SP-1246 1

Petroleum Development Oman L.L.C.

UNRESTRICTED Document ID : SP-1246

April 2010 Filing key : xxxx

Specification for

Painting and Coating of

Oil and Gas Production Facilities

PART 1

TECHNICAL REQUIREMENTS

FOR COATING SYSTEMS

Keywords: Acceptance Criteria Coatings Documentation Maintenance New Construction Painting Performance Tests Surface Protection

This document is the property of Petroleum Development Oman L.L.C. Neither the whole nor any part of this document may be disclosed to others nor reproduced, stored in a retrieval system, or transmitted in any form by any means (electronic, mechanical, reprographic

Version No. Date Author Scope / Remarks

ERD-48-01 Jan 89 ETH/5 Original ERD Document SP-1246 Ver.0 May 2002 OTT/11 Updated and in new PDO format SP-1246 Ver.1 July 2003 TTO/11 For issue

SP-1246 Ver.2 April 2010 UEC/121 For issue

INSTRUCTIONS TO USER

Make sure this is the latest issue of this specification. Refer to the EMDS for the last issue date.

Where this Specification refers to DEPs and International Standards, it refers to the issues that were in-use when the author wrote this Specification. Exceptions are references to specific issues. If you use DEPs or International Standards with this Specification, make sure you use the relevant issues.

Do not change this Specification without approval. Only the Custodian, the Corporate Functional Discipline Head (CFDH) who owns this Specification, can give approval for changes. If you think the Specification is not correct, write your comments on a copy of the User Comment Form. The form is the last page of this

Contents

1

Preface ... 5

1.1 Background...5 1.2 Applicability ...5 1.3 Units of Measurement...6

2

Introduction ... 7

2.1 General...7 2.1.1 Scope ...7 2.1.2 Exclusions...7 2.1.3 Circulation ...7

3

Technical ... 8

3.1 General...8

3.2 Paint and Coating Materials...8

3.2.1 Recommended Materials ...8

3.2.2 Paint Vendor Responsibilities...8

3.2.3 Paint Colours ...8

3.2.4 Thinners ...8

3.2.5 VOC Requirements...9

3.3 Finish Colour and Colour Coding Schedule ...9

3.3.1 Overall Top Coat Colours...9

3.3.2 Colour Identification for Plant Pipework and Pipelines...9

3.4 Metallic Coatings...9

3.4.1 Hot Dip Galvanising ...9

3.4.2 Thermal Sprayed Coatings ...10

4

Quality Assurance ... 10

4.1 Quality System ...10

5

Qualification of existing ERD 48-01 coating systems... 10

5.1 Introduction ...10

6

Related Business Control Documents... 11

6.1 ISO specifications...11

6.2 British specifications ...12

6.3 Euronorms ... Error! Bookmark not defined. 6.4 Other International Specifications ...12

6.5 PDO and SIEP Documents ...13

7

Appendix A Glossary of Definitions, Terms and Abbreviations ... 14

7.1 Standard Definitions ...14

7.2 Special Definitions...14

7.3 Abbreviations...16

8

Appendix B - Paint and Coating System Evaluation ... 17

8.1 Introduction ...17

8.2 Performance Tests ...17

8.2.1 Test Schedule...17

8.2.2 Test Methods ...17

8.2.3 Acceptance Criteria...17

8.2.4 Means of Evaluation Following Test...17

8.2.5 Application and Technical Information ...17

8.2.6 Notes to Tables B1 – B8 ...18

9

Appendix C - Cathodic Disbonding Resistance Test... 30

Tables

Table B1 Required Tests and Acceptance Criteria -External Onshore Above - Ground Structures...19

Table B2-B4 Required Tests and Acceptance Criteria – External Below-Ground Structures... 20-23 Table B5 Required Tests and Acceptance Criteria – Internals of Tanks and Vessels ...24

Table B6 Required Tests and Acceptance Criteria – Offshore Structures...25

Table B7 Required Tests and Acceptance Criteria – Miscellaneous Areas...26

1

Preface

1.1 Background

This Specification SP-1246 covers the minimum requirements for protective painting and coating systems, materials and application methods for the internal and external surface of steel structures and equipment within the oil and gas production facilities.

Relevant structures and equipment include aboveground and buried onshore tanks, vessels, in-station pipework, buried sections of above ground flowlines and pipelines, structural steel, electrical and mechanical equipment. For further information on buried sections of above ground flowlines and pipelines refer to GU-368.

Whilst the Specification is directed predominantly at protection of onshore oil and gas installations, it also covers external protective coating of marine facilities such as jetties, mooring buoys, barges and launches. Internal surfaces of pumps, valves and other mechanical equipment requiring special protective treatments are not dealt with in this Specification. For guidance on this contact UER/CFDH Materials and Corrosion. The coating of new pipelines and existing pipelines requiring rehabilitation are covered in the following alternative specifications and procedures. For guidance on this contact UER/CFDH Materials and Corrosion. GU-368 Guidelines For The Protection Of Buried Sections Of Surface Laid Pipelines/Flowlines

PR-1180 Procedure for Qualification of Pipeline Rehabilitation Coating Systems

DEP 31.40.30.31-Gen. Technical Specification for External Polyethylene and Polypropylene Coating for Line Pipe

DEP 31.40.30.32-Gen. Technical Specification for External Fusion-bonded Epoxy Powder Coating for Line Pipe DEP 31.40.30.37-Gen External Field Joint And Rehabilitation Coatings System For Line Pipe .

1.2 Applicability

All coating work shall be carried out in accordance with this Specification. If a variance is required then approval in writing from the Custodian, UER/CFDH Corrosion and Materials is required.

This Specification is not applicable retroactively.

