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TDRK-M-CS-PC-0006 Field Joints Coating Rev.0


CNPC International (Chad) CO., LTD Chad Ronier-Kome Crude Oil Pipeline Project Rev. Pages

Rev.Pages
COVER PAGE SHEET Table of Contents 4 5 6 7 8 9 10 11

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Issued for Approval Issued for Approval Issued for Approval Description

Ji Shengwu

Machenglong

Liu Changsheng

Feb. 25. 2013 JAN. 28. 2013 JAN. 16. 2013 Approved by Date

B

Ji Shengwu

Machenglong

Liu Changsheng

A

Ji Shengwu

Machenglong

Yang Liming

Rev.

Prepared by

Checked by

Reviewed by

Rev. 0 Contract No.: CNPCIC-B1227 Document No.: TDRK-M-CS-PC-0006

Page 2 of 11

Title: Field Joint Coating Procedure

CNPC International (Chad) CO., LTD Chad Ronier-Kome Crude Oil Pipeline Project

CONTENTS

1.0 2.0 3.0 4.0 5.0 6.0 7.0

Scope........................................................................................................................ 4 Standards and references ....................................................................................... 4 Definition .................................................................................................................. 4 Construction procedure and methods ................................................................... 4 Quality requirement ................................................................................................. 9 Safety measures .....................................................................................................10 Site documents .......................................................................................................11

Rev. 0 Contract No.: CNPCIC-B1227 Document No.: TDRK-M-CS-PC-0006

Page 3 of 11

Title: Field Joint Coating Procedure

CNPC International (Chad) CO., LTD Chad Ronier-Kome Crude Oil Pipeline Project

1.0 Scope 1.1 The procedure applies to the field joint coating of Chad Ronier-Kome Crude Oil Pipeline Project. 2.0 Standards and references 2.1 Project documents TDRK-M-QC-PC-0005 TDRK-M-HS-MU-0001 Project Quality Control Plan HSSE Management Plan

2.2 Standards and references GB50369—2006 SY/T0413—2002 SY 4058-93 Code for Construction And Acceptance Of Oil & Gas Transmission Pipeline Engineering Technical Standard of Polyethylene Coating for Buried Steel Pipeline Specification for Application And Acceptance of Field Jont Coating and Repair of Coating Defects on External Anti-Corrosive and Thermal Insulated Coatings for Buried Steel Pipeline

3.0 Definition Owner: PMC: CNPC INTERNATIONAL (CHAD) CO., LTD. CLZ CONSORTIUM, appointed by the Owner, CNPC INTERNATIONAL (CHAD) CO., LTD, and assists Owner for Chad Ronier-Kome Crude Oil Pipeline Project management. And the executing organization staffs will superintend the overall project works.

Contractor:CPP international. 4.0 Construction procedure and methods After the qualification of NDT, the qualify department of construction company shall release the joint coating instruction to coating crew, then the crew can start the joint coating works with the instruction. 4.1 Materials General requirement
Rev. 0 Contract No.: CNPCIC-B1227 Document No.: TDRK-M-CS-PC-0006 Page 4 of 11

Title: Field Joint Coating Procedure

CNPC International (Chad) CO., LTD Chad Ronier-Kome Crude Oil Pipeline Project

a. The coating materials used for the project shall be provided by qualified manufacturers finalized by bidding. b. The coating materials provided by the manufactures shall be available with manufacture acceptance certificate, operation manual (along with picture instruction) and inspecting report. c. The coating material shall be stored in dry place, avoiding any moisture and direct sunshine, and isolating from fire resources and heat resources. The required temperature and moisture for storage shall follow the manufacturers’ instructions. 4.2 Equipment General requirement a. The construction equipment shall run smoothly and operate safely. The safety protection devices shall be installed on the machine, once breakdown occurs, shut down the machine or cut off the power immediately. b. For machinery safety operation procedure, please refer to the HSSE document. 4.3 Construction organization Manpower compensation: joint coating crew and some members of the welding crew shall be arranged according to the requirement of each construction stage. 4.4 Process flow procedure The process flow procedure is for the sake of reference. The time required for each process is different,so the detailed arrangement be decided as per site conditions. Pipe clearing → Sand blasting → Heating → Coating &repair 4.5 Construction safety 4.5.1 All the personnel shall be trained for safety construction operation. And make up the safety construction regulation, and for more details, refers to HSSE documents. The construction staff will not allowed to work at site if not passing the safety exam. 4.5.2 All the construction personnel shall wear uniform, gloves, goggles, mask helmet. Gas mask or dust mask shall be worn in poison or dust situations.
Rev. 0 Contract No.: CNPCIC-B1227 Document No.: TDRK-M-CS-PC-0006 Page 5 of 11

