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GTL-81-2
Rev:- 01
ENGINEERING STANDARD Page 1 of 17
GTL-81-2
Α
DATE Oct 01 Feb 02
ORIG.BY KJQ RC
APP.BY (PEM) JB
APP.BY (PD) DKM
APP.BY (Owner)
SASOL TECHNOLOGY
Contents
1 PURPOSE 3
2 SCOPE 3
3 REFERENCES 3
5 DESIGN REQUIREMENTS 4
6 FABRICATION REQUIREMENTS 5
7 SURFACE PREPARATION 6
8 COATING PROCESS 6
11 INSPECTION OF COATINGS 10
12 COATING REPAIRS 14
13 PROCEDURE QUALIFICATION 14
14 DOCUMENTATION 15
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ENGINEERING STANDARD Page 3 of 17
1 PURPOSE
The purpose of this Engineering Standard is to specify the requirements for the
application, inspection and testing of external corrosion resistant coatings for
buried pipework and pressure vessels.
2 SCOPE
3 REFERENCES
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Page 4 of 17 ENGINEERING STANDARD
4.1 Responsibilities
4.1.1 Contractor shall ensure that the requirements specified herein are incorporated
into any procurement specifications, material or sub-contract requisitions and/or
other purchase documentation produced by, or on behalf of, Contractor.
4.2 Precedence
4.2.1 Any conflict between this Engineering Standard, other Owner documentation,
industry codes and standards and local regulations shall be referred to Owner for
clarification prior to proceeding.
4.2.2 Any deviations to the requirements of this Engineering Standard shall be subject
to Owner review and approval before proceeding.
5 DESIGN REQUIREMENTS
5.1 General
5.1.1 The coating system shall be suitable for the maximum surface operating
temperature of the buried pipework, vessel or tank.
5.1.2 Contractor shall take all necessary measures to protect all coating surfaces from
damage during installation, inspection etc. Particular attention shall be paid to
prevention of damage to any corrosion protective linings applied to internal
surfaces.
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ENGINEERING STANDARD Page 5 of 17
5.1.3 The coating on individual pipe lengths shall be cut back 100mm ± 10mm from the
edge of the weld bevel.
5.1.4 On sections of pipework that extend aboveground, the protective coating shall
extend at least 500mm beyond the ground surface. All protective coatings
exposed aboveground shall be resistant to ultraviolet light and weathering and
shall be colour-stable. If necessary, a supplementary coating that is compatible
with both the underground and aboveground external protective coating systems
shall be applied to achieve the necessary resistance and shall overlap the junction
of these coatings by at least 50mm.
5.1.5 Contractor shall ensure that a qualified, technical representative from each
coating system manufacturer is present during the following stages of coating
application:
6 FABRICATION REQUIREMENTS
6.1 General
6.1.2 All welds on surfaces to be coated shall be continuous with a smooth transition
from the weld metal to the base material and completely free from surface, or
surface-breaking, flaws including, but not limited to:
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Page 6 of 17 ENGINEERING STANDARD
• Lack of fusion.
6.1.3 All surface irregularities, spatter and weld defects, including but not limited to
those mentioned in paragraph 6.1.2, shall be remedied by welding and/or
grinding.
7 SURFACE PREPARATION
7.1 General
7.1.1 The entire surface to be coated shall be inspected to ensure freedom from
imperfections and surface flaws as required in Section 6.
7.1.2 All surfaces shall be degreased in accordance with SSPC-SP1, steam cleaning,
detergent scrubbing or low-pressure water cleaning to ensure removal of all
surface contaminants.
7.1.4 Open ends of components shall be plugged to prevent entry of abrasive during
blast cleaning.
7.1.5 Sand shall not be used for blast cleaning. Copper slag abrasive shall not contain
metallic copper or more than 2% by weight of copper oxide. All expendable
abrasives shall be free from measurable chlorides.
7.1.6 All compressed air contacting the prepared surface shall be free from oil and
condensed water. Filters shall be used and checked on a daily basis for
cleanliness.
