Specification for External 3LPE

Page Pa ge 1 of 25

No rd St re rea am 2

Spe cific ation f or Exter nal Thr Thr ee Layer Layer Polyet Polyet hylene Coating

Document Ow Owner ner

Michael Frame

Review Man Man ager

Klaus Schmidt

Ap A p p r o ver

Trond Gjedrem

W-MA-ENG-GEN-SPE-800-ACC001EN-02

R ev .

Dat e

01

2015-11-04

02

2016-02-24

D escr i p t i o n

 Feb 26, 2016

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Page Pa ge 2 of 25

Table of Cont ent s

1

2

3

4

5

SCOPE........................ SCOPE. .............................................. ............................................... ............................................... .............................................. ........................................ ...........................5 ..........5 1.1

Definiti ons ..................... ............................................. ............................................... .............................................. ............................................... ....................................5 ............5

1.2

Abbrevi Abb reviation ation s.... ........ ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ....... ....... ......... ..... .... .....5 .5

SPECIFICATIONS, CODES AND STANDARDS.....................................................................................5 2.1

General ...................... ............................................. ............................................... ............................................... .............................................. ....................................... ................5 5

2.2

Codes,, Standardsa nd Regulation Codes Regulations s ...................... .............................................. ............................................... .............................................6 ......................6

REQUIREMEN REQU IREMENT TS........................ S............................................... .............................................. ............................................... ............................................. ...................................8 ..............8 3.1

Operating environment and design temperature.........................................................................8

3.2

Compositi Compos iti on of the coating sys system ....................... .............................................. ............................................... ..............................................9 ......................9

Coating Materi als ...................... ............................................. .............................................. ............................................... .......................................... ...................................9 .................9 4.1

Epoxy primer ..................... ............................................ ............................................... ............................................... .............................................. ................................9 .........9

4.2

Adhesive Adh esive ... ....... ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ......... .....10 10

4.3

HDPE HD PE Layer.... Layer........................... .............................................. ............................................... ............................................... ........................................... ............................10 ........10

Storage of co ating ma teri als ....................... ............................................... ............................................... .............................................. ........................................11 .................11 5.1

6

7

Preserv Pres ervation ation of coating mater materials ials ..................... ............................................. ............................................... .............................................. ..........................11 ...11

Cleaning and surfac e prepar ation before co ating .................... ............................................ ............................................... ..................................11 ...........11 6.1

Environmental Environmen tal cond conditio itions ns...................... ............................................. ............................................... ............................................... .....................................11 ..............11

6.2

Preheating of pipes................................... pipes.......................................................... ............................................... ............................................... ................................12 .........12

6.3

Abrasive Clea ni ng..... .... ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ........ ........ ........ ........ ........ ....... ....... ........ ........ ......1 ..12 2

3 Layer Coating.......................... Coating................................................. ............................................... ............................................... ........................................ ...................................12 ..................12 7.1

Coatings Materials........................................ Materials............................................................... .............................................. .............................................. .............................12 ......12

7.2

PE appli cati catio on method methods............. s..................................... ............................................... .............................................. .............................................. .........................13 ..13

7.3

Line Li ne pipe , Buck Buckle le arrestors arrestors and transit transitio ion n piecescoat ing cut cut back.......... ........ ......... ........ ........ ....14

8

Mark ing ...................... ............................................. ............................................... ............................................... .............................................. ........................................ ...........................15 ..........15

9

Handling , Storage and Deliv ery of the coated pipes ...................... ............................................. .............................................. ..............................15 .......15 9.1

Pipe Storage ..................... ............................................ ............................................... ............................................... .............................................. ................................15 .........15











Page Pa ge 3 of 25

11

Defectiv e co ating, co ating repai rs ..................... ............................................. ............................................... .............................................. .................................16 ..........16

12

Quali ty Control and Ins pec tion ac tiv iti es ....................... .............................................. ............................................... ......................................... .....................17 ....17 12.1

Manufacturing Procedure Qualification Test...............................................................................17

12.1.1 12.2

Documentation Doc umentation for MPQT .................... ........................................... ............................................... ............................................... .................................18 ..........18

Quali fic ficatio ation n tes testing ting of coati coating ng ...................... ............................................. .............................................. .............................................. ..............................18 .......18

12.2.1

Visual Vis ual examinati examinatio on ....................... .............................................. .............................................. .............................................. ......................................... ..................18 18

12.2.2

FBE layer poros porosity ity .................... ........................................... ............................................... ............................................... .......................................... .....................18 ..18

12.2.3

Coating thick thicknes ness s ..................... ............................................ ............................................... ............................................... .......................................... .....................18 ..18

12.2.4

Degree Degr ee of cur cure...................... e.............................................. ............................................... .............................................. ............................................ .........................18 ....18

12.2.5

Holiday Test.. Test.......................... ............................................... .............................................. ............................................... ........................................... ........................19 .....19

12.2.6

Hot water soak test...............................................................................................................19

12.2.7

Qual ity requiremen requirements ts and inspection for MPQT and produc production tion ........ ........ ........ ........ ........ ......19

12.3

Reception Rec eption of bare pipes pipes.................... ............................................ ............................................... .............................................. ......................................... ..................21 21

12.4

Reception of the coating materials.............................................................................................21

12.5

Pipe identif identificati ication on....................... .............................................. .............................................. ............................................... ............................................... ........................21 .21

12.6

Control of surface cleanliness....................................................................................................22

12.6.1

Visual Vis ual inspec inspection..................................... tion............................................................. ............................................... .............................................. .............................22 ......22

12.6.2

Check Chec k o f surfac urface e roughnes roughness s and coating .................... ............................................ ............................................... ..................................22 ...........22