Title: Field Joint Coating Procedure

CNPC International (Chad) CO., LTD Chad Ronier-Kome Crude Oil Pipeline Project

4.5.3 The safety signs shall be installed on the construction machinery and construction sites, and the safety signs shall comply with the concerned administration requirement. 4.5.4 The safety inspectors shall check hidden dangers of the site regularly or irregularly. If suspension is required, obey the instructions of safety inspectors absolutely. 4.6 Environment protection 4.6.1 All the personal shall be trained for HSE. All the activities shall be followed the environmental protection construction regulations, and refer to TDRK-M-HS-MU-0001 for more details. 4.6.2 The construction staff shall not throw the wasted coating materials. 4.6.3 The environmental protection signs shall be installed at sites and the contents shall fulfill the requirement of concerned authorities. 4.6.4 After the completion of daily coating work, clear the wastages at site carefully which are left during executing the coating works to make the site cleaning. 4.7 construction method for heat shrink sleeve 4.7.1 The operation method for heat shrink sleeve shall refer to the manufacturer’s instructions. 4.7.2 the technique requirement shall follow SY 4058-93 Specification for application and acceptance of field joint coating and repair of coating defects on external anti-corrosive and thermal insulated coatings for buried steel pipeline. 4.7.3Process flow chart: Preparation →joint cleaning→preheating→sand blasting→duct removing→heating→temperature measurement→primer application→installation of heat shrink sleeve →heat shrink sleeve heating→inspection and acceptance→filling in the construction and inspection record 4.8 Preparation 4.8.1 The machinery used for the installation of heat shrink sleeve shall operate well and run smoothly.
Rev. 0 Contract No.: CNPCIC-B1227 Document No.: TDRK-M-CS-PC-0006 Page 6 of 11

Title: Field Joint Coating Procedure

CNPC International (Chad) CO., LTD Chad Ronier-Kome Crude Oil Pipeline Project
a. The output power of generator shall fulfill the requirement of field joint coating, with stable diesel supply system and sufficient fuels. b. Air compressor shall work well, with stable outgoing air, and the pressure gauge indicates normal. c. Sand used for sand blasting shall be sufficient and can be supplied in time. 4.8.2 Prepare sufficient coating material, and the material type and specification shall fulfill the requirement. 4.9 Pipe ends cleaning 4.9.1 Get the weld joint and the width range of heat shrink sleeve cleaned and free from grease and mud. 4.9.2 Main pipeline coating edges on the two sides of circumferential weld seam shall be cut into bevel angle, If existing such defects as peel off and cracking on coating layer of pipe end, it shall be removed and repaired. 4.9.3 If there is the presence of oil, grease, or other surface contaminants, clean the exposed steel and adjacent pipe coating with a solvent cleanser.and the fire flame can also be used for cleaning the grease. 4.10 Pre-heating 4.10.1 Prior to sand blasting, preheat the pipe joint and preheating temperature shall be 40℃~60℃. 4.10.2 Heat the pipeline from two sides at same time by the flame torch and move the torch along the pipe axial from the top to bottom. 4.10.3 After heating, measure the temperature of top, bottom and two sides of pipe. When the preheating temperature fulfilled the requirement, sand blasting can be started. 4.11 Sand blasting 4.11.1Sand blasting operation steps are as follows: starting air compressor, regulating air pressure, holding spray gun, and opening sand inletting valve. 4.11.2 The sand blasting shall be done continuously. After the completion of one side, the other side shall be done immediately. The blasting gun shall be kept in vertical position with
Rev. 0 Contract No.: CNPCIC-B1227 Document No.: TDRK-M-CS-PC-0006 Page 7 of 11

Title: Field Joint Coating Procedure

CNPC International (Chad) CO., LTD Chad Ronier-Kome Crude Oil Pipeline Project
the pipe surface, and blasting shall be moved along the pipe axis with smooth speed, from the pipe top to bottom. 4.11.3 Particular caution shall be made on the 5 to 7 clock positions while blasting and make sure the blasting gun keeping the vertical position with steel pipe surface. 4.11.4 The blasted surface treatment shall be at least Grade Sa2.5. 4.11.5 At Sandblast operation, the coating on both sides of loop welds overlapping with joint coating heat shrink sleeve within the specified scope shall be treated. The treating width of each side is no less than 85mm. 4.12 Duct cleaning 4.12.1 After Sandblasting, dust and foreign matters on the surface at the location of the steel and joint coating shall be cleaned with soft brush or clean cotton cloth. 4.13 Joint heating 4.13.1 Fire the flame torch, and adjust the flame length to make flame without black smoke and the blue color as the major flame color. 4.13.2 Preheating temperature shall fulfill the requirement of manufacturers. 4.14 Primer (3PE heat shrink sleeve) Mixing and Application of epoxy primer shall be according to supplier instruction. 4.15 Pipe joint heating and temperature measurement Pre heat the pipe according to supplier instruction with the appropriate propane torch. Check the temperature to ensure preheating has been obtained on the entire pipe circumference. Ensure that the epoxy primer is dry prior to sleeve installation. 4.16 Installation of Heat shrink sleeve 4.16.1 The HSS shall be inspected before installation, to make sure that it is free from cracks, bubbles, tearing or any other defects. 4.16.2 Slightly trim corners of pre-attached closure. Partially remove the release liner and gently heat the under lap approximately 150mm from the edge.
Rev. 0 Contract No.: CNPCIC-B1227 Document No.: TDRK-M-CS-PC-0006 Page 8 of 11