7.1.7 Particle size and cleanliness of the abrasive shall be checked daily and
replenished with fresh abrasive as necessary to produce the specified profile.
7.1.8 All dust, spent abrasive and debris shall be removed by brushing and vacuum
cleaning when surface preparation is complete. The surface shall be re-inspected
to ensure that cleanliness is of the specified standard and that surface-breaking
flaws are absent.
7.1.9 At girth weld margins, any existing coating affected by welding shall be removed
and a chamfered edge produced in the sound, existing coating. A further 50mm
margin of sound, existing coating shall be lightly roughened by abrasive blasting
or grinding. The coating beyond this margin shall be protected to prevent damage
during subsequent blasting and coating work.
8 COATING PROCESS
8.1 General
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ENGINEERING STANDARD Page 7 of 17
8.1.1 Coating work shall begin within two hours of the start of blast cleaning and while
the surface is at the specified standard of cleanliness.
8.1.2 The steel surface shall be maintained at a temperature at least 5oC above the dew
point and at a minimum of 10oC. The relative humidity of the air during coating
shall not exceed the maximum figure given by the coating manufacturer.
8.1.3 The dry film thickness of individual coatings shall be within ± 20% of the specified
thickness. The maximum thickness of individual layers in each system shall not
exceed that stated by the coating manufacturer.
8.1.4 The total thickness of the coating systems shall not be less than the minimum
specified thickness nor greater than 20% of the sum of the specified total film
thicknesses.
8.1.5 During and after coating application the coated surfaces shall be maintained at
the temperature and under the humidity recommended by the coating
manufacturer until curing is complete.
9.1 General
9.1.1 Contractor shall ensure that each coating manufacturer provides certificates for
each consignment of coating material confirming that all tests as required below
have been successfully completed on each batch supplied. Contractor shall
retain all such certificates and results of any additional tests performed by
Contractor and submit to Owner for review when requested:
9.1.2 All coating materials shall be supplied in original, sealed, damage-free containers,
clearly marked with the manufacturer’s name, product reference, batch number,
date and place of manufacture and storage and safety instructions.
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Page 8 of 17 ENGINEERING STANDARD
9.1.4 The following types of coating materials are acceptable. Contractor shall submit
full details demonstrating the suitability of any proposed alternative material for
review and approval by Owner.
9.2.1 Fusion bonded epoxy (FBE) powder coating is acceptable for up to a maximum
surface operating temperature of 60°C.
9.2.2 FBE shall be applied by electrostatic spray or in a fluidised bed to give a total dry
film thickness (DFT) of 350 microns minimum.
9.2.3 FBE powder applied to items shall not contain more than 20% recycled powder.
9.2.4 Immediately after blast cleaning in accordance with Section 7 and prior to
application of the powder, a chromate-silica treatment shall be applied in a
uniform manner and without excessive thickness, to the surface to be coated.
9.3.1 Liquid applied coatings shall be based on solvent-free, cold curing epoxy or
polyurethane with a total DFT of 350 microns minimum.
9.3.2 Application shall be by airless spray. All welds, corners and edges shall receive
and additional coat to ensure that the minimum specified thickness is met.
9.3.3 During and after coating, the coated surfaces shall be maintained at the
temperature and humidity recommended by the coating manufacturer until curing
is complete.
9.4.2 Rolls of wrapping tape shall have an over-width interleaf of releasing paper
between adjacent layers.
9.4.3 A primer coat shall be applied in accordance with Section 8 and as follows:
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ENGINEERING STANDARD Page 9 of 17
9.4.4 When primer is completely dry and free from contamination by oil, grease, dirt,
salt etc., tape of the appropriate width as noted below, shall be spirally wound
onto the surface with a 55% overlap to ensure a minimum of two layers of tape at
any one point:
D ≤ 3”NB 50
9.4.5 Sufficient tension shall be applied to ensure complete conformability and intimate
adhesion of the tape to the primed surface and to avoid air pockets.
