k2s-Ng01007551-Gen-ra7754-00004 Specification for Line Pipe Protective Coating Repair

EPC for Kolo Creek to Soku Gas Export Pipeline SPECIFICATION FOR LINE PIPE ROTECTIVE COATING REPAIR K2S-NG01007551- GEN-RA7754-00004

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CHANGE RECORD PAGE REV. N°

Status

Description of Revision

R01

INT

Issued For Internal Review

A01

IFR

Issued For Review

C01

AFC

Approved For Construction

This document is controlled electronically and is uncontrolled when printed


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CONTENTS LIST OF TABLES ........................... ........................... ........................... ........................... .......................... .. 4 1.0

PROJECT DESCRIPTION ............................................................................................................... 5

1.1 1.2 1.3

Objective Definitions Abbreviations

2.0

SPECIFICATIONS AND STANDARDS ............................................................................................ 7

2.1 2.2 2.3 2.4 2.5

General ........................... ........................... ........................... ........................... ................... 7 Order of Precedence ........................................................................................................................ 7 Project Documents ....................... ........................... ........................... ........................... ................... 7 Shell Standards ............................................................................................................................... 7 International Codes and Standards .................................................................................................. 8

3.0

FIELD INSPECTION OF COATING ................................. ........................... .......................... ......... 10

4.0

MATERIALS FOR COATING REPAIRS ........................... ........................... .......................... ......... 11

4.1 4.2

Repairs System for Polypropylene Coated Items ........................... ........................... ...................... 11 Repair System for Heat Shrinkable Sl eeves (HSS) Coated Items ......................... .......................... 11

5.0

COATING REPAIR PROCEDURE .......................... ........................... ........................... ................. 12

6.0

REPAIR ACTIVITIES ..................................................................................................................... 13

6.1 6.2

Surface Preparation ....................................................................................................................... 13 Material Application .......................... ........................... ........................... ........................... ............. 13

7.0

INSPECTION AND TESTS ............................................................................................................ 14

7.1 7.2 7.3

Visual Inspection .......................... ........................... ........................... ........................... ................. 14 Thickness Test ........................... ........................... ........................... ........................... ................. 14 Vacancy Detector Inspection .......................... ........................... ........................... .......................... 14

........................... ........................... ........................... ........................... ................... 5 ........................... ........................... ........................... ........................... ................... 6 ........................... ........................... ........................... ........................... ................... 6



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LIST OF TABLES

Table 1-1: Design Parameters for Pipelines ....................................................................................... Table 2-1: Project Documents .................................................................................................................. Table 2-2: Shell Standards ........................................................................................................................ Table 2-3: International Standards..........................................................................................................


5 7 7 9


1.0

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PROJECT DESCRIPTION The primary objective of the project is to sustain gas supplies to NLNG trains 1 to 6. The project was conceptualized on optimisation of SPDC s infrastructure usage by utilising spare capacity that will become available in Soku Gas Plant as from 2014. Non Associated Gas from Kolo Creek Deep (F1 and F2 reservoirs) shall be bulked in a manifold and evacuated through approx. 20 x 40km bulkline to Soku Gas Plant for processing and onward sales to NLNG trains 1 to 6. The Kolo Creek field is situated in the southern part of OML-28 in the seasonal flooding fresh-water swamp area, some 18km southeast of the Gbaran CPF and about 90km west of Port Harcourt. It is one of SPDC s Eastern Division fields considered as part of the Gbaran-Ubie nodal development to provide feed stock gas for the NLNG Trains 1 to 6. The Kolo Creek to Soku project optimizes SPDC s infrastructure usage in the short term and maximizes ullage for both the Soku and Gbaran areas. The EPC contract scope with NestOil PLC for this project is summarized as follows; 1.

Four (4) flowlines from the F2 wells to the new Kolo Creek (intermediate) production headers with the proper control, safeguarding, metering and monitoring requirements. 2. Three (3) flowlines from the F1 wells to the new Kolo Creek (intermediate) production headers with the proper control, safeguarding, metering and monitoring requirements. 3. Three (3) intermediate production headers combining the seven (7) F1 and F2 flowlines into three (3) intermediate bulklines. 4. Three (3) intermediate bulklines with HIPPS and the proper control, safeguarding, metering and monitoring requirements. 5. One (1) Kolo Creek manifold combining the three (3) intermediate bulklines into the 20inch, 40 km long bulkline to the Soku Gas Plant. 6. 20-inch, 40 km long carbon steel pipeline (including the pig launcher and receiver and proper control, safeguarding, metering and monitoring requirements) from Kolo Creek NAG manifold to the Soku Gas Plant designed for evacuation of 400 MMscf/d from Kolo Creek NAG manifold. This pipeline will traverse some communities in Niger Delta, Nigeria though the intention of the routing was to avoid it as much as possible. 7. Slug-catcher at the Soku Gas Plant and full integration with the existing Soku Gas Plant including definition of process control and safe guarding systems. 8. Utilities in Kolo Creek and Soku Gas Plant to ensure safe and cost effective evacuation of 400 MMscf/d from Kolo Creek to Soku. 9. Installation of hardwares for control of facilities at Kolo Creek from Soku control room 10. Installation of a Fibre Optics Cable (FOC) along the length of the pipeline ROW for the purpose of back-up communication for Kolo Creek Instrumentation Systems. 1.1

