LEKKI OFFSHORE TERMINAL

PIPELINE SPECIFICATIONS

JUNE 2009

2174/SPC/001 Rev B00

 PROJ DIR PM I
REV DATE WRITTEN BY CHECKED BY
APPROVAL APPROVAL

B00 24-Jun-2009 J Waldron M Bowes C Rossouw

KEY TO REVISION STATUS:

P Preliminary for Information

B Basic Engineering
A For Comment and Approval
C Approved for Construction
X As Built

(P M I : PROJECT MANAGEMENT INTERNATIONAL)

2174/SPC/001 Rev B00

June 2009
CONTENTS

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

1.1. Scope..............................................................................................................................4

1.2. Classification Society........................................................................................................4

2.0 REFERENCE DOCUMENTS AND STANDARDS ........................................................... 4

2.1. General............................................................................................................................4

2.2. Rules and Regulations ......................................................................................................4

2.3. Codes and Standards........................................................................................................5

2.4. Reference Documents .......................................................................................................5

2.5. Reference Drawings ..........................................................................................................1

3.0 LINE PIPE ..................................................................................................................... 2

3.1. Materials..........................................................................................................................2

3.2. Manufacture and Dimensional Requirements .......................................................................2

3.3. Welding ...........................................................................................................................3

3.4. Non-destructive Plate Examination .....................................................................................3

3.5. Non-destructive Pipe Joint Examination ..............................................................................3

3.6. Testing ............................................................................................................................3

3.7. Markings..........................................................................................................................4

3.8. Quality Control .................................................................................................................4

4.0 ANODES ....................................................................................................................... 4

4.1. General Requirements.......................................................................................................4

4.2. Design Criteria..................................................................................................................5

4.3. Materials..........................................................................................................................1

4.4. Fabrication .......................................................................................................................1

4.5. Bonding Cables ................................................................................................................1

4.6. Quality Assurance ............................................................................................................2

5.0 PIN BRAZING................................................................................................................ 2

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5.1. Minimum operator qualifications .........................................................................................2

5.2. Connections .....................................................................................................................2

5.3. Base Material Preparation .................................................................................................2

5.4. Cleaning ..........................................................................................................................3

5.5. Repairs ............................................................................................................................3

5.6. Testing after Installation.....................................................................................................3

5.7. Quality Assurance ............................................................................................................3

6.0 CONCRETE WEIGHT COATING ................................................................................... 3

6.1. Materials..........................................................................................................................4
6.1.1. Cement............................................................................................................................4
6.1.2. Sand ...............................................................................................................................4
6.1.3. Aggregate ........................................................................................................................4
6.1.4. Water ..............................................................................................................................4
6.1.5. Admixtures ......................................................................................................................4
6.1.6. Reinforcement ..................................................................................................................4

6.2. Concrete Mix Design.........................................................................................................5

6.2.1. Proportioning ....................................................................................................................5
6.2.2. Mixing and batching ..........................................................................................................5
6.2.3. Curing..............................................................................................................................5
6.2.4. Testing ............................................................................................................................6

6.3. Coating Control and Tolerances..........................................................................................6

6.3.1. Coating Control Data .........................................................................................................6
6.3.2. Scales or weighing devices ................................................................................................6
6.3.3. Density ............................................................................................................................6
6.3.4. Concrete Coating Thickness ..............................................................................................6
6.3.5. Placement of Reinforcement ..............................................................................................7
6.3.6. Holdback and Cleanup ......................................................................................................7

6.4. Permissible repairs to concrete coating ..............................................................................7

7.0 CORROSION COATING................................................................................................ 7

7.1. Surface Preparation ..........................................................................................................7

7.2. Coating Application ...........................................................................................................8

7.3. Curing and Testing ............................................................................................................9

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7.4. Cathodic disbondment..................................................................................................... 10

7.5. Holiday Inspection .......................................................................................................... 11

7.6. Anti-slip Bands ............................................................................................................... 11

7.7. Coating Repairs .............................................................................................................. 11

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1.0 INTRODUCTION

1.1. Scope
This document provides a basic minimum specification for the materials, manufacture, testing
and documentation for the supply of the 18 and 26 inch pipelines for the Lekki Offshore
Terminal.