9.4.6 The width of wrapping tape may be reduced at pipe bends to aid conformability
and adhesion of the tape to the internal surface (intrados) of the pipe bend.
9.4.7 The overlap between the ends of succeeding rolls of tape shall be a minimum of
150mm.
9.4.8 At flanged terminations, the tape shall continue over the pipe-flange weld for a
minimum of 25mm. The primer shall continue beyond the edge of the tape for a
further 25mm.
9.4.9 At junctions between the wrapped tape and other coatings, the tape shall extend a
minimum 50mm beyond the edge of the coating.
9.4.10 For valves, flanges and fittings, the contours of the primed surfaces shall be
blended and rounded to pack crevices, cover bolts etc., using a cold moulding
putty as recommended by the tape manufacturer. The whole surface shall be
covered with tape of the appropriate width using the same overlap and technique
as for straight pipe.
9.5.2 The primer applied in conjunction with the sleeve and tape shall be a solvent-free,
two component liquid epoxy, as recommended by the sleeve/tape manufacturer.
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Page 10 of 17 ENGINEERING STANDARD
9.6.2 The minimum requirements (i.e. thickness, application, inspection etc.) shall be in
accordance with DIN 30 670 and DIN 30 678.
10.1 General
10.1.1 Contractor shall ensure that coatings selected for application over girth welds are
fully compatible with existing coating(s).
11 INSPECTION OF COATINGS
11.1 GENERAL
11.1.1 Coating activities shall be inspected in accordance with this Engineering Standard
to an approved procedure and quality plan. Coating procedures and quality plans
shall be submitted in accordance with Section 13.
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ENGINEERING STANDARD Page 11 of 17
• Dew point and surface temperature before and during blast-cleaning and
coating operations
• Absence of oil and condensed water in air for blast-cleaning, air pressure
and delivery rate(s)
• Metal defects, dust, and surface debris, on the surface after surface
preparation
• Preliminary cleaning
• Surface preparation
• Drying of coatings
11.1.3 During blast-cleaning and coating operations, the ambient condition readings
listed below shall be taken at least four times a day, including one set of readings
before starting each day or night shift, to ensure that the requirements of this
Engineering Standard are met:
• Dew point
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Page 12 of 17 ENGINEERING STANDARD
• Relative humidity
• Surface temperature
11.2.3 Pressure of the blast-cleaning air stream shall be measured with a hypodermic
pressure gauge inserted into the blast hose close to the nozzle (with the grit
supply turned off).
11.2.4 Testing for presence of dust on surfaces to be over coated may be performed by
pressing the sticky side of a piece of transparent self-adhesive film (e.g.
“Sellotape©”) onto the surface, peeling the film off and pressing it onto a piece of
clean white paper. The dust removed from the surface shall be examined and the
tape retained as an inspection record.
11.3.1 The coating shall be visually inspected to ensure freedom from all defects
including pinholes, holidays, under-thickness, blisters, porosity, fish eyes, sags,
orange peel, foreign particles and mechanical damage.
11.3.2 Dry film thickness shall be measured using an approved thickness gauge
calibrated for the range of thicknesses being checked, using ‘United States
Institute of Standards and Technology, Certified Coating Calibration Standards for
Non-magnetic Coatings on Steel’.
11.3.3 Thickness measurements shall only be performed when the coating is hard
enough to resist indentation by the probe of the gauge. Alternatively, a shim of
known thickness may be placed under the probe and its thickness deducted from
the reading of the gauge, making due allowance for the effect on the reading of
any solvent retained in the film.
11.3.5 Film thicknesses shall be reported as actually measured. They shall not be
routinely reported as being those specified regardless of, or in the absence of,
actual measured thickness.
11.3.6 The total dry film thickness of each coat shall be measured when fully hard. At
least four readings shall be taken per square metre of applied coating.
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ENGINEERING STANDARD Page 13 of 17
11.3.7 Continuity testing for holidays shall be performed using a high voltage detector in
accordance with NACE Standards RP0188 and RP0490. The minimum voltage
shall be in accordance with the coating manufacturer’s recommendations but shall
not be less than the “suggested” voltages in NACE Standard RP0188 or the
“recommended” voltages in NACE Standard RP0490.
