Ichthys LNG Project - ICN Gateway

Ichthys LNG Project

Package Number PRO0001/1089

Package Name FBE Coated Linepipe Scope of Work For the supply of 4,500 mts DN300, API 5L Grade X65Q PSL2, STD (9.53 mm WT) pipe complete with Dual Layer Fusion Bonded Epoxy (FBE) or better.

Minimum SOW Requirements

108900-PLE-DAT-201 FUEL GAS PIPELINE - LINE PIPE AND COATING DATA SHEET - ONSHORE GAS EXPORT PIPELINE WORKS 108900-PLE-SPC-223 FUEL GAS PIPELINE LINEPIPE SPECIFICATION - ONSHORE GAS EXPORT PIPELINE WORKS 108900-PLE-SPC-201 FUEL GAS PIPELINE - LINE PIPE COATING SPECIFICATION - ONSHORE GAS EXPORT PIPELIINE WORKS ISO 9001-2008 ISO/TS 29001

Delivery / Supply Schedule

Delivery Point: Monadelphous KT Project Laydown, Blaydin Point, Darwin, Northern Territory Required: 01/12/2013

Project Registration Information INPEX is committed to ensuring Australian Industry the opportunity to participate in the Ichthys LNG Project. You are invited to register an expression of interest if you have the relevant capability and capacity to undertake the scope of work. Suppliers and contractors will only be considered for prequalification and tender lists if suitably qualified. All registrations are to be completed via ICN Gateway www.icngateway.org.au. Please contact the ICNNT if registration assistance is required. Contact details: (08) 8922 9422 or [email protected]. Note that an important part of the project registration process is registering your Expression Of Interest (EOI) at the correct Tier level. Tier level definition: Tier 1: Able to produce / supply ALL of the package. Tier 2: Able to produce / supply SOME of the package. More information about INPEX and the Ichthys Project can be found on the INPEX website www.inpex.com.au

http://www.icngateway.org.au/

mailto:[email protected]?subject=Enquiry%20from%20the%20NTNewsletter

http://www.inpex.com.au/

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108900-PLE-DAT-201 Rev B

REV

A

B Issued for Review KMC PTT MJW

-29Design Pressure kPag 9650Maximum Design Factor 0.8

CHK APP

15/05/13 Internal Review KMC

Project

Area 1089Client/End User

DATE ISSUE ORIG

27/05/13

300

DESIGN CONDITIONS

Design Code AS2885.1-2012Maximum Design Temperature °C 65

NOTES

SUPPLIER shall comply with API 5L Annex B and G API5L3, AS2885.1 Appendix K-K3

2PURCHASER's review of SUPPLIER's documents shall not relieve SUPPLIER of the responsibility for accuracy of dimensions and compliance to codes, specifications and all other requirements.

For induction bends refer to datasheet 108900-PLE-DAT-202 and specification 108900-PLE-SPC-202

TBC = To be confirmed by PURCHASER

Wall Thickness mm 9.5

Coating Total Dry Film Thickness µm TBCInternal Coating No

Material Grade X65Specification API 5L PSL2 (Refer to 108900-PLE-SPC-223 Fuel

Gas Pipeline Line Pipe Specification) with resistance to ductile fracture propagation

Manufacturing Process

Onshore Gas Export Pipeline Works

Fuel Gas Pipeline - Linepipe and Coating DatasheetSheet 1 of 1

Service Gas Pipeline Standard Wall Externally Coated

UnitGENERAL

Line No TBA

P & ID L660-DP-PID-10000.001Location Darwin, Northern Territory, Australia

Nominal Diameter DN

Service Natural Gas (non-sour)

LINE PIPE SPECIFICATION

Outside Diameter mm 323.9

Minimum Design Temperature °C

ERWExternal Corrosion Coating Dual Layer FBE (Refer to FGP Linepipe Coating

Specification 108900-PLE-SPC-201)

27 J at -30°C (full sized specimen) Refer to API 5L Annex G Table G.3

DWTT Minimum 85% shear area at -29°CResidual Magnetism 20 gauss maximum, 3 checks per shift

Joint Lengths m 18 (Triple Random Length (Note 5))Charpy Testing

Total Length Required m 4500 (TBC, Note 6)

Doc No.

Proj No

Ichthys Onshore LNG Facilities

Onshore Gas Export Pipeline Works

Monadelphous KT

3Should a conflict exist between documents, it shall be the responsibility of the SUPPLIER to call attention to the discrepancy and request written confirmation.

4

All codes and specifications referenced herein shall be to the latest edition and addenda. The most stringent conditions shall govern between latest editions of the codes and specifications, unless otherwise specified. If SUPPLIER finds it necessary to sublet equipment design and drawing for fabrication, the SUPPLIER must notify and obtain approval from the PURCHASER. This must be identified with the Bid Package.18 meter long random lengths to be Maximum 18.300m and Minimum 12.000m, Min Average 17.000m

6Quantity to be confirmed following site survey and revision of alignment sheets. Includes 15% nominal allowance on alignment sheet chainage for routing allowance, qualifications and wastage.

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SHEET 1 OF

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Subcontractor's name MONADELPHOUS KT PTY LTD

Subcontract No. 0 - 6037- P-31P0-GEP-1

Subcontract Package Name: ONSHORE GAS EXPORT PIPELINE WORKS

DOCUMENT TITLE: FUEL GAS PIPELINE LINEPIPE SPECIFICATION – ONSHORE GAS EXPORT PIPELINE WORKS

Subcontractor's Doc. No.: 108900-PLE-SPC-223

ICHTHYS ONSHORE LNG FACILITIES

Darwin, Australia

Subcontractor ISSUE PURPOSE □FA □FR □FI □FC □AB □CA

CTR RESULT CODE □A □B □N □F

NEXT STATUS : □FA □FR □FI □FC □AB □NA Subcontractor RESUB / NEXTSUB DATE : Approval or review hereunder shall not be construed to relieve Vendor / Subcontractor of his responsibilities and liability under the Contract. CTR ORGANIZATION DEPT. NAME SIGNATURE

PJ DEPT. RESPONSIBLE DEPT. RELATED DEPT.

CTR REVIEW DATE :

JOB. NO. 0-6037-2 REVIEW CLASS

CPY DOC.no.

SYSTEM no. - CLASS/DISC. - TYPE - SERIAL no. REV

L XXX - XX - XXX - XXXX X CTR

DOC.no.

Subcontract No. - SERIAL no..

V - 31P0 - GEP - 1 - XXXXX

SHEET 2 OF

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JKC AUSTRALIA LNG PTY LTD


CONTRACT NO. P-31P0-GEP-1

ONSHORE GAS EXPORT PIPELINE WORKS

FUEL GAS PIPELINE LINEPIPE SPECIFICATION

108900-PLE-SPC-223

INPEX Doc No:

JKC Doc No:

REV DATE DESCRIPTION PREPARED CHECKED APPROVED CLIENT (if applicable)

A 08/04/2013 Internal Review DOW KMC MJW

B 24/04/2013

Once printed this document becomes uncontrolled. Refer to Monadelphous KT Pty Ltd project document control for controlled copy. Please consider the environment before printing this document.

ONSHORE GAS EXPORT PIPELINE WORKS FUEL GAS PIPELINE

LINEPIPE SPECIFICATION

Doc No. : 108900-PLE-SPC-223 JKC Ref :

INPEX Ref : Rev: B Page : 3 of 14

REVISION DETAILS

Revision Date Summary of Changes

HOLDS STATUS

HOLD No.

Section / Page

Paragraph / Item Description of HOLD





CONTENTS 1 INTRODUCTION .......................................................................................................................................... 6

1.1 Document Purpose .............................................................................................................................. 6

1.2 Project Overview.................................................................................................................................. 6 2 SCOPE ......................................................................................................................................................... 6

3 REFERENCES, ABBREVIATIONS & STANDARDS ................................................................................... 7

3.1 Definitions and Abbreviations .............................................................................................................. 7

3.2 Codes and Standards .......................................................................................................................... 8

3.3 Order of Precedence ........................................................................................................................... 8 3.4 Concession Requests .......................................................................................................................... 9

4 DESIGN AND MATERIAL REQUIREMENTS .............................................................................................. 9

4.1 General Requirements ........................................................................................................................ 9

4.2 Process of Manufacture ....................................................................................................................... 9

4.2.1 General Specification....................................................................................................................... 9

4.2.2 Microstructure .................................................................................................................................. 9 4.2.3 Pre-Production Requirements ....................................................................................................... 10

4.2.4 Chemical Properties ...................................................................................................................... 10

4.3 Mechanical Properties ....................................................................................................................... 10

4.3.1 Tensile Properties .......................................................................................................................... 10

4.3.2 Ductile Fracture Toughness .......................................................................................................... 10

4.3.3 Drop Weight Tear Tests ................................................................................................................ 11 4.3.4 Macro Section Hardness ............................................................................................................... 11

4.4 Workmanship ..................................................................................................................................... 11

5 DIMENSIONS, WEIGHTS AND LENGTHS ............................................................................................... 11

5.1 General .............................................................................................................................................. 11

5.2 Diameter ............................................................................................................................................ 11

5.3 Length ................................................................................................................................................ 11 5.4 Straightness ....................................................................................................................................... 12

5.5 Jointers .............................................................................................................................................. 12

5.6 Squareness ........................................................................................................................................ 12

5.7 Pipe Ends .......................................................................................................................................... 12

5.8 Weld Shape ....................................................................................................................................... 12 6 MARKING AND COATING......................................................................................................................... 12

6.1 General .............................................................................................................................................. 12

6.2 Marking .............................................................................................................................................. 12

7 SHIPPING AND HANDLING ...................................................................................................................... 12

8 SUPPLIER REQUIREMENTS.................................................................................................................... 13

8.1 Data Requirements ............................................................................................................................ 13 8.2 Inspection and Testing ...................................................................................................................... 13





8.2.1 Mechanical Testing Frequency ...................................................................................................... 13

8.2.2 Hydrostatic Testing Frequency ...................................................................................................... 13

8.2.3 Surface Conditions, Imperfections and Defects ............................................................................ 14

8.2.4 Residual Magnetism ...................................................................................................................... 14 9 HANDLING, TRANSPORT AND STORAGE ............................................................................................. 14

9.1 General .............................................................................................................................................. 14

9.2 Transport ........................................................................................................................................... 14

9.3 Delivery to Coating Plant ................................................................................................................... 14





1 INTRODUCTION

1.1 DOCUMENT PURPOSE This Line Pipe Specification has been prepared by OSD Pty Ltd (Lower Tier Subcontractor) to document the minimum requirements for the manufacture and supply of bare line pipe required for the Fuel Gas Pipeline in accordance the Ichthys Onshore Gas Export Pipeline Works (Contract No. P-31P0-GEP-1) awarded to Monadelphous KT Pty Ltd by JKC Australia LNG Pty Ltd (Contractor).

