qatar petroleum engineering department (offshore) - coating activities.pdf · qatar petroleum...

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)