Post on 02-May-2018
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Qatar PetroleumQatar PetroleumEngineering DepartmentEngineering Department
(Offshore)(Offshore)
Jassim AlhorJassim AlhorPipelines EngineerPipelines Engineer
Offshore Pipelines and Risers Offshore Pipelines and Risers CoatingCoating
••Three pipelinesThree pipelines••Oil and gas Oil and gas servicesservices••88--12in diameter12in diameter••14km long14km long••Two weeks coating Two weeks coating periodperiod
BHBH--N09 WHJ & PipelinesN09 WHJ & PipelinesProjectProject
Assignment ObjectivesAssignment Objectives
Develop Better Understanding of Pipeline
Coatings Processes
Participate in Production and Laboratory Tests on
Pipelines Coatings
Office PreparationsOffice Preparations
Project Procedures1592-NP-ON-033, 1592-NP-ON-008
QP SpecificationsQP-SPC-L-004, QP-SPC-L-003
International CodesBS, ISO, AWWA, ASTM
Developed Activities Sheets
Coating Activities SheetsCoating Activities Sheets
Yard ActivitiesYard Activities
Neoprene Coating
Coal Tar Coating
Concrete Weight Coating
Anode Installation
MaterialsMaterials
Coal Tar CoatingCoal Tar CoatingMaterials QualificationsMaterials Qualifications
Review ManufacturerReview Manufacturer’’s Test s Test Certificates for Coating MaterialsCertificates for Coating Materials
PrimerPrimerCoal Tar EnamelCoal Tar Enamel
Inner WrapInner WrapOuter WrapOuter WrapWhite WashWhite Wash
Coating ProcessCoating Process
Coal Tar CoatingCoal Tar CoatingProcessProcess
BlastingBlasting(Visual inspection, pipe (Visual inspection, pipe
identification)identification)
PipePipePrim
er
Primer
Inner
Wrap
Inner
Wrap
Outer W
rap
Outer W
rapWhite
Wash
White W
ash
Coal T
ar
Coal T
arCoating ProcessCoating Process
Coating ProcessCoating Process
Coal Tar CoatingCoal Tar CoatingProcessProcess
BlastingBlasting(Visual inspection, pipe (Visual inspection, pipe
identification)identification)
PrimingPriming(Visual inspection, pipe (Visual inspection, pipe
handling, cut back handling, cut back preparation)preparation)
BlastingBlasting(Visual inspection, pipe (Visual inspection, pipe
identification)identification)
PipePipePrim
er
Primer
Inner
Wrap
Inner
Wrap
Outer W
rap
Outer W
rapWhite
Wash
White W
ash
Coal T
ar
Coal T
arCoating ProcessCoating Process
Coating ProcessCoating Process
Coal Tar CoatingCoal Tar CoatingProcessProcess
BlastingBlasting(Visual inspection, pipe (Visual inspection, pipe
identification)identification)
PrimingPriming(Visual inspection, pipe (Visual inspection, pipe
handling, cut back handling, cut back preparation)preparation)
PrimingPriming(Visual inspection, pipe (Visual inspection, pipe
handling, cut back handling, cut back preparation)preparation)
CoatingCoating(Visual inspection, 460(Visual inspection, 460--
500500ooF kettle temp., 25mm F kettle temp., 25mm min. overlap, 225mm cut min. overlap, 225mm cut
back, white wash back, white wash application)application)
BlastingBlasting(Visual inspection, pipe (Visual inspection, pipe
identification)identification)
PipePipePrim
er
Primer
Inner
Wrap
Inner
Wrap
Outer W
rap
Outer W
rapWhite
Wash
White W
ash
Coal T
ar
Coal T
arCoating ProcessCoating Process
Production TestsProduction Tests
Coal Tar CoatingCoal Tar CoatingProduction TestsProduction Tests
Climatic MonitoringClimatic Monitoring(Humidity < 85%)(Humidity < 85%)Surface RoughnessSurface Roughness
(50(50--100 microns)100 microns)
Residual ParticlesResidual Particles(ISO Sa 2.5, Class 2, no rust)(ISO Sa 2.5, Class 2, no rust)
Primer ThicknessPrimer Thickness(35(35--50 microns)50 microns)
Surface TemperatureSurface Temperature(Less than 50(Less than 50ooC)C)
Salt ContaminationSalt Contamination(2 micro g/cm(2 micro g/cm22))
Coal Tar ThicknessCoal Tar Thickness(4(4--6 mm)6 mm)
Holiday DetectionHoliday Detection(none @ 15KV & 300mm/s)(none @ 15KV & 300mm/s) Bond TestBond Test
(adhesive on metal)(adhesive on metal)
Lab TestsLab Tests
Coal Tar CoatingCoal Tar CoatingLaboratory TestsLaboratory Tests
PRIMERViscosity Test (35-60 sec.)