This specification does not apply to concrete structures. For concrete structures in corrosive environment consult UER/CFDH Materials and Corrosion.

This is Part 1 of a five part Specification and must be read in conjunction with Parts 2, 3, 4 and 5.

PART 1 specifies technical and related requirements. This part includes performance tests and acceptance

criteria for assessing the acceptability of paint/coating/lining systems for each service specified in Parts 2 and 3.

PART 2 contains recommended protective coating systems for the following categories with respect to new

construction painting/coating activities:

- External surfaces of carbon steel structures, piping and equipment, onshore and marine - External surfaces of buried carbon steel structures, piping and buried sections of above ground

flowlines and pipelines. (except Class I and Class II pipelines) - Internal surfaces of tanks and vessels

- Stainless steel and galvanised piping and equipment - Areas beneath insulation

- Specialist applications

This Part also gives descriptions of the generic types of paint used for new construction projects. The descriptions apply equally to the maintenance paint systems presented in Part 3.

Protective coatings for new pipelines based on Polyethylene (PE), Polypropylene (PP) or Fusion Bonded Epoxy (FBE) are not covered in this Specification but the general good practices described in this volume are equally applicable to the coating of line pipe.

.

PART 3 contains recommended Maintenance Coating Systems for the following categories with respect to

location and painting/coating activities and inspection of old coatings:

- External coatings on carbon steel structures, piping and equipment, onshore and marine - External coatings of below ground carbon steel structures and piping including Class I and

Class II pipelines

- Internal coated surfaces of tanks and vessels - Stainless steel and galvanised piping and equipment

PART 4 contains the detailed requirements for surface preparation and application of coatings to the categories

stated in Parts 2 and 3. This Part contains HSE advice and general inspection requirements.

PART 5 Contains the list of approved coating systems and is a live document that will be updated by UER. This

includes coating systems that have been grandfathered in.

New Projects

PARTS 1, 2 and 4 apply in their entirety to new projects where painting and coating activities are carried out at

site or in the shop.

For painting and coating of package items, carried out prior to delivery to site or to existing facilities, the requirements, stated in PARTS 1 and 4, apply in their entirety, whilst those of PART 2 apply where applicable.

Maintenance

Where maintenance painting is to be done, PDO’s technical requirements are stated in PART 1 and those sections of PART 3 and 4 as appropriate, dependent upon the Scope of Work.

1.3 Units of Measurement

This specification uses and requires the use of the International System (SI) units of measurement in all documentation. Paint film thicknesses are expressed in microns, 1micron is 0.001mm.

2

Introduction

2.1 General

This Specification (Parts 1, 2, 3, 4 and 5) has been prepared for the use of PDO staff and by their Contractors, Inspectors, Painting Contractors, Equipment Vendors and Paint Vendors as a reference or as a contractual document (as appropriate) for all painting and coating contracts. This applies to both New Construction and Maintenance as appropriate.

2.1.1 Scope

Part 1 of this Specification establishes the minimum requirements of PDO as regards materials performance requirements to be employed for new construction and maintenance painting and coating of offshore structures and facilities and onshore process facilities. It details the PDO technical and related requirements. In general PDO requires coating systems to be of medium durability that is 5-15 years life, in medium corrosive conditions as defined in the various parts of ISO-12944. Attention is drawn to the performance requirements specified in Appendix B. The acceptable coating systems from ERD 48-01 are listed in Part-5 of the specification. Part 2 of this Specification gives the recommended generic coating systems for New Construction

Part 3 of this Specification gives the recommended generic coating systems for Maintenance and includes how old coatings should be assessed and repaired.

Part 4 of the Specification states the detailed requirements as regards to materials, surface preparation, application, testing, inspection and HSE requirements to be employed.

Part 5 of the Specification lists the approved coating systems for each Paint Coating System (PCS)

2.1.2 Exclusions

This Specification is not applicable to:

- pipelines and risers except as explicitly stated

- reinforcing steel for concrete structures, where it will be fully embedded in concrete - drilling facilities

- Temporary construction items that are to be removed during the installation phase and to which only a primer shall be applied.

2.1.3 Circulation

3

Technical

3.1 General

This section of the Specification covers the minimum performance requirements for painting and coating materials, and outlines the requirements for equipment, surface preparation, paint and coating application, testing and inspection, and HSE requirements. Full details of these requirements are given in Part 4. The requirements, unless otherwise indicated within this Specification, are applicable to all activities concerned with New Construction work, Repair and Maintenance wherever these activities are done.

3.2 Paint and Coating Materials

3.2.1 Recommended Materials

Recommended generic materials are detailed in the relevant section for each system in Parts 2 and 3 of this Specification may only be used if they meet the performance criteria defined in Appendix B of this

Specification. Demonstration of performance criteria to the requirements of Appendix B is necessary before any paint/coating system can be used.

The materials specified in Parts 2 and 3 of this Specification are those appropriate to large scale application. For local treatment brushable grades of these materials may be found to be necessary and the number of coats may need adjusting to achieve the necessary dry film thickness (DFT). The use of brushable grades of the materials specified in Parts 2 and 3 will not require any additional testing in accordance with Appendix B.

All coatings, applied to surfaces that will be buried or wetted in service, will be subject to cathodic protection with design criteria in accordance with PDO Specification SP-1128.

3.2.2 Paint Vendor Responsibilities

The Paint Vendor shall submit original test data and test results as performed by an independent testing authority to show compliance with the requirements of Appendix B. If this is not available then in house testing will be acceptable provided the testing is witnessed by a PDO approved third party inspection company such as BV and Velosi. Test results, from previous testing programmes provided they are less than 3 years old will be considered acceptable provided the coating systems are generically the same with no changes to any formulations.