Table 12.6.2. Re Requirements quirements for ins pection of surface preparation and coating ...............................22 12.7

Quali ty Ins Inspecti pection on during produ producti ction on ....................... ............................................... ............................................... ..........................................24 ...................24

12.7.1

Tests Tes ts and Tes Testt Fr Frequencies............................. equencies.................................................... .............................................. .............................................24 ......................24

12.7.2

Visual Vis ual inspec inspection..................................... tion............................................................. ............................................... .............................................. .............................24 ......24

12.7.3

Hot water soak test...............................................................................................................24

12.8

Repair Contr Control ol ....................... .............................................. ............................................... ............................................... .............................................. ............................24 .....24

12.9

Residual Res idual magneti magnetis sm.............................. m..................................................... ............................................... ............................................... ....................................24 .............24

13

Documenta tion ...................... ............................................. ............................................... ............................................... ............................................. .......................................24 .................24

14

Load Out ..................... ............................................. ............................................... .............................................. ............................................... ........................................ ..........................25 ..........25











Page Pa ge 4 of 25

SPECIF SP ECIFICAT ICAT IO ION N FOR EXTERN EXTERNAL AL THREE THRE E LAYER POL POLYE YETHYL THYLEN ENE E COATING

Documen ocumentt N° W-MA-ENG-GEN-SPE-800-ACC001EN

OLD Docum ent N° N°. N-E N-EN-PLM-SPE-000 N-PLM-SPE-000-EXT -EXTACC ACCCO CO N°. N-E N-EN-PIE N-PIE-SPE-000-SPE-000-00 0000 0000 0003 03











Page Pa ge 5 of 25

Specif Spe cif icat ion f or Ext Ext ernal Three-Lay hree-Layer er Polyethylene Polyethylene Coating

1

SCOPE

Thi s Specifi cation defines the functio nal requirements for the exter external nal threethree-layer layer PE anti-cor anti-corros rosion ion coating sys ystem tem to be appli ed on the Nord Nord Stream 2 Offs Offshore hore Pipeli ne through the Balti c Sea. The pipes may also also be coat coated ed with conc concre rete te coating prior to installation installation in or order der to pr provide ovide sufficient sufficient negative buoyancy. Requiremen Requirements ts for Internal Flow Coat and Conc Concrete rete Weight Weight Coating are covered in a separate specification. 1.1

Definitions

COMPANY

Nord Stream 2

CON ONTR TRAC ACTOR TOR

Coat oating ing Cont ontrrac acto torr, or their their age agent nts s, who who is res espon pons sible to to COMP COMPAN ANY Y for for the performance of the WORK as addressed within this specification.

SUPP SU PPLI LIER ER

Vendoror Vend oror ma manu nufa fac ctu turrer fo forr sup uppl ply y of ma matter erial ial,, equ equip ipme ment nt an and d ser serv vic ices es to th the e CONTRACTOR

1.2

Abbre Abb rev v ia ti tions ons

APS

Application Applicatio n Pr Proc oced edur ure e Specif Spe cif icatio ication n Exempl Exe mpligrati igratia a (for the sake sak e of exa examp mple le)) Envir Env iron on m ent al St re res s Cracking Resistanc Resistance e H igh D ens it y Poly Pol y ethy len lene e

g. e.g e. ESCR H D PE H SE

DSC Et c .

Differee ntial Scanning Differ Calorimetry Et c et era (and m ore)

FBE

Fusion Bon Bonded ded Epo Epoxy xy

IR

I nf ra-R ed

NS2 PE TBD

H ealt h, Saf ety & ITP Env ironment Manufacturing Procedure No . Qualification Test Nord Nor d Str Strea eam m 2 Offsh Offshor ore e Ga Gas s Pi Pipe peli line ne Poly et hy lene Para To Be D ec ided PTS

YS

Y ield St rengt h

3LPE

Three Lay er Poly et hy lene UV

MPQT

TS

2

SPECI SPE CIFICA FICATI TION ONS, S, CODE CODES S A ND STA ND NDA A RD RDS S

2.1

General

Inspectio Ins pectio n and Testing Plan Number

Paragraph Pipe Trac k ing Sy s t em Tens ile St rengt h Ultra Vio Violet let

A certi certifi fi ed qua li ty sys ystem tem accordi ng to ISO 900 1 shal l be app l ie d to ass assii st com compl pl ia nce with the requirements requi rements of thi s docum document. ent. A mate rial and pi pe trackin tracking g sys system tem ha s to be establi shed accordi ng Company’s Compan y’s procedures and ma nual referenced referenced in pa ra 2.2. 2.2. The Coating Coating to be produced shal l mee meett al alll requirements of DNV RP-F106. RP-F106. CON CONTRACTOR TRACTOR shall shall be respons responsibl ibl e for the quality of material s











Page Pa ge 6 of 25

2.2

Codes, Co des, Standards and Regulations

Th e lates The la testt issue issue of the fol lo lowi wing ng speci speci fication ications s, codes, codes, standa standards rds and regul regulati ations ons shal shal l form part of thi s speci ficat fication. ion. In the event event of conflict between t hi his s speci ficat ficatio ion n and an d other ot her speci speci fica ficatio tions ns,, data da ta sheets, sheets, appl icab icable le codes or references references,, the speci pecifica ficatio tio n W-MA-ENGW-MA-ENG-GEN-SPE-800-AC GEN-SPE-800-ACC001EN C001EN tak takes es precedence. The Nor Nord d Stream Offs Offshore hore Pipel ine shall shall be designed designed to meet DNV DNV OS-F101 OS-F101 Submarine Pipe li ne Systems Sys tems (2013). (2013). The refer references ences li sted be low shall be cons considered idered by CO CONTRAC NTRACTOR TOR in their latest latest version and shall be regarded as an integral part of this Specification together with the contract documents. Compl ia ian nce with wi th DNV DNV OS-F101, mea mean ns comp compliance liance with DNV-RP-F DNV-RP-F106 106 which provide provides s addit ion ional al requi reme rements nts,, above abo ve indus i ndustry try stan standard dard do cument ISO 21809-1: 201 20 11. T his speci fi fication cation includes add addii tional requirements requi rements speci pecifi fied ed by b y COMPANY. COMPANY.