1.2 PROJECT OVERVIEW INPEX Operations Australia Pty Ltd (Company) is the proponent for the construction and operation of hydrocarbon production and export facilities that will be required for the development of the Ichthys gas field located off the northern coast of Western Australia.

Gas from the Ichthys Field will undergo preliminary processing at the offshore central processing facility (CPF) to remove water and raw liquids. The gas will be transported from the CPF through a subsea pipeline more than 885 kilometres to the onshore LNG processing plant that will be located at Blaydin Point on Middle Arm Peninsula near Darwin in the Northern Territory. At this facility, the gas will be cooled to produce liquefied natural gas (LNG).

The Onshore Pipelines Works generally include the detailed design, procurement, construction, testing and handover of approximately 7 km of the 42” onshore Gas Export Pipeline (GEP), approximately 3 km of the 12” Fuel Gas Pipeline (FGP), and associated facilities.

The main elements of the GEP part of the Works are: Civil enabling works along Wickham Point Road and the LNG plant site access road Wickham Point Road crossing 42” Pipeline installation and associated Pig receiver, and inlet facility works Optional Beach Valve works including the Road Intersection, Valve Station, and Tie-in to offshore

pipeline.

The main elements of the FGP part of the Works are: Tie-in Station to Power and Water Corporation (PWC) gas supply pipeline off-take 12” Pipeline and associated Tie-in station, and Inlet facility works

2 SCOPE This Specification covers the minimum requirements for the manufacture, testing and inspection of “API 5L Line Pipe” for the Ichthys Gas Field Development Fuel Gas Pipeline in NT, Australia.

This Specification supplements the requirements of API specification 5L, 45th edition.

Refer to the FGP Line Pipe Data sheets (108900-PLE-DAT-201) and FGP Line Pipe Requisition (108900-PLE-REQ-201) for the line item descriptions.





This Specification is not all-inclusive and the use of the guidelines set forth does not relieve the Supplier of his responsibility to provide a finished product capable of performing its intended service.

Supplier shall have full responsibility for manufacturing process design, fabrication, testing, inspection, quality and selection of materials and quality of workmanship. Review of the Supplier’s drawings or inspection by the Purchaser will not relieve the Supplier of any of these responsibilities.

Systems audit by Purchaser to ensure that the Supplier’s operations and Quality System are fully in compliance with ISO 9000 Quality management.

3 REFERENCES, ABBREVIATIONS & STANDARDS

3.1 DEFINITIONS AND ABBREVIATIONS The following definitions apply to this document:

Table 1 Definitions

Abbreviation Definition KT / Subcontractor Monadelphous KT Pty Ltd

JKC / Contractor JKC Australia LNG Pty Ltd

INPEX / Company INPEX Operations Australia Pty Ltd

LTSC OSD Pty Ltd, Lower Tier Subcontractor

ASTM American Society for Testing and Materials API American Pipeline Institute CVN Charpy V-notch Test DWTT Drop Weight Tear Test ERW Electronic Resistance Welding FGP Fuel Gas Pipeline GEP Gas Export Pipeline HAZ Heat Affected Zone ITP Inspection and Test Plan LNG Liquefied Natural Gas MPS Manufacturing Procedure Specification MPI Magnetic-particle inspection PSL Product Specification Level PT Dye Penetrant Testing PWC Power and Water Corporation UT Ultrasonic Test WPS Welding Procedure Specification Purchaser Subcontractor or Lower Tier Subcontractor SMYS Specified Minimum Yield Stress Supplier Company contracted by Purchaser to supply line pipe for the Project

The following documents and specifications shall be used in conjunction with this Specification:

Table 2 References

Document No. Description 108900-ENG-BOD-200 Fuel Gas Pipeline Basis of Design





108900-ENG-BOD-201 Fuel Gas Pipeline Design Premise 108900-PLE-SPC-203 Fuel Gas Pipeline Linepipe Coating Specification 108900-PLE-DAT-201 Fuel Gas Pipeline Linepipe & Coating Datasheet 108900-PLE-REQ-201 Fuel Gas Pipeline Linepipe Requisition

3.2 CODES AND STANDARDS 1. The codes, standards and statutory regulations listed below shall be used in conjunction with this

Specification, Data sheet(s) and the referenced specifications. 2. Where there are conflicts between standards, the more stringent criteria shall apply.

Table 3 Australian Standards

Document No. Description AS 2885.1: Appendix K

Pipelines – Gas & Liquid Petroleum; Part 1: Design & Construction. With particular attention given to: Fracture toughness test methods

AS 2885.5 Pipelines – Gas & Liquid Petroleum; Part 5: Field Pressure Testing

Table 4 API Codes

Document No. Description API 5L: Annex B Annex G

Specification for Line Pipe. With particular attention given to: Manufacturing procedure qualification for PSL2 pipe PSL2 pipe with resistance to ductile fracture propagation

API 5L1 Recommended Practice for Railroad Transportation of Line Pipe

API RP 5L3 Recommended Practice for Conducting Drop-Weight Tear Tests on Line Pipe

API RP 5LW Recommended Practice for Transportation of Line Pipe on Barges & Marine Vessel

Table 5 Applicable Material Testing Codes

Document No. Description ASTM E23 Notched Bar Impact Testing of Metallic Materials

ASTM E29 Practice for using significant digits in Test Data to Determine Performance with Specifications

ASTM E112 Test Methods for Determining Average Grain Size AS 1330 Metallic Materials – Drop Weight Tear Test for Ferritic Steels

3.3 ORDER OF PRECEDENCE Any conflicts between the referenced documents shall be identified to the Purchaser in writing by the Supplier for resolution. The following general order of precedence shall apply to conflict resolution:

Level 1: Purchase Order Level 2: Data Sheet Level 3: This Specification Level 4: Referenced specifications Level 5: Industry Codes and Standards





3.4 CONCESSION REQUESTS 1. Any requests or variance from the codes, standards and referenced document specified herein shall

be submitted in writing to the Purchaser in advance for approval. 2. The Supplier shall prepare a concession request to be submitted to the Purchaser for review and

approval prior to any changes to be implemented. 3. Technical changes implemented prior to Purchaser’s written approval are subject to rejection.

4 DESIGN AND MATERIAL REQUIREMENTS

4.1 GENERAL REQUIREMENTS 1. All items shall be new and suitable for onshore, buried natural gas service. Used items are not

permitted. 2. All items shall be provided per the purchase requisition line item descriptions and the requirements of

this Specification. 3. Material Test Certificates and full traceability shall be provided for all materials. 4. There are no special hydrostatic test requirements for the mill. However, all items will be subject to a

field hydrostatic test pressure (after installation) in accordance with the requirements of AS 2885.1 and AS 2885.5: a. The minimum field hydrostatic test pressure at the highest point in the test section will be not less

than that required by AS 2885.1 and AS 2885.5 (typically approaching 100% Specified Minimum Yield Stress (SMYS))

b. The maximum field hydrostatic test pressure will not exceed 110% SMYS c. Pipe which fails to achieve these requirements without failure, leakage or impairment of

serviceability at the test pressure will be deemed not to comply with this Specification d. The Project Quality Plan must specify a minimum factory test pressure sufficient to ensure

compliance with the above, and not less than that required by API 5L

4.2 PROCESS OF MANUFACTURE

4.2.1 GENERAL SPECIFICATION 1. The pipe shall conform to the specifications of API 5L line pipe, with grade as per line item

description in Line Pipe Requisition (108900-PLE-REQ-201) and Data sheets (108900-PLE-DAT-201), and as modified by these supplemental requirements.

2. The pipe product specification level shall be PSL 2 per API 5L designation. 3. A higher grade of API pipe, designated and certified as such, shall not be substituted for the grade of

pipe specified on the purchase requisition without the approval of the Purchaser in writing. 4. All steel used to manufacture/fabricate pipe shall be manufactured by basic oxygen furnace or

electric arc furnace. 5. Strip of plate used for the manufacture of welded pipe shall be rolled from continuously cast (strand

cast) or pressure cast slabs. 6. The strip of plate used for the manufacture of welded pipe shall not contain repair welds. 7. Pipes shall be delivered in properly heat treated condition, as required. Detail of the proposed heat

treatments shall be submitted for Purchaser approval prior to the start of production. 8. Jointers shall not be used.

4.2.2 MICROSTRUCTURE 1. Steel shall be fully killed and fine grained. 2. Ferrite grain size shall be determined on one pipe per heat, and grain size shall meet requirements of

ASTM E112 #7 or finer. Ferrite grain size requirement shall not apply to quenched and tempered pipe.

3. The specimen shall be prepared and etched for metallographic examination at 100 times magnification.

4. Pipe Supplier shall submit for Purchaser approval its method(s) for preventing centre line segregation and associated stereological procedures for assessing the degree of banding or orientation of microstructures. Methodology as per ASTM E1268 is preferred.

5. Supplier shall submit oxygen analysis of steel for Purchaser information.





4.2.3 PRE-PRODUCTION REQUIREMENTS 1. Prior to the initiation of pipe production, the Purchaser shall be allowed to visit the production facilities

for the purpose of witnessing all procedures to be used in the manufacture, testing, inspection, identification and storage of pipe throughout all stages of manufacturing process.

