Вы находитесь на странице: 1из 20

JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT

Specification for Subsea Coating

Comment Record Sheet for Rev C1

Section/
Item Comments
Reference

No changes on Rev D2 – Document updated to Rev C1 - Issue for Construction

Comment Record Sheet for Rev D2

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

Page 2 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating

Table of Contents
COMMENT RECORD SHEET FOR REV C1.......................................................................................................2

COMMENT RECORD SHEET FOR REV D2.......................................................................................................2

1 1.0 INTRODUCTION ....................................................................................................................................4


1.1 SCOPE ...................................................................................................................................................4
1.2 DEVIATIONS ............................................................................................................................................4
1.3 REFERENCES ..........................................................................................................................................4
1.4 QUALITY SYSTEMS ..................................................................................................................................6
1.5 SAFETY AND ENVIRONMENTAL .................................................................................................................6
1.6 ABBREVIATIONS AND DEFINITIONS............................................................................................................7
1.6.1 Abbreviations ................................................................................................................................7
1.6.2 Definitions .....................................................................................................................................7
2 GENERAL REQUIREMENT.........................................................................................................................8
2.1 ANTI-CORROSION COATING .....................................................................................................................8
2.2 COATING DESIGN REQUIREMENT .............................................................................................................8
2.3 COATING SYSTEM REQUIREMENTS ........................................................................................................10
2.4 COATING PROCEDURE ..........................................................................................................................10
3 SURFACE PREPARATION .......................................................................................................................12
3.1 PRE-BLASTING INSPECTION ...................................................................................................................12
3.2 DEGREASING / CLEANING ......................................................................................................................12
3.3 AMBIENT CONDITIONS ...........................................................................................................................12
3.4 ABRASIVES ...........................................................................................................................................12
3.5 BLASTING EQUIPMENT ...........................................................................................................................13
3.6 BLAST CLEANING ..................................................................................................................................13
4 COATING APPLICATION..........................................................................................................................14
4.1 STORAGE OF COATING MATERIALS ........................................................................................................14
4.2 APPLICATION OF THE COATING ..............................................................................................................14
4.3 COATING SYSTEMS ...............................................................................................................................15
5 INSPECTION AND TESTING ....................................................................................................................16
5.1 GENERAL..............................................................................................................................................16
5.2 INSPECTION AND TESTING REQUIREMENTS .............................................................................................16
5.3 PRODUCTION AND INSPECTION TESTING.................................................................................................16
5.3.1 Adhesion Testing ........................................................................................................................17
5.3.2 Holiday (Pin-hole Detection) .......................................................................................................17
5.3.3 Documentation Requirements ....................................................................................................18
5.3.4 Access and Facilities ..................................................................................................................19
5.4 REPAIRS OF COATING ...........................................................................................................................19
6 DOCUMENTATION....................................................................................................................................20
6.1 DOCUMENTATION PRIOR TO COMMENCING WORK ..................................................................................20
6.2 FINAL DOCUMENTATION ........................................................................................................................20

Page 3 of20
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.

The coating system materials specified by CONTRACTOR shall be documented as suitable


for subsea service having continuous operating temperatures up to 80°C, at water depths of
200 metres with cathodic protection applied. The applied coating system shall be resistant to
direct solar / UV exposure for a period of up to 2 years during storage prior to installation. If
necessary, an additional outer solar protection coating shall be applied in order to achieve
the required resistance.

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

Page 4 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating
with applicable Statutory requirements. In addition, the latest editions of the following
specifications and international standards shall apply, as referenced:

Document Number Document Title

Specification for 3-Layer Polyethylene Coating of


JK-4LSSZZ-MT-SPE-0002
Linepipe

Codes and Standards

Document Number Code / Standard

Test Method for Measuring MEK Resistance of Ethyl Silicate


ASTM D4752
(Inorganic) Zinc Rich Primers by Solvent Rub.

Quality Systems- Model for Quality Assurance in production


BS EN ISO 9002
and Installation

BS EN ISO 2808 Paints and varnishes – Determination of film thickness.

