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Section/
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Reference
Section/
Item Comments
Reference
Background : Specification updated to include a Glass Flake Vinyl Ester coating
system for subsea pipeline bends
Title for Table 2.1 changed for clarity and to highlight that it is applicable for
1.0 Table 2.1
subsea components, except pipelines and bends
Added Table 2.2 with details of the glass flake vinyl ester coating system for
2.0 Table 2.2
subsea pipeline bends.
Title for doc. No JK-4LSSZZ-MT-SPE-0002 changed to read Specification
3.0 Section 1.3
for 3-Layer Polyethylene Coating of Linepipe
Hold Record
Ref.
Hold Ref. Description / Reason for Hold
Section
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JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating
Table of Contents
COMMENT RECORD SHEET FOR REV C1.......................................................................................................2
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JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating
1 1.0 Introduction
1.1 Scope
This specification has been prepared to define the minimum requirements for subsea epoxy
corrosion barrier coatings applied to external surfaces of subsea systems manufactured from
carbon-and low alloy steel and corrosion resistant alloys (CRAs) in order to provide a
corrosion barrier in combination with cathodic protection (CP), in the form of sacrificial
anodes, for the COP subsea components, except for pipelines. The corrosion coating for the
pipelines is covered separately in the specification for 3-layer Polyethylene, JK-4LSSZZ-MT-
SPE-0002.
The specification defines the minimum requirements to be met with regard to coating
materials, surface preparation, application, inspection and testing of subsea compatible
generic epoxy, epoxy phenolic and glass flake vinyl ester (GFVE) coatings.
The subsea components to be coated may include spool pipes and bends, flanges, valves,
wyes and fabricated steel structures.
The application of generic epoxies are limited up to a maximum surface temperature of 50°C
and higher temperatures are more suited to the application of immersion grade epoxy
phenolics, and GFVE coating systems. If epoxy systems are to be used above 50°C for
continuous operation, the specific products shall be proposed for COMPANY approval and
supported by third party test data with track records of previous use.
For general data on operating pressures, temperatures for specific components, reference
shall be made to the applicable project datasheet for the component.
Unless otherwise approved in writing by COMPANY, all primary surface preparation and
coatings application activities shall be carried out under environmentally controlled
conditions. Only field weld areas shall be coated in external conditions, and this work shall
only be performed when weather conditions are suitable, as agreed with the INSPECTOR.
1.2 Deviations
All proposed deviations to this Specification and other documents referenced herein shall be
made in writing by the CONTRACTOR and shall require written approval by COMPANY prior
to commencement of the work.
In the event of conflict between this Specification and the referenced codes and standards,
CONTRACTOR shall obtain written clarification from COMPANY. In principle, the
requirements of the most stringent document shall apply.
1.3 References
All work carried out by the CONTRACTOR shall be in accordance with this Specification and
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Specification for Subsea Coating
with applicable Statutory requirements. In addition, the latest editions of the following
specifications and international standards shall apply, as referenced:
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Specification for Subsea Coating
CONTRACTOR shall maintain an effective programme for quality assurance and quality
control planned and developed in conjunction with all manufacturing, storage and application
functions necessary to meet the requirements of the Contract or Purchase Order of which
this Specification forms part. The requirements shall be met by the establishment and
implementation of procedures that shall ensure that acceptable services are provided to
COMPANY. The programme shall demonstrate both recognition of the quality requirements
of the Contract or Purchase Order and an organised approach to satisfy those requirements.
The programme shall ensure that quality requirements are determined prior to
commencement of the work and are maintained throughout.
The coating batch, shift and sample of origin shall be fully traceable.
CONTRACTOR's quality systems and quality control procedures shall be in accordance with
ISO 9002.
All surface preparation and coatings work shall comply with all applicable environmental and
safety provisions, laws, regulations, ordinances, etc., of the place or country pertaining to the
work being performed and the coating materials being used.
The CONTRACTOR shall comply fully with the occupational safety and health act (OSHA) of
the country in which the work is carried out. Material Safety Data Sheets shall be provided
by the materials supplier and available at the place of application for review.
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Specification for Subsea Coating
The volatile organic compound (VOC) content of all materials shall meet the Local and
Statutory regulations.