This document has been produced as part of the Basic Engineering phase, and is not
intended to be a fully comprehensive specification. The main purpose of this document is to
provide a minimum specification for structural steel to form a basis for the EPC bidding
process. It will be the responsibility of the successful EPC tenderer (the Contractor) to
perform all of the necessary detailed design, and to draw up the detailed specifications for
Client approval.

1.2. Classification Society

The American Bureau of Shipping (ABS) will be appointed as the Classification Society for
this project.

2.0 REFERENCE DOCUMENTS AND STANDARDS

2.1. General
The following Rules, Regulations, Codes and Standards shall apply to this specification. The
Contractor is responsible for the quality of the work and compliance with the applicable
regulations, or Client approved equivalent.

The latest editions of the regulations, national or industry codes and standards, including all
parts and amendments current at the date of order shall apply to the work defined in the
specification below. If there is any conflict between this specification and the requirements of
other industry codes and standards, the more stringent requirements shall apply .

2.2. Rules and Regulations

[1] ABS Rules for Building and Classing Single Point Mooring Systems (1996).

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 [2] ABS Rules for Building and Classing Offshore Installations (1997).
[3] ABS Rule Requirements for Materials and Welding, Part 2 (2007).

2.3. Codes and Standards

[1] API Spec 5L: Specification for Line Pipe.
[2] API 1104: Welding of Pipelines and Related Facilities
[3] ASTM A-36: Standard Specification for Carbon Structural Steel
[4] ASTM A-153: Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel
Hardware
[5] ASTM A-185: Standard Specification for Steel Welded Wire Reinforcement, Plain, for
Concrete
[6] ASTM A-578: Standard Specification for Straight-Beam Ultrasonic Examination of Rolled
Steel Plates for Special Applications
[7] ASTM C-33: Standard Specification for Concrete Aggregates
[8] ASTM C-39: Standard Test Method for Compressive Strength of Cylindrical Concrete
Specimens
[9] ASTM C-150: Standard Specification for Portland Cement
[10] ASTM C-494: Standard Specification for Chemical Admixtures for Concrete
[11] ASTM E-337: Standard Test Method for Measuring Humidity with a Psychrometer (the
Measurement of Wet- and Dry-Bulb Temperatures)
[12] ISO 8501-1: Preparation of Steel Substrates before Application of Paints and Related
Products - Visual Assessment of Surface Cleanliness

2.4. Reference Documents

[1] 2174-RPT-001: Lekki Offshore Terminal - Design Basis
[2] 2174-RPT-002: Lekki Offshore Terminal - Basic Engineering Summary Report
[3] 2174-RPT-007: Lekki Offshore Terminal - 18 Pipeline Structural Analysis
[4] 2174-RPT-008: Lekki Offshore Terminal - 26 Pipeline Structural Analysis

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2.5. Reference Drawings

DRAWING NO TITLE
2174-DWG-001 BATHYMETRY
2174-DWG-002 GENERAL ARRANGEMENT: 1:50 000 PLAN

2174-DWG-100 CBM TERMINAL : GENERAL ARRANGEMENT

2174-DWG-101 CBM TERMINAL : PLEM AND SUBMARINE HOSES
2174-DWG-102 CBM TERMINAL : PLEM CONCEPTUAL LAYOUT
2174-DWG-103 CBM TERMINAL : 18" PIPE LONGSECTION

2174-DWG-200 SPM TERMINAL : GENERAL ARRANGEMENT

2174-DWG-201 SPM TERMINAL : PLEM AND SUBMARINE HOSES
2174-DWG-202 SPM TERMINAL : PLEM CONCEPTUAL LAYOUT
2174-DWG-203 SPM TERMINAL : 26" PIPE LONGSECTION

2174-DWG-300 TEMPORARY WORKS : PIPELINE LANDFALL

2174-DWG-400 18 CBM TO SPM PIPELINE: LONGSECTION

2174-DWG-500 PLEM CONNECTION GENERAL ARRANGMENT

2174-DWG-501 DISCONTINUED
2174-DWG-502 DISCONTINUED
2174-DWG-503 PIGGING ROUTES
2174-DWG-504 ONSHORE PIPELINE :TANK FARM TIE IN DETAILS
2174-DWG-505 LEKKI TERMINAL :OFFSHORE PIPING DIAGRAM