COMPANY Specification/Procedure W-HS-HSE-GEN-PRO-800-LPCOATEN W-QY-QAC-GE W-QY-QA C-GEN-SP N-SPE-8 E-80000-PQS PQSRCSEN RCSEN W-MA-OFP-POF-SPE-800-INDBENEN W-MA-OFP-POF-SPE-800-LINEPIEN W-MA-ENG-GEN-SPE-800-FLC001EN W-LC-CWC-GEN-SPE-800-CWC001EN W-LC-CON-GEN-SPE-800-PTSFSPEN W-MA-OFP-POF-SPE-800-MEASUMEN

Title HSES Minimum Minimum Standard Standards s f or Line Line Pipe, Pipe, Weight Coating Coating and Logistics Project Pro ject Quali Quality ty Sy stem req requir uirements ements for Contrac Contractors tors and Sup Supplie pliers rs Specification Specification Specification Specification Pipe Tr Track ackii n g Meassur em ent Mea

f or Bends Manufactured Manufactured by inductio induction n Hea H eating ting f or Lin Line e Pip Pipe, e, (Inc. (Inc. Buckle Buckle Arrestors Arrestors and Tran Transition sition Pieces) f or Inter Interna nall Coa Coatin ting g - Flow Coa Coatt f or Con Concre crete te Weight g ht Coa Coating ting - CWC Sysstem Functi Sy Functi o n al Spec Specifi ifi cati o n of Resi Residu dual al Mag agne netism tism in Ste Steel el Line Line Pipe

DNV OS-F10 1

Su bm a ri n e Pi pe l i ne System s.

DNV-RP-F10 6

Factory ap app l i ed ed ex externa l co coa ti n gs for corrosi on on con trol

DIN EN EN ISO 30 6

Pl as asti cs cs-De te rm i na nati on on o f Vi ca cat so fte ni ng ng te m pe ra tu re of thermoplastics.

DIN EN EN ISO 52 7

Pl as asti cs-De te rm i n ati on on o f te nsi le le pro perti es es

DIN EN ISO 81 8130 30--1

Coa oati ting ng po pow wde derrs – Pa Parrt 1: Det eter ermin minat atio ion n of of pa parrtic icle le siz ize e di dis str trib ibut utio ion n by sievin sievin g

DIN EN IS ISO O 85 8503 03--4

Prepar Prep arat ation ion of ste teel el sub ubs str trat ates es be befo forre ap applic plicat ation ion of pa paint ints s an and d related products – Surfac Surface e roughnes roughness s charac characteris teristics tics of blastcleaned steel subs ubstr trates ates – Par Partt 4: Method for the calibrat calibration ion of ISO surface profile comparators and for the determination of surface profile; stylus instrument procedure

DIN 30670

Polyethylene coatings of steel pipes and fitti ngs ngs;; requirements and testing

ISO 62

Pl a sti cs-De te rm i nati on o f wa ter a bsorpti on

ISO 17 9

Pl a sti cs- De te rm i n ati on o f Ch arpy i m pa ct p ro pe rti es

ISO 86 8

Pl a sti cs-De te rm i n ati on o f i nd en ta ti o n ha rd ne ss by m ea ns o f a durometer (Shore Hardness)













Page Pa ge 7 of 25

ISO 13 04

Ru bb er-Carbo n bl b l ack. Dete rm i n ati on o f i o di ne -a bsorpti on n um b er. Ti tr trimetric imetric method

ISO 18 72

Pl a sti cs- Pol yethyl en e (PE) m o ul di n g a nd e xtru si on m ateri al s – Part 2: Preparation of tes testt specimens specimens and determin ation of properties

ISO 28 08

Pa i nt a nd va rni she s – De te rm i n ati on o f fi l m th i ckn ess

ISO 85 01 -1

Pre para ti on on of of st ste el su su bstrates be fo re app l ic ica ti on on o f pa i nt nts and relate d products products.. – Vi Vis sual ass asses ess smen mentt of surface surface cle anl in ines ess s. Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel steel substrates substrates after overall removal of prev previous ious coatings coatings

ISO 85 02 -3

Pre para ti on on of stee l su bstrate be be fo re a pp l i ca cati on on o f p ai nt nt an d rel at ated products tests tests for the as ass ses ess smen mentt o f surface surface clean li ness – Part 3: Assess Ass essme ment nt of dust on stee teell surface urfaces s prepa red for pai nti ng (press (pres sure-s ure-sens ensit itive ive tape method )

ISO 85 02 -9

Pre para ti on on of stee l su bstrate be be fo re a pp l i ca cati on on o f p ai nt nt an d rel at ated products tests tests for the as ass ses ess smen mentt o f surface surface clean li ness – Part 9: Field method for the conductometric determination of water-soluble salts

ISO 85 03 -1

Pre para ti on on of stee l su bstrate be be fo re a pp l i ca cati on on o f p ai nt nt an d rel at ated products surface roughness characteristics of blast cleaned steel substrate

ISO 85 03 -4

Pre para ti on on of stee l su bstrate be be fo re a pp l i ca cati on on o f p ai nt nt an d rel at ated products surface roughness characteristics of blast cleaned steel subs ubstrate trate – Part 4: Method for the the cali bration of ISO surfac surface e profile comparators comparator s and for the determinati on of surface profil profil e

