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1、TECHNICAL SPECIFICATION EXTERNAL FUSION-BONDED EPOXY POWDER COATING FOR LINE PIPE DEP 31.40.30.32-Gen. October 1995 DESIGN AND ENGINEERING PRACTICE This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prior written consent of
2、Shell International Oil Products B.V. and Shell International Exploration and Production B.V., The Hague, The Netherlands. The copyright of this document is vested in these companies. All rights reserved. Neither the whole nor any part of this document may be reproduced, stored in any retrieval syst
3、em or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owners. PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of: Shell International Oi
4、l Products B.V. (SIOP) and Shell International Exploration and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, and other Service Companies. They are based on the experience acquired during their involvement with the design, construction, operation and
5、maintenance of processing units and facilities, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is to set the recommended standard for g
6、ood design and engineering practice applied by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum technical and economic benefit from standardization. The information set fo
7、rth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual ope
8、rating companies to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for
9、 those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsib
10、ility, consult the Principal or its technical advisor. The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies of the Royal Dutch/Shell Group and other companies receiving technical advice and services from SIOP, SIEP or SIC. Consequentl
11、y, three categories of users of DEPs can be distinguished: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by these Operating companies is subject in all respects to the terms and conditions of the relevant Service Agreement. 2)Other pa
12、rties who are authorized to use DEPs subject to appropriate contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf
13、 of the said users comply with the relevant standards. Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and SIC disclaim any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person who
14、msoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this disclaimer shall inure in all respects to SIOP, SIEP, SIC and/or any company affiliated to these companies that may issue DEPs or require the u
15、se of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of SIOP and SIEP, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purp
16、ose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of SIOP and SIEP. The copyright of DEPs vests in SIOP and SIEP. Users shall arrange for DEPs to be held in safe custody a
17、nd SIOP or SIEP may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in SIOP. NOTE: In addition to DEP publications there are Standard Specifications and Draft DEPs
18、for Development (DDDs). DDDs generally introduce new procedures or techniques that will probably need updating as further experience develops during their use. The above requirements for distribution and use of DEPs are also applicable to Standard Specifications and DDDs. Standard Specifications and
19、 DDDs will gradually be replaced by DEPs. DEP 31.40.30.32-Gen. October 1995 Page 2 TABLE OF CONTENTS 1.INTRODUCTION.4 1.1SCOPE 4 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS4 1.3DEFINITIONS 4 1.4ABBREVIATIONS5 1.5CROSS-REFERENCES5 2.GENERAL INFORMATION.6 2.1COATING SYSTEM DESCRIPTION.
20、6 2.2INFORMATION TO BE SUBMITTED BY THE PRINCIPAL.6 2.3INFORMATION TO BE SUBMITTED BY THE COATING CONTRACTOR .6 3.COATING SYSTEM REQUIREMENTS7 3.1GENERAL 7 3.2COATING MATERIAL.7 3.3PIPE SURFACE PREPARATION7 3.4COATING APPLICATION.8 3.5FINISHED COATING SYSTEM.9 4.COATING SYSTEM QUALIFICATION.11 4.1SY
21、STEM IDENTIFICATION11 4.2COATING MANUFACTURERS DATA.11 4.3COATING SYSTEM QUALIFICATION12 4.4APPLICATOR QUALIFICATION.12 5.QUALITY CONTROL15 5.1GENERAL 15 5.2IDENTIFICATION OF EPOXY POWDER RESIN.15 5.3AMBIENT CONDITIONS.15 5.4INSPECTION BEFORE BLASTING15 5.5INSPECTION AFTER BLASTING.15 5.6APPLICATION
22、 TEMPERATURES15 5.7APPEARANCE, THICKNESS AND HOLIDAYS16 5.8ADHESION AND IMPACT TESTING16 5.9FLEXIBILITY TEST, HOT WATER TEST AND CATHODIC DISBONDING TEST 16 5.10DEGREE OF CURE AND MICROSCOPIC EXAM.16 5.11ACCEPTANCE OF DEFECTS17 5.12TRACEABILITY OF PIPES AND COATING.17 6.INSPECTION AND TEST PROCEDURE
23、S.19 6.1PROPERTIES OF THE EPOXY RESIN19 6.2COATING APPLICATION.19 7.COATING REPAIR25 8.DOCUMENTATION.26 9.HANDLING, STORAGE AND TRANSPORT OF BARE AND COATED PIPE 27 9.1GENERAL 27 9.2HANDLING OF PIPES.27 9.3STORAGE AND STOCKPILING OF PIPES.27 9.4TRANSPORT OF COATED PIPE.27 10.REFERENCES28 DEP 31.40.3
24、0.32-Gen. October 1995 Page 3 1.INTRODUCTION 1.1SCOPE This DEP specifies the minimum requirements and the test procedures for factory-applied external fusion-bonded epoxy powder coating of steel pipes, bends and fittings used for buried or submerged pipelines, and includes the material, application,
25、 inspection, repair, handling and storage requirements. This DEP replaces Standard Specification L-5-1/2/3 issued in September 1986. 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by SIOP and SIEP, the distribution of this DEP is confined to companies forming
26、 part of the Royal Dutch/Shell Group or managed by a Group company, and to Contractors and Manufacturers/Suppliers nominated by them (i.e. the distribution code is “F“, as defined in DEP 00.00.05.05-Gen.). This DEP is intended for use in oil refineries, chemical plants, gas plants, oil and gas produ
27、ction facilities, and supply/marketing installations. If national and/or local regulations exist in which some of the requirements may be more stringent than in this DEP the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requi
28、rements will be acceptable as regards safety, environmental, economic and legal aspects. In all cases, the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or local regulations. The Princ