The Paint Vendor shall ensure that all parties mentioned in Section 2.1 are supplied with up-to-date data sheet before any painting and coating commences. In the event of any changes to Paint Vendor’s Technical Data Sheets, product number etc, the related product shall be subject to the formal approval procedure, by testing of the complete paint/coating system to the requirements of Appendix B.

The Paint Vendor shall comply with PDO environmental requirements and submit Materials Safety Data Sheets for each product to PDO. Paint Vendors shall assist PDO Production Chemistry Department in development of Safe Handling of Chemicals (SHOC) cards for each generic type of paint.

Vendors are to notify PDO of any changes to the PCS shown in Part 5 as only approved coatings that are included in this part will be acceptable for use.

3.2.3 Paint Colours

The colours of alternate paint coats of the generic and proprietary systems listed in Parts 2 and 3 of this Specification should be contrasting.

3.2.4 Thinners

Only thinners as specified by the Paint Vendor shall be used. Mixing and thinning directions, as furnished by the Paint Vendor, shall be followed.

3.2.5 VOC Requirements

There are no statutory requirements in Oman for control of Volatile Organic Compound (VOC) and PDO uses the American Conference of Governmental Industrial Hygienists (ACGIH) publication which covers the current USA statutory regulations for controlling the exposure levels to paint solvents (VOCs). This publication lists the maximum exposure limits and occupational exposure standards.

The levels of VOCs that can be admitted to the atmosphere through both the manufacture and application of paints and associated products shall be in accordance with the above.

Paints and other coatings, specified in this Specification, shall not contain any components that are carcinogenic or possess high toxicity (eg. isocyanates) which can be released during application, in service or during removal.

3.3 Finish Colour and Colour Coding Schedule

3.3.1 Overall Top Coat Colours

The final coat of a coating system shall be of a colour in accordance with PDO colour scheme for equipment and process facilities shown in Table 1 below.

Table 1 Recommended Colours for Oil and Gas Installations

Facility Description Colour BS 4800 RAL

Oil and gas installations in the Interior and Government Gas installations on the Coast, including above-ground tanks, vessels, piping and structural steel. See also SP-1166

White 00 E 55 9010

Bottom strake of oil and water storage tanks Black 00 E 53 9005 Oil installations in Mina al Fahal including above-ground tanks,

vessels, piping and structural steel. Camouflage 1019 Stacks and heat transfer equipment Aluminium 00 A 05 9006

Electrical equipment Light Grey 7036

Instrument panels Silver Grey 18 B 21 7032 Safety markings including handrails Yellow 08 E 51 1021

Pipeline isolating joints Red 3000

Offshore mooring buoys topside steelwork Yellow 08 E 51 1021

3.3.2 Colour Identification for Plant Pipework and Pipelines

Colour coding shall be in accordance with SP-1166 the technical specification for Identification of On-plot Piping

3.4 Metallic Coatings

3.4.1 Hot Dip Galvanising

All carbon steel gratings, ladders, handrails, fences, stairways, walkways, cable trays, and other items as specified by the Project Technical Information shall be hot dip galvanised in accordance with BS EN ISO 1461: covering hot dip galvanised coatings on iron and steel articles. The minimum coating weight shall comply with the values laid down in Table 1 of BS EN ISO 1461: and shall not be less than 610 g/m2_.

All sealed tubes must have a small weep-hole to allow hydrogen gas to escape.

Small areas of galvanised coating, damaged by cutting, welding, drilling or any preparation during fabrication, erection, transportation or installation, shall be repaired in accordance with Part 3.

Painting systems for galvanised items that are to be painted are detailed in Sections 5 of Part 2 and Part 3 of this Specification, for new construction and maintenance painting respectively.

3.4.2 Thermal Sprayed Coatings

If required all thermally applied coatings shall comply with DEP.30.48.40.31 with a minimum DFT of 100 microns.

4

Quality Assurance

4.1 Quality System

The Paint Vendor shall operate a Quality System in line with recognised PDO standards and in general accordance with ISO-9002. PDO reserves the right to audit the Paint Vendors manufacturing facilities.

5

Qualification of Existing ERD 48-01 Coating Systems

5.1 Introduction

The existing coating systems approved for use under ERD 48-01 and elsewhere are shown in Part 5. The tables show which systems can be carried forward and do not require testing in accordance with the following tables in Appendix B of this part.

6

Related Business Control Documents

The following standards, codes and specifications shall form part of this Specification. Except where a specific edition or revision is identified by date or revision/edition number, the latest edition in effect at the date of contract shall govern.

6.1 ISO specifications

ISO 1513 Paints or varnishes – Examination and preparation of samples for testing ISO 2063 Metallic Coatings and other inorganic coatings – Thermal spraying –

Zinc, aluminium and their alloys

ISO 2808 Paints or varnishes – Coating thickness measurements ISO 2815

ISO-3233

Paints or varnishes – Hardness testing

Paints and varnishes - Determination of percentage volume of non-volatile matter by measuring the density of a dried coating

ISO 3248 ISO 3549

Paints and varnishes – Determination of the effect of heat Zinc Dust Pigments for Paints- Specification and Test Methods ISO 4624 Paints and varnishes – Pull-off test for adhesion

ISO 4628-1 Paints and varnishes – Evaluation of degradation of paint coatings – Designation of intensity, quantity and size of common types of defect – Part 1: General principles and rating schemes

ISO 4628-2 Paints and varnishes – Evaluation of degradation of paint coatings – Designation of intensity, quantity and size of common types of defect – Part 2: Designation of degree of blistering

ISO 4628-3 Paints and varnishes – Evaluation of degradation of paint coatings – Designation of intensity, quantity and size of common types of defect – Part 3: Designation of degree of rusting

