Petroleum Development Oman L.L.C.

RESTRICTED
Document ID: SP-2095
Oct-23
Filing Key: Business Control

[Material and Corrosion]

Specification Of Internal Liquid Coating Systems

For
Carbon Steel Piping and Line pipes

User Note:

The requirements of this document are mandatory. Non-compliance shall only be authorised by
the Document Owner or his Delegate through STEP-OUT approval.

A controlled copy of the current version of this document is on PDO's EDMS. Before making
reference to this document, it is the user's responsibility to ensure that any hard copy, or
electronic copy, is current. For assistance, contact the Document Custodian or the Document
Controller.

Users are encouraged to participate in the ongoing improvement of this document by providing
constructive feedback.

Please familiarise yourself with the

Document Security Classification Definitions
They also apply to this Document!
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

This page was intentionally left blank

Page 2 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

i Document Authorisation
Authorised For Issue

Page 3 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

ii Revision History
The following is a brief summary of the 4 most recent revisions to this document. Details of all
revisions prior to these are held on file by the issuing department.

Version No. Date Author Scope / Remarks

Version 1.0 Sep 09 Ahmed AL- Initial issue.
Harthy ,UEC121

iii Related Business Processes

Code Business Process (EPBM 4.0)

iv Related Corporate Management Frame Work (CMF) Documents

The related CMF Documents can be retrieved from the Corporate Business Control Documentation
Register TAXI.

Doc. ID Document Title

SP-1246 Specification for painting and coating of Oil and Gasproduction
facilities

DEP-30.48.00.31-Gen Protective Coatings For Onshore Facilities

Page 4 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

TABLE OF CONTENTS
Contents
i Document Authorisation...........................................................................................3
ii Revision History........................................................................................................ 4
iii Related Business Processes.....................................................................................4
iv Related Corporate Management Frame Work (CMF) Documents............................4
1 .0 Introduction..................................................................................................................... 7
1.1 Background................................................................................................................... 7
1.2 Purpose......................................................................................................................... 7
1.3 Changes to the Specification..........................................................................................7
1.4 Specification Owner's Responsibility..............................................................................7
1.5 Effective period.............................................................................................................. 8
1.6 Review and Improvement............................................................................................... 8
2.0 General Information................................................................................................... 9
2.1 General............................................................................................................................ 9
2.2 Information to be submitted by the company.....................................................................9
2.3 Information to be submitted by the supplier or applicator.................................................10
2.4 Operating conditions....................................................................................................... 11
3.0 Coating System Application and Quality Control..................................................12
3.1 Surface preparation........................................................................................................ 12
3.2 Coating application......................................................................................................... 13
3.3 Quality Control................................................................................................................ 13
4.0 Coating system qualification..................................................................................19
4.1 Coating Materials............................................................................................................... 19
4.2 Coating System Qualification............................................................................................. 19
4.2.1 Preparation of test panels......................................................................................19
4.2.2 Conditioning of test panels....................................................................................20
4.2.3 Coating thickness test...........................................................................................20
4.2.4 Pinhole/holiday detection Test...............................................................................20
4.2. 5 Cathodic disbondment Test...................................................................................20
4.2. 6 Adhesion Testing.................................................................................................. 21
4.2. 6.1 Pull-off test......................................................................................................... 21
4.2.6.2 Knife test........................................................................................................... 21
4.2.2.6.3 Pull off Adhesion after water immersion............................................................21
4.2. 7 Hot water resistance.............................................................................................. 21
4.2. 8 Penetration test..................................................................................................... 21
4.2. 9 Impact resistance test............................................................................................22
4.2. 10 Abrasion test....................................................................................................... 22

Page 5 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

4.2. 11 Water vapour permeability test.............................................................................22