2174-DWG-511 CBM TERMINAL : CATHODIC PROTECTION LAYOUT

2174-DWG-512 CBM TERMINAL : PLEM GENERAL ARRANGEMENT
2174-DWG-513 CBM TERMINAL : PLEM STRUCTURE DETAIL 1
2174-DWG-514 CBM TERMINAL : PLEM STRUCTURE DETAIL 2
2174-DWG-515 CBM TERMINAL : PLEM PIPING ARRANGEMENT

2174-DWG-521 SPM TERMINAL : CATHODIC PROTECTION LAYOUT

2174-DWG-522 SPM TERMINAL : PLEM GENERAL ARRANGEMENT
2174-DWG-523 SPM TERMINAL : PLEM STRUCTURE DETAIL 1
2174-DWG-524 SPM TERMINAL : PLEM STRUCTURE DETAIL 2
2174-DWG-525 SPM TERMINAL : PLEM PIPING ARRANGEMENT SHEET 1 OF 2
2174-DWG-526 SPM TERMINAL : PLEM PIPING ARRANGEMENT SHEET 2 OF 2

2174-DWG-531 CBM MOORING SYSTEM : ANCHOR LEG 1,2,3 & 4 DETAILS

2174-DWG-532 SPM MOORING SYSTEM : ANCHOR DETAILS

2174-DWG-901 PIPELINE GENERAL ARRANGEMENT AND DETAILS

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3.0 LINE PIPE

This Specification covers the materials, and fabrication of the 18 and 26 inch offshore
pipelines for the terminal at Lekki. API Specification 5L will be the minimum requirement. The
line pipe shall be of the type, sections and lengths shown on the drawings.

3.1. Materials
All mechanical properties of the steel, tolerances, production and testing of the finished
product shall also conform to API 5L (PSL 2). The following minimum grade steel shall apply,
namely:
a) 18 weight coated off shore pipeline - Grade X65
b) 18 non weight coated off shore pipeline - Grade X65
c) 26 weight coated off shore pipeline - Grade X52
d) 26 non weight coated offshore pipeline - Grade X65
e) 18 and 26 weight coated onshore pipeline - As above

The physical properties of all materials and welding, are to be consistent with the specific
application and operational requirements of subsea pipelines. Verification of all materials is to
be done by a suitable qualified person acceptable to the authorities and client.

3.2. Manufacture and Dimensional Requirements

All dimensions and tolerances of pipe joints, diameters, wall thicknesses, joint lengths, out of
roundness and out of straightness shall conform to API Specification 5L.

Pipe joints shall be manufactured by the High Frequency Induced Electric Resistance Welding
(HFI-ERW) process in accordance with qualified procedures complying with API Standard
1104 or alternatively by a seamless process.

A manufacturing specification is to be produced before fabrication/production begins. The

manufacturing specification is to state the type and extent of testing, the applicable
acceptance criteria for verifying the properties of the materials and the extent and type of
documentation, record and certificate.

No jointers are permitted.

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3.3. Welding
Welding procedures, welder and welding machines operators shall be qualified in accordance
with relevant authority.

Plate edges to be HFI-ERW welded, shall be machine profiled. Abutting plate edges shall be
aligned for welding so that local offsets do not exceed 1.5 mm, and adequate provision shall
be made to insure alignment is maintained during welding operations. HFI-ERW weld seams
shall be normalized after welding.

HFI-ERW weld seam tracking shall be controlled by automatic systems and not manually.

3.4. Non-destructive Plate Examination

All edges used in HIF-ERW pipe joint manufacture shall be inspected prior to welding by
Ultrasonic Testing (UT) non-destructive examination methods. Plate shall be examined the full
length of both long edges, for 25 mm width, and over the plate body in accordance with
procedures defined in ASTM A-578.

3.5. Non-destructive Pipe Joint Examination

The UT procedures to be employed for joint examinations must detail the following:
a) Transducer sizes
b) Frequency
c) incident angles
d) Details necessary to demonstrate full HIF-ERW weld coverage

UT weld inspection equipment must employ audible and / or visual warning systems indicating
any loss of transducer coupling during pipe joint surface inspection.