29、ipal may then negotiate with the Authorities concerned with the object of obtaining agreement to follow this DEP as closely as possible. 1.3DEFINITIONS 1.3.1General definitions The Contractor is the party which carries out all or part of the design, engineering, procurement, installation, and commis
30、sioning or management of a project or operation of a facility. The Principal may sometimes undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Princi
31、pal is the party which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant authorised to act for and on behalf of the Principal. The word shall indicates a re
32、quirement. The word should indicates a recommendation. 1.3.2Specific definitions The Applicator is the party which applies the fusion-bonded epoxy powder coating system in the coating plant. A batch is the amount of materials produced within one uninterrupted production run of maximum 8 hours under
33、constant production conditions. Chemical pre-treatment is the treatment of the blast-cleaned pipe surface with a chemical solution (e.g. phosphate, chromate) before application of the first coating layer to improve the adhesion of the coating to the substrate. The Coating Contractor is the party whi
34、ch is ultimately responsible for the coating operation which may include supply of coating materials, application of the coating and transport of uncoated and coated line pipe as specified in the relevant contract. The coating contractor may be the Applicator, the Coating Manufacturer, the Line Pipe
35、 Manufacturer or the Pipeline Construction Contractor. DEP 31.40.30.32-Gen. October 1995 Page 4 The Coating Manufacturer is the party which manufactures the epoxy powder and, if applicable, additional coating materials supplied to the Applicator. The coating system is the specific combination of pre
36、-treatment, primer and powder coating meant to have the corrosion protection properties as described in this DEP. A holiday is a defect penetrating through the coating to the steel pipe surface, of such dimensions that it is detectable using the specified procedures. The Line Pipe Manufacturer is th
37、e party which manufactures or supplies the line pipe to be coated. The Pipeline Construction Contractor is the party responsible for the construction of the pipeline in the field. A shift is a set of pipes coated in one production run of which the beginning and end coincide with a change in personne
38、l. In the context of the quality control procedures of this DEP, the maximum duration of a shift is 10 hours. A Unit of Production is, unless otherwise specified, a set of pipes coated in one production run on the same coating line, having the same nominal diameter and wall thickness and coated with
39、 the same coating products. Breaks in production caused by equipment or plant breakdown, factory shutdown, or any break in production exceeding three days shall be the end of a production run. Subsequent start-up constitutes a new unit of production. 1.4ABBREVIATIONS FBE-Fusion Bonded Epoxy HSE-Heal
40、th, Safety and Environment(al) 1.5CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section is shown in brackets. Other documents referenced in this DEP are listed in (10). DEP 31.40.30.32-Gen. October 1995 Page 5 2.GENERAL INFORMATION 2.1COATING SYSTEM DESC
41、RIPTION The coating system described in this DEP shall be manufactured using FBE powder as the main coating material, using suitable surface preparation and application techniques to obtain the coating properties required for the intended installation and operating conditions. 2.2INFORMATION TO BE S
42、UBMITTED BY THE PRINCIPAL The Principal shall submit all technical information to the Coating Contractor regarding the project, in particular the installation and operating conditions. This information shall include as a minimum: -Project name; -The type of coating required; -The maximum operating t
43、emperature of the pipeline; -The pipeline diameter and wall thickness; -The applicable line pipe specification; -The geographical area (land/sub-sea); -Expected ambient temperatures during installation; -Installation method; -Soil and backfill conditions for land pipelines; -Sea bed trenching, layin
44、g and burial conditions for sub-sea pipelines; -Subsequent coatings to be applied (weight coating, insulation); -Requirement for anti-slip treatment; -Requirements for temporary protection of pipe ends; -Types of cathodic protection. The Principal shall indicate whether a specific brand of coating s
45、hall be used or whether the selection of coating shall be made by the Coating Contractor. The Principal shall indicate whether, and to what extent, he intends to witness coating application and quality control. 2.3INFORMATION TO BE SUBMITTED BY THE COATING CONTRACTOR The Coating Contractor shall sub
46、mit information to the Principal on the coating system to be used. This information shall include as a minimum: -System identification (4.1); -Manufacturers data (4.2); -System qualification information (4.3); -Coating application procedures related to pipe diameter and wall thickness; -The name(s)
47、of the proposed Coating Applicator(s); -Applicators qualification information (4.4); -Quality plan. The Coating Contractor shall confirm that the coating system is suitable to be used under the specified conditions (2.2). DEP 31.40.30.32-Gen. October 1995 Page 6 3.COATING SYSTEM REQUIREMENTS 3.1GENE
48、RAL The coating system shall be suitable for the installation and operating conditions of the pipeline as specified by the Principal (2.2). The Coating Contractor shall demonstrate that the coating system will fulfil the requirements before production starts. This shall be done by following the coat
49、ing qualification procedures (4). Any modification of a qualified coating system shall require re-qualification of the modified system. The Contractor shall demonstrate that the coating, as applied during normal production, fulfils the requirements by effective quality control procedures in accordance with (5). 3.2COATING MATERIAL 3.2.1Supply of epoxy powder resin Each batch of epoxy powder supplied to the Applicator shall be tested by the Coating Manufacturer for the properties specified in (4.2.1). Each batch shall be accompanied by a certificate in accordance with ISO 10474 type-3.1.B or