4.2. 12 Water absorption test...........................................................................................22
4.2.13 Flexibility test....................................................................................................... 22
4. 2.14 Salt spray test (salt fog )......................................................................................22
4.2. 15 DSC Test for Glass Transition Temperatures.......................................................23
4.2. 16 Linear Thermal Expansion...................................................................................23
4.3 Test results........................................................................................................................ 23
4.4 Approved Laboratories....................................................................................................... 23
4.5 Product Fingerprinting........................................................................................................ 24
5.0 Applicator Qualification.......................................................................................... 25
5.1 Genaral.............................................................................................................................. 25
5.2 Coating process and applicator selection............................................................................25
5. 3 Coating plant..................................................................................................................... 25
5. 4 Qualification...................................................................................................................... 26
5.5 Quality plan, inspection and test plan, manufacturing plan..................................................26
6.0 Documentation............................................................................................................... 27
7.0 Storage and Handling.............................................................................................. 28
APPENDIX A 1.0................................................................................................................... 29
A 1.1 Testing Methods............................................................................................29
A.1.2 Roles and Responsibilities.............................................................................31
A.1.3 Execution of the Procedure............................................................................31
A.1.4 Related Business Control Documents............................................................32
A.1.5 Review and Improvement...............................................................................32
APPENDIX A 2.0 PDO Approved Coating Systems for Internal protection of Pipelines. 33
APPENDIX B.1 AUTOCLAVE TEST METHOD.................................................................34
APPENDIX B.2 KNIFE TEST............................................................................................36
APPENDIX B.3 CATHODIC DISBONDING RESISTANCE................................................37
APPENDIX B.4 CHEMICAL RESISTANCE TEST.............................................................40
APPENDIX B.5 FLEXIBILITY TEST..................................................................................41
APPENDIX B.6 HOT WATER TEST.................................................................................43
APPENDIX B.7 Resistance to gas pressure variations..................................................44
APPENDIX C.1 User Comment Form...............................................................................46
APPENDIX-D - Glossary of Definitions, Terms and Abbreviations....................................48
APPENDIX-E – References.................................................................................................... 49

Page 6 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

1 .0 Introduction

1.1 Background

The Company has been successfully using Fusion Bonded Epoxy systems as internal anti
corrosion coatings for a number of years. Due to increased project demand, shortage of local FBE
applicators and improved liquid epoxy coating technologies it has been decided to allow liquid
coatings providing their performance can be demonstrated to be equivalent to the powder coating
systems. The life expectancy of liquid epoxy systems is expected to be in the range 10 – 12 years.
The coating manufacturers are required to demonstrate the performance of their proposed coating
system for internal protection of a pipeline in accordance with this specification. The coating
system shall meet all the specified acceptance criteria before approval can be granted for its use.

1.2 Purpose

This specification sets requirements and gives recommendations for the factory application of
internal anticorrosion coatings for line pipe and piping for use in liquid pipelines with the objective of
protecting against internal corrosion from the corrosive transported fluids. It specifies the
requirements for coating materials, qualification, coating application, inspection and testing and
gives procedures to qualify both coating material and coating applicators.
Qualification of a coating system and applicator is essential before use and is not necessarily
related to a specific project. With this process, a list of qualified coating systems and applicators is
developed, from which the company may select a coating system and applicator for a specific
project. The approved applicator will be included in the company approved list of contractors for
applying internal liquid epoxy coating.
This specification shall only be applied for temperatures up to 85ºC. External coating shall be
applied prior to the application of the internal coating unless otherwise approved by the company.
The coating material shall be a solvent free epoxy coating system. It shall not contain any
substances which will be released from the paint film after it has cured .The surface preparation,
coating processes and inspection shall be fully automated and be suitable for a minimum of 12
meter pipe length and shall have the facilities for custom coating fabricated spools. The size of the
spool shall not be less than two inch diameter.

1.3 Changes to the Specification

This specification shall not be changed without approval from the Custodian, the Materials and
Corrosion Functional Discipline Head (CFDH), UER (UEC/1), who owns this specification. Any
user of this specification, who encounters an inaccuracy or ambiguity, is requested to notify
UEC/12, using the User Comment Form provided at the end of this specification and send the copy
with comments and personal details to DCS.

1.4 Specification Owner's Responsibility

The owner of this specification, UEC/1, as CFDH Materials and Corrosion, is responsible for
authorizing all proposed deviations or amendments to the specification and for the instigation of
periodic reviews and updates in accordance with Clauses 1.3and 1.5.

Page 7 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

1.5 Effective period

The requirements of this specification shall remain in force indefinitely unless superseded by an
authorized revision.

1.6 Review and Improvement

This specification will be reviewed and updated once every three years. The review authority will
be UER (UEC/1, CFDH Materials and Corrosion). Any revision and updates before three years
period, is at the discretion of the reviewing authority, UER (UEC/1).