2. Pipe production shall not commence without written approval of the Purchaser and until a pre-production quality control meeting has been completed by the Purchaser’s representative and the Supplier’s production and quality assurance personnel.

3. The following documents shall be submitted to the Purchaser for review at least two weeks prior to the pre-production meeting, which would be attended by the Purchaser representatives: a. Manufacturing Procedure Specifications (MPS) b. Inspection and Test Plan (ITP) for steel making and pipe production listing all the key activities in

a sequential manner and specifying the personnel responsible, reference document, acceptance criteria, test report and inspection involvement of the Supplier for each activity. Third Party inspection involvement where applicable will be advised by the Purchaser following a review of the ITP

c. Procedures as required by the Line Pipe Requisition (108900-PLE-REQ-201), including but not limited to:

i. Pipe heat treatment ii. CVN tests iii. DWT tests iv. Hardness tests v. Non-destructive tests vi. Hydrostatic tests vii. Welding procedure specification (WPS) and test plan for weldability tests or previous

weldability data applicable to the same material specification

4.2.4 CHEMICAL PROPERTIES The chemical composition based on requirements for PSL2 of API 5L shall be applied for pipe with t ≤ 25.0 mm and shall be as given for standard grades and as agreed for any intermediate grades.

4.3 MECHANICAL PROPERTIES The mechanical properties shall conform to the requirements given in API 5L specifications for the grade of pipe specified in the Line Pipe Requisition (108900-PLE-REQ-201), and as modified by the supplemental requirements of this Specification and the Data sheets (108900-PLE-DAT-201).

4.3.1 TENSILE PROPERTIES 1. The yield and tensile strength of the steel shall be in accordance with API 5L for the grade of pipe

specified on the purchase requisition. 2. Tensile tests shall be carried out on both strip and pipe. Both longitudinal and transverse pipe

specimens shall be subject to tensile tests.

4.3.2 DUCTILE FRACTURE TOUGHNESS 1. The fracture toughness of the pipe shall be determined and evaluated by conducting a Charpy V-

notch test in accordance AS 2885.1 Appendix K4 and with ASTM A 370 and in accordance with the API 5L (including applicable Annex) and the requirements stated in this Specification.

2. CVN tests shall be performed at a temperature of 0°C unless stated otherwise on the Data sheet (108900-PLE-DAT-201).

3. CVN tests shall be performed on both strip and pipe. Full size specimens shall be used where possible.

4. Minimum CVN toughness values for individual pipe wall thicknesses and grades will be shown on the Data sheet (108900-PLE-DAT-201), for full size specimens. Full size CVN toughness may be converted to a sub-size requirement where required.

5. Minimum CVN toughness shall apply to the pipe body, weld area and heat affected zone (HAZ). 6. The minimum Charpy toughness specified by the Data sheets (108900-PLE-DAT-201) shall be the

average of the three transverse specimens that are required per test. Minimum individual results shall exceed 75% of this value.





7. In addition to the minimum CVN energy requirement, a minimum average of 85% shear is required.

4.3.3 DROP WEIGHT TEAR TESTS 1. The pipe shall be subjected to Drop Weight Tear Testing (DWTT) in accordance with API 5L Annex

G. For diameter <300 mm or WT <5 mm, DWTT is not required in accordance with AS 2885.1. 2. Test specimens shall be full thickness and taken from the circumferential direction. 3. The test specimens, testing procedure and rating of the specimens shall be in accordance with API

Recommended Practice 5L3 and/or AS 1330 Metallic materials – Drop Weight Tear Test for Ferritic Steels in line with and AS 2885.1 Appendix K3.

4. The DWTT shall be performed at a temperature of 0°C unless stated otherwise on the Data sheets (108900-PLE-DAT-201).

5. A minimum acceptance requirement of 85% shear area shall be achieved per DWTT test.

4.3.4 MACRO SECTION HARDNESS The macro section hardness of the longitudinal weld seam shall conform to the requirements for PSL2 given in API 5L for the grade of pipe specified on the purchase requisition unless otherwise stated.

4.4 WORKMANSHIP The workmanship visual inspection, repair and disposition of defects shall be performed by the Supplier in accordance with API 5L.

1. All first day production tests will be witnessed by the Purchaser representative. 2. In addition, all pipes will be subject to inspection by the Purchaser’s representative. 3. Sufficient notice (at least 14 days) shall be given to the Purchaser by the Supplier of the time when

production is to begin. 4. The Purchaser’s representative shall have free entry at all times to all parts of the manufacturing

works, which concern the manufacture, testing, inspection, quality control, storage and shipping of the pipe ordered, including the steel mill and pipe mill.

5. The pipe mill and steel mill shall make available to the Purchaser’s representative without charge, all reasonable facilities to inspect, measure, and check the pipe in all stages of production, including ultrasonic equipment for wall thickness measurements after grinding.

6. The Purchaser’s representative shall have the option to examine all materials rejected for any reason. If any test specimen fails to meet the requirements for any reason, the cause shall be brought to the attention of the Purchaser’s representative, and all affected materials shall be retained until examined by the Purchaser’s representative.

7. The Supplier shall take all reasonable precautions to ensure that the pipe surface is free of imperfections which might interfere with the efficient application of an external coating. In addition, the metal surfaces shall be sufficiently clean (free from oil, grease and any other contaminants) and smooth so as to permit non-destructive examination.

5 DIMENSIONS, WEIGHTS AND LENGTHS

5.1 GENERAL All dimensions for ‘Diameter – Line Pipe Body’, ‘Diameter – Line Pipe Ends’, ‘Out of Roundness – Line Pipe Ends’, ‘Out of Roundness – Line Pipe Body’, ‘Wall Thickness’ and ‘Weight’ shall be in accordance with API 5L requirements.

5.2 DIAMETER The tolerance on outside diameter shall be plus/minus (±) 0.5% in the pipe body and plus 0.5%, and minus 0.4 mm at the pipe end.

5.3 LENGTH Pipe lengths shall be nominated by the Supplier, and agreed by the Purchaser.

The Supplier shall measure the length of each line pipe and it shall be included as part of the line pipe tracking record.





5.4 STRAIGHTNESS All completed pipe lengths shall be rolled over a proven flat bed to demonstrate straightness. Any straightening shall be undertaken using procedures fully reviewed and/or approved by the Purchaser.

5.5 JOINTERS Mill jointers shall not be permitted.

5.6 SQUARENESS Pipe ends shall be machined square to the pipe centreline to within 1.0 mm.

5.7 PIPE ENDS Pipe ends shall be beveled at 30°, (+ 5°, -0°) with a 1.6 mm root face (bevel land) (+/- 0.5 mm) for the entire circumference.

Pipe ends shall be cut square with centreline through ends of pipe to a tolerance of 1.6 mm as measured across the face of the bevel land.

Filing of land faces shall be permitted to remove burrs provided the land is not face affected, burrs shall be removed from the inside edge by filing or the use of a deburring tool provided the land face is not affected. Damaged pipe ends shall be removed as a cylinder, if necessary, and machine re-beveled beyond the damaged area.

5.8 WELD SHAPE The Supplier shall inspect all pipe lengths in accordance with API 5L to ensure the external and internal profiles of the weld comply with the requirements set forth in this Specification.

6 MARKING AND COATING

6.1 GENERAL The Supplier shall mark all pipe supplied to this Specification for identification against a certificate. When material is stored, the identification markings shall be easily accessible. Materials which cannot be identified shall be rejected. Marking shall, generally, comply with the requirements of API 5L, but die stamping shall not be used.

6.2 MARKING The minimum requirements for marking of bare line pipe are a hand written pipe number and length, written in one end of each pipe and a barcode label, encoding the full pipe identity and length and also listing this information in human readable form:

1. Pipe Number (barcode and stencil) 2. Pipe Size (stencil) 3. Measured length (stencil) 4. Wall Thickness (stencil) 5. Material Specification (stencil) 6. Pipe Heat Number (stencil)

All such markings shall be carried out by a method reviewed and agreed to by the Purchaser.

The marking method shall allow for the marking details to be maintained during the application of an external coating to the pipe.

7 SHIPPING AND HANDLING 1. All pipes shall be handled, loaded and shipped in accordance with API RP 5L1 Recommended

Practice for Railroad Transportation of Line Pipe and API RP 5LW, Recommended Practice for Transportation of Line Pipe on Barges and Marine Vessels.

2. The Supplier shall submit loading instructions and diagrams for approval for all pipe shipped by truck,





rail, or marine vessel; however, approval of these shall not relieve the Supplier of his responsibility for any damage during shipment.

3. All dimensional tolerances and pipe surface conditions specified herein, as well as those specified in API 5L, shall apply to the pipe condition as received at the shipping destination.

8 SUPPLIER REQUIREMENTS

8.1 DATA REQUIREMENTS 1. Supplier shall provide documents and drawings in accordance with the documentation requirements

of the Line Pipe Requisition (108900-PLE-REQ-201). 2. The records, test reports and traceability documents for all materials and testing shall be submitted to

the Purchaser by the Supplier at no cost, including but not limited to: a. Heat treatment records when any pipe is subject to heat treatment b. Certified chemical analysis and mechanical properties tests c. A report giving the results of the grain size evaluation d. CVN V-notch impact tests e. DWTT test results f. Hardness test results g. Result reports for any other applicable testing

3. In addition to the above listed records and test reports, the following documents shall be submitted in electronic format (CD-ROM) in addition to hard copies as part of the final documentation for Purchaser records. a. Approved steel and pipe Manufacturing Procedure Specification (MPS) b. Procedures for all treatments and mechanical tests as required c. Procedures for non-destructive testing of pipe (UT, MPI and PT as applicable) d. Approved Inspection and Testing Plan (ITP) e. Mill certificates of pipes supplied f. Traceability and pipe identification reports

8.2 INSPECTION AND TESTING 1. The inspection and testing requirements, in addition to those already described under Section 4, shall

conform to the specifications of API 5L PSL2 line pipe, with grade as per line item description in purchase requisition, and as modified by the supplemental requirements of this specification and the Data sheets (108900-PLE-DAT-201).

