temperature as well as at high test temperature. Prior to high Temperature Peel Test, test pipe shall be cut and conditioned for one hour. The Peel test machine method shall be used for tests, in this test method it does not require to cut the pipe for 1 hour conditioning prior to carrying out the test.The result shall be recorded on report form QF07-5 (Appendix 1). 5.3.16 A Cathodic Disbondment test shall be performed as per BSMEL ITP 07-2, in accordance with clause 14.8 & Table 9 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. The test criteria and requirement as per BSMEL ITP 07-2. The result shall be recorded on report form QF 07-6 (Appendix 1) Note: the pipe requires to be cut to perform the test (One Sample). 5.3.17 Impact test shall be performed as per BSMEL ITP 07-2. The impact test shall be performed using a falling weight described in DIN 30678. The falling weight shall have a smooth hemispherical head with a diameter of 25 mm. The impacts shall not be on welds, coating overlaps or within 1.5 DN or 300mm, whichever is smaller from the edge of the coating. No failure of the pipe shall be found during the holiday detection of the impact points. The impact resistance test criteria and requirement as per BSMEL ITP 07-2. Result shall be recorded on form QF 07-4. 5.3.18
Indentation test shall be performed as per BSMEL ITP 07-2. The test shall be performed in accordance with DIN 30678. Indentation resistance shall be tested at room temperature and at a temperature related to the maximum operating temperature. The test criteria and requirement as per BSMEL ITP 07-2.. The requirement shall be as per clause 14.5 & Table 8 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. Result shall be recorded on form QF 07-6 Test Report f rom.
5.3.19 Elongation at break shall be carried in accordance with DIN 30678 and DIN 53455. Elongation at break shall be tested at ambient temperature and the result shall be greater than 400%. The requirement shall be as per clause Table 8 of A DCO Doc. No. 30.99.37.0017.1 Rev.0. 5.3.20 Flexibility test: The test shall be carried out as per BSMEL ITP 07-2. Coated pipe sample coupon shall be prepared (200 x 25mm) subject to bend test at a temperature as per ITP. The coating shall not exhibit any signs of cracking, disbondment or pinholes. The Coated sample shall be cut in longitudinal direction of pipe. The test requirement shall be as per Clause 14.10 & Table 8 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. The test sample shall be 300 mm x 50mm. 5.3.21 Delamination Resistance test shall be performed as per BSMEL ITP 07-2. A coated sample 150 x 100mm shall be, immersed in potable water at 95 +/-3°C. For qualification the samples shall be examined after 48 hours. Using a sharp and pointed knife, Press the blade into the interface and rotate it on the longitudinal axis to lift off any of the loose coating. If any loss of adhesion is found, remove the non-adherent coating system with a sharp knife to expose the substrate under the disbonded coating, the maximum and average of adhesion loss shall be measured. The test criteria and requirement shall be as per BSMEL ITP 07-2. The test shall be carried out as per Clause 14.11 & Table 8 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. 2
5.3.22 The defect area shall not exceed 10 cm and the total number of defects being repaired shall not exceed one defect per meter length of pipe unless otherwise specified. If the size or number of defects exceeds these limits the affected pipe shall be stripped and recoated. The inspector shall ensure that repairs carried out by repair personnel are in accordance with Clause 4.15.