For seamless pipe, after all manufacturing and heat treatment procedures have been
completed, the entire volume of each pipe length shall be inspected by ultrasonic methods in
accordance with Supplementary requirement SR4, API Specification 5L. The equipment shall
be capable of detecting both longitudinal and transverse defects. Calibration shall be based
on N5 notches. Each seamless pipe shall have full length wall thickness measurements.

3.6. Testing
Testing shall be carried out after final heat treatment and hydrostatic pressure testing.
Mechanical properties shall comply with the requirements of API SPEC 5L .

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3.7. Markings
Markings shall comply with the requirements of API SPEC 5L and shall be applied to the
inside of both pipe joint ends. Each pipe joint shall have a unique sequential number hard
stamped on each end face, diametrically opposite the weld, and round nose, low stress
stamps shall be used. All markings shall be in English

3.8. Quality Control

A quality control procedure, for all materials of the pipelines, is to indicate that the materials
satisfy the requirements of the relevant specifications. The quality control procedure is to
identify the standard with which the product is in complete compliance, the size and weight
designations, material grade and class, process of manufacture, heat number and joint
number. Where applicable, procedures for storage and transportation of the linepipe fromthe
fabrication and coating yards to the offshore destination are to be given. .

The contractor is to maintain a data system of materials and pipeline components. Data
concerning place of origin and results of relevant materials tests are to be retained and made
available for inspection.

4.0 ANODES

This Specification covers the design, materials, and fabrication of sacrificial anode bracelets
to provide cathodic protection for the 18 and 26 inch offshore pipelines for the terminal at
Lekki.

4.1. General Requirements

The latest editions of the following specifications, national or industry codes and standards,
including all parts and amendments current at the date of order placement shall apply to the
work defined in this specification. If there is any conflict between this specification and the
requirements of other industry standards/codes, the more stringent requirements shall apply.

The contractor shall determine the anode sizes based on design criteria specified in Section
4.2 below. All anode dimensions, weights and welding arrangement shall be clearly shown on
asbuilt drawings.

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4.2. Design Criteria
Design of the cathodic protection system shall be based on:
a) Service life - 30 years
b) Current density - 0.93 mA/m, (10 mA/m) of bare surface
c) Exposed bare material - 3 percent of total surface area
d) Seawater temperature - 22.8C to 30.44C
e) Anode Type - Bracelet
f) Recommended Anode Spacing - 125 m (410ft) to 200 m (650ft)
g) Maximum Anode Spacing - 300 m (1000 ft)
h) Anode Utilization Factor - 0.80
i) Coating breakdown - 0% initial and final coating breakdown
- 1.5% mean coating breakdown
j) Anode Potential - 1.075
k) Anode Efficiency - 95%
l) Anode Embedment - 50%

The criteria for protection shall be a negative 0.80 volt potential with a reference to a
saturated silver/silver chloride reference electrode. Product temperature shall be used in
determining anode efficiencies. The effect of the pipeline being covered with silt may be
considered in the design.

Anodes for concrete coated pipe will use a welded attachment.

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4.3. Materials
Aluminum bracelet anodes shall be Galvalum III, or similar approved aluminum-zinc-indium
alloy anode. The anodes shall be made up as follows:

Weight % Weight %
Material
minimum maximum
Zinc 4.75 5.75
Indium 0.014 0.02
Silicon 0.08 0.2
Iron - 0.12
Copper - 0.004
Other Elements - 0.02
Total other Elements - 0.05
Aluminum Balance Balance

The contractor shall certify that anodes have a closed circuit potential reading of between -
1.03 and -1.13 volts referenced to a standard calomel electrode, and that the anode current
capacity is 2536amp-hr/kg or greater based on weight loss laboratory tests. All steel used in
anode bracelet construction shall be ASTM A-36 plate.

4.4. Fabrication
Anode bracelets shall be either molded cylindrical type or segmented type. Bracelets shall be
sized to fit the outside diameter of the pipe plus the thickness of the corrosion coating.
Anodes to be installed on bare pipe must have a tapered configuration.

Anode weight shall be defined as the minimum acceptable weight of the bracelet excluding
internal and external supporting structure. The flat bar and rods used for the steel anode
core shall be indicated on asbuilt drawings. Steel anode cores shall be degreased and sand-
blasted to white metal finish immediately prior to anode casting.