2. Inspection and testing frequency, and acceptance criteria shall meet the requirements for PSL2 of API 5L.

8.2.1 MECHANICAL TESTING FREQUENCY Mechanical testing shall be performed at a minimum of once per heat unless otherwise specified.

8.2.2 HYDROSTATIC TESTING FREQUENCY The Supplier shall hydrostatically test all pipe lengths at the mill in accordance with API 5L and for PSL 2 pipe. Test pressures will be equivalent to 95% SMYS for a hold time of 10 seconds. End cap effects shall also be included in the hydrostatic test calculation.

The hydrostatic testing gauge shall be calibrated against a dead weight tester before start of production. The pressure chart recorder shall be calibrated against the hydrostatic testing master gauge. All hydrostatic pressure tests shall be chart recorded and available to the Purchaser upon request.

The identification number of the pipe length being tested shall be legibly recorded on the hydrostatic test pressure charts. Pressure gauges used in the hydrostatic testing shall have a range of 1½ to 3 times the minimum test pressure. The longitudinal seam orientation during hydrostatic testing shall be such that any pinhole leak in the seam area shall be clearly visible to the hydrostatic testing operational personnel. A permanent record of each test shall be produced showing the pipe identification, test pressure and hold time.





8.2.3 SURFACE CONDITIONS, IMPERFECTIONS AND DEFECTS 1. All pipes shall be free from defects in the finished condition and be suitable for external and internal

corrosion coatings. 2. All pipes shall be free from cracks, sweats and leaks. 3. The acceptance criteria for imperfections found by non-destructive inspection shall be in accordance

with Annex E of the API 5L specifications. 4. Defects shall be classified and resolved in accordance with Section 9.10 of the API 5L specifications. 5. Cracks or crack like defects, slivers, scabs, flame cuts, disc cutter marks, conveyor roll pick-up or

rolled in objects of any depth are not acceptable. 6. Roll marks and head roll pick up may be acceptable if the effected depth is less than 5% of the

nominal wall thickness. 7. Contact marks, gouges, surface scratches, pits or weld splatter are not acceptable if the effected

depth is greater than 5% of the nominal wall thickness. 8. Dents with scratches and dents in the weld are not acceptable. 9. Smooth dents may be acceptable if the effective depth is less than 3 mm.

8.2.4 RESIDUAL MAGNETISM 1. Pipe shall be randomly tested for residual magnetism during final inspection prior to dispatch from the

mill. 2. Residual magnetism shall not exceed 20 gauss.

9 HANDLING, TRANSPORT AND STORAGE

9.1 GENERAL The Supplier shall submit, to the Purchaser for review and/or approval, information detailing the proposed method of handling, stacking, and securing line pipe lengths during manufacture, storage and shipment.

No welding of temporary attachments for handling, stacking or securing shall be permitted. All handling, loading and unloading shall be performed in such a safe manner as to avoid mechanical damage and corrosion.

9.2 TRANSPORT Tail cars, trucks, lighters, ships or other conveyances shall be cleaned of debris or any substance that might damage the line pipe during handling and load out. Suitable timber and other dunnage shall be used to protect the line pipe against damage in transit.

Loading onto or into rail cars, trucks, lighters, ships or other conveyances shall be performed in accordance with API 5L or API RP 5LW as appropriate. In all cases loading shall be in accordance with the Supplier’s standard Packing and Shipping and Handling Procedures.

9.3 DELIVERY TO COATING PLANT Where required, the Supplier shall be responsible for delivery of the uncoated pipe to the coating plant.

SHEET 1 OF XX

Subcontractor's name MONADELPHOUS KT PTY LTD

Subcontract No. 0 - 6037- P-31P0-GEP-1

Subcontract Package Name: ONSHORE GAS EXPORT PIPELINE WORKS

DOCUMENT TITLE: FUEL GAS PIPELINE – LINE PIPE COATING SPECIFICATION – ONSHORE GAS EXPORT PIPELINE WORKS

Subcontractor's Doc. No.: 108900-PLE-SPC-201


Darwin, Australia

Subcontractor ISSUE PURPOSE □FA □FR □FI □FC □AB □CA

CTR RESULT CODE □A □B □N □F

NEXT STATUS : □FA □FR □FI □FC □AB □NA Subcontractor RESUB / NEXTSUB DATE : Approval or review hereunder shall not be construed to relieve Vendor / Subcontractor of his responsibilities and liability under the Contract. CTR ORGANIZATION DEPT. NAME SIGNATURE

PJ DEPT. RESPONSIBLE DEPT. RELATED DEPT.

CTR REVIEW DATE :

JOB. NO. 0-6037-2 REVIEW CLASS 2

CPY DOC.no.

SYSTEM no. - CLASS/DISC. - TYPE - SERIAL no. REV

L 280 - AV - SPC - 10006 X CTR

DOC.no.

Subcontract No. - SERIAL no..

V - 31P0 - GEP - 1 - 12005

SHEET 2 OF XX

JKC AUSTRALIA LNG PTY LTD


CONTRACT NO. P-31P0-GEP-1

ONSHORE GAS EXPORT PIPELINE WORKS

FUEL GAS PIPELINE – LINE PIPE COATING SPECIFICATION

108900-PLE-SPC-201

INPEX Doc No: L280-AV-SPC-10006

JKC Doc No: V-31P0-GEP-1-12005

REV DATE DESCRIPTION PREPARED CHECKED APPROVED CLIENT (if applicable)

A 16/05/2013 Internal Review DAA

Once printed this document becomes uncontrolled. Refer to Monadelphous KT Pty Ltd project document control for controlled copy. Please consider the environment before printing this document.

ONSHORE GAS EXPORT PIPELINE WORKS FUEL GAS PIPELINE - XXX SPECIFICATION

Doc No. : 108900-PLE-SPC-XXX JKC Ref : V-31P0-GEP-1-120XX

INPEX Ref : L280-AV-SPC-100XX Rev: A Page : 3 of 17

REVISION DETAILS

Revision Date Summary of Changes

HOLDS STATUS

HOLD No.

Section / Page

Paragraph / Item Description of HOLD

ONSHORE GAS EXPORT PIPELINE WORKS FUEL GAS PIPELINE – LINE PIPE COATING

SPECIFICATION

Doc No. : 108900-PLE-SPC-201 JKC Ref : V-31P0-GEP-1-12005

INPEX Ref : L280-AV-SPC-10006 Rev: A Page : 4 of 17

CONTENTS 1 INTRODUCTION .......................................................................................................................................... 6

1.1 Scope ................................................................................................................................................... 6

2 REFERENCES, ABBREVIATIONS & STANDARDS ................................................................................... 6 2.1 Definitions And Abbreviations .............................................................................................................. 6

2.2 References And Codes ....................................................................................................................... 6

2.3 Project Documents .............................................................................................................................. 7

2.4 Concessional Requests ....................................................................................................................... 7

3 Coating Properties and Materials Requirements ......................................................................................... 7 3.1 Approved Materials .............................................................................................................................. 7

3.1.1 Fusion Bonded Epoxy Powder Base Coat ...................................................................................... 7

3.1.2 Coating for Abrasion and Impact Protection .................................................................................... 8

3.2 Materials Properties, Compatibility and Performance ......................................................................... 8

3.3 Materials Certificates and Data Sheets ............................................................................................... 8

3.4 Materials Identification ......................................................................................................................... 8 3.5 Batch Information for FBE Material ..................................................................................................... 8

3.6 Coating Materials Storage ................................................................................................................... 9

3.7 Reclaimed Coating Materials ............................................................................................................... 9

3.8 Material Substitution ............................................................................................................................ 9

3.9 Abrasive Materials ............................................................................................................................... 9

3.10 Materials Sequencing .......................................................................................................................... 9 4 COATING PROCEDURE AND QUALIFICATION ....................................................................................... 9

4.1 Proposed Work Procedures ................................................................................................................ 9

4.2 Coating Procedure Qualification (CPQ) ............................................................................................ 10

4.2.1 Raw Materials Tests ...................................................................................................................... 10

4.2.2 Tests on Coated Pipes .................................................................................................................. 10

4.2.3 Testing Report ............................................................................................................................... 11 4.2.4 Test Pipes ...................................................................................................................................... 11

4.2.5 Test Ring Retention ....................................................................................................................... 11

4.2.6 Procedure Re-qualification ............................................................................................................ 11

5 PIPE SURFACE PREPARATION .............................................................................................................. 12

5.1 Surface Contaminants ....................................................................................................................... 12 5.2 Pre Inspection .................................................................................................................................... 12

5.3 Abrasive Blast Cleaning .................................................................................................................... 12

5.4 Pipe Surface Imperfections ............................................................................................................... 12

5.5 Acceptance of Surface Preparation ................................................................................................... 13

5.6 Coating Interval.................................................................................................................................. 13

6 COATING APPLICATION .......................................................................................................................... 13 6.1 Line Pipe Heating .............................................................................................................................. 13


SPECIFICATION



6.2 Temperature Monitoring .................................................................................................................... 13

6.3 Coating Application and Coating Thickness ...................................................................................... 13

6.4 Coating Appearance .......................................................................................................................... 14

6.5 End Cut Back ..................................................................................................................................... 14 6.6 Rejection of Coating .......................................................................................................................... 14

7 PRODUCTION REPORT ........................................................................................................................... 14

8 INSPECTION AND TESTING .................................................................................................................... 15

8.1 General .............................................................................................................................................. 15

8.2 Visual Inspection................................................................................................................................ 15

8.3 Gel Time Test .................................................................................................................................... 15 8.4 Thickness Test ................................................................................................................................... 15

8.5 Holiday Detection............................................................................................................................... 16

8.6 Rate for Pipe Rejection ...................................................................................................................... 16

8.7 COMPANY’s Approval ....................................................................................................................... 16

9 COATING PATCHES AND REPAIRS ....................................................................................................... 16

9.1 Pipe Damage ..................................................................................................................................... 16 9.2 Pipe Repair ........................................................................................................................................ 16

10 HANDLING, TRANSPORTATION AND STORAGE ............................................................................. 17

10.1 General .............................................................................................................................................. 17

10.2 Lifting and Separation ........................................................................................................................ 17

10.3 Final Acceptance ............................................................................................................................... 17 11 MARKING AND PIPE IDENTIFICATION .............................................................................................. 18

Appendix A - Piping Material Specification Summary ....................................................................................... 19

Appendix B - Testing Summary for Coating CPQ ............................................................................................. 20

Appendix C - Production Testing of Coating ..................................................................................................... 22


SPECIFICATION



1 INTRODUCTION This Line Pipe Coating Specification describes the minimum technical requirements for the manufacture, testing and supply of Dual-Layer Fusion-Bonded Epoxy (FBE) external coating for use on the Fuel Gas Pipeline (FGP) as part of the Ichthys Onshore Gas Export Pipeline Works.