Objective This specification provides the minimum requirements to execute field repairs on the shopapplied external coating of pipes and fittings to be buried for the Kolo Creek to Soku Export Pipeline Project. Design life is 30 years for the pipelines and facilities. Pipeline

Kolo Creek to Soku Pipeline

Diameter (inch)

20

Length (km)

40

Material

Design Pressure (bar)

Max. Design Temp ( C)

150

90

ISO 3183 L450

Table 1-1: Design Parameters for Pipelines This document is controlled electronically and is uncontrolled when printed




1.2

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Definitions The following definitions shall be applied to the standard terms used throughout this document. Principal

Shell Petroleum Development Company of Nigeria Limited (SPDC)

Contractor

NestOil PLC, The Contractor is the party, which carries out all or part of the design. The Company may undertake all or part of the duties of the Contractor.

Manufacturer/Supplier

the party, which manufactures or supplies equipment and services to perform the duties specified by the Contractor.

Adhesive

an intermediate coating layer to improve adhesion between the primer and the coating (three layer system) or between the steel and the coating (two layer system).

Applicator

the party that applies the coating to the line pipe in its coating plant.

Holiday

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

Primer

an intermediate coating layer, applied directly onto the pre-treated steel surface to improve the adhesion of the final coating to the pipe surface. In two layer coating systems both the words primer and adhesive are sometimes used to name the same layer.

The word shall indicates a requirement. The word should indicates a recommendation. 1.3

Abbreviations 3-LPP API

Three-layer Polypropylene American Petroleum Institute

DEP

Design and Engineering Practice

DSS

Duplex Stainless Steel

HSS

Heat Shrinkable Sleeves

ISO

International Standards Organization

NAG

Non Associated gas

NLNG

Nigerian Liquefied Natural Gas

PE

Polyethylene

PP

Polypropylene

SPDC

Shell Petroleum Development Company of Nigeria Limited

SSPC

Steel Structures Painting Council



2.0

SPECIFICATIONS AND STANDARDS

2.1

General

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This section details the codes, standards, specifications and project contract standards applicable to this design philosophy. The regulations, codes and standards to be applied shall always be the latest revision. 2.2

Order of Precedence The order of precedence for the Regulations, Code and Standards shall be as follows; ·

Nigerian National Standards and Regulations

·

Project documents

·

SHELL Standards

·

International Codes and Standards

In the event of any conflict between these specifications, codes and standards the more stringent requirements shall take precedence and the latest edition of each code or standard shall be applied. 2.3

Project Documents Document Number

Title

K2S-NG01007551-GEN-LA5507-00001

Pipeline Design Basis

K2S-NG01007551-GEN-RA7754-00001

Specification for 3-Layer PP Extenal Coating of Carbon Steel and DSS Line Pipe

K2S-NG01007551-GEN-RA7754-00002

Specification for Extenal Coating of Carbon Steel and DSS Bends

K2S-NG01007551-GEN-RA7754-00003

Specification for Field Joint Coating

Table 2-1: Project Documents 2.4

Shell Standards DEP Number

Title

30.48.00.31

Coating for Onshore facilities

31.40.30.31

External Polyethylene and Polypropylene Coating for Line

31.40.30.32

External Fusion-Bonded Epoxy Power Coating for Line pipe

61.40.20.30

Welding of Pipelines and Related Facilities (Amendments/Supplements to ISO 13847:2000) Table 2-2: Shell Standards



2.5

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International Codes and Standards Standards

Title

API RP 5L1

Recommended practice for railroad transportation of line pipe

ASTM D3418

Standard guide for locating combustion test methods for polymeric materials

ISO ISO 527

Plastics

Determination of tensile properties

ISO 1133

Plastics - Determination of the melt mass flow rate (MFR) and the melt volume flow rate (MVR) of thermoplastics

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 and of steel substrates after overall removal of previous coatings

ISO 8502-2

Preparation of steel substrates before application of paints and related products - tests for the assessment of surface cleanliness - Part 2: Laboratory determination of chloride on cleaned surfaces

ISO 8502-3

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)

ISO 8503-1

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 ISO surface profile comparators for the assessment of abrasive blast cleaned surfaces