Page 8 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

2.0 General Information

2.1 General

The coating system shall be suitable for use in a pipeline installation under the operating conditions
specified in table 1 listed in section 2.4.
Prior to beginning any coating application, the Contractor shall demonstrate that the coating
system will fulfill the qualification requirements in accordance with section 4. Modifications
including change of brand name, manufacturer, or origin of manufacturing plant of a qualified
coating system shall require re-qualification of the modified coating system or plant.
The Contractor shall demonstrate by effective quality control procedures in accordance with
section 3.3, that the coating, as applied during normal production, fulfils the requirements of this
Specification

2.2 Information to be submitted by the company

For a project qualification, the company shall supply technical information to the supplier or
applicator regarding the project, in particular the installation and operating conditions. This
information shall contain as a minimum:
 Project name
 The type of coating required
 The maximum and minimum operating temperatures of the pipeline/piping
 Description of the steel pipe (grade, specification, dimensions, drawing of spools)
 The applicable line pipe/piping specification
 The geographical area (Land/ Subsea).
 Expected ambient temperature during installation
 Expected pipeline pressure, maximum operating pressure, and comment on the
probability of rapid pressure loss and duration of decompression if any
 Installation method (welded/mechanical connection)
 External coating type to be applied, if required
 Fluids to be transported , including hydro testing fluid

 Length of internal coating cut back is 65 mm 5 mm if robotic coating will be carried out

for coating field joint. For mechanical coupling, the cut back shall be 25 mm 5mm
 Whether temporary protection of bare pipe ends is required
 Predicted corrosion rate of bare steel
 Level of H2S including region of severity in accordance with ISO 15156/NACE MR0175
Section 7.2.1.2
 Type of protection for the field weld joint (coated, through sleeve, positive seal coupling,
flanges)
 Design fluid velocity and erosion possibility

Page 9 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

 Pigging of the line and type of pig used

 Internal pipe marking requirements
 The company shall indicate whether a specific brand of coating shall be used or whether
the supplier or applicator shall select the coating

2.3 Information to be submitted by the supplier or applicator

The supplier or applicator shall submit information to the company on the coating system
to be used. This information shall contain as a minimum

 Coating manufacturer’s product data sheet

 Coating system qualification information (Appendix A.1.0)
 Proposed coating dry film thickness (to be agreed with the company)
 List of completed projects with the relevant specification.
 Coating application procedures
 Repair procedures and materials
 Name(s)of the proposed coating applicator (s)
 Applicator’s qualification information (section 5)
 Quality plan
 Safety plan
The supplier or applicator shall confirm that the coating system is suitable for use under the
specified conditions

Page 10 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

2.4 Operating conditions

The coating qualified according to this specification shall be used for the following applications

Table 1: Operating Systems

System 1 System 2
(water only) (Production fluids
containing oil, gas
and water )
Design Temperature 85 85
ºC

Design Pressure NA 50
Bar
GOR 0 <300

% Water cut NA 50%

CO2 Pp NA 3 bar
Bar
0

H2S Pp NA 0.5 bar

Bar
0

Solid/velocity Less than erosional Less than erosional

velocity velocity
Chlorides (Cl-) <100000 ppm <100000 ppm

Page 11 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

3.0 Coating System Application and Quality Control

3.1 Surface preparation

3.1.1 Initial inspection

Before blast cleaning and application of the coating system all pipes and panels shall be visually
inspected for the presence of oil, grease, dirt, mill lacquers, or primers on the internal surface. Oil,
grease and other contaminants shall be removed before blast cleaning by using a suitable solvent,
detergent, fresh water or combination of these. Cleaning methods shall be proposed by the
applicator and incorporated in the approved procedure The presence of dirt, mill lacquer, or primer
may be require the use of additional cleaning steps such as pre-blasting prior to the start of normal
cleaning process.

Chemical cleaning agents and remaining detergents shall be removed by washing with deionized
water.

Note: If solvent cleaning is used in the qualification then it becomes part of the procedure

Salt contamination shall be measured using an Elcometer SCM 400. If salt contamination is
greater than 1µg/cm2 the pipe ID shall be blast cleaned followed by a high-pressure wash with
deionized water (≥3000 psi/20.7MPa).

The pipe surface shall be dry before the final blast cleaning and surface preparation

3.1.2 Cleanliness & profile

The pipe shall be subjected to either blast cleaning with metallic grit using abrasive air blasting or
centrifugal, mechanical cleaning with abrasive to achieve the minimum specified cleanliness and
surface profile.

