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P-GEP-HO-PR-0054

HOLIDAY TEST PROCEDURE

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HOLIDAY TEST PROCEDURE

P-GEP-HO-PR-0054 EPCC CONTRACTOR MIDDLE EAST ENGINEERING

PREPARED BY REV DATE STATUS NAME & SIGN A 0 09-Nov-2011 09-Nov-2011 Issued for internal Review Issued for PCIHBV Approval G.R G.R

CHECKED BY NAME & SIGN A.A G.R

QA REVIEW BY NAME & SIGN O.R O.R

APPROVED BY NAME & SIGN O.R O.R

OWNERS COMMENT Approved / Reviewed Approved with Comment Resubmit for Approval Resubmit for Review Name Signature Title Date

TABLE OF CONTENTS 1. SCOPE

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2. 3. 4. 5. 6. 7. 8. 9. 10.

PURPOSE DEFINITIONS & ABBREVIATIONS REFERENCES ROLES AND RESPONSIBILITY WORK METHODOLOGY ACCEPTANCE CRITERIA DEFECTS OF COATINGS SEQUENCE OF OPERATIONS ATTACHMENTS

1.

SCOPE

P-GEP-HO-PR-0054 Rev.1 Holiday Test Procedure

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This procedure defines the types and extent of inspection and testing to be carried out to verify activities related to holiday detection of applied external coating of piping which are to be installed on the EPCC extent pipeline for Garraf Contract Area. 2. PURPOSE To detail the quality requirements for holiday detection method and process with reference to project specifications. Holiday test is non-destructive test chosen to detect unacceptable discontinuities along pipeline coating surfaces 3. DEFINITIONS PCIHBV MEE Project EPCC Holiday Detector Petronas Carigali Iraq Holding BV Middle East Engineering Company Export Pipeline for the Garraf Contract Area Engineering, Procurement, Construction and Commissioning An electrical inspection device that locates defects not detectable by visual inspection in applied coating. The detector shall be of type approved by company and shall maintain intimate contact with the coating (constant of pulsed voltage type) Quality Assurance Quality Control National Association of Corrosion Engineers -- SIEI or any Government or private approved agencies that carry out inspection and testing specified by PCIHBV. Construction Companies working under the MEE

QA QC NACE Third party Sub-Contractor 4. REFERENCES

Holiday Tester Manufactures Specification (subject to client approval prior to start work)
1

NACE-RP-0188-88 Detection (Holiday) testing for protective coatings

P-GEP-HO-PR-0054 Rev.1 Holiday Test Procedure

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Voltmeter Tester Manufacturers Specification (subject to client approval prior to start work) Shrink Sleeves Manufacturers Specification (subject to client approval prior to start work) ASTM G62-07 Standard test methods for holiday detection in pipeline coatings Exhibit 1Scope of work P-GEP-HO-QC-001Project Quality Plan P-GEP-HO-PR-0079 Inspection & Test Plan P-GEP-HO-PR-0051 Painting & Coating Specification

5.

ROLES AND RESPONSIBILITY 5.1 PROJECT MANAGER / CONSTRUCTION MANAGER Shall ensure that all personnel involved in this work are aware of this procedure and implemented as per project specific requirements.

5.2 HSE MANAGER Shall ensure this procedure function safely and reliable in compliance with PCIHBV requirements 5.3 QA/QC MANAGER shall monitor all testing activities to ensure that they performed it accordance with procedure and to ensure that acceptable result for quality check. 1 5.4 PIPING SUPERVISOR To ensure full compliance regarding the execution of work in accordance with PCIHBV requirements and specification 5.5 QUALITY CONTROL INSPECTOR Carry out the inspection as per Inspection Test Plan Submit the request for inspection to PCIHBV Co-ordinate to conduct field testing according to the instruction of PCIHBV/MEE representative and in compliance with the project specifications & codes

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5.6 SUBCONTRACTOR TECHNICIAN Carryout the testing activities in accordance with this procedure and Ensure equipment shall be calibrated at the start of each working day and every 4hours thereafter in compliance with approved procedure by PCIHBV Shall ensure each lot shall be tested with the witness of PCIHBV representative. Test reports shall be submitted as per attached format

WORK METHODOLOGY 6.1 The coating film shall be allowed to cure for at least four days, and then tested in accordance with NACE standard RP-0188 using a DC holiday detector inspection shall be carried out. 6.2 Make sure to connect the ground of a detector to a re-bar, or by placing a bag of wet sand over the ground wire positioned on the concrete surface. The concrete in contact with the ground wire should be wetted down. 6.3 Prior to commence work Holiday detector equipment shall be of an approved type and operating voltage and settings shall be demonstrated and submitted manufacturers datasheet to get approved from PCIHBV. 6.4 The holiday detector shall be operated strictly in accordance with the manufacturers recommendations. 6.5 All Horizontal Directional Drilling (HDD) pipelines section after welding & NDT completed with acceptance then field joint coatings are applied to each completed joint and holiday tested in accordance with this procedure. 6.6 Holiday detection shall be carried out only in dry weather conditions. 6.7 Inspection for holidays are carried out on all buried field and shop components prior to backfilling. All field joint coated areas to be tested & free from contaminants such as sand, grease and moisture. It shall be performed on completely finished coatings. 6.8 Field girth welds & Tie-in welds and adjacent bare metal shall be free from rust, scale, weld spatters, dirt, oil, grease and other contaminants shall be removed by using wire brush or rotary power brush. Surface shall be prepared in accordance with required profile approved painting and coating specification.