1.6.1 Abbreviations
Abbreviation/
Description
Acronym
ASTM American Society for Testing and Materials
BS British Standards
COSHH Control of Substances Hazardous to Health
CP Cathodic Protection
CRA Corrosion Resistant Alloy
DFT Dry Film Thickness
DNV Det Norske Veritas
GFVE Glass Flake Vinyl Ester
HSE Health, Safety and Environment
ISO International Standards Organisation
ITP Inspection and Test Plan
NACE National Association of Corrosion Engineers
SSPC Steel Structures Painting Council
RH Relative Humidity
VOC Volatile Organic Compounds
WFT Wet Film Thickness
UV Ultraviolet
1.6.2 Definitions
Term Meaning
COMPANY AIOC
CONTRACTOR Company selected by COMPANY responsible for the coating Scope of Work
or his approved sub-contractor.
Shall Indicates a requirement that is mandatory.
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Specification for Subsea Coating
2 General Requirement
CONTRACTOR shall furnish all labour, materials and equipment necessary for the handling,
cleaning, surface preparation, coating and inspection of the coated subsea components in
accordance with this specification.
Any inspection work conducted by COMPANY shall not relieve CONTRACTOR of his
obligations to carry out the work fully in accordance with the requirements of this
specification.
The workmanship will be of the highest standard incorporating the current best practices.
The methods and materials used shall meet the applicable health and safety regulations. In
particular the relevant health and safety data sheets for the coating used shall be adhered to
and must be available for reference at all times. CONTRACTOR shall also ensure that the
surface preparation and coating is carried out in a safe working environment, particularly
when coating inside enclosed spaces.
CONTRACTOR shall carry out COSHH and environmental assessments (with COMPANY
participation) before start of the work.
All blast cleaning and spray-coating equipment shall be continuously electrically bonded
from the nozzle to the surface being painted and backwards from the nozzle to the
compressor, which shall be earthed. Compressors used shall meet HSE requirements
specified by COMPANY, including those relating to noise levels. In hazardous areas,
CONTRACTOR shall use non-spark tools for cleaning purposes and flameproof equipment
shall be compulsory.
CONTRACTOR shall propose suitable subsea corrosion barrier systems in accordance with
NORSOK 501 for COMPANY review and approval. Typical corrosion barrier options
acceptable to COMPANY are presented in Table 2.1.
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Specification for Subsea Coating
Table 2.1
Typical Coating Barrier Systems for Subsea Components, except for Pipeline and Bends
High temperature [Surface temp 50°C to 100°C] – Ref. Norsok Coating System
No. 6 or 9. (note 1, 2)
(1) One (1) coat of an immersion grade epoxy phenolic. 375 -450
(2) One (1) coat of an immersion grade epoxy phenolic. µm
Notes
1- For high temperature systems, a qualified GFVE coating system may also be proposed
for COMPANY consideration.
2- For epoxy applications above 50°C, COMPANY approval must be requested as stated in
clause 1.1.
Table 2.2
Coating Barrier System for Subsea Pipeline Bends
The selected coating system shall be applied to external and in some cases, internal
surfaces, in a controlled environment for the purpose of attaining long term subsea
protection and shall be suitable for the intended duties, which shall include:
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Specification for Subsea Coating
Coating shall be from systems and manufacturers approved by COMPANY for the particular
application. Details of coatings systems with datasheets and any supporting performance
qualifications shall be submitted for COMPANY approval.
The proposed coating systems shall be qualified by the CONTRACTOR through testing
laboratory coated test specimens for each applicable test and by meeting the acceptance
criteria as set out NORSOK M501 – Table 1 and shall be fulfilled and documented prior to
commencement of any work.
• Cathodic disbonding according to ISO 20340, at 50°C and at 80°C if proposed for
high temperature applications,
• Seawater immersion according to ISO 20340, at 50°C and at 80°C if proposed for
high temperature applications
• Ageing resistance according to ISO 20340, procedure A
The laboratory coated test specimens shall be prepared and coated using the same
procedure that CONTRACTOR has proposed for the coating scope of work.
The various procedures shall also be qualified under the same conditions and at each
coating site as the intended application, and shall be assessed according to the
requirements defined in Table 5.1. As a minimum, two (2) 300mm square sample plates
shall be prepared and coated with each coating system required for scope of work, and shall
be witnessed by CONTRACTOR and COMPANY.
The applied coating systems shall also conform to the following requirements:
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Specification for Subsea Coating
The procedure shall be submitted immediately after the placement of the purchase order and
before any pre-production meetings.