This document shall be read in conjunction with the following Datasheets: 108900-PLE-DAT-201 Line Pipe Datasheet

Supply of FBE Linepipe Coating shall be in accordance with the requirements of this specification, and AS/NZS 3862:2012. The requirements of this specification shall take precedence in the event of any conflict.

1.1 SCOPE The coating shall consist of FBE of minimum coating thicknesses, including weld areas, in accordance with Table 6.1.

The dual-layer coating shall: Prevent corrosion to the pipe by providing an impervious barrier between the steel pipe and the

external environment. Adhere firmly to the pipe throughout its design life with coating. It should be suitable for use at the

pipeline maximum design temperature and shall be compatible with the Cathodic protection system. Provide sufficient toughness and surface friction to allow for the use of conventional lay and HDD. A base coat layer of fusion bonded epoxy (FBE) minimum 0.400mm A top layer of abrasion resistant overcoat (ARO) minimum 0.400mm or 0.600mm (for trenchless

crossing). Only approved materials in accordance with Clause 3.1 shall be used and the finished colour shall be black.

This Specification covers: Pipe surface preparation prior to application of the external coating. Application of the external coating. Supply of an approved patching material and repairs. Testing requirements. Handling, storage and transport.

2 REFERENCES, ABBREVIATIONS & STANDARDS

2.1 DEFINITIONS AND ABBREVIATIONS The following definitions and abbreviations have been used during the preparation of this document:

KT / SUBCONTRACTOR Monadelphous KT Pty Ltd JKC / CONTRACTOR JKC Australia LNG Pty Ltd INPEX / COMPANY INPEX Operations Australia Pty Ltd LTSC Lower Tier Subcontractor (OSD Pty Ltd) FGP Fuel Gas Pipeline ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materials FBE Fusion Bonded Epoxy FGP Fuel Gas Pipeline GEP Gas Export Pipeline NDE Non Destructive Examination

2.2 REFERENCES AND CODES AS 2885.1-2012 Pipelines – Gas and liquid petroleum Part 1: Design and construction


SPECIFICATION



AS/NZS 3862:2002 External Fusion-Bonded Epoxy Coating for Steel Pipes AS 1627 Metal Finishing – Preparation and Pre-treatment of surfaces AS/NZS 1518:2002 External extruded high-density polyethylene coating system for pipes AS 3894 Site Testing of Protective Coatings ASME B16.20 Metallic Gaskets for Pipe Flanges: Ring-Joint, Spiral-Wound, and Jacketed AS 4352-2005 Tests for coating resistance to cathodic disbonding

2.3 PROJECT DOCUMENTS L280-AV-BOD-10001 OSD’s FGP Basis of Design

L280-AB-PRC-10002 Concession, Technical Deviation, And Material Substitution Procedure (108900-QAC-PRC-001).

108900-PLE-DAT-201 Linepipe Datasheet L280-AV-BOD-10001 FGP Basis of Design L280-AV-BOD-10000 GEP Basis of Design B091-AV-DAT-0008 DN 1050 GEP Onshore Linepipe / Road Crossing Datasheet B091-AL-DAT-0013 DN 1050 GEP Onshore Induction Bends Datasheet B091-AL-DAT-0004 GEP Onshore Pig Trap Isolation Valve Datasheet B091-AL-DAT-0017 GEP Monolithic Isolation Joint Datasheet B091-AL-DAT-0020 GEP Onshore In-plant Mainline Valve Datasheet L281-AV-SPC-0001 GEP Onshore Mainline Valves Specification

L281-AL-SPC-0003 GEP Carbon Steel Flanges, Forged Outlet Fittings, Bolting and Gaskets Specification

L281-AL-SPC-0004 GEP Carbon Steel Fittings Specification L281-AL-SPC-0009 GEP Monolithic Isolation Joint Specification L281-AL-SPC-0017 GEP Pipeline Induction Bend Specification L281-AL-SPC-0019 GEP SAW Linepipe Materials Specification L290-AX-SPC-0005 Inpex Specification for Manual Piping Valves 108900-PLE-SPC-213 Spool Fabrication Specification

2.4 CONCESSIONAL REQUESTS Any requests for variance from the codes, standards and referenced documentation specified herein shall be submitted in accordance with the Concession, Technical Deviation, And Material Substitution Procedure L280-AB-PRC-10002 (108900-QAC-PRC-001).

3 COATING PROPERTIES AND MATERIALS REQUIREMENTS

3.1 APPROVED MATERIALS

3.1.1 FUSION BONDED EPOXY POWDER BASE COAT The external corrosion protection system shall be a shop applied Dual Layer FBE system. The inner layer (thermosetting epoxy powder) of the base coat shall be Nap-Gard 7-2500 or an equivalent material as approved by the COMPANY.

This shall be used in conjunction with an outer layer of Nap-Rock 7-2610 or an equivalent material as approved by the COMPANY. The outer layer shall be compatible with the inner layer.

The APPLICATOR shall submit compliance test results for the powder(s) being offered. The characteristics tested and submitted shall be those specified in Tables B1 and B2 of AS/NZS 3862:2002


SPECIFICATION



The FBE powder to be used for the base coat shall not be changed without the written approval of the COMPANY.

3.1.2 COATING FOR ABRASION AND IMPACT PROTECTION External coating suitable for providing additional abrasion and impact protection is required. FBE coating for additional protection shall be applied over the base layer as a two-layer system. The base shall be materials as specified in Section 3.1.1. The abrasion resistant overcoat (ARO) shall be Protogol 32-55R or equivalent material as approved by the COMPANY.

The FBE powder to be used for the ARO shall not be changed without the written approval of the COMPANY.

3.2 MATERIALS PROPERTIES, COMPATIBILITY AND PERFORMANCE The properties of the epoxy powder shall be in accordance with AS/NZS 3862:2002 and shall achieve the functional requirements and properties of the coating system as stated in this Specification. The APPLICATOR shall provide a reference list of epoxy powders having such properties, applied by the APPLICATOR in similar coating systems and for similar service conditions.

The material brands offered by the APPLICATOR shall have proven compatibility. The APPLICATOR shall submit at the time of tender an adequate track record demonstrating the compatibility of the materials offered. Only COMPANY-approved materials or combinations of materials shall be used.

The pipe coating shall be suitable for the required duty detailed in the Schedule of Specific Requirements (Linepipe).

The coating shall withstand minimum and maximum continuous in-service design temperatures of 0°C and 80°C respectively and comply with the performance requirements of this Specification. In open storage, finished pipe coating shall withstand exposure to sunlight, with a daytime coating temperature of up to 80°C, for a period of 12 months without any detrimental change to coating performance.

Both the inner and outer FBE layers shall be chemically compatible with and offer good adhesive bond substrate for epoxy-based joint coating system selected

The external anti-corrosion coating will be resistant to low pH environments to protect against potential acid sulphate soils.

3.3 MATERIALS CERTIFICATES AND DATA SHEETS Prior to the use of any materials the APPLICATOR shall obtain from all materials MANUFACTURERs, the relevant certificates of material conformity and test results, including material safety data sheets (MSDSs). All certificates shall be submitted to the COMPANY for approval.

3.4 MATERIALS IDENTIFICATION All materials shall be suitably marked with the following minimum information:

Name of the MANUFACTURER. Type of material and product designation. Batch Number. Manufacture and expiry dates. Storage temperature limits, special storage conditions. Relevant manufacturing standards and specification.

Alternatively, separate material data sheets may accompany the packaged materials but there shall be a clear means of linking data sheets with packages. All materials noted to be without the foregoing identification shall be deemed suspect and shall be rejected by the COMPANY. Such materials shall be removed from site and replaced by the APPLICATOR at no cost to the COMPANY.

3.5 BATCH INFORMATION FOR FBE MATERIAL The APPLICATOR shall obtain from the FBE resin MANUFACTURER the information listed below for each batch of powder produced in a 24-hour interval in a continuous run. Standards for comparison shall be provided for each item. This information shall be used by the APPLICATOR to check that the epoxy


SPECIFICATION



formulation remains unchanged. The following certified data shall be obtained from the MANUFACTURER for each batch of epoxy powder before acceptance for use in the coating facility:

Sieve analysis Density Moisture content Thermal analysis (Differential Scanning Calorimeter) Flexibility Spectrographic Infrared scan of powder and typical powders for comparison. Gel time at recommended application temperature. Particle size distribution.

The powder shall be segregated by batch numbers during shipment, storage, and handling. Batches shall be used consecutively during coating application and shall not be mixed, except when necessary to keep the coating process continuous, and with prior approval of the COMPANY.

3.6 COATING MATERIALS STORAGE Materials shall be stored, handled and transported strictly in accordance with the coating MANUFATURER’s written recommendations, and shall be used according to the APPLICATOR’s batch sequence.

The containers or packages of materials to be used for coating shall be carefully handled to avoid any damage during loading, unloading and storage.

All material with damaged packaging, an expired shelf life, without full traceability or suspected of contamination/deterioration shall be rejected and not applied to the pipe.

3.7 RECLAIMED COATING MATERIALS Reclaimed FBE materials in continuous process shall be limited to 20%. The APPLICATOR shall submit its’ method for reclaiming such materials for the COMPANY’s approval.

3.8 MATERIAL SUBSTITUTION The APPLICATOR shall not substitute materials in place of those approved by the COMPANY, without the COMPANY’s written approval.