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
5.3.23 In such occasions that a pipe has been rejected, the inspector shall ensure that the rejected pipe is marked “R” on the external coated surface, hazard tape attached to the pipe, removed to a quarantine area and is not stacked with accepted pipes. 5.3.24 The Polypropylene manufacturer shall provide independent laboratory test results for “Thermal Ageing” as per clause 14.7 and ”Ageing under exposure to light” as per clause 14.6 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. The test results shall be in accordance with DIN 30678. 5.3.25 Extrusion process of PP degradation test shall be carried between raw PP and extruded/coated PP material. The test criteria and requirement shall be as per BSMEL ITP 07-2.. The test shall be carried out as per ISO 1133 as described in Table 8 of 30.99.37.0017.1.Rev.0 5.3.26 In the event of a test failure, BSMEL shall propose and agree with the customer a test programme to identify suspect pipe. Further testing shall involve inspection and testing similar to the original failed test. 5.3.27 After completion of all the production tests, Inspection release notes shall be submitted to BSMEL from Customer Representative, when all QC Documents are approved. Partial release shall be issued for load-out of coated pipes. The final documentation shall be submitted to customer by BSMEL once entire documentations are completed. 6.0
HANDLING, TRANSPORTATION & STORAGE
6.1
MATERIAL The Handling, Storage and Transport of bare and coated pipe shall be as per clause 10 of ADCO Doc. No. 11.99.12.1615. The Material used for production coating shall be checked upon receiving. Packaging secure, marking containing batch number and expiry date shall be legible. Coating material shall be stored in a dry room, protected from UV light, as manufacturer recommendation. Shelf life of material shall be controlled; the first in first out order shall be applied. Any deterioration in material shall be rejected. 6.1.1 The FBE, Adhesive and Polypropylene material properties’ Certificate of Analysis shall be in reference to Inspection certified test results.
6.2
HANDLING After coating, pipes shall be rolled on bearing racks for inspection/repair. Pipe shall be transferred from outgoing racks to trucks by means of crane with padded or aluminum hooks or loader fitted with suitable padding.
6.3
TRANSPORTATION Flat bed trucks or pole trailers with suitably padded supports to prevent damage to the coating shall transport coated pipes. Front-end fork loaders may also be used providing the lifting cradle is lined with soft rubber or foam.
6.4
STORAGE Coated pipe shall be stored with bevel protectors supplied by the manufacturer, on sand berms comprising of two baulks of sand, 50 cm high with a bearing surface 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 sand. All pipes shall be stored in stacks segregating the pipe by source, grade, diameter, and wall thickness, coating type. Pipes shall be positioned clear of the ground. Pipe interiors shall be kept clean and free from mud splashing or dirt deposits during storage. Pipe will be stacked with due consideration to impact effects.
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
7.0
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
LABORATORY QUALITY CONTROL TESTING ON INCOMING RAW MATERIALS Laboratory testing on incoming raw materials is controlled by BSMEL f orm TRNM –001 Test Requirement Notification Memorandum for Incoming Raw Materials. Each batch of FBE powder shall be t ested for as per Clause 6.5 of ADCO Doc. No. 30.99.37.0017.1 Rev.0. Rev.0 • • • •
Moisture content Gel Time Thermal analysis (DSC) Density
Each batch of adhesive material shall be tested for: Melt Flow Index • Each batch of Polypropylene material shall be tested for: Melt Flow Index • Raw materials shall be stored as per the manufacturer’s recommendations. Raw material batches or lots shall not be used until released by the laboratory and the manufacturer’s certificate of conformance is received. Each new batch of material certificate shall be submitted to Customer’s representative prior to release the material for Production. 8.0
DOCUMENTATION
QF 07-1 QF 07-2B QF 07-3 QF 07-4 QF 07-5 QF 07-6 QF 021 QF 023 QF 024 QF 500-1 QF 07-7 QF 07-9 QF 01-3 QF 001 RF 012 RF 002
Surface Preparation Report Environment & Profile Report PP/PE Final Inspection Report PP/PE Impact Test Report Adhesion Peel Test Report PP/PE Laboratory Test Report Compressed Air Blotter Test Report Phosphoric Acid Wash Report Differential Scanning Calorimetry Report Daily Instrument Calibration report Dust Cont. Retention form PP PE Repair Report Form General Report Form Pipe incoming Pre-inspection report Pipe cutting Register Nonconformance/ concession request report
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number
Three Layer Polypropylene Coating Procedure Customer
Project
ALSA Engineering & Construction Co. LLC.
EPC for Nitrogen Gas Injection (Pure Case)
Document No: Revision No: Revision Date:
QP 07-2 0 25th Nov13
PO Number