ISO 4628-4 Paints and varnishes – Evaluation of degradation of paint coatings – Designation of intensity, quantity and size of common types of defect – Part 4: Designation of degree of cracking

ISO 4628-5 Paints and varnishes – Evaluation of degradation of paint coatings – Designation of intensity, quantity and size of common types of defect – Part 5: Designation of degree of flaking

ISO 4628-6 Paints and varnishes – Evaluation of degradation of paint coatings – Designation of intensity, quantity and size of common types of defect – Part 6: Rating of degree of chalking by tape method

ISO 6270-1 Paints and varnishes – Determination of resistance to humidity- Part 1: Corrosion by condensation

ISO 6272 Paints and varnishes – Falling weight test

ISO 7253 Paints and varnishes – Determination of the resistance to neutral salt spray

7079-A1 Supplement products – Representative photographic examples of the change of appearance of steel when blast-cleaned with different abrasives ISO 8502-3 Preparation of steel substrates before application of paints and related

products – Tests for the assessment of surface cleanliness - Part 3: Assessment of dust on steel surfaces prepared for painting (pressure-sensitive tape method).

ISO 11997-2 Paints and varnishes – Determination of the resistance to cyclic corrosion conditions – Part 2: Wet (salt fog)/dry/humidity/UV light

ISO 12944 –all parts Paints and Varnishes- Corrosion protection of steel structures by protective paint systems

6.2 British specifications

BS EN ISO 1461 Specification and test methods for hot dip galvanised coatings on iron and steel articles

BS 3900 F10 Methods of tests for paints. Determination of resistance to cathodic disbonding of coatings for use in marine environments

BS 4800 Schedule of paint colours for building purposes

BS 6920 Suitability of non-metallic products for use in contact with water intended for human consumption

BS 7079-0 Preparation of steel substrates before application of paints and related substances. Introduction

6.3 Other International Specifications

API RP-5L2 Recommended Practice for Internal Coating of Line Pipe for Non-corrosive Gas Transmission Service

ASTM C868 Standard Test Method for Chemical Resistance of Protective Linings ASTM D257 Standard Test Method for DC Resistance or Conductance of Insulating

Materials

ASTM D822 Standard Practice for Filtered Open-Flame Carbon-Arc Exposure of Paint and Related Coatings and Materials

ASTM D870 Standard Practice for Water Resistance of Coatings using Water Immersion

ASTM D1002 Standard Test Method for Apparent Shear Strength of Adhesively Single-Lap-Joint Bonded Metal Specimens by Tension Loading (Metal-to-Metal)

ASTM D1653 Standard Test Method for Water Vapour Transmission of Organic Coating Films

ASTM D1894 Standard Test Method for Static and Kinetic Coefficients of Friction of Plastic Film and Sheet

ASTM G6 Standard Test Method for Abrasion Resistance of Pipeline Coatings ASTM G14 Standard Test Method for Impact Resistance of Pipeline Coatings

(Falling weight Test)

ASTM G17 Standard Test Method for Penetration Resistance of Pipeline Coatings (Blunt Rod)

ASTM G154 Standard Practice for Operating Fluorescent Light Apparatus for Exposure of Nonmetallic Materials

ASTM E96 Standard Test Method for Water Vapour Transmission of Materials NACE TM0184 Accelerated Test Procedure for Screening Atmospheric Surface

Coating Systems for Offshore Platforms and Equipment NACE TM0185 Evaluation of Plastic Coating by Autoclave Testing

NACE RP0188 Recommended Practice. Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates

SSPC-SP-3 Surface Preparation Specification. Power Tool Cleaning to Bare Metal SSPC-SP-12 Joint Surface Preparation Specification NACE No. 5/SSPC SP 12.

Surface Preparation and Cleaning of Steel and Other Hard Materials by High-and Ultrahigh-Pressure Water Jetting Prior to Recoating

6.4 PDO and SIEP Documents

DEP 31.40.30.31.Gen Technical Specification for External Polyethylene and Polypropylene Coating for Line Pipe

DEP 31.40.30.32.Gen Technical Specification for External Fusion-bonded Epoxy Powder Coating for Line Pipe

DEP 30.48.40.31- Gen Technical specification- Thermal Sprayed Coatings

DEP 31.40.30.35.Gen Technical Specification – Internal Coating of Line Pipe for Non-corrosive Gas Transmission Service

GU-368 Guidelines For The Protection Of Buried Sections Of Surface Laid Pipelines/Flowlines

PDO-SP-1166 Identification of On-Plot Pipework

PDO-PR-1180 Procedure for Qualification of Pipeline Rehabilitation Coating Systems

7

Appendix A

Glossary of Definitions, Terms and

Abbreviations

7.1

Standard Definitions

Within the context of this specification the following words shall have the meanings stated: must/shall Indicates a mandatory requirement.

should Indicates a preferred course of action. may Indicates one acceptable course of action. API American Petroleum Institute

SIEP Shell International Exploration and Production bv. PDO

SHOC

Petroleum Development Oman. Safe Handling of Chemicals

Contractor The PDO appointed Contractor for a defined piece of work.

Vendor The supplier of materials or equipment - not necessarily the Manufacturer. Manufacturer The company responsible for the manufacture - not necessarily the Vendor. Paint Vendor The supplier of paint and coating materials.

Paint Vendor’s

Technical Data Sheet Data sheet, published and maintained by the Paint Vendor, detailing the properties of the paint/coating materials and the requirements for their application. These data sheets also state the conditions for surface preparation prior to application of paint/coating materials and associated acceptance criteria.