4.5. Bonding Cables

Bonding cables shall have a conducting area equal to six American Wire Guage (AWG)
standard insulated copper wires. These cables should be approximately 30 cm long, brazed
or thermite welded to the flat steel core of the circumference bands. Bracelets shall have two
(2) bonding cables. Care shall be taken to avoid sharp bending of the cables during
installation, handling and shipping.

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 A copper adaptor sleeve for a 6 no. Stranded cable (Cadweld Part CAB-112 or equivalent)
shall be provided for each cable and to be attached to pipe.

4.6. Quality Assurance

Certified test reports of each heat, signed by the factory quality control supervisor, shall be
provided on laboratory tests of anodes produced. The tests shall include chemistry, closed
circuit potential data and anode capacity in ampere hours per kilogram. Anode assemblies
shall be rejected for the following reasons:

a) Failure to meet the test criteria

b) Failure to provide mill certificates
c) Failure to meet inspection criteria
d) Failure to meet chemical composition, electro chemical properties and dimensional
tolerances.

5.0 PIN BRAZING

The following specification details the minimum requirements for pin brazing of cathodic
protection continuity cables. Contractor shall furnish all labor, materials, equipment, services
and consumables required to perform this work. Cadwelding may be used in place of pin
brazing for connecting anode continuity cables, if cadwelding is used qualification tests
equivalent to those specified for pin brazing will be required

5.1. Minimum operator qualifications

Pin brazing operator qualification shall be in accordance with applicable industry standards.

5.2. Connections
Contractor shall submit a pin brazing Qualification Procedure for approval. All pin brazing
shall be made with cable lug type connectors, Cable Iug size shall be for connecting No 6
AWG stranded type C.P. cable. All lugs shall be attached using a correctly sized die in an
industry standard compression tool. All pin braze connections shall be carried out in
accordance with the manufacturers recommendations

5.3. Base Material Preparation

The pipe coating shall be removed over an area of approximately 50 mm X 50 mm. The pipe

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 surface shall then be cleaned to bright metal using a small hand grinder. All traces of oil,
grease, mill scale and any other contamination shall be removed. Care must be taken not to
reduce the base material wall thickness

5.4. Cleaning
The area of the joint and surrounding coating shall be thoroughly cleaned of all traces of
conductive grease and other contaminants using a suitable solvent.

5.5. Repairs
Repairs to the pipeline coating will be done immediately after pin brazing in accordance with
the relevant industry specifications.

5.6. Testing after Installation

On completion of pin brazing all connections shall be mechanically tested by tapping lu g with
a sharp blow from a hard rubber headed hammer. The completed cable connection shall then
be tested by pulling with the weight of 100-kg in the direction of the cable lay.

5.7. Quality Assurance

Records of all pin brazing qualifications and installations must be kept by the contractor.
Records of installation shall include the following:

a) Line Number and diameter

b) Date, Procedure and Operator Number
c) Connection Number
d) Nearest Mainline Weld Number (Positive)
e) Megger Test Results in ohms (when required)

6.0 CONCRETE WEIGHT COATING

This Specification covers the application of the concrete coating to line pipe for the Lekki
Offshore Terminal. The contractor shall furnish all materials, labor, equipment, utilities,
supervision, services, and all other items required to perform the work, Contractor shall make
all arrangements and obtain permits required for his performance of work at the coating site
whether on property owned or arranged for by Contractor, by Client, or by others.

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6.1. Materials
Materials shall be subject to the Client approval. Sand and aggregate certificates shall be
available to Client. The grading and purity of sand and aggregate shall be checked at least
once a week. The Client reserves the right to reject any material not deemed acceptable by
virtue of either source or quality.

6.1.1. Cement

Cement shall be Portland cement conforming to ASTM C- 150 Type I.

6.1.2. Sand

Sand shall be clean and free of salt, alkali, deleterious material or organic impurities.
Suitability of the natural sand for use in concrete shall be determined in accor dance with
ASTM C-33.

6.1.3. Aggregate

The aggregate shall be granite, iron ore, or any other approved aggregate. The aggregate
shall be clean and free from salt, alkali, deleterious material or organic impurities. It shall
conform to ASTM C-33

6.1.4. Water

Water shall be clean fresh water, free from oil, salt, alkali, deleterious material or organic
impurities. Water shall not contain more than 250 ppm of chlorides.

