BREDERO PIPELINE SERVICES LIMITED

BNCL

CLIENT:
PROJECT:

SHELL PETROLEUM DEVELOPMENT COMPANY LTD

TBA
QUALITY PROCEDURE
THREE LAYER COATING COATING REPAIRS

Clause
1
1.1
2

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QP075
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12 April 13
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Description
SCOPE
This document describes the procedures to be followed repairing defects in three layer
polyethylene coating. Adherence to this procedure by the relevant personnel is
mandatory.
REFERENCES

2.1

DEP 31.40.30.31-GEN February 2011

2.2

ISO 8501-1

2.3

ISO 21809-1 : 2009

RESPONSIBILITIES

3.1

Project Manager is responsible for the provision of personnel, equipment and resources
necessary for the full and correct execution of this procedure.

3.2

Yard Superintendent is responsible for ensuring that all personnel observe the
requirements of this procedure. This responsibility is normally delegated to the
Production Supervisors under his immediate charge.

3.3

Quality Manager is responsible for ensuring that the quality requirements of this
procedure are met at all times. This responsibility is normally delegated to the QC
Inspectors under his charge. Quality Manager is also responsible for raising nonconformance reports (NCRs) where discrepancies are noted and for ensuring that any
identified corrective actions arising from such NCRs are carried out fully and completely.

3.4

Materials Controller is responsible for the call-off, storage and issue of raw materials
required during execution of the project, and for the establishment and maintenance of a
materials control system such that raw materials usage is accurately recorded and any
necessary stock rotation requirements are met.

4
4.1

4.1.1

Revision

PROCESS DESCRIPTION
MINOR REPAIRS (TOPCOAT ONLY)
The damaged polyethylene is removed using a chisel or suitable knife and the
surrounding area roughened using a mechanical burr. The damaged surface area is
abraded, providing a key for the polyethylene repair material. The repair area is gently
heated to eliminate surface moisture, then filled with PE Melt Stick material to the same
thickness as the parent coating. It is then blended smooth with the mechanical burr.
Once cool, the repair area will be made flush with the parent coating and any excess
material removed by scraper and rasp. The completed repair is subjected to electrical
inspection for holidays.

Number in Revision column denotes change over previous issue using current revision number

BREDERO PIPELINE SERVICES LIMITED

BNCL

CLIENT:
PROJECT:

SHELL PETROLEUM DEVELOPMENT COMPANY LTD

TBA
QUALITY PROCEDURE
THREE LAYER COATING COATING REPAIRS

Doc. Ref.:
Revision:
Rev. Date:
Page #

QP075
00
th
12 April 13
2 of 3

Clause

Description

4.1.2

Polyethylene melt sticks, or hand-held extruders may be used to repair this type of
damage, and the methods and procedures for application will be as recommended by the
repair materials manufacturer.

4.2

MAJOR REPAIRS (FULL SYSTEM)

4.2.1

The FBE substrate is gently preheated to eliminate surface moisture, and is then
feathered by abrasive paper at the FBE/steel interface. The exposed steel is power
brushed to at least ISO 8501-1 St3, and masking tape applied. Surface dust is removed
immediately prior to FBE repair material application.

4.2.2

FBE repair material is a two-part epoxy compound. The quantity required is mixed in
correct proportion with a clean knife or spatula, and spread evenly over the damaged
area such that all exposed steel is covered and there is an overlap of approximately
25mm onto sound FBE. The compound is allowed to cure before proceeding further. The
thickness of the cured repair compound must be not less than 150 microns.

4.2.3

After cure, the topcoat is repaired using the procedure detailed in Clause 4.1 above. Only
one repair per pipe is acceptable.

5
5.1

Revision

QUALITY REQUIREMENTS
SURFACE CLEANLINESS ON EXPOSED STEEL
Inspect every repair area before application of repair material.
Acceptance Criteria: ISO 8501-1 St3

5.2

REPAIR AREA TEMPERATURE

Check every repair by measuring the temperature of the exposed coating or steel in the
repair area using a contact pyrometer.
Acceptance Criteria: Not less than 15 deg. C, and at least 3 deg. C above the dew
point.

5.3

HOLIDAY DETECTION
100% coverage of every repair area at 25kV using a portable holiday detector.
Acceptance Criteria: No holidays

5.4

SIZE OF REPAIR AREA

Immediately following coating application, each coated pipe shall be visually checked for
imperfections and irregularities of the coating, for coating thickness and for the absence
of holidays. Pipes that do not comply with the requirements shall be marked and
removed from the coating line for repair or recoating. If subsequent pipes do not comply
with the requirements, the coating process shall be checked or stopped to eliminate the
cause of the problem.

Number in Revision column denotes change over previous issue using current revision number

BREDERO PIPELINE SERVICES LIMITED

BNCL

CLIENT:
PROJECT:

SHELL PETROLEUM DEVELOPMENT COMPANY LTD

TBA
QUALITY PROCEDURE
THREE LAYER COATING COATING REPAIRS

Clause

Doc. Ref.:
Revision:
Rev. Date:
Page #

QP075
00
th
12 April 13
3 of 3

Description

Revision

Per joint or fitting, the maximum allowable number of holidays to be repaired is two
pinholes or one larger area of damage (max. 40 cm). If the number or size of damage
sites exceeds these figures, the whole pipe shall be re-blasted and re-coated. If two
consecutive pipes are rejected for this reason, the coating process shall be checked to
determine the cause of the high holiday rate. If the cause is not resolved after further
rejection of consecutive joints, the complete process shall be stopped for full
investigation.
All holidays detected shall be repaired in accordance with the qualified repair procedure.
Acceptance Criteria: Repair of surface defects (depth < 20% of the overall coating
thickness); such defects shall be filled, ground or sanded to merge smoothly with the
surrounded coating. Pinholes, scratches & small defect (depth is > 20% of the overall
coating thickness but not showing bare steel); such defects shall be repaired by means
of a melt stick or approved equivalent, maximum allowable of defects per pipe is 2.
Defect showing bare steel with max 40 cm; such defects shall be repaired by using a
combination of liquid epoxy and a repair patch; only one repair per pipe is allowed.
SPDC retains the right to reject any shifts or days production if the reject rate of that
production is more that 10% and/or if sample test results are found to be outside the
specification.

CALIBRATION
Thickness gauges and holiday detectors will be calibrated before use using the method
detailed in procedure QP073.

DOCUMENTATION
The following documents will be completed as required:

7.1

QF046 Three Layer Coating Repair Inspection Report

7.2

QF058 Pipe Damage Report

7.3

RF002 Nonconformance Report

Number in Revision column denotes change over previous issue using current revision number