3.9 ABRASIVE MATERIALS Abrasive materials shall furnish the specified level of surface preparation, shall be free from contaminants, shall contain less than 100mg/kg chlorides, and less than 0.3% copper. The APPLICATOR shall maintain records to demonstrate compliance with these requirements.

3.10 MATERIALS SEQUENCING The APPLICATOR shall use all materials on a first in, first used basis.

4 COATING PROCEDURE AND QUALIFICATION

4.1 PROPOSED WORK PROCEDURES Prior to the commencement of the work, the APPLICATOR shall submit a pipe Coating Procedure Specification (CPS) giving full details of all the characteristics of the proposed coating process. The project specific CPS shall be formulated by the APPLICATOR and submitted for the COMPANY’s approval in the form of a bound manual such as the approved quality plan. No element of the pipe coating process shall proceed without the COMPANY’s written approval of the CPS. The CPS shall include, but not be limited to, the following information:

The APPLICATOR’s personnel and their roles and responsibilities. Pipe receival and initial inspection. Quarantining of defective pipe. Steel surface preparation, including preheating, steel defect removal, cleanliness, profile, methods of


SPECIFICATION



measurement and consumables. Pipe heating, temperatures and control. Complete details of raw materials together with quality control and MANUFACTURER’s data

including thermal stability. Application of materials, including characteristics, application temperature, etc. Pipe and coating quenching and cooling, including time and temperature. Quality assurance system, Inspection and Testing Plan (ITP) and reporting formats, documentary

proof of current 3rd party calibration of all test and measurement equipment, equipment types, makes and uses, etc. The ITP shall encompass all required testing and test frequencies, including but not limited to:

o Proposed substrate chloride contamination test method. o Proposed substrate cleanliness test method. o Proposed coating adhesion test. o Proposed cathodic disbondment resistance test methods. o Proposed holiday testing method.

Complete details and inventory of laboratory and equipment. Detailed method of repair of coating defects duly classified based upon the nature and magnitude of

defects and repairs thereof. Spark testing and repairs. Cutback procedure. Pipe handling, stockpiling, load out and transportation procedures. Sample of recording and reporting formats, including laboratory reports, certificates, etc. Complete details of test certificates for raw materials, including test methods and standards. PE compound manufacturer’s test certificates for thermal aging tests and aging under exposure to

light. Test certificates shall be no older than three years Environmental provisions for raw materials storage. Procedure for transferring of pipe identification numbers, barcode labels, and applying pipe

identification marking. Coating manufacture Coating Procedure Qualification (CPQ). Not less than fourteen (14) days before coating commences, the APPLICATOR shall convene a pre-

production meeting of representatives of the following: a) COMPANY and/or his inspection organisation. b) APPLICATOR.

The meeting shall review the CPS, and the testing schedule, and shall finalise details of procedures covering pipe cleaning, surface preparation, application of coating repair methods, etc. These procedures shall be subject to the COMPANY’s approval.

4.2 COATING PROCEDURE QUALIFICATION (CPQ) Prior to commencing production, the APPLICATOR shall, at its own expense, carry out Coating Procedure Qualification trials to verify that its plant, materials, and coating procedures can produce a consistent quality of product conforming to the requirements of this Specification and the material MANUFACTURER’s recommendations.

Only after satisfactory CPQ including AS/NZS 3862:2002 Table B1 “Resistance to Cathodic Disbondment, 48 hour test and upon written approval from the COMPANY shall the APPLICATOR commence production coating.

CPQ requirements are summarised in Appendix B - Testing Summary for Coating CPQ.

4.2.1 RAW MATERIALS TESTS The APPLICATOR shall provide test certificates from the MANUFATURER(s) for the properties specified in Section 3.5 for each batch of raw materials used in the CPQ tests.

4.2.2 TESTS ON COATED PIPES The APPLICATOR shall prepare and submit a schedule, in matrix form, of all the tests to be conducted during CPQ. For each test the schedule shall state the following information as a minimum:


SPECIFICATION



Test name/type Duration Conditioning parameters APPLICATOR’s in-house procedure reference Reference standard Start date and time, planned and actual Test result Compliance/non-compliance Space for sign off by the APPLICATOR when test is complete Space for sign off by the COMPANY when test is complete (This will not signify acceptance by the

COMPANY of the test result) Any additional remarks

The schedule shall serve as an instrument for the APPLICATOR to coordinate testing and the COMPANY to track testing progress.

At least 5 (five) test pipes of the least wall thickness shall be coated in accordance with the approved coating procedure. All tests shall be witnessed by the COMPANY or the COMPANY’s Representative. Where test rings are cut from the pipes, additional test rings shall be retained and supplied to the COMPANY for independent testing if requested. Balance of the testing rings shall be retained until the final delivery is completed. Coated pipes shall be subjected to procedure qualification testing as described below.

Coating Thickness - All pipes shall be subject to coating thickness measurements. Acceptance criteria shall be in accordance with the Inspection and Testing requirements of this Specification.

Holiday Testing - All the pipes shall be subject to holiday testing in accordance with AS/NZS 3862:2002, and shall meet the criteria identified in the Inspection and Testing requirements of this Specification.

Impact Resistance - At least five test pipes shall be selected for impact test and each test on each pipe shall be in accordance with DIN 30670.

Cathodic Disbondment Resistance Tests - One batch of tests shall be conducted on each of four coated pipes in accordance with the test procedure in AS/NZS 3862:2002 Table B1. Tests shall only be performed on samples that have been confirmed to be holiday-free.

Adhesion Following Hot Water Soak - A single hot water soak test shall be conducted on two pipes coated with FBE to the project thickness. The test shall be in accordance with AS/NZS 3862:2002.

4.2.3 TESTING REPORT After completion of the foregoing tests, the APPLICATOR shall prepare and issue for the COMPANY’s approval a detailed report of the tests, including test reports and certificates of all materials and coatings tested.

4.2.4 TEST PIPES Test pipes coated with COMPANY-approved materials may be sold as good pipe providing they meet the requirements of this Specification.

4.2.5 TEST RING RETENTION Samples from test rings shall be retained by the APPLICATOR for two years from the date of completion of the contract.

4.2.6 PROCEDURE RE-QUALIFICATION The APPLICATOR shall re-establish the requirements of the Coating Procedure Qualification to the full Specification requirements, or to the extent considered necessary by the COMPANY, in the event of, but not limited to, the following:

Every time there is a change in the previously qualified CPS. Every time there is a change in the MANUFACTURER of any of the raw materials. Any time during regular production tests when, in agreement with the COMPANY, the properties are

deemed inadequate.


SPECIFICATION



Any time an unqualified pipe wall thickness is delivered to the coating plant. However, production may proceed whilst CPQ is in progress.

5 PIPE SURFACE PREPARATION

5.1 SURFACE CONTAMINANTS The APPLICATOR shall ensure the pipes are free from all mill-applied oils and/or coatings.

All pipes shall be monitored visually for chloride contamination on the internal and external surfaces. Three extracts per day shall be taken from a drip line using the soak method and chloride titration or COMPANY-approved method. If the chloride level exceeds 20 mg/m² on the external surface, phosphoric acid pre-treatment shall be used. If the chloride level exceeds 20 mg/m² on the internal surface, the COMPANY shall be immediately advised. The residual chloride contamination on the external surface of phosphoric acid pre-treated pipe shall be monitored. Three tests per shift shall be carried out and the chloride level shall not exceed 20 mg/m². Testing for the presence of salt on the pipe surface from one pipe per five hundred pipe joints is required to ensure salt concentration is less than 20mg/m².

Any oil, grease, salt or other contaminants shall be removed prior to coating application.

Organic contaminants may be removed by the use of non-oil solvents. Gasoline or kerosene shall not be used for this purpose. Visible oil and grease spots shall be removed by solvent wiping. Solvent cleaning shall be in accordance with AS 1627.1.

5.2 PRE INSPECTION Prior to the pipe cleaning operation, each pipe shall be inspected for split seams, dents, gouges, slivers or other imperfections that would make the pipe unsuitable for use. The APPLICATOR shall report all such imperfections to the COMPANY upon receipt, during all stages of the coating process and subsequent handling and load out operations. All pipes containing such defects shall be quarantined by the APPLICATOR who shall then arrange for any repairs as directed by COMPANY.

Surface preparation shall not reduce the pipe wall thickness below the minimum specified by the COMPANY.

5.3 ABRASIVE BLAST CLEANING All pipes shall be preheated to a temperature of not less than 3°C above dew point prior to abrasive blast cleaning. The abrasive blasting shall comply with AS/NZS 3862:2002. The external surface of the pipe shall be cleaned by an abrasive blast cleaning machine. The standard of finish for cleaned pipe shall conform to AS 1627.4-2005, Class 2.5 and shall have a peak to trough height of 50 to 100 µm with an angular and open anchor pattern. This shall be measured at the COMPANY-approved frequency. At least one pipe at the start and end of each shift shall be measured with Testex Press-O-Film replication tape. Remaining pipes may be measured by a suitable instrument, such as an Elcometer, providing that the instrument has been calibrated and crosschecked against the replication tape.

Abrasive blast cleaning shall not be performed when the relative humidity exceeds 85% or when the steel temperature is less than 3°C higher than the dew point, unless the pipes are preheated in accordance with the approved procedure.

Abrasives shall contain less than 100 mg/kg total chlorides, less than 0.3% copper and shall be free of moisture.

5.4 PIPE SURFACE IMPERFECTIONS After blast cleaning, all surfaces shall be thoroughly inspected to determine the anchor pattern, quality of blasting and to identify any surface defects prior to coating application. Each pipe shall be inspected for split seams, dents, gouges, slivers or other imperfections that would make the pipe unsuitable for use. All detrimental defects, as per Table 6.1 shall be reported to the COMPANY and, on permission from the COMPANY, such defects shall be removed by filing or grinding in accordance with the limitations in Table 5.1. The method of surface defect removal should not contaminate the surface. Should the anchor pattern be destroyed it shall be restored by suitable means. Pneumatic tools shall not be used unless they are fitted with effective air/oil and water traps.