6.1.5. Admixtures

Admixtures shall be limited by the requirements of ASTM C-494

6.1.6. Reinforcement

Reinforcement shall be high quality 38mm x 38mm galvanized woven or welded wire mesh. At
the time concrete coating is applied, the wire fabric shall be free from dust, scale dirt, oil, or
other coatings that may reduce the bond with the concrete. Other reinforcement may be used

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 if approved by Client in writing. Wire fabric shall conform to ASTM-185 with galvanizing per
ASTM A-153. All reinforcing to have a minimum yield stress of 460MPa

6.2. Concrete Mix Design

6.2.1. Proportioning

The contractor shall select the necessary proportioning of materials to produce strength and
density. The mix design shall be submitted for review before con struction.

Concrete shall have minimum compressive strengths of 45MPa at 28 days.

Prior to commencement of production coating, Contractor shall have compressive strength

test specimens of the design mix prepared and tested in accordance with ASTM Method C -
39. If more than one design mix is to be used because of the use of more than one source of
any one material for the concrete, testing shall be done for all design mixes. Testing shall be
by an approved independent agency

6.2.2. Mixing and batching

Primary mixed concrete shall be placed within a time/temperature controlled period so that it
will produce a homogenous cohesive grout.

The concrete materials shall be accurately proportioned and mixed in a machine that will
ensure a thorough intermingling of all materials in the concrete. The metering and feed
systems shall be initially calibrated by weight before the start of the concr ete application. The
amount of water and the method of its introduction into the mix shall result in a mixture
providing the physical properties stipulated in this specification.

6.2.3. Curing

The concrete coating shall be cured for a minimum of 4 days at temper atures of not less than
4C. During curing, the concrete coated pipe shall be supported to eliminate any detrimental
deflection. The concrete shall not be allowed to dehydrate.

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6.2.4. Testing

Samples of the mixed concrete shall be taken to determine the compressive strength of the
concrete coating mix. Testing shall be in accordance with ASTM Method C-39.

Density shall be determined twice daily by weighing the samples for the 24 -hour compressive
strength test before making the compressive strength test, and calcu lating density based on
the measured volume. Test results shall be submitted daily once construction begins

6.3. Coating Control and Tolerances

6.3.1. Coating Control Data

Contractor shall weigh each concrete-coated pipe immediately after coating, and shall
measure the outside diameter of the concrete either on the scale or as soon as the joint is
placed on the curing rack. The outside diameter shall be measured at a minimum of five
points evenly spaced along the length of the pipe joint. The average of these measurements
shall be reported and be used in calculations for coating thickness and concrete density.

6.3.2. Scales or weighing devices

Weighing devices used to determine the weight of the concrete-coated joints shall be certified
in writing to an accuracy of 0.5%.

6.3.3. Density

The design density of all concrete weight coating is 3040 kg/m. The density of concrete
coating shall not vary from the design density by more than plus 10% or minus 5%. If the
density varies from the specified density by more than the stated tolerance, the contractor
shall take necessary corrective measures to obtain the specified density.

6.3.4. Concrete Coating Thickness

Coating thickness shall not vary by more than minus 0 or plus 6 mm from the nominal
specified thickness.

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6.3.5. Placement of Reinforcement

The reinforcement shall be spirally applied simultaneously with the co ncrete and shall have
an overlap of not less than 19 mm. One wrap of reinforcing wire shall be used for concrete
thickness up to 70mm. The reinforcement wire shall be placed so as to provide maximum
reinforcing properties to the coating. A minimum cover of 10mm to the reinforcement is
allowed. The reinforcement shall not protrude at the concrete coating holdback.

6.3.6. Holdback and Cleanup

Concrete coating shall terminate to provide the holdback distance of 350mm. Coating edge
shall be perpendicular to the axis of the pipe and the steel reinforcement wire shall not
protrude through the concrete coating edge.

6.4. Permissible repairs to concrete coating

Concrete coating with defects or damage or which does not conform otherwise to this
specification shall be promptly repaired to the satisfaction of Client.

Hairline cracks less than 1.5 mm in width need not be repaired. Circumferential cracks
exceeding 1.5 mm in width at the surface and exceeding more than 180 degrees shall be
repaired. Longitudinal cracks exceeding 1.5 mm in width at the surface and in excess of
300mm in length shall be repaired.