Data for the proposed coating systems, abrasive materials and solvents shall be provided to
COMPANY in order to permit area classifications to be determined for the duration of the
coating works.
COMPANY reserves the right to reject any coatings that have not been applied according to
an approved procedure.
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Specification for Subsea Coating
3 Surface Preparation
Prior to blasting the surface of the metal shall be inspected for any discontinuities or defects
such as laminations that would affect the adhesion of the coating. These may be removed by
light dressing. If shop primers have been used for temporary corrosion protection, then these
shall be removed prior to or during abrasive blasting.
Welds shall be free from porosity and shall have a smooth profile, without sharp edges or
recesses. All edges shall be ground to minimum 2mm radius. CONTRACTOR shall ensure
all grinding / dressing operations are supervised and inspected by qualified personnel.
CONTRACTOR shall mask the component according to the requirements of the applicable
specification requirements. The masking shall ensure that no damage shall come to
susceptible areas such as threads and seal surfaces, etc. If there is any doubt as to which
areas are to be masked then CONTRACTOR must contact COMPANY for clarification.
All surfaces shall be washed with clean fresh water and allowed to dry thoroughly prior to
blast cleaning.
Any oil and grease contamination shall be removed using suitable degreasing solvent or
emulsion cleaner prior to blasting operations, in accordance with SSPC-SP-1. Slow
evaporating solvents such as paraffin shall not be permitted.
Where steel has been shipped or stored in an open coastal or marine atmosphere, water-
soluble salts shall be removed by scrubbing with a 1% detergent solution using hard bristle
brushes, followed by fresh water rinsing. Surfaces shall be allowed to dry thoroughly before
blasting.
Blast cleaning shall only take place when air humidity is below 85% and when the steel
temperature is at least 5°C above dew point. Following blasting, these conditions shall be
maintained until coating application is completed. Any blasted surfaces, which have been
exposed to humidity levels above 85% or temperatures less than 5°C above the dew-point,
shall be re-blasted. If necessary, to maintain surface temperature above the specified
criterion, a non-contaminating heat source may be used.
A whirling hygrometer or approved digital instrument shall be used to measure the relative
humidity, before and during blast cleaning and coating, in order not to exceed the specified
limits.
3.4 Abrasives
The type and size of abrasive grit shall be selected such that the required surface profile
shall be achieved. The abrasives shall be of angular metallic grit for carbon and low alloy
steels. Size of abrasive particles for blast cleaning shall be suitable for consistently achieving
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Specification for Subsea Coating
an angular surface profile in the range 50 to 70 microns (µm), with peaks of maximum
amplitude of 120 microns.
CRAs, specifically, stainless steels, nickel and copper alloys shall be grit blast cleaned with
chloride free abrasives, such as alumina in order to achieve a minimum angular surface
profile of 50 microns. Copper slag abrasives are not acceptable. It shall be noted that
stainless steel surfaces shall be protected from contamination by debris produced during grit
blast cleaning of adjacent carbon steel.
The surface profile or roughness of the blast cleaned surfaces shall be assessed in
accordance with ISO 8503-4 or ISO 8503-5 or COMPANY agreed equivalent.
All abrasive grit shall be clean, dry and free from contaminants such as chlorides. Abrasives
shall not be re-used unless they are processed through proprietary recycling equipment
before re-use. If re-cycling is proposed, this shall be subject to COMPANY approval.
CONTRACTOR shall ensure that the blasting equipment is in good condition and is able to
meet the requirements of this specification. The air compressor shall be capable of supplying
a continuous flow of air volume of at least 6 m3 per hour at a minimum pressure of 7 kg /
cm3, at the nozzle of each blast gun.
The air supply shall be free from water or oil and shall have separators and filters installed.
The discharge air temperature shall not exceed 115oC. Cleanliness shall be assessed by
use of a white blotter to ASTM D4285.
All abrasive blast cleaning shall be carried out in accordance with requirements of ISO 8504-
2.
Dust, blast abrasives etc. shall be removed from the surface after blast cleaning.
The cleanliness of the blast cleaned surface shall be at least to grade Sa 2 ½ in accordance
with ISO 8501 -1. The level of dust on the steel surfaces shall not exceed rating 2 when
assessed in accordance with ISO 8502-3.
The maximum content of soluble impurities on the blasted surface as sampled using ISO
8502-6 and distilled water shall not exceed a NaCl content of 20 mg/m2.