Volatile Test (<75% loss)
COAL TAR ENAMELSoftening Point (120-130oC)
Penetration Depth (1-9mm)
RepairsRepairs
Coal Tar CoatingCoal Tar CoatingRepairsRepairs
InspectionInspectionCriteriaCriteria
••200cm200cm22 maximum defect areamaximum defect area••Maximum 4 repairs per pipeMaximum 4 repairs per pipe••Thickness check after repairsThickness check after repairs••Holiday detection after repairsHoliday detection after repairs
ProcessProcess
Concrete Weight CoatingConcrete Weight CoatingProcessProcess
Pipe
Pipe
Con
cret
eC
oncr
ete
Wir
e M
ish
Wir
e M
ish
Wir
e M
ish
Wir
e M
ish
Con
cret
eC
oncr
ete
Con
cret
eC
oncr
ete
Concrete Weight Coating ProcessConcrete Weight Coating Process1181 pipes to be concrete coated with a thickness 1181 pipes to be concrete coated with a thickness
range from 35mm to 105mmrange from 35mm to 105mm
Tests & InspectionsTests & Inspections
Concrete Weight CoatingConcrete Weight CoatingTests & InspectionsTests & Inspections
Average Average ThicknessThickness
(+/(+/--10%)10%)
Cut Back Cut Back LengthLength(300mm)(300mm)
Concrete Concrete CoverCover(15mm)(15mm)
Dry Dry DensityDensity
(3040kg/m(3040kg/m33))
Wet Wet DensityDensity
(3192kg/m(3192kg/m33))
Curing Curing PeriodPeriod(7 days)(7 days)
Strength Strength TestsTests
(20(20--30N/mm30N/mm22))
Iron Ore Iron Ore SizeSize
(<10mm)(<10mm)
ProcessProcess
Neoprene CoatingNeoprene CoatingProcessProcess
CoatingCoating
PrimingPriming
Lab TestLab Test
Neoprene CoatingNeoprene CoatingLaboratory TestsLaboratory Tests
Tensile Strength & ElongationTensile Strength & Elongation
Abrasion TestAbrasion Test
Specific GravitySpecific Gravity
Tear StrengthTear Strength
Production TestsProduction Tests
Neoprene CoatingNeoprene CoatingProduction TestsProduction Tests
••Visual inspection Visual inspection (no porosity)(no porosity)
••Hardness Hardness (65 shore A)(65 shore A)
••Thickness Thickness (12mm)(12mm)
••Hammer Test Hammer Test (uniform sound)(uniform sound)
••Holiday Test Holiday Test (none @ 1.7KV/mm)(none @ 1.7KV/mm)
••Adhesion Test Adhesion Test (rubber layer presence)(rubber layer presence)
••Ultrasonic Inspection Ultrasonic Inspection (3% inspection)(3% inspection)
AnodesAnodes
Anodes InstallationAnodes InstallationInspection CriteriaInspection Criteria••Physical identification Physical identification (conforming to design)(conforming to design)
••Doubler plate size Doubler plate size (50x50x6mm)(50x50x6mm)••Electric cable length and size Electric cable length and size (20cm, 25mm(20cm, 25mm22))
••CadweldCadweld powder weight powder weight (32g)(32g)••Mechanical integrity Mechanical integrity (stands 1kg hammer blow)(stands 1kg hammer blow)
••Electrical continuity Electrical continuity (resistance <0.01ohm)(resistance <0.01ohm)••Gaps coating Gaps coating (coal tar & concrete mix)(coal tar & concrete mix)