7.0 CORROSION COATING

This specification defines minimum quality and acceptability standards governing preparation
of carbon steel pipe joints and application of anti-corrosion coating suitable for offshore
pipelines. This specification includes the materials, application, inspection and other
requirements for complete mill application of Fusion-bonded Epoxy coating to the pipe and
pipe joints.

7.1. Surface Preparation

Pipe joints shall be supplied free of mill coating. The contractor shall remove any oil, grease
or paint from exterior pipe joint surfaces before blasting, by washing with an approved
solvent.

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 Each pipe joint shall be uniformly heated prior to blast cleaning, to completely remove all
moisture and to prevent condensation on the pipe joints. Substrate temperature shall be a
minimum 3C above dew point, but not exceeding 66C, during surface penetration,
application and drying. Temperature, dew point, and relative humidity shall be determined
following procedures in ASTM E-337. Readings are required at the start of work and every
four (4) hours thereafter.

Exterior pipe joint surfaces shall be abrasive blast cleaned to ISO 8501:1 Grade SA 2 1/2
near-white metal. Maximum particle size shall be able to pass through a 16-mesh screen
(1.18 mm), U.S. Sieve Series. The largest commercial metal grit grade permitted by this
Specification is SAE No.G-25. Abrasive working mixes shall be selected to produce an anchor
pattern profile of between 0.038 mm and 0.064 mm. Compressed air for blasting shall be free
of water and oil, with provision of adequate separators, filters, or traps.

Following abrasive cleaning and prior to coating application, all dust, grit, metal particles or
other loose contaminants remaining on the surface, or entering pipe joint interiors, shall be
blown off with clean, dry, oil-free compressed air without affecting other clean pipe joints or
pipe joints to be coated. Cleaned pipe joint surfaces shall not be allowed to flash rust before
coating. Any pipe joints not coated within four (4) hours after blasting shall be re -blasted.

Any raised slivers, scabs, laminations or bristles of steel remaining on newly cleaned pipe
joint surfaces shall be removed using abrasive sanders, without burnishing or destroying
surface anchor patterns. Bevel ends shall be protected from impact damage at all times.

7.2. Coating Application

Nap-Gard Mark X 7-2501 Fusion-bonded Epoxy (FBE) or similar approved coating shall be
used. The coating manufacturer's application specification shall be considered supplemental
to and part of this Specification. The contractor shall strictly follow the manufacturer's
application specifications, curing temperatures and curing time for the FBE system used.

Pipe joints shall be preheated within the coating manufacturer's recommended tolerances;
however, pipe joints shall not be heated in excess of 260C at any time. No oxide formations
will be allowed on the steel prior to coating. Pipe joints heated in excess of 260C shall be
rejected. If oxidation occurs, pipe joints shall be cooled to ambient temperature and re -
cleaned.

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 After the first blast-cleaning unit, where appropriate surface cleanliness has been achieved,
pipe joints shall be treated as follows:

a) A solution of ten percent (10%) (100,000 ppm) Oakite 33, or similar approved
equal, shall be applied by spray or gravity feed. The solution shall be agitated
periodically, or continuously as required to prevent mix settlement.
b) A uniform pH of 1.0 or less shall be maintained over the entire treated surface
area, as checked with pH paper.
c) Treatment shall be for a minimum of 20 seconds, with pipe joint surface
temperatures of 45 to 65C.
d) High-pressure clean water rinse with a minimum of 35 - 70 bar tip pressure must
follow to remove any treatment residue. To minimize oxidation (flash rust), rinse
water shall be treated with a zero point one percent (0.1 %) (1,000 ppm) Oakite NC
concentration.
e) Contractor shall properly handle and dispose of waste water, including neutralizing
if required

Coating shall be uniformly applied, using best commercial practices and manufacturer's
recommendations, for a total cured Dry Film Thickness (DFT) of 0.35 to 0.55 mm. Coating
shall be applied by electrostatic powder spray over the full pipe joint lengths, to within 230 mm
of each pipe joint end. Cutback shall be measured from bevel shoulders.

Recycled powder shall only be used when proper filtration equipment, approved by the
powder manufacturer and Client, is installed. The Client shall be notified when recycled
powder is being recovered and processed for reuse. At no. time shall the contractor use more
than twenty-five percent (25%) recycled powder mixed with virgin powder.