Paint Vendor’s Health

and Safety Data Sheet Data sheet, published and maintained by the Paint Vendor, detailing the hazardous properties of the paint/coating materials and the health and safety requirements for their storage, preparation and application.

Painting Contractor The company responsible for a defined piece of painting, coating or lining work.

7.2 Special Definitions

Amplitude Peak to valley height in a steel surface profile, usually after surface preparation. Atmospheric Zone That part of the structure above the splash zone.

Dew point Temperature of an air-water mixture, at which condensation starts. ie where the mixture has reached water saturation point.

DFT Dry Film Thickness (thickness of paint film in its dry cured state)

Holidays Pinholes or small defects in a coating film that penetrate through the film to the underlying substrate.

Micron One thousandth part of a mm (μ).

Pot Life The length of time a two-pack paint will remain usable, at a given temperature, after mixing.

Shop Permanent enclosed facility used for painting/coating with temperature and humidity control.

Site Place of new construction/repair painting and coating works for onshore or offshore projects. (Approved by PDO).

Submerged Zone That part of a fixed offshore structure below the splash zone or that permanently wetted area below the water line of a floating vessel.

Surface Profile (Anchor

Pattern) The cross-section of a prepared steel surface. Measured distance from depth of _{troughs to tops of peaks on the blast cleaned surface. (Amplitude)} WFT

Tidal zone

Wet Film Thickness (thickness of a wet paint film prior to evaporation of any solvent

That part of a fixed offshore structure between + 2m above mean high water spring tide and the lowest level at which the preparation for, and application of, repair coatings is possible without recourse to underwater techniques

7.3 Abbreviations

ACGIH American Conference for Government Industrial Hygienists ASTM American Society for Testing and Materials

BS British Standard

CFDH Corporate Function Discipline Head DIN Deutsches Institut Für Normung ISO

SHOC

International Organisation for Standardisation Safety Handling of Chemicals

NACE National Association of Corrosion Engineers

TA Technical Authority

TPI UER

Third Party Inspection CFDH Materials and Corrosion VOC Volatile Organic Compound WRC Water Research Council

8

Appendix B -

Paint and Coating System Evaluation

8.1 Introduction

Coating systems proposed by the Paint Vendors are to comply with the generic painting systems as specified in Parts 2 and 3 and may only be used if they can be demonstrated, by testing performed by an independent test house, to satisfy the performance criteria defined in this appendix. Each coating system must pass each of the criteria detailed in the tables shown in this appendix. In general the assessment guidelines used in ISO12944 and ISO 4628 have been used and the systems proposed should meet the requirements of medium durability with a life of 5-15 years before maintenance is required.

The performance tests shall be carried out on samples coated from paint manufactured in a regular production batch and not from specially prepared laboratory samples. Test data shall be provided that verifies the composition of the coatings as detailed on the technical data sheets.

For status of existing approved coatings refer to tables in Part 5. Systems with performance significantly in excess of that required by this Specification may be used, provided any additional capital expenditure associated with the enhanced performance can be justified on the basis of a lifecycle cost assessment.

8.2 Performance Tests

8.2.1 Test Schedule

The required tests for each system are defined in Table B1-to B7

8.2.2 Test Methods

The test methods for each of the tests listed in Tables B1 to B7 are defined in Table B8

8.2.3 Acceptance Criteria

The acceptance criteria for each evaluation test are defined in Table B1 to B7. To pass the coating system must pass all the acceptance criteria.

8.2.4 Means of Evaluation Following Test

After performing the tests the samples shall be evaluated by the methods shown in Tables B1 to B8

8.2.5 Application and Technical Information

Under the local prevailing site conditions, the coating systems shall be capable of being applied at the specified thickness using application equipment recommended by the Vendor. The coating so applied shall be of uniform thickness, free of runs, sags, blemishes, inclusions and holidays.

The Vendor shall supply technical data relating to the following: All product data and all test data shall be supplied electronically in a read only format such as pdf. File. As part of qualification the Vendor shall provide test data that verifies the solids content and zinc content (if required) as detailed on the technical data sheets. The testing shall be done in accordance with ISO 3233 and ISO 3549.

Solids content Specific gravity Flash point Pot life

Mixing method and ratio

Identification of thinners and cleaners Theoretical/practical spreading rates (m2_/litre)

Application data, including spray pressure, nozzle tip sizes, hose lengths and diameter Health and Safety data

8.2.6 Notes to Tables B1– B8

RQD Test required N/R Test not required N/A Not applicable

1. For New Construction: The coating system should be subjected to cyclic exposure and then evaluated against the specified requirements.

For Maintenance and repair: The procedure is:

- apply a new coating (to be compatible with the selected maintenance coating) - subject to cyclic exposure

- apply maintenance coating to a selected area - conduct test to the specified requirements

Testing in this way qualifies the adhesion of new coating, adhesion of the maintenance system and overcoatability of new system.

2. Test to be conducted at manufacturers recommended maximum service temperature.

3. Measurement of disbondment from X-cut to be carried out in accordance with annex A of ISO-12944-6 4. Test solution details and duration are given in table B8

5. Where CP is not proposed, ie as for GRE and glassflake coatings, cathodic disbondment qualification is not required.

6. Required for vessels only. Rate of depressurisation shall be at 5 bar per minute from 85 bar to 5 bar. 7. Coating system to have potable water certification. ie listed by Water Research Council/Water Byelaws

Schemes (UK), KIWA, or compliance with BS6920.