ISO 90 01

Qu al i ty M a na gem en t System s - Re Re qui rem e nts

ISO 11 12 4

Pre para ti on of of st ste el su su bstrates be fo re app l i ca ti on o f pa i nts and related products – specifi cation for metall ic bla st-c t-cleani leani ng abrasives abrasives

ISO 11 12 7-6

Pre para ti on on of o f st ste el su su bstrates be fo re a pp l ic ica ti on on o f pa i nt nts and related products – tes testt methods for non-metall ic blast-c blast-clean lean ing abrasives abras ives – Part 6: Determine Determine of waterwater-s solubl e contaminants by conductivity meas measurement urement

ISO 11 35 7

Pl a sti cs – Di ffe re nti al sc sca nni n g ca l o ri m e try (DSC) – Part 2: Determination of glass transition temperature

ISO 15 51 2

Pl a sti cs – Dete rm i n ati on o f wa te r co nten t











Page Pa ge 8 of 25

AST M D638

T ensil e properti p roperti es of pl astics

AST M D1505

Flow Flo w rates o f th ermo ermopl pl astics by extrusion pl as astom tom ete eter r

AST M D1525

Vi cat soft ofteni eni ng tem perat perature ure of o f pl p l as asti ti cs

AST M D 1693 169 3

Envi ronm ronment ental al stres tress s-crack -crackii ng of eth ethyle yle ne pl as asti ti cs cs..

AST M D 2240 224 0

Rubbe r prope rty – Durome Durometer ter hardne h ardne ss

AST M D 4060 406 0

Abrasion res resii stan tance ce of organ organii c coati coa ti ngs by th e T abe aberr Abraser

AST M D 4940 494 0

Sta nda rd T es Standa estt M eth ethod od for Con duct ductii me metric tric Ana Anall ys ysii s of Water So lu bl e Ionic Contami nation of Blast Cleani Cleani ng Abrasives Abrasives

AST M G8

T est for cathod cat hodii c di sbon di ng of pi pel i ne coat coatii ngs

AST M G 14

T est for i mp mpact act res resistance istance of pi pel in e coati co ati ngs (fal li ng wei weight ght test)

AST M G 42

Cathodi Catho di c di sbon bondi di ng of pipel pi pel i ne coatin coat in gs subj ecte ected d to elevate ele vated d or cyclic temper cyclic temperatur ature e

SSPC-AB-1

M i ne ral and Sl a g Abra si ves

SSPC-AB-2

Cl ea nl i ness of Recycl ed Ferrous M etal l i c Ab ra si ves

SSPC-AB-3

Ferro us M etal l i c Abra si ve

3 3.1

REQUIREMENTS Operating env env ironment and desi gn temperature temperature

The PE exter external nal anti -c -corr orros osion ion coating shall shall be able to withstand withstand a maxim um design design temp eratur erature e of 80°C, and a minimum design temperature of -40°C both in an offshore and onshore environment involving attack by chemical agents and/or of microbiological type. Storage conditi ons of coated pipes: pipes: coating shall shall be able to withstand withstand a mini mum tem peratur perature e of -40°C -4 0°C and a maximum temperatur temperature e of +80°C +80°C. Design life of the 48” O.D. pipelines is 50 years and shall include several (3 or 4) wall thicknesses. Line pipes for offshore use have a minimum design temperature equal to -10°C, maximum design temperature equal to +40°C. Some e li ne pipe quan quantities tities intend intended ed for above ground ground use at lan dfa dfalls lls may may be order ordered ed wi thout coating Note: Som and wi th wi der design tem temperatur perature e range (typically these pipes shall have mini mini mum design temperatur temperature e equal to -38°C and maximum design temperature of +60°C). The design pressures range from 177.5 barg to 220 barg.











Page Pa ge 9 of 25

Compo s itio ition n of the coating sys te tem m

3.2

The pi pe external external coating shall shall consis consistt of: -

One laye layerr of fus fusion ion bonded bonded epox epoxy; y; thic thick knes ness s shall be minimum 0.150 0.150 mm.

-

One On e layer layer of adhe adhes sive ive;; th thick icknes ness s shall shall be minimum 0.2 0.200 00 mm. mm.

-

One On e layer layer of HD HDPE bas base e with with addit additive ives s.

-

One layer layer of PE Pow Powder der (R (Rough ough Surf Surface ace Finis Finished, hed, mini mum particle particle size size 0.5 mm).

-

The overall coating thicknes thickness s, excluding poss possible sinter powder powder used used for increas increasing ing the surface roughness, obtained by adding the thickness of the individual layers shall be minimum 4.2 mm and max maximum imum aver average of of 7.2 7.2 mm. The minimum thickness may be reduced by a maximum of 10% on top of the longitudinal weld seam. (Mini mum coat coating ing thicknes thickness s is 3.8 mm on top of the weld). weld). Minimum and average thickness values shall be measured in accordance with the clause 12.2.3 of thi s document.

4

Coating Coa ting Mater ia ials ls

Th e m aterials shal The shal l be fully f ully compatible compatible with each other for use use i n a Th Three-Laye ree-Layerr Polye Pol yethylen thylene e coating sys system. tem. The Th e adhes ad hesive ive copolymer and the po lyeth lyethylen ylene e top coat shal shal l p refe referably rably be produ p roduced ced by the same same Manufacturer. Man ufacturer. Contractor shal l propos propose e a Three Layer PE Coating Coating System System i n complian compliance ce with the requirements requi rements of th is speci speci fica fication tion and shal shal l have a proven track record on simi lar projects. projects.