Dry film thickness shall be measured with a properly calibrated magnetic film thickness gauge;
or equivalent, to ensure each coated pipe joint has a minimum DFT of 0.35 mm. The film
thickness gauge shall be calibrated frequently. Any pipe joints with a measured coating
thickness less than 0.35 mm at any location shall be rejected.

7.3. Curing and Testing

During application and curing, pipe joints shall be handled so as to avoid coating damage,
including contamination by foreign material from any source. Knurled steel, or other type
wheels, capable of marking or damaging pipe joints or coatings shall not be used.

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 Wet film thickness coating measurements shall be made using an approved wet film
measuring device. The contractor shall maintain records of each measurement. Test results
must be made available within 72 hours of taking samples.

After coating has cured, it shall be cooled with air or water spray to a temperature that will
allow proper handling and inspection.

Differential Scanning Calorimeter (DSC) analysis shall be performed on the first and last pipe
joint coated and on one percent (1%) of all other pipe joints. Delta T g shall be less than 5C
for coatings to be considered fully cured. If analysis shows any samples to be partially cured,
it must be determined which pipe joints were not properly cured. Any pipe joints not properly
cured will be rejected and repaired.

The contractor shall perform bend tests on a 25mm x 200mm two specimens cut from the
coated end of a pipe. For acceptance, the coating shall withstand a three percent strain
without cracking or disbanding. The contractor shall size the radius of the mandrel to achieve
the three percent strain at a deflection rate of 25mm per minute.

At production start-up, after production interruptions, at the start of a new powder batch, and
once every 20 pipe joint lengths (whichever is more frequent), coating adhesion will be
determined at one location on a pipe joint. If three tests have been successful, the frequency
may be reduced to once every two hours, or 50 joint lengths, whichever is less.

7.4. Cathodic disbondment

Cathodic disbondment tests shall be conducted on the first and last pipe joints coated, and
on one percent (1%) of all other pipe joints. The contractor shall cut a 100 x 100 mm plate
from production coating ring samples, and a 3.2 mm holiday shall be drilled through the
coating to steel substrate. A 75 mm diameter PVC cell shall be centered over the intentional
holiday, fixed to the coating surface with silicone. The cell shall be filled with three percent
(3%) NaCl electrolyte with a platinum wire anode inserted below the electrolyte level. A 3.5
Volt DC (referenced to saturated calomel) shall be impressed and the entire test plate and
apparatus maintained at 66 C for 24 hours.

At test completion, a 30 degree "V" cut shall be made through the coating, originating at the
intentional holiday. The amount of coating removed in the "V" is evaluated and expressed in

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 millimeters radius, as measured from holiday edge to the area where well bonded coating
remains. Maximum disbonding allowed is 8 mm.

7.5. Holiday Inspection

Holiday inspection shall be at 1900 Volts for a coating thickness of 0.35 mm.

7.6. Anti-slip Bands

All pipe joints coated in accordance with this specification will have concrete weight coating
applied. To ensure installation slippage does not occur, anti-slip bands shall be applied.

Anti-slip bands shall be applied over FBE coating, consisting of a two -part epoxy paint650
microns (minimum) DFT, with flint granules embedded in the coating. The Anti-slip bands
shall be 1.0 m (-0 0 m, + 0.1 m) wide. One band shall be applied approximately 3 m from one
end of each pipe joint, except those joints designated for anode attachment. For "anode"
joints, two anti-slip bands shall be applied per joint, each band located 3 m from the pipe joint
ends.

7.7. Coating Repairs

Pinhole type holidays, except if located within 300 mm of each pipe joint end, shall be
repaired using heat melt sticks recommended by the coating manufacturer. Surfaces to be
repaired shall be heated with a small torch until the stick starts to me lt, then the stick shall be
rubbed over the heated surface, building up a small puddle of patching compound over the
entire repair area.

Two-part liquid epoxy compound recommended by the coating manufacturer shall be used to
repair areas larger than pinholes, and all defects located within 300 nun of each pipe joint
end. Repair coating shall be applied to a minimum thickness of 0.6 mm and shall overlap
undamaged areas by a minimum 25 mm.

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