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6.9 Shrink sleeves shall be installed in accordance with manufacturers recommendations and PCIHBV requirements. 6.10 All rust, scale, weld spatters, dirt, oil, grease, loosened coating material and other contaminations are remove and thoroughly clean with wire brush or rotary power brush. 6.11 After pipelines field joints are wrapped with shrink sleeves are completely allow to cool and perform holiday inspection to verify bubbles, dimples, punchers, burn holes and holidays. 6.12 Holidays test shall be carried out using calibrated holiday detector and approved in accordance with NACE PR 0490-01 and PCIHBV specification. 6.13 Testing by single pass shall cover 100% of the dry coated surface. The speed of travel shall be accordance with NACE PR-0490-01 and shall be minimum of 0.3 meter/second and maximum of 0.5meter/second shall not allow to remain stationary while the power is on. 6.14 Holiday detector voltage output shall be checked using calibrated direct current voltmeter at least once before and after end of use, in accordance with the tester manufactures. 6.15 To prevent damage to a coating film when using high voltage test instrumentation total film thickness and dielectric strength (in accordance with ASTM 1 D1000) in a coating system shall be considered in selecting the appropriate voltage for detection of discontinuities or Voltage level for holiday detection shall be 5volts per micron thickness of coating applied . 6.16 All holidays and other defects revealed shall be marked on pipe with a water proof marker and recorded in test report immediately upon discovery of discontinuity (like pinholes, voids and metal particles) and In compliance with approved painting & coating specification all holidays repair shall be repaired and re-tested at the original voltage setting. 6.17 Holiday testing of coating and acceptance of which shall be recorded on the applicable forms. 7. Acceptance criteria shall follows:

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No more than two point discontinuity shall occur within an area having a radius of six inches as measured from a point of discontinuity (pin hole). No more than 40% of the total number of allowable point of discontinuity shall occur within any one area equal to 25% of the total area under consideration.

8. Defects of coatings: Coating defects which are completely not acceptable below. Such defects shall repair with approved painting specification and assure that the pipeline coating is defect-free coating and perform holiday inspection. 1. Blistering: Localized loss of adhesion caused by contamination with grease, oil, salts, rust, trapped moisture, retained solvent, hydrogen vapor pressure (on coating used with cathode protection etc.). Osmotic blistering can also occur in immersed conditions. 2. Adhesive failure: surface contamination or condensation 3. Brush marks: Viscosity of material may be too high for brush application, Incorrect thinners used in the paint, Inadequate mixing or poor application technique. Two-pack paints may have exceeded application pot-life 4. Bubbling: Trapped air/solvent with the coating which is not released before the surface dries. Can be found with factory applied coatings where application is by dipping, electrode position. 5. Cissing: Surface contamination by either moisture or foreign matter such as oil, grease, silicon etc. also known to happen when incorrect solvent blends have been used. 6. Holidays: poor application techniques. Lack of quality control (use correct application techniques and apply good painting practices) 7. Cracking: cracking is generally a stress related failure and can be attributed to surface movement, ageing, absorption and desorption of moisture and general lack of flexibility of the coating. The thicker the paint film the greater the possibility to coating cracks. 8. Cratering : trapped air bubbles which have burst to leave small craters as the coating dries. The coating has insufficient time to flow into a uniform film. 9. Sagging: Over application of paint, excessive thinners, wrong(lack) of curing agent or just poor workmanship. Could, in extreme circumstances, be a formulation problem.

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10. Rust spotting: Low film thickness, voids and holidays, also defects in the steel i.e. laminations. Too high a surface profile may cause penetration of peaks through a paint film and cause rust spotting. May also occur from metallic contamination of a coated surface by grinding dust etc. 9. Sequence of Operations: 1. 2. 3. 4. 5. 6. 7. Pre-blast cleaning Abrasive blast cleaning/power brush cleaning Profile checking inspection Priming (if required by the specification) Coating/Wrapping Visual inspection & Holiday Inspection Coating rework or loading for pipeline right of way

10. ATTACHMENTS: 1 2 Holiday detection and coating repair for under- ground piping Field joint coating inspection for under- ground piping

P-GEP-HO-PR-0054 Rev.1 Holiday Test Procedure