BS EN ISO 4624 Paints and Varnishes – Pull-off Tests for Adhesion.

Preparation of steel substrates before application of paints


and related products -- Visual assessment of surface
BS EN ISO 8501-1 cleanliness -- Part 1: Rust grades and preparation grades of
uncoated steel substrates and of steel substrates after
overall removal of previous coatings

Preparation of steel substrates before application of paints


and related products -- Tests for the assessment of surface
BS EN ISO 8502-3
cleanliness -- Part 3: Assessment of dust on steel surfaces
prepared for painting (pressure-sensitive tape method).

Preparation of steel substrates before application of paints


and related products -- Tests for the assessment of surface
BS EN ISO 8502-6
cleanliness -- Part 6: Extraction of soluble contaminants for
analysis -- The Bresle method

Preparation of steel substrates before application of paints


and related products -- Surface roughness characteristics of
blast-cleaned steel substrates -- Part 4: Method for the
BS EN ISO 8503-4
calibration of ISO surface profile comparators and for the
determination of surface profile -- Stylus instrument
procedure

Preparation of steel substrates before application of paints


and related products -- Surface roughness characteristics of
BS EN ISO 8503-5
blast-cleaned steel substrates -- Part 5: Replica tape
method for the determination of the surface profile

Page 5 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating

Preparation of steel substrates before application of paints


BS EN ISO 8504-2 and related products -- Surface preparation methods -- Part
2: Abrasive blast-cleaning

Paints and varnishes – Performance requirements for


ISO 20340
protective paint systems for offshore and related structures

NACE RP0188 Discontinuity (holiday) Testing of Protective Coatings.

Corrosion Control of Steel Fixed Offshore Platforms


NACE RP0176
Associated with Petroleum Production.

Field Measurement of Surface Profile of Abrasive Blast-


NACE RP 02 87
Cleaned Steel Surfaces Using a Replica Tape

NORSOK M501 Surface Preparation and Protective Coatings.

SSPC-SP 1 Structural Steels Painting Council- Solvent Cleaning

SSPC Structural Steel Painting Manual.

Where CONTRACTOR identifies additional Codes and Standards that CONTRACTOR


considers are applicable to the Work the CONTRACTOR will provide the requisite
justification of their applicability to the Work.

1.4 Quality Systems

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 measuring equipment shall be calibrated within last six months.

1.5 Safety and Environmental

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.

Page 6 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating

The volatile organic compound (VOC) content of all materials shall meet the Local and
Statutory regulations.

1.6 Abbreviations and Definitions

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.

INSPECTOR The person, firm or organisation, appointed by the CONTRACTOR to verify


compliance with the requirements of this specification.

MANUFACTURER The provider / maker of materials, or equipment, to the CONTRACTOR, in


order to meet the requirements of this specification.

Page 7 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating

2 General Requirement

2.1 Anti-Corrosion Coating

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.

It is the responsibility of CONTRACTOR to meet the requirements of this specification, to


use equipment capable of meeting the requirements and to perform all inspections
necessary to ensure compliance.

In addition to CONTRACTOR'S scheduled inspections, COMPANY may perform various


inspections at any time to verify compliance with this specification. Inspection may include
any and all work, equipment, inspection equipment, materials or procedures.
CONTRACTOR shall allow COMPANY access to the application and test facilities at all
times during the Contract.

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.

2.2 Coating Design Requirement

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.

Page 8 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating
Table 2.1
Typical Coating Barrier Systems for Subsea Components, except for Pipeline and Bends

Sequence Coating Components Min - Max


DFT
Submerged carbon-low alloy steel or CRAs [Surface temp < 50°C] – Ref. Norsok
Coating System No. 7.
One (1) coat of an epoxy or an epoxy zinc phosphate
(1)
primer. 450 – 525
Two (2) coats of a two-pack amine or amide cured µm
(2)
epoxy.