11.3.9 Coating defects in accordance with the following criteria shall be repaired:
• For pipes (random lengths), fittings and bends, the number of holidays shall
not exceed the following:
8” < D ≤ 18” 10
D > 24” 15
• For fittings and bends, the maximum number of other defects shall not exceed
four (4) per component or two (2) per square metre
11.3.10 Components with a greater number of defects than those stated in paragraph
11.3.9 shall require the coating to be removed in its entirety and the component
re-coated.
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Page 14 of 17 ENGINEERING STANDARD
11.3.11 In case of dispute with respect to the integrity of the coating system, Owner
reserves the right to instruct Contractor to perform additional adhesion tests to BS
EN 24624/ASTM D4541 and cross-cut tests to BS EN ISO 2409.
12 COATING REPAIRS
12.1 General
12.1.1 Coatings which fail to meet the requirements of this Engineering Standard shall be
repaired in accordance with NACE Standard RP0184 and the following:
• Surface preparation for repair purposes shall include all the measures
necessary to achieve adequate adhesion between repair and original
coatings
• Repair coatings shall be of the same type and manufacture as the original
coating or a two-pack epoxy compound supplied or recommended by the
original coating manufacturer. Components of two-pack epoxy compounds
shall be thoroughly mixed in the proportions specified by the manufacturer
and shall not be used beyond the maximum stated pot life. Peel test sites
or areas of minor damage to heat-shrinkable sleeves shall be repaired
using a patch of the same material as the sleeve, applied in accordance
with the manufacturer’s recommendation
• All glossy or waxy surfaces and those whose over-coating delay time has
expired shall be thoroughly degreased/de-waxed and rendered matt by
abrading with emery paper or light abrasive disc grinding prior to over-
coating
12.1.2 All repaired areas shall be inspected in accordance with the requirements of
Section 11.3.
13 PROCEDURE QUALIFICATION
13.1 General
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ENGINEERING STANDARD Page 15 of 17
13.1.1 Contractor shall provide full details of the proposed coating systems for Owner
review and approval and shall provide evidence that the proposed coatings are, in
principle, acceptable for the service temperatures and meet the requirements of
this Engineering Standard.
13.1.2 Contractor shall establish a detailed programme to demonstrate that each coating
system will be applied correctly in accordance with the manufacturer’s
recommendations and this Engineering Standard by means of qualification
procedure trials. These qualification procedure trials shall cover the initial
application of coatings to all components (pipes, fittings, bends etc.) and girth
weld margins, and subsequent repair to all coatings.
13.1.3 The qualification procedure trials shall be witnessed by Contractor and Owner
representatives and shall be completed and approved by Contractor and Owner at
least 30 days prior to commencement of coating activities.
13.1.4 The trials shall be performed on components of the same material, diameter and
wall thickness as the actual installed components. For girth weld margins, the
same welding process as proposed for the production welds shall be used to
simulate the weld bead.
13.1.5 To qualify repair procedures, a simulated holiday shall be made in the coating and
this holiday prepared in accordance with Section 12.
13.1.6 The prepared surfaces and applied coatings shall be inspected in accordance
with the requirements of Section 11.
13.1.7 For application of FBE powder at girth welds, the following requirements shall be
met:
14 DOCUMENTATION
14.1 General
14.1.1 Contractor shall ensure that a detailed procedure and quality plan is submitted, in
accordance with Engineering Standard GTL-84-6, covering all coating activities
and shall include, but not be limited to, the following:
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• Liquid coating application method and film curing method, (if applicable),
time and temperature measurement method (if applicable)
14.1.2 Contractor shall submit detailed records covering each equipment item and pipe
spool subject to coating. As a minimum, each record shall be individually and
uniquely numbered and shall contain, but not be limited to, the following
information:
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ENGINEERING STANDARD Page 17 of 17
SASOL TECHNOLOGY