4.1

Epoxy primer

The epoxy resins to be used shall: a) b)

be comp complete letely ly comp compat atible ible with with the the adhes adhesive ive sha hall ll be in com complia plianc nce e with with Table Table 1

Table 1 — Requ equireme irement nts s fo forr the epoxy epoxy material material Pr o p er t i es

Un i t

Tes t Met h o d

R eq u i r em en t s











Page Pa ge 10 of 25

4.2

Adhes Adh es i v e

The adhesive adhesive (polyethy (polyethylene lene compatible grafted grafted type type)) shall be in compliance with with Table 2 Table 2 — Requiremen equirements ts for the the adhesiv adhesiv e material (grafted ad hes esive ive in pellet) Pr o p er t i es

Un i t

Tes t Met h o d


Elongation at break at Elongation 23 °C +/- 2 °C (a) (a)

%

I SO 527-2 or I SO 527-3



600

Tensile y ield strength at Tensile 23°C 23 °C +/+/-2 2 °C

Mpa

I SO 527-2 or I SO 527-3



8

Vicat sof tenin tening g temperature A/50 (9.8N)

°C

I SO 306



85

Water content

%

I SO 15512



0,1

(a) 2 mm thick compression moulded sheet, sheet, t est specimen ty pe according according to ISO 527-3, 527-3, strained at 50 mm/min

4.3

HDPE Layer

The PE compound shall: a) be able to withstand withstand the maximu maximum m design design tempera temperature ture (80° (80°C) C) and pipes storage conditi conditions ons of the pi peline and be dyed by the CONTRACTOR CONTRACTOR with 2-3% of carbon black with i od odine ine absorpti absor pti on number nu mber always over 110 (ISO 130 4), stabi liz lized ed with a ddit dditives ives to with stand o xygen action acti on and the applica application tion and service service tem temp peratu eratures res.. Addii ti ves used Add used shal l not fl float oat to the surface of the coat coatin in g whi l e i t i s bei ng app li ed. b) be in co complian mpliance ce with Table 3.

Table 3 — Minimu Minimum m require requiremen ments ts for PE top top layer layer Pr o p er t i es

Un i t

Melt f low index/rate

g/ 10m n

I SO 1133

Manuf ac t urer dat a s heet

Density of the base base resin resin

g/cm 3

ISO 1183 1183 (al (alll parties) parties)



0.930

%

I SO 527-2 or I SO 527-3



600

Elongation at break at 23°C 23°C +/-2° +/-2°C C **

Tes t Met h o d












Page Pa ge 11 of 25

R es is t anc e t o abras ion UV Resistance and thermal ageing

m g/ 1000 turns %

ASTM D 4060 Annex G ISO 21809-1

10

 MFR 

35

** 2 mm thick compression compression moul moulded ded sheet, sheet, specimen ISO ISO 18721872-2, 2, strained strained at 50 mm/min

5

Stor age of coa coating ting m ater ia ials ls

5.1

Preserv ation of coating materials

Material s that shall shall be used used for coating shall be stored stored as foll ows in the CONTRACTOR’ CONTRACTOR’s s facil iti es es:: Al l cleani cle ani ng and coat coatii ng ma materi teri al s shal l be stored in such a m ann anner er that th at the they y are not det detrim riment ental al l y affected by cli mati c or other inj urious conditi ons and according to the suppli suppli er’ er’s s rec recommend ommend ations. The containers holding l iquid products products shall be kept kept hermeticall y sealed, sealed, and be protec protected ted from sun sun rays and stored at a proper distance distance from hea t sources sources and from those areas areas where free free fl ame ames s are used. The containers shall not be i n di rec rectt contact with the ground. Solid products shall be kept in sheltered areas with controlled temperature and humidity, in accordance accor dance of th e suppli suppli er’ er’s s rec recommen ommen dations. Products suppli Products suppli ed packaged packaged shall be kept in thei r pack packing ing until they are are us used; ed; any handl ing shall shall be carried out taking care not to damage these packages. Packaged materials shall not be placed nor stored on wet or damp surfaces or environments, nor in places that can be fl ooded o r are are near to pos poss sibl e sources sources of fire. Al l produ products cts that beco become me al tered for any a ny reas rea son shal l be remo removed ved from the ma manuf nufactu acturin ring g areas. a reas. Raw material s shall be used used i n a m anner First First In / First First Out.

6

Cleaning Clea ning and s ur face pr eparat paration ion be fore coating coating

Before pi pes are are cle aned aned,, al l pipe s shal l be carefull y visuall y ins in spected to check me tal surfaces surfaces for













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6.2

Preheating of pipes

The equip ment used for preheating preheating the pi pes shall be approved by COMPANY. COMPANY. If CON CONTRACTOR TRACTOR us uses es open fl ames in direct contact contact with with the pipe surfac surface, e, the surfac surface e shall shall be kept in motion in respect to the flame at a minimum rate of 10 mm/sec, along a helically winding path. T he flame shall als also o be adjusted adjusted in its combus combustion tion ratio ratio so that no soot or mois moistur ture e is deposited on the metal. The preheat temperature shall be kept between 35°C and 80°C; it shall be checked at least three time s for every every work work shift (at the start, middl e, and en d) and whenever stoppages occur in the product pr oduction ion li ne. Preheat tem peratur perature e shall be checked checked using using contact thermometers or sim sim il ar COMPANY COMPANY approved approved devices.. All temperature measurements devices measurements shall be recorded recorded on the production rec record. ord. 6.3