The surface to be coated shall be clean, dry, free from oil/grease, and have the specified
roughness and cleanliness until the first coat is applied.
The maximum time between blasting and coating shall not exceed four (4) hours and before
any signs of rusting or contamination. Preparation and application shall be programmed to
ensure that this condition is met. However, if this time limit elapses, then the part or sub-
assembly, etc., shall be re-blasted.
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Specification for Subsea Coating
4 Coating Application
The contents of each container shall be thoroughly mixed according to the coating
MANUFACTURER’S recommendations. For a two-component system then only the amount
that can be used within the manufacturers pot life shall be mixed. Air agitation of the pots is
not permitted.
Thinning is permitted only when specified by the MANUFACTURER, and then in accordance
with their instructions.
CONTRACTOR shall prepare test plates for adhesion and cathodic disbondment testing and
shall propose test methods for COMPANY review and approval prior to commencement of
testing.
Unless otherwise stated by COMPANY, coating shall not take place under the following
conditions:
Prepared surfaces shall be coated before visible re-rusting occurs or within 4 hours,
whichever is the sooner. This requirement may be relaxed at COMPANY’s discretion if the
work is fully enclosed, the ambient temperature is above 15 oC, and the humidity is below
85%.
The applied coatings shall be applied evenly and shall be free from defects such as runs,
sags, pin-holes, holidays or blisters, etc.
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Specification for Subsea Coating
An additional coat of paint shall be applied by brush to all weldments, edges, corners etc,
and prior to main coating over and above that described in the coating schedule to ensure
that DFT is met.
Contamination of painted surfaces between coats shall be avoided. Any contamination shall
be removed.
The minimum and maximum overcoat times between coats shall be as per the coating
MANUFACTURER’S recommendations. The cure times specified prior to handling shall be
adhered to.
The wet film thickness (WFT) and dry film thickness (DFT) shall be in accordance with the
requirements of the coating MANUFACTURER.
WFT shall be spot checked by comb gauge in random areas as a means of indicating
whether or not the required DFT is to be achieved.
DFT of each individual coat and of the total coating system shall be checked by magnetic
thickness gauge. The gauge shall be calibrated, at least twice daily using (a) foils in the
thickness range being measured and (b) over steel plate with a surface profile representative
of that being achieved in practice.
DFT measurements shall be taken at a frequency of at least four (4) per square meter (m2)
of coated surface.
CONTRACTOR may use one of the corrosion barrier systems listed in Table 2.1 for the
scope of work; however, CONTRACTOR shall provide documentation verifying the suitability
of the coating to meet the requirements of this specification.
CONTRACTOR may propose alternative coating systems provided that they meet the
requirements of this specification and NORSOK M501. The coating system details must be
submitted to COMPANY for approval prior to application. Any coating that has not been
approved prior to application shall be rejected.
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Specification for Subsea Coating
5.1 General
Prior to the commencement of any work, COMPANY shall approve all coating and inspection
procedures. CONTRACTOR shall provide an inspection and test plan (ITP) for COMPANY
approval prior to the commencement of any coating. This ITP shall include the definition of
all processes, the frequency of testing and all witness and survey requirements.
All test equipment shall be regularly and routinely recalibrated. All inspection and test
results shall be recorded and shall be maintained by CONTRACTOR.
Ambient temperature, humidity, and metal surface temperature, shall be recorded for each
separate component or sub-assembly, etc., or at least three (3) times per shift, whichever is
the more frequent.
Inspection and testing during the coating application, and of the finished applied coating,
shall include the presenting of details of the following variables as a minimum, with all results
recorded on test reports in an approved format:
• Environmental conditions;
• Grading and cleanliness of abrasive;
• Surface profile after blasting cleaning;
• Visual cleanliness and residual dust test on blasted surfaces;
• Coating equipment parameters and settings;
• Coating thickness;
• Coating adhesion strength;
• Coating appearance and uniformity;
• Curing test
CONTRACTOR shall ensure that all personnel used for inspection are experienced and are
qualified to recognised standards. All measuring equipment, etc., shall be calibrated.
COMPANY also reserves the right to carry out unscheduled tests.