Table B1

Required Tests and Acceptance Criteria -External Onshore Above Ground

Structures

Tests and Parameters Measured Method

PCS-1 External A/G <100°C PCS-3 External A/G 100-400°C PCS-6 Galvanised C.Steel <100 oC PCS-6 Stainless Steel <100oC Acceptance Criteria

Holiday Testing NACE RP0188-99 No defects No defects No defects No defects Adhesion (dry) at 230C

Pneumatic pull-off MPa min ISO 4624 5 5 5 5

Cyclic Exposure ISO 11997-2 RQD N/R RQD RQD

Disbonding from X- cut3 mm max

ISO-12944-6 5 5 5

Rusting, cracking, blistering, ISO 4628 0 0 0

Chalking % max ISO 4628 2 2 N/R

Hardness - Buchholz ISO 2815 90% of as new

90% of as new

90% of as new

Adhesion MPa min ISO 4624 5 5 5

Overcoatability Adhesion (of repair) MPa min 1

ISO 4624 5 5 5

Salt Spray ISO 7253 RQD RQD RQD RQD

Disbonding 3 mm max

ISO-12944-6 5 5 5 5

Rusting ISO 4628 0 0 0 0

Heat Resistance (dry)2 ISO 3248 N/R 400 oC N/R N/R

Adhesion pneumatic pull-off MPa min ISO 4624 >90% of new Hardness Buchholz Indentor ISO 2815 Within ±10% of original Chemical Analysis

Part Solids ISO 3233 RQD RQD RQD RQD

Zinc content ISO-3549 RQD N/A N/A 0

Notes:

Table B1

Required Tests and Acceptance Criteria – External Below-Ground Structures

up to 70C

Tests and Parameters Measured

Method

PCS-2A <70°C Buried CS and stainless steel

structures

Acceptance criteria

Holiday Test NACE RP0188-99 No defects

Cathodic Disbondment Appendix C RQD

70oC mm max 5

Adhesion (dry) RQD

Pull-off MPa min ISO 4624 10 Shear 70o_{C MPa min ASTM D1002 10}

Salt Spray ISO 7253 RQD

Disbonding3 _{mm max ISO-12944-6 <5mm}

Rusting ISO 4628 0

Adhesion. Pull-off MPa min ISO 4624 10 Overcoatability. Pull-off 1

(of repair) MPa min

ISO 4624

10

Adhesion (wet) Distilled water

immersion 70o_C

RQD Pneumatic pull-off MPa min ISO 4624 10

Resistance to Loading ASTM G17 RQD

Penetration at 23o_{C <5%}

Penetration at 70o_{C <10%}

Impact Resistance ASTM G14 No breaks

Water Vapour Permeability ASTM D1653 RQD

at 23o_{C g/m}2 _<300 at 50o_{C g/m}2 _<1500

Water Absorption ASTM D870 RQD

at 23o_{C g/m}2 _<40 at 50o_{C g/m}2 _<70

Part Resistivity ASTM D257 RQD

Table B3

Required Tests and Acceptance Criteria – External Below-Ground Structures

for more than 70C

Tests and Parameters Measured

Method

PCS-2B >70°C Buried CS and stainless steel

structures

Acceptance criteria

Holiday Test NACE RP0188-99 No defects

Cathodic Disbondment Appendix C RQD

95C mm max 10

Adhesion (dry) RQD

Pull-off MPa min ASTM D

4541 5

Shear 95o_{C MPa min ASTM D1002 5}

Salt Spray ISO 7253 RQD

Disbonding3 _{mm max ISO-12944-6 <5mm}

Rusting ISO 4628 0

Adhesion. Pull-off MPa min ASTM D

4541 5

Overcoatability. Pull-off 1 (of repair) MPa min

ASTM D

4541 ₅

Adhesion (wet) Distilled water

immersion 95o_C

RQD Pneumatic pull-off MPa min ASTM D

4541

5

Resistance to Loading ASTM G17 RQD

Penetration at 23o_{C <5%}

Penetration at 95o_{C <10%}

Impact Resistance ASTM G14 No breaks

Water Vapour Permeability ASTM D1653 RQD

at 23oC g/m2 <300 at 50o_{C g/m}2 _<1500

Water Absorption ASTM D870 RQD

at 23o_{C g/m}2 _<40 at 50o_{C g/m}2 _<70

Part Resistivity ASTM D257 RQD

Wet panels ρv Ωm >107

Notes

Tests to be carried out at manufacturers recommended maximum allowable operating temperature. Some acceptance criteria will vary based on the proposed temperature and has to be agreed upfront with material and corrosion CFDH. Hardness and glass transition temperature acceptance criteria may be used based on the chemistry of the proposed coating

Table B4

Required Tests and Acceptance Criteria – External Below-Ground Structures

up to 70C using Visco Elastic Wrapping Coating

The required tests for this coating system are listed in table B4 below based on ISO 21809-3. Some of the tests require aged samples of the coating system. Aging of the samples must be accomplished in two ways: according to ISO 21809-3 Annex N (dry 100 days at +90C) and according to Shell shrink sleeve document MF95/0290-Rev 1 (immersion in water for 100 days at +90C). All tests on steel pipes will be conducted on carbon steel pipes with 100mm pipe diameter, in three fold.