Abr as iv e Cleani Clea ni ng

The grit used used in the coating plant shall be in acc accor ordance dance with with the requirements requirements of ISO 11124. The abras abrasives ives shall be mai ntained clean, dry and free from contami nants in accor accordance dance to SSPC-AB SSPCAB 1, SSPC-AB SSPC-AB 2 and SSPC-AB SSPC-AB 3 so so as not to contami contami nate the subs substrate. trate. The use of shot (round) abrasives is not allowed. Pipe surfac surfaces es shall be cleaned cleaned to a degree cor corres respondi pondi ng as a m ini mum to Sa 2 1/2 of ISO 8501-1, i.e. white metal fini sh. After completi on of the blastin blasting g operati operation on the steel surfac urface e shall shall be tho roughly checked. Any slivers, swabs, burns, laminations and gouges shall be removed by grinding. The remaini ng wall thick thicknes ness s shall comply with mi nim um requi rements of Document No. W-MA-MA-OFPOFP-POFPOF-SPE-800SPE-800-LINEPIEN LINEPIEN Specifi cation for Line Pi pe. The maxim um all owable area of 2 grinding shall be 10 cm per 1m pipe l ength. The Th e average surface surface roughness roughness Rz (cut off 2.5) shal l be between 50 an d 90 microns microns,, measured measured











Page Pa ge 13 of 25

7.2

PE application methods

Coating materials shall be appli ed according according to the Manufacturer Manufacturer’s ’s rec recommen ommen dations and foll owing the CONTRACTOR’s CONTRACTOR’s appl icat icatio ion n procedure approved by COMPANY. COMPANY. Note:: Us Note Use e of recycled recycled FBE material is not allowed. It is not all owed to stop stop and restart restart the coating coating a ppli cation sequence sequence on any pipe. If stoppage stoppage cannot be avoided, the coating al ready appli ed shall be stripped stripped and the pipe shall shall be sent back to the process starting point (blast cleaning). The maximum temperature of the steel shall be limited to 225°C. Unless the CONTRACTOR can prove prov e that the Internal Fl ow Coating Coating and steel steel p roper roperties ties define in specifi cations W-MA-MA-ENG ENG-GEN -GEN-800-800-FLC FLC001EN 001EN and W-MA-OF W-MA-OFP-POF P-POF-SPE-SPE-800-LIN 800-LINEPIEN EPIEN res respectively pectively are not affected by the highe r steel steel temperature. Cons Constant tant meas measurement urement of pipe tem peratur perature e shall be tak taken en by autom atic pyr pyrometers ometers and recorded recorded before and after FBE applicati on. Line speed speed shall shall also be recorded. PE application shall result in a homogeneous and solid coating, showing good adhesion, no wrink wr inkles les,, no caviti caviti es es,, no air bubbles and no air entrapment entrapment al ong the weld seam; seam; this appli es in particular to where weld beads protr protrude ude from the res restt of the pi pe surface. surface. The surfac surface e of the PE coated pipes shall shall be special special ly treated treated in order to obtai n a rough rough surface which provides prov ides high l evel of shear shear res resis istance tance between PE and Concrete Concrete Coating. The rough coat shall be applied applied in such as man manner ner as to provi de a u ni niform form finished, finished, securely securely ad her hered ed to 100% of the 3 LPE coated coated surface. surface. CONTRACTOR CONTRAC TOR and Weight Weight Coating CONTRACTOR CONTRACTOR shall shall prove that this surfac surface e is sufficien t by testing tes ting pipes which have received received a concrete coatin g layer on top of the PE l ayer, see see M PQT requirements, section 12.1











Page Pa ge 14 of 25

7.3

Line pipe, pipe, Buckle arrestors and transi transi tion pieces coating cut back back

External coating shall External shall b e removed (cut (cut back back)) from the pipe ends with a tol erance of +/-10 +/-10 m m over a length to be specifi specifi ed by COMPANY COMPANY at later stage. stage. T he exact exact l ength and tolerance tolerance depends on selected pipe lay contr contractor actor and has to be confirmed by CO COMPANY MPANY no later than six (6) weeks weeks before Manufacturing Procedure Qualifi cation Test. Test. Cut back incl udes full removal of both PE layer and of the a dhes dhesive ive layer, while the epoxy layer shall be left to a di stance of 50 ± 20 mm from PE bevel. bevel. No damage of the protruding epoxy primer layer shall shall be accepted over a di stance of mini mum 30 mm to the base base of the PE bevel . In cas case e of dam age in that area the cut back length of the PE- and adhesive adhesive layers shall shall b e i ncr ncreas eased ed to reach a 30 mm wide undamaged primer layer. In case case the total cut back length exceeds the specifi specifi ed maximum value the pipe shall shall be reduced reduced in length by re-beveli re-beveli ng. The rere-fini fini shed pipe end shall shall comply with the requirements of W-MA-MA-OFPOFP-POFPOF-SPE-800SPE-800-LINEPIEN LINEPIEN..

30mm

Damages of l es ess s than 4 cm² are acceptable on the protruding protruding epoxy prim prim er layer located outside outside the above mentioned 30 mm wide undamaged primer z











Page Pa ge 15 of 25

Note: For Buck Buckle le Arr A rres estors tors and Transiti Transiti on Pi Pieces eces,, cut back len gth and tol erance depe depends nds on sel elected ected pipe lay contr contractor actor and has to be conf confirmed irmed by CO COMPAN MPANY. Y. Schemat Schematic ic shall shall be provided by the COMPANY. Buckle Buck le a rr rres estors tors and transit transitio ion n pi pieces eces shal l be manuf actured from standa standard rd pipe leng ths with m achi achini ning ng taking tak ing place after 3LPE appli cation.