The pipe surface shall be cleaned of mill scale, rust and other foreign matter by blast cleaning to
achieve the minimum surface cleanliness of SA.2.0 ½ in accordance to ISO 8501-1. The anchor
profile shall be 50 – 75 µm for coatings with a dry film thickness of up to 600 µm and shall be 75 –
100 µm for coatings above 600 µm. Anchor profile shall be measured by comparator and X-coarse
Testex press-O-Film replica tapes in accordance with ISO8503-2 and ISO 8503-5. The amount of
dust shall be measured in accordance with ISO 8502-3.

Line speed and blasting parameters shall not cause any over blasting of pipe surface or result in
microscopic steel delamination that may disbond from the pipe surface.

3.1.3 Temperature during blasting

During blast cleaning the pipe surface temperature shall be higher than 5 °C and the ambient
temperature shall be more than 3 °C above the water dew point. Blast cleaning shall not be carried
out when the pipe surface to be blasted is wet.

Page 12 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

The relative humidity (RH) shall be monitored and recorded. Below 85% RH, up to four hours may
be allowed after blasting prior to coating. Above 85% RH coating is not allowed. Any pipe with
visible rusting, or which has not been coated within the specified time above, shall be re-blasted.

3.2 Coating application

Prior to and during application the temperature of the coating materials and pipe surface will be
measured and recorded and shall meet the manufacturer’s requirements to ensure that the coating
has the required application characteristics. The coating shall be applied by using a suitable
spinning airless spray head mounted on an automated travel buggy for internal application. The
travel speed shall be automatically controlled. This is to assure that the coating is applied in a
uniform thickness end to end, without any sag, floods, runs, blisters, bare spots or over spray. The
internal cutbacks shall be as per the company’s written requirement (section 2.2). When rubber-
sealing gasket joints or mechanical couplings are used, the coating shall extend to the ends of the
pipe. The minimum DFT of the coating in this area shall be in accordance with the coupling
manufacture’s recommendations.

3.3 Quality Control

3.3.1 General

During application of the coating , the applicator shall carry out all quality control activities needed
to ensure that the coating is being applied in accordance with the approved coating application
procedures and that the final product complies with the requirement of this specification. The same
quality control check shall be made into inspection and test plan.

The minimum quality control tests to be performed shall be as indicated in Tables 1-5 of this
specification; which shall be part of the approved inspection testing plan

Records of all coating application and quality control test results shall be kept in accordance with
Section 6.

3.3.2 Identification of materials

The applicator shall ensure that all materials supplied for the coating operation have been
inspected and identified in accordance with Section 4.0. The inspection and identification of
material shall be part of the applicator QA/QC activities in the quality management system
approved by PDO

3.3.3 Ambient temperature

The applicator shall measure the ambient conditions at regular intervals during blasting and coating
and keep records of prevailing temperature, humidity and dew point. If the conditions are outside
the limits set in this specification, the process shall be suspended until the requirements are met.
Page 13 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

3.3.4 Inspections of uncoated pipes before blasting

Before blasting preparation starts, each pipe shall be visually examined for dents, laps, defective
bevels and any other defects to avoid coating unusable pipes. Defective pipes shall be set aside
for inspection by the company representative who will advise remedial actions for any pipes that
can be used.

3.3.5 Compressed air

Compressed air used for blast cleaning, dust removal, or other purposes where contact is made
with the pipe surface, shall be free of oil and water as checked with a clean white rag. The
compressor shall be equipped with oil and water traps.

3.3.6 Inspection after blasting

Each pipe shall be inspected for surface cleanliness and damage. Pipes that do not comply with
the requirements in Section 5.1.1 shall be re-blasted.

The abrasive used for the final blast cleaning shall be metallic grit. Before coating operations;
conductivity of the abrasive materials extract shall be monitored. If the conductivity of the abrasive
material extract exceeds 50µmhos/cm further testing shall be performed on blast cleaned pipe
surfaces to determine the residual chloride concentration on the pipe surface. Grit samples shall be
taken and examined through a microscope to establish the presence of new angular grit.

If the surface roughness is outside the specified limits, the blasting material shall be checked and
replaced as necessary. Company representatives shall advise on the disposition of the rejected
pipe.

3.3.7 Application temperatures

If applicable, the temperature of the pipe surface shall be monitored and recorded by means of
suitable instruments, e.g. infrared sensors, contact thermometers or thermocouples.
Temperatures shall be in accordance with this specification and with manufacturer’s
recommendations for all substrates, coating materials and environment.