Table B5

Required Tests and Acceptance Criteria – Internals of Tanks and Vessels

Oil/ Water Tanks

Vessels and Separators Tests and Parameters

Measured Method PCS-7a <60 oC PCS-8 60 - 93 oC PCS-7b <60 oC PCS-8 60 - 93 oC PCS-10 Potable7 Water Tanks Acceptance Criteria

Holiday Test NACE

RP0188-99

No defects No defects No defects No defects No defects

Adhesion new 60/93oC MPa min ISO 4624 10 10 10 10 10 Chemical Resistance In specified solution 4 ASTM C868 RQD RQD RQD RQD RQD

X-cut test3 _{ISO-12944-6 <4mm <4mm <4mm <4mm <4mm}

Rusting, cracking, blistering ISO 4628 0 0 0 0 0

Adhesion wet ISO 4624 10 10 10 10 10

Cathodic Disbondment 5 Appendix C RQD RQD RQD RQD RQD

60o_{C / 93}o_{C mm max 5 5 5 5 5}

Salt Spray ISO 7253 RQD RQD RQD RQD RQD

Disbonding 3 _{mm max 3 3 3 3 3}

Rusting ISO 4628 None None None None None

Heat Resistance (dry)2 N/R RQD N/R RQD N/R

Adhesion pneumatic pull-off MPa min ISO 4624 >90% of new >90% of new Hardness Buchholz Indentor ISO 2815 Within ±10% of original Within ±10% of original Depressurisation6 N/R N/R RQD RQD N/R

Holiday Test No defects No defects

Visual examination Blistering Cracking Adhesion ISO 4628 ISO 4628-2 ISO 4628-4 ISO 4624 0 0 10 0 0 10

Water Vapour Permeability ASTM D1653 RQD RQD RQD RQD RQD

at 23o_{C g/m}2 _{<300 <300 <300 <300 <300}

at 60o_{C g/m}2 _{<1500 <1500 <1500 <1500 <1500}

Water Adsorption ASTM D380 RQD RQD RQD RQD RQD

at 23o_{C g/m}2 _{<40 <40 <40 <40 <40}

at 60o_{C g/m}2 _{<70 <70 <70 <70 <70}

Part Resistivity ASTM D257 RQD RQD RQD RQD RQD

Wet panels ρv Ωm >107 >107 >107 >107 >107 Note: For operation >93oC UER to be consulted.

Table B6

Required Tests and Acceptance Criteria – Offshore Structures

Tests and Parameters Measured Method PCS-11a Atmospheric Topsides PCS-11b Submerged and Tidal PCS-11c Splash Zone Acceptance Criteria

Holiday Testing NACE

RP0188-99

No defects No defects No defects

Adhesion (dry) RQD RQD RQD

Pneumatic pull-off MPa min

ISO 4624 5 10 10

Cyclic Exposure ISO 11907-2 RQD RQD8 RQD

Disbonding3 _{mm max 5 5 5}

Rusting, cracking, blistering ISO 4628 0 0 0 Chalking % max ISO 4628 2 2 2 Adhesion MPa min ISO 4624 5 10 10 Overcoatability Adhesion (of

repair) MPa min1

ISO 4624 5 10 10

Salt Spray ISO 7253 RQD RQD RQD

Disbonding3 _{mm max 5 5 5}

Rusting ISO 4628 0 0 0

Cathodic Disbondment Appendix C N/R RQD N/R

23o_{C mm max 5}

Immersion Exposure (Seawater) ASTM C868 N/R RQD N/R

Disbonding from X-cut3 _{mm max 4 4}

Rusting, cracking, blistering ISO 4628 0 0

Water Adsorption ASTM D380 N/R RQD RQD

at 23o_{C g/m}2 _{<40 <40}

at 50o_{C g/m}2 _{<70 <70}

Impact Resistance ASTM G14 N/R RQD RQD

No breaks No breaks

Abrasion Resistance ASTM G6 N/R RQD RQD

Time to failure hrs >25 >50

Chemical Analysis

Part Solids ISO 3233 RQD N/R N/R

Table B7

Required Tests and Acceptance Criteria – Miscellaneous Areas

Tests and Parameters Measured Method

PCS-4 Insulated Up to 100oC PCS-5 External >400oC PCS-12 Internal Flow coat gas

lines

Acceptance Criteria

Holiday Testing NACE RP0188-99 No defects No defects No defects Adhesion (dry)

Pneumatic pull-off MPa min

ISO 4624 5 3 See DEP

31.40.30.35.Gen

Corrosion Resistance Salt Spray ISO 7253 RQD RQD RQD

Disbonding3 _{mm max 5 5 See DEP} 31.40.30.35.Gen

Rusting ISO 4628 0 0 0

Heat Resistance (dry)2 _{ISO 3248 100}o_{C 400}o_C

Adhesion pneumatic pull-off MPa min ISO 4624 >90% of as new >90% of as new Hardness Buchholz Indentor ISO 2815 Within ±10% of original Within ±10% of original Chemical Analysis

Part Solids ISO 3233 RQD RQD RQD

Notes

• Tests to be carried out at manufacturers recommended maximum allowable operating temperature. • For PCS-12 acceptance criteria refer to DEP 31.40.30.35.Gen.

Table B8

Summary of Performance Tests

Test/Method Test Type Basic Test Requirements

Duration Notes

Holiday Test

NACE RP0188 _{DC spark 5 - 6V/1μ DFT Periodic checks}

Cathodic Disbondment

Appendix C Electrical stress

Test at specified temp. 28 day cycle

Test temperature as stated in previous tables. Measure disbondment from X-cut

Adhesion (dry) ISO 4624 Pneumatic pull-off Test at 23 o_{C and} maximum recommended service temperature

Tests at service temperature where appropriate for heat resistance qualification.