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

Sequence Coating Components Min - Max


DFT
Subsea pipeline bends with design temperatures up to 80°C
(1) One (1) coat of a vinyl ester primer. 0.75mm –
(2) Two (2) coats of glass flake vinyl ester 1.5mm

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:

• Design/operating temperatures from -4 to 80°C as applicable to the specific


equipment or piping;
• The subsea system shall have a 25 year design life;
• The coating system to be applied to external and in some cases, internal
structural surfaces, shall also be protected by cathodic protection (CP) in the form
of sacrificial anodes and therefore the coating shall be selected based on its
ability to resist cathodic disbondment;
• Specifically for operation as high temperature;
• Specifically for operation as high temperature resistance to elevated temperature
cathodic disbondment;

Page 9 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
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.

2.3 Coating System Requirements

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.

Qualification testing shall include as a minimum the following tests:

• 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:

• CONTRACTOR shall provide documentation verifying the suitability of the coating


for total immersion in sea water at an operating depth of 200m and a maximum
operating temperature of up to 80°C as stated by COMPANY;
• Specifically for operation at high temperature in seawater, the resistance to
blistering and disbondment, and the resistance to cathodic disbondment shall be
documented;
• Each coating deposit / layer shall be of a contrasting colour;
• The topcoat colour shall be Yellow RAL 1004 or an equivalent regime to be
proposed by CONTRACTOR for COMPANY approval. If required an additional
top-coat may be applied in the designated system identification colour. This top-
coat shall not be considered as part of the corrosion protection;
• Coatings to be applied in enclosed spaces / structures shall be suitable for
internal use, and shall have a low VOC content. CONTRACTOR shall also
ensure that the necessary health and safety procedures are rigorously applied
when coating inside enclosed spaces.

2.4 Coating Procedure

Prior to coating application, CONTRACTOR shall submit to COMPANY for approval, a


detailed coating procedure specification that it proposes to use for the application and repair
of subsea coatings to subsea components. This document shall describe the procedures to
be followed by CONTRACTOR before, during and after coating application.

Page 10 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating

The procedure shall be submitted immediately after the placement of the purchase order and
before any pre-production meetings.

The procedure shall include, but shall be not limited to:

• List of applied standards and codes;


• Identification of coating and blasting equipment;
• Coating application details;
• Details of any solvents to be used;
• Inspection and testing plan and schedule;
• Marking and documentation;
• Handling and storage of coated components;
• Coating repairs and stripping of non-repairable coating
• Methods, equipment and materials for surface preparation
• The minimum permitted degree of cleanliness referenced to ISO 8501, and the
permitted range of surface profile and roughness for the surface to be coated
• Methods, equipment and materials for coating application
• Coating systems to be used as defined in this Specification including the coating
manufacturer’s product data sheets, the Material Safety Data Sheets (MSDS),
and the colour shade for each layer of coating
• Permissible ranges of substrate temperature, air temperature, relative humidity
and dew point during all surface preparation, coating application and drying /
curing activities
• Minimum and maximum times between surface preparation and first coat and
subsequent coats
• Number of coats and minimum and maximum dry film thickness per coat and for
the total system
• Permissible minimum adhesion strength to substrate
• Type and methods of inspection and testing, and criteria for acceptance
• Frequency of monitoring, inspection, and testing
• Surface preparation and coating record sheets
• Safety and environmental controls

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.

Page 11 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating

3 Surface Preparation

3.1 Pre-blasting Inspection

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.

3.2 Degreasing / Cleaning

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.

3.3 Ambient Conditions

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

Page 12 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
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.

3.5 Blasting Equipment

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.

3.6 Blast Cleaning

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.

Page 13 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating

4 Coating Application

4.1 Storage of Coating Materials

The coating materials shall be stored according to the MANUFACTURER’S


recommendations. They shall be clearly marked with the MANUFACTURER’S name, batch
number and shelf life. If any portion of the coating shows sign of degradation then it shall be
discarded. In addition no coatings that have exceeded their shelf life shall be used.

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.

4.2 Application of the Coating

The coating shall be applied in accordance with the MANUFACTURER’S recommendations.