SPECIFICATION



Table 1: Permissible Maximum Pipe Wall Thickness Reduction

Pipe Permissible Maximum Pipe Wall Thickness Reduction

FGP - DN 300 Grinding to remove no more than 5% of actual wall thickness is allowed but any reduction shall ensure that the remaining wall thickness equals or exceeds the minimum specified in API 5L table 11. Gouges are to be assessed separately in using guidelines provided in API 5L and AS 2885.1

5.5 ACCEPTANCE OF SURFACE PREPARATION Upon completion of abrasive blasting, the APPLICATOR’s quality control supervisor shall accept the pipe for coating, or return it for re-blasting. Where imperfections are considered detrimental to the coating quality, the same shall be reported to the COMPANY for final decision on rejection or re-blasting/removal of defects.

The COMPANY reserves the right to initiate any of the foregoing actions during periodic inspections for contamination, imperfections and inadequate surface preparation.

5.6 COATING INTERVAL The total allowable elapsed time between completion of the surface preparation and commencement of the coating and heating operations shall be such that no detectable surface rusting occurs. Relative humidity readings shall be recorded every two hours during the blasting operations in the immediate vicinity of the operations. Blast cleaning shall not be performed when the relative humidity exceeds 85% or when the steel temperature is less than 3°C above the dew point. All pipes shall be coated within four hours of blast cleaning irrespective of the above requirements. Any pipe that is not coated within four hours, or where rust blooming has occurred, shall be completely re-cleaned.

6 COATING APPLICATION

6.1 LINE PIPE HEATING The selected pipe heating method shall maintain uniform temperature along the total length of the pipe. Oxidation of the cleaned pipe surfaces prior to coating (in the form of bluing or other apparent oxide formation) is not acceptable.

6.2 TEMPERATURE MONITORING The specified pipe temperature shall be determined using approved temperature-indicating crayons. The specified temperature shall be maintained as the pipe enters, and throughout, the coating chamber and shall be carefully monitored. If approved pyrometers are used for continuous temperature monitoring, the pyrometer shall be calibrated twice per shift and/or as per the COMPANY’s instruction using approved temperature-indicating crayons.

The surface temperature during coating application shall be no less than that required for complete melt, flow-out, wetting of the pipe surface and fusion; nor shall it be higher than that at which optimum polymerisation occurs without premature gelation before completion of fusion, flow-out and wetting. Post-application cure temperature and time shall not be less than that required for full cure of the applied coating.

The pipe temperature shall not be allowed to exceed 260°C. Any pipe or part of pipe heated in excess of 260°C shall be quarantined and may be rejected, subject to inspection by the COMPANY. The cost of the rejected pipe shall then be deducted from the APPLICATOR’s charges.

6.3 COATING APPLICATION AND COATING THICKNESS The external surface of the cleaned pipe shall be immediately coated with dual-layer coatings. In general the procedure shall be as follows: 1. The external surface of the pipe shall be heated to a temperature as recommended by the powder

MANUFACTURER followed by application of the following coating materials. 2. The coating materials shall be applied to the minimum thicknesses in accordance with Table 6.1 below.


SPECIFICATION



Table 2: FGP Required Coating Thickness

SERVICE REQUIREMENT

COATING THICKNESS (µm) FBE Base Layer FBE ARO Layer TOTAL

Standard 400 400 800

Trenchless Crossing 400 600 1000

3. The coated pipe shall be quenched and cooled in water sufficiently to allow handling and inspection

without damage to the coating. 4. During application, curing, and handling, the coating shall not be physically damaged, nor shall it be

contaminated with any foreign material whether airborne or from application equipment or enclosures, cutback rings or pipe handling mechanisms.

5. Individual layer coating thickness checks on partial/partly coated pipe shall be carried out. The frequency shall be minimum 1 pipe per shift and after any interruption.

6.4 COATING APPEARANCE The resultant coating shall have a uniform appearance and shall be free from air bubbles, wrinkles, holidays, irregularities, discontinuities and separation between layers of FBE.

6.5 END CUT BACK Coating materials shall be cut back to 300 [HOLD] ± 25 mm from the ends of the pipe.

The pipe end faces, bevels and uncoated external surface of the pipe at pipe ends shall be free of all coating and foreign material.

6.6 REJECTION OF COATING Failure to comply with any of the foregoing applicable requirements and the approved procedure shall be cause for the rejection of the coating. Such coating shall be removed in a manner approved by the COMPANY at the APPLICATOR’s cost.

7 PRODUCTION REPORT The APPLICATOR shall prepare and maintain a detailed production reporting system, which shall provide a detailed history of each pipe length.

The APPLICATOR shall obtain from the pipe supplier, as a minimum, the following data:

Pipe number Heat number Pipe grade Diameter Length Wall thickness Pipe weight

Prior to acceptance of the pipe the APPLICATOR, in the presence of the COMPANY, shall identify and record any minor defects such as dents, flats or damaged bevels that are found during the acceptance inspection. The APPLICATOR shall be responsible for any subsequent damage to the pipe.

To the records received from the pipe MANUFACTORER the APPLICATOR shall typically add the following information:

Details of defect repairs Coating material batch numbers Prequalification tests for raw materials Coating procedure qualification tests Coating material balance


SPECIFICATION



Coated pipe sampling details Coated pipe test results Coated pipe weight Coating defects Coating repairs Hold points Rejected pipe

In addition, the records shall provide the dates on which the APPLICATOR:

Took possession of the bare pipe Placed bare pipe into its stockpile Coated the pipe Placed the coated pipe into stockpile Loaded coated pipe onto haulage APPLICATOR’s transport

Final report details shall be agreed by the COMPANY and the APPLICATOR prior to the commencement of production coating. The complete production report shall be submitted to the COMPANY every seven (7) days. The report shall be submitted as a single sheet Excel format or COMPANY-approved alternative. In addition a daily production report shall be submitted to the COMPANY, the details shall be agreed with the COMPANY prior to the commencement of production coating.

8 INSPECTION AND TESTING

8.1 GENERAL The APPLICATOR shall establish and maintain a comprehensive Quality Assurance system to ensure that all of the requirements of this Specification are met.

The minimum testing requirements shall comply with requirements of Appendix C - Production Testing of Coating and AS/NZS 3862:2002. All other tests shall be as detailed in this specification.

8.2 VISUAL INSPECTION Visual inspection of finished coating includes colour, blisters, sags, porosity, burns and handling damage during coating, stacking and loading, for each pipe.

8.3 GEL TIME TEST To confirm that the epoxy powder has been manufactured, handled, shipped and stored properly, the APPLICATOR shall perform a Gel Time Test on each batch of powder one week prior to its use, in accordance with the method and acceptance recommended by the powder MANUFACTURER. The APPLICATOR shall inform the COMPANY each and every time they are to perform a Gel Time Test.

8.4 THICKNESS TEST The coating thickness shall be determined by taking at least 10 measurements at locations on the same point along the pipe circumference and uniformly distributed over the length of each pipe. In case of pipes with raised seams, five readings shall be made at the apex of the weld seam, uniformly distributed over the length of the coated pipe. Measurements shall be made on start-up pipe and upon recommencement after interruption to production or as agreed with the COMPANY.

All readings must meet the minimum requirements. However, localised coating thickness of less than the permissible minimum thickness can be tolerated on the condition that it does not attain a total extent of more than 5 cm² per meter length of coated pipe and, at these locations, the coating thickness does not fall by more than 10% below the permissible minimum coating thickness. Measurements must be taken to confirm that the under thickness is localised.

Initially, every pipe shall be tested for thickness at the frequency stated above. The frequency may be reduced thereafter depending upon consistency of results, at the sole discretion of the COMPANY.

Coated pipes not meeting the foregoing requirements shall be rejected. The APPLICATOR shall remove all the coating and the pipe shall be re-cleaned and coated in accordance with the approved procedure and at


SPECIFICATION



the APPLICATOR’s cost.

8.5 HOLIDAY DETECTION The entire coated surface of each pipe shall be tested with a “holiday detector”. The holiday detector shall maintain intimate contact with the coating of a type approved by the COMPANY. The holiday detector shall be a low pulse direct current full circle electronic detector or COMPANY-approved equal.

The APPLICATOR shall have the necessary instruments or devices for calibrating the holiday detector. The holiday detector operation shall be checked on the bare end of each pipe and shall be calibrated at least once every 4 hours of production.

8.6 RATE FOR PIPE REJECTION Any pipe with three or more repairs (as defined in section 9) shall be rejected.

Any pipe so rejected shall have the coating removed and the pipe recycled through the complete cleaning and coating system in accordance with the approved coating application procedure, and shall be to the APPLICATOR’s cost.

8.7 COMPANY’S APPROVAL The COMPANY reserves the right to perform inspection and witness tests on all activities concerning the pipe coating operations, starting from bare pipe to finished coated pipe, ready for despatch.

The APPLICATOR shall give reasonable notice of time and shall provide, without charge, reasonable access to facilities required for inspection to the COMPANY.

Where the rate of defective or rejected pipes and/or sample tests are 10% or more for a single shift (typically 8 hours), the APPLICATOR shall cease production and carry out a full and detailed investigation and shall submit the findings to the COMPANY for approval. The APPLICATOR shall recommence production only after receiving written permission from the COMPANY.

Under no circumstances shall any action or omission of the COMPANY relieve the APPLICATOR of its responsibility for material and quality of coating produced.

No pipes shall be transported from the coating plants unless authorised in writing by the COMPANY.

9 COATING PATCHES AND REPAIRS

9.1 PIPE DAMAGE Damage to pipe is defined as follows:

All cracks; All notches or ground areas that reduce pipe wall thickness by more than the allowable Negative tolerance specified by the project line pipe specification; All dents in the pipe body Diameter Bevel damage

Damage to pipe coatings shall be repaired prior to subsequent processing or load-out;

9.2 PIPE REPAIR Repairs shall be carried out in accordance with AS/NZS 3862:2002 except for modifications as follows:

Coatings shall be defect free. Defects are defined as any holiday, pinhole, blowhole, irregularity due to contamination, damage and are subject to repair;

For any individual pipe, the number of holidays in external coating shall not exceed three; There shall not be more than 20 repairs of the external coating on any 10 consecutive pipes; and In any 8-hour shift, the average number of holidays in the external coating shall not exceed two per

pipe. Note: The unit of measurement for the number of holidays in clause 4.1 (d) of AS/NZS 3862:2002 is subject


SPECIFICATION



to typographical error and should read “shall not exceed the rate of 1 per metre of pipe length.” This revision forms part of this Specification.