Title: Field Joint Coating Procedure

CNPC International (Chad) CO., LTD Chad Ronier-Kome Crude Oil Pipeline Project

4.16.3 Centre the sleeve over the joint so that the overlaps between the 10 and 2 o’clock position. Press under lap firmly into place. Remove the remaining release liner and hold-down strip tape on the under lap of the closure. 4.16.4 Press the closure firmly. Gently heat the closure and pat it down with a gloved hand. Smooth any wrinkles by gently pressuring outward from the center of the closure with a roller. Continue heating from the center toward one end of the sleeve until recovery is complete. Shrinking has been completed when the adhesive beings to ooze at the sleeve edges all around the circumference. 4.16.5While the sleeve is still hot and soft, use a hand roller to gently roll the sleeve surface to ensure a uniform bond and push any trapped air up and out of the sleeve. 4.17 Peeling strength test Taking one joint for peeling strength test per 100 joints.The peeling strength is not less than 50N/cm,if it is unqualified, the adjacent heat shrink sleeve shall be tested. All the peeling strength test must be supervised by PMC. 5.0 Quality requirement 5.1 Analyses the coating processes and finalize the sand blasting, pipe heating, heat shrink sleeve installation, holiday detecting as the four major control focuses and quality control points that required special measurements. 5.2 The coating staff shall be trained for coating construction and available with qualification certificate then the coating work can be processed. 5.3 Prior to the construction activities, all the construction staff involved shall be illustrated about technical disclosure, and familiar with the quality index and requirement. And make the staff familiar with quality duties and execute the works as per specifications and design. 5.4 The coating materials used shall have the quality certification. And the storage of heat shrink sleeve shall fulfill the product instructions, manufacturer’s recommendations, and free from the pollution like sand and oil. 5.5 The sand used for blasting shall be even and blasting ranking shall be grade Sa2.5. The iron rust shall be well removed, and particularly care shall be made on the sand blasting at 6clock position.
Rev. 0 Contract No.: CNPCIC-B1227 Document No.: TDRK-M-CS-PC-0006 Page 9 of 11

Title: Field Joint Coating Procedure

CNPC International (Chad) CO., LTD Chad Ronier-Kome Crude Oil Pipeline Project
5.6 The heating temperature shall comply with requirement and use the digital thermo detector to check the temperature of top, sides and bottom of the pipe surface with the difference less than ±5 ℃, only after it reaches the tem perature requirement, primer can be applied. If the temperature is not fulfilled the requirement, coating application shall not be allowed. 5.7 The application of heat shrink sleeve shall comply with requirement, and check the width of axial lap joint and circumferential lap joint to make sure it complied with the standards. 5.8 Visual quality on coating shall be free from defects such as cavity, wrinkle, burnt, charring; electric holiday detecting shall be used for needle checking on every joint coating and the voltage shall comply with design and specifications; the standard regulations shall be followed while checking on the binding power of coating. 5.9 The area where damaged and leakage is found shall be marked out by marker pen. 5.10 The damage with diameter less than 30mm can be repaired by repairing piece; for the damage diameter more than 30mm, cut the damage edge into round with bevel angle less than 45°,fill in the materials, heat and roll the repair piece, make it level, and then utilize the 2layer heat shrink sleeve to cover the damage. 6.0 Safety measures 6.1 The air compressor used for sand blasting and all the connecting of the air supply system shall be well fastened. 6.2 The operation of air compressor shall strictly follow the safety operation procedure. 6.3 The devices and safety valve on the blasting equipment shall be periodically calibrated and certificated. 6.4 All the coated coating crew shall wear the labor protection equipment. 6.5 Pay close attention to the changing of wind direction while blasting to protect people from getting hurt. 6.6 The quality inspection markings shall be available on the gas cylinders used for coated coating and repairing. The gas cylinder shall not be utilized if the markings are not clear or the cylinder’s validity is out of date. The gas cylinder shall not be utilized upside down and directly exposed under the sunshine.
Rev. 0 Contract No.: CNPCIC-B1227 Document No.: TDRK-M-CS-PC-0006 Page 10 of 11

Title: Field Joint Coating Procedure

CNPC International (Chad) CO., LTD Chad Ronier-Kome Crude Oil Pipeline Project
6.7 Preserve certain of length connecting hose, fasten the connect joint with particular fastener and pull the hose generally while operation. 6.8 The wasted tools and materials shall be recollected while processing the coating and repairing works. 7.0 Site documents 7.1 The field joint coating record shall be recorded daily, after PMC signature and will be filed into “As built documentary”. 7.2 The inspection record based on the EPC site checking items and contents, shall be filled properly, after PMC signature then filed into the “As built documentary”.

Rev. 0 Contract No.: CNPCIC-B1227 Document No.: TDRK-M-CS-PC-0006

Page 11 of 11

Title: Field Joint Coating Procedure


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