The environmental conditions during application shall be recorded. Coating application is not
permitted if the relative humidity, or if the ambient temperature is outside of the range
specified by the MANUFACTURER.

Unless otherwise stated by COMPANY, coating shall not take place under the following
conditions:

• Under adverse weather conditions, when conditions impede the curing/drying


of the coating system
• If the ambient temperature is below 15 oC
• If the ambient temperature is above 40 oC
• If the relative humidity is >85%
• Metal surface temperature < 5 oC above the ambient dew point
• Outside daylight hours on field site locations

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%.

Coatings shall be applied in accordance with the MANUFACTURER’S recommendations


and shall usually be by airless spraying. Inaccessible areas may be brushed or rolled as
required.

The applied coatings shall be applied evenly and shall be free from defects such as runs,
sags, pin-holes, holidays or blisters, etc.

Page 14 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
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.

4.3 Coating Systems

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.

Page 15 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating

5 Inspection and Testing

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.

5.2 Inspection and testing 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

5.3 Production and Inspection Testing

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.

The inspection testing required is defined in Table 5.1.

Table 5.1 – Inspection & Testing Requirement

Test Frequency Acceptance Criteria


Edge control 100 % Edge radius shall be 2mm min.
Surface defects 100 % As per this specification.
Environmental At least 3 times per
As per this specification.
Conditions shift

Page 16 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating

Test Frequency Acceptance Criteria


100 % visual of all At least Sa 2 1/2 in accordance with
Blast cleaning and surfaces ISO 8501-1.
cleanliness Dust contamination below rating 2 in
Spot checks
accordance with ISO 8502-3.
Below 20 mg/m2 in accordance with
Salt contamination Spot checks
ISO 8502-6
As per this specification in
Roughness / Each component or
accordance with ISO 8503-4 or
surface profile once per 10m2
8503-5
Solvent testing on As per ASTM D4752, and also as
Spot checks
coating per this specification - Section 5.3.4
at least four (4) per
As per this specification and in
DFT square meter (m2) of
accordance with ISO 2808
coated surface
Curing test on As per this specification - Section
Spot checks
coating 5.3.4
One test per operator As per this specification - Section
Adhesion testing
per shift and per batch 5.3.1
As per this specification - Section
Pin-hole / holiday 100 % as per Section
5.3.2, in accordance with NACE
detection 5.3.2
RP0188
Each applied coat is cured; free from
Visual examination 100 % of surface after contamination, solvent retention,
of coating each coat pinholes/popping, sagging and
surface defects

5.3.1 Adhesion Testing

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.

5.3.2 Holiday (Pin-hole Detection)

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.

Page 17 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating

5.3.4 Additional Tests

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.

5.3.3 Documentation Requirements


A daily log must be prepared by CONTRACTOR, and shall record, as a minimum;

• 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.

Page 18 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
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.

5.3.4 Access and Facilities

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.

5.4 Repairs of Coating

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.

Page 19 of20
JK-4LSSZZ-MT-SPE-0010 REV C1 CHIRAG OIL PROJECT
Specification for Subsea Coating

6 Documentation

6.1 Documentation Prior to Commencing Work


The work procedures shall be submitted for COMPANY approval, and as a minimum shall
include the following:

• 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

6.2 Final Documentation

The As built documentation shall be submitted for COMPANY approval, and as a minimum
shall include the following:

• Organisation chart and any changes during the Work


• Subcontractor Performance and Lessons Learnt
• Location of coating facilities and any changes
• Quality plan showing the QA/QC programme and what checks were carried out
• Details of items coated (dates, quantities, id numbers)
• List of instruments used
• Records of specified measurements and tests
• Calibration records
• Detail of items repaired
• Coating schedule planed vs actual
• Surface preparation methods, standards, type of abrasives and equipment
• Coating application method
• Coating procedures ref
• Coating system data/material safety data sheets
• Work plan
• Inspection and testing procedures
• HSE method statement for handling the hazards identified

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.

Page 20 of20