8

Marking

CONTRACTOR CONTRAC TOR shall as ass sure th at neither the hard stamped m ark arkings ings on pipe ends (bevels (bevels), ), the bar codes nor the internal stencil stencil mark marking ing are damaged during the coating and ha ndli ng process process. Marking Mark ing shall be performed at l ine pipe mil l and internal coating coating facil ities in accor accordance dance with W-MAOFP-POF-SPE-800-LINEPIEN OFP-POF -SPE-800-LINEPIEN and W-MA-ENG-GENW-MA-ENG-GEN-SPE-800-FLC001EN SPE-800-FLC001EN res respecti pecti vely.

9

Handlin g, Stor age and Deliver Deliver y of th e coated pip es

9.1

Pipe Storage

Pipe storage areas withi withi n the CON CONTRACTOR’ TRACTOR’s s facil iti es shall meet the foll owing requirements: requirements: -

Storage ar Storage area ea shall shall be at least least thirty thirty (30) (30) meter meters s dis distanc tance e fr from any any ty type pe of elect electrrical pow power er li ne, the distance distance being m eas easured ured from from the vertical projection on the g round of the neares nearestt conductor.

-

Shall be free free or be freed freed befor before e use use fr from om all kinds of plant life; the same applies to a surrounding area of a width sufficient to keep fires from propagating to the pipe stacks.

-

Shall be free or fr freed eed before before use use from from protr protruding uding stones stones and foreign foreign matter. matter.











Page Pa ge 16 of 25

Handling operations and equipment shall all strictly comply with the applicable safety regulations and laws Suspended pipes shall Suspended shall be kept kept from swiveli swiveli ng around, around, either by the type of li fting device selected or by the addition side guide ropes attached to the lifting equipment. Al l personnel i nvol ved in the han handl dl in g operat o peratii ons shal shal l be ade adequa quatel tel y trai ned . When hand le led, d, pipes shal l be kept kept from f rom strik strikin in g or scraping agai ns nstt othe r bodi es or pipes pip es;; positi pos iti oni ng of the pipe s on thos th ose e al ready stack tacked ed shal l be carried carried out o ut using utmost care. Slin Sl ings gs equi pped wit h hooks shal l al so nei ther strik strike e nor scrape scrape the pi pes. Handling p roc rocedure edure shall shall have to be submi submi tted and approved by COMPANY. COMPANY. Stack height Calculati ons shall be s submi ubmi tted to COMPAN COMPANY Y for approval. Pipe Su rfac rface e temperatures of the coating can reach reach - 40°C in winter and + 80°C in summer Careful vis Careful visual ual inspection inspection shall be p erfor erformed med during trans transportation, portation, and all pipe s showing damage and/orr surface d efects shal l be properly repai red (s and/o (see ee § 11). Bevels with depth dama ges over one (1) (1) mm caused caused by handl ing operations operations shall be re-beveled. re-beveled. Damages to pipes caus caused ed during coating process process shall shall not be accepted and the cause cause for such such damages shall be rectified prior to production start. start.

10

Lo cal safe ty re quir eme ements nts and HSE r eq uir eme ements nts

It is the duty of CONTRAC CONTRACTOR TOR to observ observe e the local regulati ons on safety safety and health appl icabl e to













Page Pa ge 17 of 25

CONTRACTOR CONTRAC TOR shall propos propose e a repair repair procedure, procedure, includin g materials which shall shall be quali fied and approved by COMPANY before use. The propos proposal al shall shall specify specify the mater material ial char character acteris istics tics,, as well as appl ication and tes testt / ins inspect pection ion method. The area to be repaired shall shall be adequately prepared prepared by removing the damag ed coating until soun ound d coati ng is reached, a nd the edge edges s smoo smoothed thed down to th e steel or FBE surface surface to ensure ensure an even transiti trans iti on b etween the top of the repair and the bottom. Maxim um tem peratur perature e during Strippi ng / Recoating & Repair shall shall not exceed 225°C. 225°C.

12

Quality Contr ol and and Ins Ins pect ion activitie activitie s

12.1

Manufacturing Proc edure Qualifi Qualifi cati on Test Test

CONTRACTOR CONTRAC TOR shall prepar prepare e a test test program program and submi submi t this for approval approval to the COMPAN COMPANY. Y. Thi s MPQT hall be performed under the s eil lance of Company.











Page Pa ge 18 of 25

12.1.1 12. 1.1 Do Documentat cumentatio ion n for MPQT In li ne with COMPANY COMPANY approved schedule, schedule, CONTRACTOR CONTRACTOR shall shall supply the foll owing documents for COMPANY CO MPANY approval: -

Coating application procedur Coating procedure e specification specification (APS) (APS) in accord accordance ance with with DNVDNV-RP RP--F106 F106.. Inspect Ins pection ion and test test plan (ITP) (ITP) in accor accordance dance with DNV DNV-R -RPP-F1 F106. 06. Where Wher e p os oss sibl e, all i nformation shall shall be included under one manufacturing and inspection inspection document.

Al l ma manuf nufactu acturin ring g and a nd i ns nspect pectio io n steps requi red for f or the th e proces p rocess s shal l be i ncl ude d. Testing Test ing and i ns nspection pection shall shall be performed performed in a sys ystemati temati c manner to ensure ensure repeatabil ity of testing. MPQT shall be documented in a separate report and approved by COMPANY prior to start of mass production and shall meet the requirements of DNV-RP-F106, section 6.4. CONTRACTOR CONTRAC TOR shall prepare a Daily Log For Format mat in accordance accordance with DN DNV-R V-RP-F P-F106 106 for COMPANY COMPANY approval prior prior to the start start of production. production. During During production the daily log shall shall be updated on a dail