ISO 8503-2

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

ISO 8503-3

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 ISO surface profile comparators and for the determination of surface profile - f ocusing microscope procedure

ISO 8503-4

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 ISO surface profile comparators and for the determination of surface profile - stylus instrument procedure

ISO 8504-2

Preparation of steel substrates before application of Paints and related products surface preparation methods part2



ISO 21890-1: 2009

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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-layer PP)

SSPC SSPC-SP3

Power Tool Cleaning

SSPC-SP10

Near-white Metal Blast Cleaning

Table 2-3: International Standards



3.0

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FIELD INSPECTION OF COATING Before the commencement of construction activities and laying of the pipelines, coating repair procedures must be prepared, qualified and approved by Principal in accordance with DEP.31.40.30.31-Gen. Also, coating shall be carefully inspected to detect damages that can be caused by stacking, storage, shipping, transport and assembly operations. Coating Contractor shall repair all coating defects (vacancies) and damages. Each repair of coating damage shall be reported. Relevant report shall include: date, line pipe number, type of damage(classification), location of damage, dimension of damage, results of check, remarks etc.



4.0

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MATERIALS FOR COATING REPAIRS Coating used for field - repair of defects shall be of same original coating system and shall be supplied by the same coating Supplier. All materials used for pipeline coating and wrapping repairs shall be entirely compatible with the existing coating and wrapping materials.

4.1

Repairs System for Polypropylene Coated Items Repair Systems for Polypropylene coated line pipes and Induction bends, shall be performed according to Section 12 of DEP 31.40.30.31-Gen. Records shall be kept of all repaired pipes and shall i nclude the repair and re-test details

4.2

Repair System for Heat Shrinkable Sleeves (HSS) Coated Items HSS is a material made from cross linked polyolefin backing, precoated with semi-crystalline adhensive. Coating defects on HSS coating that may occur during or after construction or shipping shall be repaired. Coating and any other material used for the repair of defects and damages shall be supplied by the same Coating Manufacturer of the original coating system. Ref Doc. No K2S-NG01007551-GEN-RA7754-00003.



5.0

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COATING REPAIR PROCEDURE The acceptability of coating repair and the repair procedure shall be subject to agreement between the Principal and the Coating Contractor. The Contractor shall submit detailed procedures f or coating repairs. All coating repair procedures shall be qualified under both coating system and Applicator qualification in accordance with sections 11.1.5 and 12 of DEP 31.40.30.31-Gen. These procedures shall contai n as a minimum: ·

Repair of surface defects;

·

Repair of pinholes, scratches and small defects (e.g. by means of a melt stick);

·

Removal of rejected coating and cleaning the pipe to the required standard for recoating;

·

Testing to prove the effectiveness of the repairs.

All pipes that have been repaired shall be fully re-examined in accordance with the quality control procedures. Records shall be kept of all repaired pipes and shall i nclude the repair and re-test details. Cut back :The coating at cut back area shall be i n accordance with section 10.3 DEP 31.40.30.31



6.0

REPAIR ACTIVITIES

6.1

Surface Preparation

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All the steel surface containing coating damages shall be properly prepared before the application of the repair material by means of a special wire brush, air or electrically powered. The damaged area shall be cleaned according to SSPC - SP3 to provide a surface cleaning grade St 3 in compliance with ISO 8501-1 and slightly enlarged in order to assure a regular shape. The surrounding coating edges shall be tapered to be sure that the coating layer along the perimeter of the damaged area shall be adherent to the metal substrate. The treated area shall be perfectly cleaned and dried and free of loose coating. Surface preparation generally shall be in accordance with relevant sections of SSPC SP10, ISO 8501-1 and Section 10.1 of DEP 31.40.30.31-Gen. 6.2

Material Application The thickness of the coating, applied in damaged area, shall not be lower than the thickness of the adjacent existing coating layer. Coating material application shall be in accordance to Supplier s recommendations.



7.0

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INSPECTION AND TESTS After repairs, EPC Contractor shall inspect the repairs to guarantee a defect free- coating. No vacancies or damages shall be permitted in pipeline finishing.

7.1

Visual Inspection Every coating repair shall be visually inspected. The coating surface shall be uniform in colour and gloss and without any surface defects such as blisters, orange peeling, sags, voids, etc.

7.2

Thickness Test The coating thickness shall be measured out on each repaired surface. All measured values shall correspond at least to the minimum thickness of the existing shop applied coating.

7.3

Vacancy Detector Inspection Each repair shall be 100% inspected with vacancy detector set to 10 kV per mm of coating thickness. The vacancy detector shall be operated in strict accordance to Supplier s instructions.


k2s-Ng01007551-Gen-ra7754-00004 Specification for Line Pipe Protective Coating Repair

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