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Specification for Subsea Coating
Adhesion testing shall be conducted on 5mm (min) thick test panels in accordance with
NORSOK M501 in parallel with the coating application. The pull-off force shall be a
minimum of 5 MPa for the standard organic coating and 7 MPa for glass flake epoxy using
hydraulically operated test equipment, in accordance with ISO 4624. Adhesion tests shall
be conducted as part of the pre-qualification of the coating and also during production
coating. Testing shall be at a frequency of one test per operator per shift and per batch for
all coating systems.
COMPANY may request additional adhesion testing in the event that there are deviations
from the requirements of this specification.
100% holiday detection in accordance with NACE RP0188 shall be carried out on all
subsea coatings. The coatings shall be free of pores and holidays.
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Specification for Subsea Coating
COMPANY reserves the option to require the SUPPLIER to perform such testing of coating
materials as may be necessary to prove that the quality is in accordance with the coating
manufacturer’s specifications and data sheets and is suitable, without reduction in
performance, for use under the prevailing application conditions. Qualities to be tested
may include, but not be limited to, the following:
• Volume Solids
• Viscosity
• Pigment Dispersion
• Adhesion to Substrate
• Drying Time
• Cure Time
• Percentage Zinc in Dry Film (zinc-rich primers only)
• Percentage glass flake in dry film (glass flake containing coatings only)
• Percentage epoxy resin in the dry film.
Test methods shall generally be in accordance with methods approved by the COMPANY,
and shall be carried out under conditions that reflect the prevailing environmental and
application conditions.
100% holiday detection in accordance with NACE RP 0188 shall be carried out on all
coatings used for direct burial, partial or total immersion service. The coatings shall be
free of pores and holidays.
All coatings shall be tested for adequacy of cure. The test method and frequency shall be
submitted by the SUPPLIER for the COMPANY’S approval and can involve solvent wiping,
pencil hardness testing or other chemical or mechanical methods.
• Temperature and humidity during blasting and coating, recorded at least 4 times
a day at the coating facility;
• Location of coating facility;
• Condition of abrasives and equipment;
• Surface preparation quality and profile;
• Wet and dry film thickness measurements;
• Time interval between blasting and coating and between coating layers;
• Identification of component(s) being coated;
• Receipt and correct storage of coating materials including batch numbers and
product reference numbers;
• Results of all inspections and tests in accordance with the inspection and test
plan (ITP);
• Calibration of inspection instruments;
• COMPANY name;
• Repairs or other further work necessary.
COMPANY shall approve the inspection equipment before start of the work. Up-to-date
calibration certificates shall be available for inspection instruments.
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Specification for Subsea Coating
The coating log shall form part of the final inspection report and shall be submitted with the
component on completion of coating. COMPANY reserves the right to reject any coating
where the coating log has not been completed.
Access and facilities shall be provided for COMPANY in order to be able to carry out
intended monitoring/inspection duties and reasonable notice shall be given before
commencement of any surface preparation and painting work.
CONTRACTOR shall submit a repair procedure prior to the commencement of any coating.
This procedure must be in accordance with the coating MANUFACTURER’S
recommendations.
Areas where only the topcoats are damaged shall be solvent cleaned and left to dry. The
adjacent areas shall be feathered to allow a smooth transition between sound coating and
the repair. The film thickness shall then be built up to the specified requirements in
accordance with COMPANY approved blasting and coating procedures.
For areas that are damaged down to the base metal, they shall be cleaned and re-prepared
by either re-blasting or re-abrading (i.e. limited to a maximum of 200cm2) to the required
angular surface finish. The adjacent areas shall be feathered to allow a smooth transition
between sound coating and the repair. The coating shall then be re-applied per the
standard defined in COMPANY approved blasting and coating procedures.
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Specification for Subsea Coating
6 Documentation
• Organisation chart
• Identification of any subcontractors
• Location of coating facility
• Quality plan showing the QA/QC programme and what checks will be carried out
• Detail of items to be coated
• Coating schedule
• Surface preparation methods, standards, type of abrasives and equipment
• Coating application method
• Coating procedures
• Coating system data
• Work plan
• Inspection and testing procedures
• HSE method statement for handling the hazards identified
• Reporting system
• Qualification of operators/applicators
The As built documentation shall be submitted for COMPANY approval, and as a minimum
shall include the following:
Within one month of completion of the work, the As Built shall be issued to COMPANY
presenting the above full details of the recorded standards of surface preparation and
application of the coating systems used, together with the MANUFACTURER’S data sheets
and records of specified measurements, details of instruments, and corresponding
calibration tests.
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