Page Pa ge 19 of 25

12.2.5 12. 2.5 Holiday Tes Testt Th e hol iday detecto The detectorr shal l be operated according to ISO Standard Standard 21809.1. 21809.1. Annex B. The voltag e shal l be set at 25 KV. 12.2.6 12. 2.6 Ho Hott water water soak tes testt During coating qualification, During qualification, at the beginni ng of production, at each start start up and at each FBE batch changes chang es CO CONTR NTRAC ACTOR TOR shall provide minim um three three (3) samples coate coated d with FBE FBE primer primer layer only for hot water water soak soak tes tests ts that certify long term bonding proper properties ties of the coating. The tes testt section section shall shall be subjected subjected to to water water immers immersion ion testing testing at 80ºC ± 3ºC (C (COMPAN OMPANY Y shall consider cons ider al ternative methods that do not require pipe cutti ng). The coating shall shall show no loss of adhes adhe sio ion n afte r 48 hours hours,, tested tested by b y cros cross s cut test. A detai le led d tes testt and evalua ti tion-procedure on-procedure for thi s test shall be prepared by CONTRACTOR and shall be approved by COMPANY. In addi tion, the ful l 3 LPE sys system tem shall be tes tested ted i n accordance accordance with ISO 2180 9-1, Annex M. Note: COMPANY reserves the right to have the results of the certified tests confirmed through testing at other laboratories.











Page Pa ge 20 of 25

Vi sua l In spe cti on

/

Holiday test

ISO 21809-1 And Para 12.2.5

So un d a nd contin uo us coating

e ach pi pe

e a ch p i p e

25 KV. No h ol i day

e ach pi pe

e a ch p i p e

Adh esii on (peel Adhes strength)

ISO 21809.1 Annex Ann ex C (Fig (F igure ure C2)

Mi n 150 N/cm at 20°C Mi n 40 N/cm at 80°C In each case case tol erance ± 2° 2°C C

Im pa ct resi sta nce

ISO 21 2 180 9-1 Annex Ann ex E

10 i mpacts at 7 J/mm J/mm at 23°C 23°C ± 2° 2°C C 7 J/mm at -40° -40°C C ± 2° 2°C C

3 pipes 1 pipe

> 1 5 M Pa. 2 3°C ± 2° 2°C

o n ce

-40°C test on pipe samples Tensile strength (a)

ISO 527-2 or ISO 527-3

all pipes

First pi pe and First a nd start up/lead pipe, then one per shift both pipe ends at 20°C and 80°C

once p per er PE batch batch at 23°°C ± 2° 23 2°C C

o n ce p e r P E b a t ch











Page Pa ge 21 of 25

Requirements Requi rements for in specti on o f Surface preparation preparation and coatin coating g as per tabl e 12 .6.2 A “ST “ST ART UP” i s def defii ned as a modi mod i fication of produ cti ction on param ete eters rs recorded duri ng the MP MPQT QT or a stop of the coating li ne of more than 24 hours hours.. Al l MPQT MP QT production parameters used, based based on man ufa ufactur cturer er requ requ irement and tolerances, shal l be recorded duri ng quali qu aliffi cation tests to ensure they t hey are reprodu ced during du ring the produ product ctii on phas phase. e. During Durin g produ cti on, shou should ld a change request request of agree d parameter paramet ers s excee exceed d the recommendation reco mmendations s of manufacturer man ufacturer tolerances tolerances and / or li ne speed speed ab ove or below 5% of the actual speed speed q ualifie ualified d defined during MPQT , a new MPQT shal l be performed. performed. COMPANY shal shal l define define what production production parameter parameters s shal l be be recorded with CON CONTRACTOR TRACTOR to confirm tha t MPQT quality is repl repl icate icated d i n production. production. 12.3

Reception Re ception of bare pipes

Upon rec receivi eivi ng the pipes to be coated, coated, CONTRAC CONTRACTOR TOR shall fi rs rstt verify at once that the pipes are not damaged and that there are are no ap parent defects. defects. If da mag mages es such as dents, cuts or scratches scratches are foun d on the bevel , these these damage s shal l be recorded rec orded without fail in the shippi shippi ng documents, documents, m ak aking ing reference reference to the serial serial number of the pi pes concerned.













Page Pa ge 22 of 25

Note: Internal coating (flow-coating) Note: (flow-coating) shall shall be compl eted before any external external anti-cor anti-corros rosion ion coating is applied, except for special pipes requested by COM OMP PANY . The serial serial number shall shall foll ow the pipe in all production stages and appear i n the pipe final mark marking. ing. It shall shall be recorded recorded on all production documents and on the qual ity control record. record. Al l pi pes shal shal l be tracea traceabl bl e to t o the t he coat coatii ng ma materi terial al bat batch ch Num ber.











Page Pa ge 23 of 25

Env ironn ironnemental emental conditions

Pipe temperature bef ore blasting

/ Calculation

°C

Thermocouple

as determined at time of measur measuremen ementt Mini inimum mum 3°C abo abov ve the dew point. (Minimum ambient temperature 5°C)

onc e

ev ery 4 h

onc e

ev ery 4 h











Page Pa ge 24 of 25

Temperature of Temperature extruded adhesiv adhesiv e and polyolef polyolef in

12.7

°C

Py rome rometer ter

Quality Inspecti on during production

Compliance to material supplier(s)

onc e

Ev ery 1 h











Page Pa ge 25 of 25

CONTRACTOR CONTRAC TOR shall p rov rovide ide to COMPAN COMPANY Y the ir historical historical data proving proving the trac track k record record of polyethylene coated pi pes for offshore offshore us use, e, incl uding m aterial certificates and laboratory tes tests ts.. Thi s documentati on shall shall be submi submi tted together with the bi d. The final Data Book shall include the following details as a minimum: 

Coating material qualification report.



Coating ma terial ba tch certifi certifi cates cates..

Specification for External 3LPE

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