Pipe identification markings shall be preserved during all repairs. Pipes shall be re-measured and the new lengths entered into the pipe tally system whenever a cylinder is removed.

The pipe tally system shall identify all repairs performed and the nature of the repair, in particular where the pipe length has changed.

All inspection following repairs shall be documented and included in the APPLICATOR’s data books. If, following removal of a cylinder, pipe coating has to be removed to reinstate the uncoated (cut-back) pipe ends, the coating shall be removed in a manner preventing damage to the pipe steel.

10 HANDLING, TRANSPORTATION AND STORAGE

10.1 GENERAL Coated pipe shall at all times be handled in a manner to avoid damage to the coating, pipe wall and bevel ends. The APPLICATOR shall submit all details regarding transport, handling and stockpiling procedures for both coated and uncoated pipe, including stockpile location and layout, to the COMPANY for approval no less than 3 weeks before commencing the work.

Handling, storage and transport procedures shall comply with AS/NZS 3862:2002 except if otherwise required by this Specification.

Bare and coated pipe shall not be stored in stockpiles in proximity to the sea where airborne salt contamination to the pipes could occur. The proposed location(s) for storage of both the bare and coated linepipe shall be advised by the APPLICATOR to the COMPANY in the stockpiling procedures and the locations of these stockpiles shall be subject to approval by the COMPANY.

All pipes and coating materials shall be coated or used on a first in, first out (FIFO) basis.

The coated pipe shall be supplied with three protective rope rings so that the pipes are not in contact with each other during transport and storage.

10.2 LIFTING AND SEPARATION Use of vacuum lifting equipment is permitted for lifting and handling coated pipe.

10.3 FINAL ACCEPTANCE Final acceptance of coated pipes shall be conditional upon the following tests at the loadout delivery points, unless otherwise agreed by the COMPANY:

All pipes shall receive a complete visual inspection for defects. Holiday detection of pipe at loadout shall be done by batch, randomly selected to the COMPANY’s

satisfaction, but in order not to hinder loadout. The COMPANY and the APPLICATOR shall select the subject pipe up to a maximum of 200 pipes per shipment. Reduction of holiday detection pipe on subsequent loadouts shall be at the COMPANY’s discretion.

Holiday testing voltage may be reduced to 80% of the value specified in AS 3894.1 if the coating has been subject to moisture absorption and with the COMPANY’s approval. The APPLICATOR shall be liable for repair of any coating defects identified.

Patches and repairs shall be in accordance with the COMPANY-approved procedures. Random tests for chlorides on the cut-back area Random tests for magnetism. The maximum shall be 20 gauss Random tests for salt contamination and corrosion of the exposed ends of the pipe and the coating to

pipe overlap at the cutback locations. Acceptance criteria salt level maximum 20 mg/m². The maximum number of patch repairs allowable on three consecutive pipes is fifteen (15). If this is exceeded pipes shall be quarantined and remedial action implemented immediately.

All patch repairs shall be recorded.

A certificate of compliance shall be provided to the COMPANY before loading coated pipe onto transport vehicles. The certificate shall show that all inspections, tests and quality assurance requirements have been


SPECIFICATION



met. Pipes shall not be loaded onto transport vehicles until the COMPANY has certified the lot(s) to be loaded as acceptable.

11 MARKING AND PIPE IDENTIFICATION The APPLICATOR shall preserve pipe identity by maintaining the identity of each joint of pipe. Final markings shall be applied as per Table 11.1. Table 3 Pipe Identification Requirements

Type Location Qty Orientation Position

Adhesive barcode External 2 Evenly-spaced around the circumference

One 0.65 m from each end of pipe

Adhesive barcode External 2 Evenly-spaced around the circumference

One on cut back at each end

Adhesive barcode Internal 2 Bottom of pipe One 0.65 m from each end of pipe

Stencil Internal 2 One 0.65m from each end of pipe

The marking shall indicate, but not be limited to, the following information:

The pipe MANUFACTURER’s unique number and job number Heat number Diameter, wall thickness, weight and length, specification and class Method of pipe manufacture Coated pipe number Coating type and thickness Coating date & shift (DS or NS) Colour band to clearly differentiate standard from trenchless crossing coating thickness White centreline mark fully circumferential. This mark shall be located in the centre of the Line Pipe

joint to a tolerance of ± 50 mm COMPANY Any other information considered relevant by COMPANY

The APPLICATOR shall reattach barcode labels from inside the pipe, or replace labels. The APPLICATOR shall submit for approval, by the COMPANY, the type of suitable robust adhesive to be used to adhere the barcodes to the pipeline coating. Adhesive shall be of tenacity to securely fasten barcodes to the pipe for at least two years of exposure to the elements.

The APPLICATOR shall obtain prior approval from the COMPANY for the marking procedure.


SPECIFICATION



APPENDIX A - PIPING MATERIAL SPECIFICATION SUMMARY


SPECIFICATION



APPENDIX B - TESTING SUMMARY FOR COATING CPQ CPQ testing shall be proposed in APPLICATOR’s quality plan and submitted for COMPANY approval. The following tests shall also be performed in addition to CPQ tests to confirm compliance with surface preparation and application requirements of this specification and AS/NZS 3862:2002. The APPLICATOR’s proposed methods, acceptance criteria and testing frequency shall be submitted for COMPANY approval. Table B1 Coating CPQ Testing Requirements

Test Test Method Acceptance Criteria Test Frequency

FBE Coating Performance

Individual Coating Thickness

(Topcoat is removed by a COMPANY-approved method)

AS 3894.3-2002

APPLICATOR to propose number and location of readings, and

tolerance, for COMPANY review and approval

Every pipe

Adhesive AS/NZS 3862:2002

APPENDIX J 2 rating Three pipes

DSC Analysis AS/NZS 3862:2002

APPENDIX H ∆Tg = ±4°C Three pipes

Foaming (Cross Section) AS/NZS 3862:2002

APPENDIX I 3 rating Three pipes

Foaming (Interfacial) AS/NZS 3862:2002

APPENDIX I <3 rating Three pipes

Interface Contamination AS/NZS 3862:2002

APPENDIX R Rating <5% of area Three pipes

Determination of Surface Dust

AS 3894.6-2002

Clause 8 or

ISO 8502-3

Rating 2 Three pipes

Impact Resistance ASTM G14

<550 µm = 1.5 J

>550 µm = 3 J

There shall be no holidays

Three pipes

Flexibility AS/NZS 3862:2002

APPENDIX L Min of 1.5°/pipe dia for >=600 µm coating thickness. No cracking. Three pipes

Adhesion Following Hot Water Soak

AS/NZS 3862:2002

APPENDIX K Rating <2 after 24 hours Three pipes

Hot Water Absorption 90 days water

absorption (deionised) at 20 & 60°C

No loss of adhesion, blisters or softening

Report water absorption(1)

Three pipes

Cathodic Disbondment Resistance

AS 4352-2005

Test cell A or ASTM G95 constant voltage

method

<6 mm, 48 hrs, 65 ±3°C

<7 mm, 28 days, 22 ±2.5°C

28 days 65 ±3°C(1)

Three pipes


SPECIFICATION



Holiday Testing AS 3894.1-2002 or NACE No holidays Every pipe

Holiday Testing 111 days water

immersion 22 ±2.5°C, 8 weeks air drying

Report new holidays detected(1) Three pipes

Repair Qualification

Adhesive AS/NZS 3862:2002

APPENDIX J <2 rating Three

repairs


AS/NZS 3862:2002

APPENDIX K Rating <2 after 24 hours Three

repairs


AS 4352-2005


method

<6 mm, 48 hrs, 65 ±3°C

<7 mm, 28 days, 22 ±2.5°C

28 days 65°C(1)

Three repairs

Holiday Testing AS 3894.1-2002 or NACE No holidays Three

repairs

(1) Report results for information only


SPECIFICATION



APPENDIX C - PRODUCTION TESTING OF COATING Production testing shall be proposed in APPLICATOR’s quality plan and submitted for COMPANY approval.

The following tests shall be performed in addition to tests to confirm compliance with surface preparation and application requirements of this specification and AS/NZS 3862:2002. The APPLICATOR’s proposed methods, acceptance criteria and testing frequency shall be submitted for COMPANY approval. Table C1: Production Testing Requirements

Test Test Method Acceptance Criteria Test Frequency

FBE Coating Performance

Coating Thickness, First Layer

(Topcoat is removed by a COMPANY-approved method)

AS 3894.3-2002



Shall be measured

on one pipe at the start of shift and after any

interruption to

production.

Total Coating Thickness AS 3894.3-2002



All pipes

DSC Analysis AS/NZS 3862:2002

Appendix H ∆Tg <4°C Twice per

shift

Foaming (Cross Section) AS/NZS 3862:2002

Appendix I 3 rating Once per

shift

Foaming (Interfacial) AS/NZS 3862:2002

Appendix I <3 rating Once per

shift

Interface Contamination AS/NZS 3862:2002

Appendix R Rating <5% of area Once per

shift

Impact Resistance ASTM G14

<550 µm = 1.5 J

>550 µm = 3 J

There shall be no holidays

Once per shift

Flexibility AS/NZS 3862:2002

Appendix L Min of 1.5°/pipe dia for >=600 µm

coating thickness. No cracking. Once per

shift


AS/NZS 3862:2002

Appendix K Rating <2 after 24 hrs Once per

shift

Holiday Testing AS 3894.1-2002 or NACE No holidays All pipes


AS 4352-2005


method.

<6 mm, 24 hrs, 65 ±3°C Once per shift