Adhesion (Shear)

ASTM D1002 Lap shear

strength Test at 70

o_{C 14 days For buried structures} Cyclic Exposure 20 cycles over 3000hrs Specimen preparation to ISO 1513

Test time may be reduced for external onshore above-ground coatings

salt spray 70hrs Systems to be tested at low DFT (i.e. 75% of the Paint Vendors recommended nominal DFT). Alternative acceptance criteria may be proposed for systems tested at the Paint Vendor's

recommended nominal DFT. Accelerated

weathering

dry in ambient air 16hrs ISO 11997-2

UV light

exposure ‘Weatherometer’ exposure - 80 hrs Alternative light source – carbon arc to ASTM D822 Performance Observations ISO-4628-2 ISO-4628-3 ISO-4628-4 ISO-12944-6 annex-A ISO-4624 ISO-2815 Degree of blistering Degree of rusting Degree of cracking Level of disbondment Adhesion Hardness Salt Spray

ISO 7253 Corrosion testing Inspection of X-cut test panels min. 3000 hrs Specimen preparation to ISO 1513 System DFT and criteria comments, as for cyclic test

Quantitative assessment to ISO 4628-2/3/4

Test/Method Test Type Basic Test Requirements Duration Notes Chemical/Immersion Resistance ASTM C-868 Exposure to

potable water Distilled or de-ionised water test media. 6 months Condition in accordance with ASTMC-868 and inspect for coating deterioration using ISO 4628

Exposure to

saline water

Solution to be 15% NaCl @ pH4.0

6 months Condition in accordance with ASTMC-868 and inspect for coating deterioration using ISO 4628 Test at manufacturers recommended maximum service temperature. Evaluation Tests ISO 4628-2/3/4 ISO-12944-6 annex-A ISO-4624 ISO-2815 Resistance to Loading

ASTM G17 Blunt rod Test at 23o _{and 50}o_{C After 24}

hours heating

Check % depth of penetration

Impact Test

ASTM G14 Falling weight Min .10 repetitions

Test at 23o _{and 50}o_C Inspect for coating damage Abrasion Resistance

ASTM G6 Surface wear Electrical resistance

check Measure time to failure

Hardness

ISO 2815 Surface

hardness Check change in hardness using Buchholz Indentor

Water Vapour Permeability

ASTM D1653 Wet cup Distilled or de-ionised water

Test at 23o _{and 50}o_{C 90 days 30 day monitoring}

Water Absorption

ASTM D870 Immersion Test at 23o _{and 50}o_{C 90 days 30 day monitoring} Part Resistivity

Conductivity 30 day monitoring ASTM D257

Immersion in sea water

Test at 50o_{C 90 days}

Visually inspect

Heat Resistance (dry)

ISO 3248 (modified for test temperature)

Test at manufacturers recommended maximum service temperature.

200hrs Condition in accordance with ISO 3248 and inspect for coating deterioration using tests below.

ISO 4624 Pneumatic pull-off

Adhesion Test ISO 2815 Hardness Change in

Test Method Test Type Basic Test Requirements Duration Notes Resistance to Depressurisation NACE TM0185 Pressurise at 5 bar/hour Depressurise at 5 bar/min from 85 bar to 5 bar at temperature of 93o_C

Blowdown

simulation Pressure cycling with hydrocarbon gas. Gas content methane with 2 barg partial pressure CO2 60 days with 4 depressurisation cycles at 15 day intervals. Visual assessment to ISO 4628 Evaluation Tests ISO 4628-2 ISO 4628-4 ISO 4624 Blistering Cracking Adhesion Chemical Analysis

ISO 3233 Check for solids

content. Result to be in accordance with technical data sheets ISO 3549 Check for zinc content Result to be in

accordance with technical data sheets

9

Appendix C -

Cathodic Disbonding Resistance Test

The cathodic disbonding resistance of the coating shall be tested as follows:

The test sample shall be free of holidays when tested in accordance with NACE RP0188.

A 6 mm hole shall be drilled in the coating, by means of a flat-faced mill. The hole shall not penetrate more than 0.5 mm into the pipe steel. The hole shall be at least 50 mm from any weld. The sample shall be placed inside an electrolytic cell or an electrolytic cell shall be constructed on the pipe surface. All metallic parts other than the test defect shall be sealed from the electrolyte by means of a resin or other suitable compound. The volume of the cell shall be at least 250 ml.

The cell is filled with a 3 % sodium chloride solution.

An inert auxiliary electrode (e.g. platinum wire or mesh) shall be placed in the electrolyte, remote from the test defect.

A saturated calomel reference electrode (SCE) shall be placed in the electrolyte with the tip 10 mm from the test defect.

By means of a potentiostat, the electrochemical potential of the steel shall be polarised to -1500 ± 10 mV with respect to the SCE. This potential shall be maintained throughout the test.

The current required to maintain the potential shall be continuously recorded.

The duration of the test shall be 28 days, after which the sample shall be removed from the cell and examined.

For tests at elevated temperatures, the temperature shall be controlled as follows:

When the sample is immersed in the cell, the solution, including the sample, shall be kept at the test temperature by the cell being placed in a thermostatically controlled water bath.

When the cell has been constructed on the pipe sample, the steel sample shall be placed in a thermostatically controlled furnace or sand bath that also covers the top surface of the sample with at least 1 cm of sand. The furnace or bath shall be adjusted to maintain the required test temperature on the pipe surface in the test defect.

During tests at elevated temperatures, suitable reflux coolers shall be used to prevent evaporation of the test electrolyte.

At the end of the test period, the sample shall be rinsed with fresh water and wiped dry.

Two cuts shall be made through the coating in the longitudinal direction of the pipe and two similar cuts shall be made in the circumferential direction, each pair of cuts being 5 mm apart and approximately following the tangent of the test defect. The length of the cuts shall extend to approximately 20 mm each side of the defect; see Figure 1.

By means of a knife, the strips of coating between the cuts shall be peeled from the pipe surface as far as possible, starting at the test defect. The distance over which the coating is detached and the metal is exposed, measured from the edge of the original test defect, shall be recorded for all four directions. The radius of disbonding shall be the arithmetic mean of the four measurements. A photograph of the test sample after testing, showing the disbonded area, should be included in the test report.

10

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