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BREDERO PIPELINE SERVICES LIMITED

BNCL

CLIENT:
PROJECT:

SHELL PETROLEUM DEVELOPMENT COMPANY LTD


TBA
QUALITY PROCEDURE
THREE LAYER COATING SURFACE PREPARATION

Clause
1
1.1
2

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Revision:
Rev. Date:
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QP071
00
th
12 April 13
1 of 3

Description
SCOPE
This document describes the procedure to be followed during surface preparation of
pipes for three layer polyethylene coating. Adherence to this procedure by the relevant
personnel is mandatory.
REFERENCES

2.1

DEP 31.40.30.31-GEN February 2011

2.2

ISO 8501-1

2.3

ISO 8503-1, -2, -3 and -4

2.4

ISO 21809-1 : 2009

RESPONSIBILITIES

3.1

Project Manager is responsible for the provision of personnel, equipment and resources
necessary for the full and correct execution of this procedure.

3.2

Yard Superintendent is responsible for ensuring that all personnel observe the
requirements of this procedure. This responsibility is normally delegated to the
Production Supervisors under his immediate charge.

3.3

Quality Manager is responsible for ensuring that the quality requirements of this
procedure are met at all times. This responsibility is normally delegated to the QC
Inspectors under his charge. Quality Manager is also responsible for raising nonconformance reports (NCRs) where discrepancies are noted and for ensuring that any
identified corrective actions arising from such NCRs are carried out fully and completely.

3.4

Materials Controller is responsible for the call-off, storage and issue of raw materials
required during execution of the project, and for the establishment and maintenance of a
materials control system such that raw materials usage is accurately recorded and any
necessary stock rotation requirements are met.

4
4.1

4.1.1

Revision

PROCESS DESCRIPTION
PIPE RECEIPT
Pipes will be placed on the incoming rack and, if fitted, bevel protectors or end caps will
be removed. Pipe identification will be made at this stage in accordance with the
provisions of procedure QP001. Foam end plugs will be fitted to prevent abrasive
collecting in the bore and the pipe external surface will be examined. Any oil or grease
contamination will be removed using a suitable non-toxic solvent. Each pipe is then
lowered onto the helical conveyor.

Number in Revision column denotes change over previous issue using current revision number

BREDERO PIPELINE SERVICES LIMITED

BNCL

CLIENT:
PROJECT:

SHELL PETROLEUM DEVELOPMENT COMPANY LTD


TBA
QUALITY PROCEDURE
THREE LAYER COATING SURFACE PREPARATION

Clause
4.2

4.2.1

4.3

Doc. Ref.:
Revision:
Rev. Date:
Page #

QP071
00
th
12 April 13
2 of 3

Description
PREHEATING AND BLAST CLEANING
The conveyor takes the pipe through a diesel-fired pre-heater and then a two-wheel
centrifugal up-blast abrasive cleaning machine. This process raises the steel
temperature above the local dew point, dries any water that may be present on the
external surface and creates the required surface cleanliness and blast profile.
POST CLEANING INSPECTION AND HANDLING

4.3.1

After blast cleaning, pipes are kicked off the blasting conveyor and onto the blow-out
station. The foam plugs are removed and a high volume stream of air is passed through
the bore of the pipe to remove dust and any residue of blasting abrasive.

4.3.2

The pipe is then moved onto the inspection station. As the pipe rotates on this station, a
full visual inspection of the bevel ends and external surface is made. Any defects in the
steel which may affect subsequent coating operations will be noted. If the defects are
such that the pipe cannot be further processed or requires significant remedial work, a
non-conformance report (NCR) will be raised and the pipe removed from the plant by
means of the reject conveyor. Such pipes will be quarantined pending further inspection.
Minor defects which can be rectified inline will be removed by light grinding with a
pneumatic or electric grinder.

4.3.3

After inspection, accepted pipes are moved off the inspection station. Couplings are
installed in the leading end of each pipe, and the pipe is lowered onto the coating
conveyor. Pipes must be coated not more than four hours after blast cleaning.

5
5.1

Revision

QUALITY REQUIREMENTS
PIPE IDENTIFICATION AND PRE-BLAST VISUAL INSPECTION
Check every pipe. Pipe unique identification will be checked against manifest(s) or
packing list(s) provided. Visual inspection for contamination and damage.
Acceptance Criteria: Pipe uniquely identified against manifest(s) or delivery note(s). No
oil or grease contamination present. No damage outside agreed limits.

5.2

ENVIRONMENTAL CONDITIONS IN BLASTING AREA


Check at the start of each morning and afternoon production shift, or where production is
continuous not less than once every five hours, using a digital thermo-hygrometer or
whirling hygrometer and calculator disk. Record ambient temperature, relative humidity
and dew point.
Acceptance Criteria: Relative humidity in the blasting area may not exceed 85%.

5.3

BLAST MEDIUM TESTING


Once per shift a sample of abrasive from the blast cleaner will be taken from the working
mix and tested in the laboratory in accordance with the requirements of procedure
QP074.

Number in Revision column denotes change over previous issue using current revision number

BREDERO PIPELINE SERVICES LIMITED

BNCL

CLIENT:
PROJECT:

SHELL PETROLEUM DEVELOPMENT COMPANY LTD


TBA
QUALITY PROCEDURE
THREE LAYER COATING SURFACE PREPARATION

Clause
5.4

Doc. Ref.:
Revision:
Rev. Date:
Page #

QP071
00
th
12 April 13
3 of 3

Description

Revision

PIPE SURFACE CLEANLINESS


Visual inspection of every pipe against ISO 8503-2. Check all pipes and record twice per
shift.
Acceptance Criteria: Abrasive blast surface cleanliness Sa2.5 or maximum allowable
dust level shall be class 1.

5.5

PIPE SURFACE PROFILE


Check first five production pipes and thereafter once per 20 pipes against ISO 8503-2.
Acceptance Criteria: Surface profile within the range 40 to 100 microns.

5.6

CHLORIDE CONTAMINATION
Check first 5 production pipes of each morning and afternoon shift, or where production
is continuous not less than 1 per 100 pipes. Check will be made using an SCM400
automated test apparatus.
Acceptance Criteria: Chloride level not greater than 20 milligrams per square metre

5.7

SURFACE TEMPERATURE PRIOR TO INDUCTION HEATING


Continuous monitoring (not less than once every hour) and record first production pipe
and thereafter one pipe in 20 using a contact pyrometer.
Acceptance Criteria: Surface temperature between 40 and 85 deg. C., and not less
than 3 deg. C above the dew point.

5.8

TIME FROM BLAST CLEANING TO COATING


Monitor throughout production. In the event of plant stoppage for any reason, the time of
stoppage will be noted as will the time of restart. Any pipes which remain blast cleaned
but uncoated for more than four hours must be removed from the plant and re-blasted
again before coating.
Acceptance Criteria: All pipes must be coated not more than fours hours after blast
cleaning.

DOCUMENTATION
The following documents will be completed at the end of each shift as required:
QF007 Blast Cleaning Inspection Report
QF008 PE Daily Audit Round Report
RF002 Non-conformance Report

Number in Revision column denotes change over previous issue using current revision number