3.3.8 Coating appearance

Immediately following coating application, each coated pipe shall be visually inspected and shall be
free from blisters, pinholes, runs, sags, scratches or any other irregularities detrimental to coating
performance and shall have a uniform colour and gloss when inspected from each end of the pipe
and shall be free from any holiday . Batch Repair shall not be allowed.

3.3.9 Coating thickness

The coating thickness shall be measured by means of a thickness meter based on Eddy Current or
electromagnetic techniques in accordance with ISO 2808. The acceptance criteria shall be as
stated in SP1246 part 4 for internal coating (The 90-10 Rule). The coating thickness shall be as per
the specified thickness.
Page 14 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

Calibration of digital thickness gauges shall be carried out with plastic calibration shims on a steel
plate having a similar surface profile as the samples to be measured. The plate thickness shall be
a minimum of ¼ in (6.35mm). For gauges that allow calibration with two shims of different
thickness, the thickness of the shims shall bracket the nominal thickness of the coating system to
be measured. For gauges that allow only one shim for calibration, the shim thickness shall be +/-
20% of the nominal thickness of the coating system.

For quality control purposes the coating thickness shall be measured at both ends of each pipe. At
each location, the thickness shall be measured at four positions, equally spaced around the
internal circumference of the pipe.

Pipes that do not comply with the requirements of this specification shall be marked and removed
from the coating line for repair or recoating. If subsequent pipes do not comply with the
requirements, the coating process shall be checked or stopped to eliminate the cause of the
problem.

3.3.10 Holiday detection

100% of the surface shall be tested using a metallic brush type holiday detector in accordance with
NACE RP0188-99. Contractor shall get approval from company for holiday detection methods. The
earth connection shall be made directly on the pipe. The electrode shall be moved over the pipe
surface at a speed of not more than 0.3m/s. The entire inner pipe surface shall be inspected by the
holiday test.

Holiday tests may be carried out by means of a low-voltage 67.5 V holiday detector and a wet
sponge that is cut to fit snugly in the ID of the pipe. The sponge shall be supported so that it
maintains constant contact with the full circumference of the pipe.

Alternatively holiday detection may be carried out using a high voltage detector with an internal
conductive rubber electrode. The inspection voltage shall be 5V/micron. When a high voltage
detector is used the internal pipe surface shall be free of moisture.

The test voltage shall be checked and recorded at least once per shift by means of a special
voltage meter. Care must be taken on all coatings under 500 microns, as the hot spark can burn
through the coating.

3.3.11 Hardness Test

Hardness shall be checked using a Shore D hardness test (ASTM D2240-05), the result of which
shall meet manufacturer’s reported figures.

3.3.12 Destructive Testing

At predetermined intervals which will be at least twice per shift, a pipe shall be selected for
destructive testing of the coating. A sample length of approximately 0.5m shall be cut from one end

Page 15 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

of this pipe and samples cut from this pipe section and subjected to the tests indicated in Table 5.
Tests shall be in triplicate.

The tests shall commence as soon as possible after the coating is fully cured.

After cutting the test sample, the remaining pipe shall be marked with the remaining length and the
coating cutback reinstated in accordance with section 2.2. The pipe end bevel shall be re-
machined to the original pipe specification before repair of coating cutback.

3.3.13 Acceptance of suspect coating

In the event of pipes failing to meet the requirements of this section, preceding pipes coated after
the last acceptable pipes and the pipes coated following the failed pipe shall be considered suspect
and shall be marked for further testing.

The applicator shall propose and agree with the company or its representative a test program to
trace any defects related to the identified problems in the rejected pipes. Further testing shall
involve inspection and examination similar to that carried out on the original rejected test pipe.
Based on the test results, the final acceptance or rejection of the suspect pipes shall be made by
the company.

No pipes shall be dispatched from the coating yard before the company has approved the quality
control results.

3.3.14 Trace ability of pipes and coating

The applicator shall ensure that individual pipes are fully traceable during and after the coating
process. The applicator shall address trace ability in his quality procedure. If the serial number of
the pipe as given in the pipe mill is removed or obliterated, it shall be reapplied. The applicator’s
own serial number shall be indicated on the pipe and records shall be kept to identify the sequence
and time of coating and the batch of materials used for each pipe.

Test frequency

Table 1 – Receipt of materials

Property Standard Section Test frequency

Identification of materials 3.3.2 All material

Initial visual coating 3.3.4 and 3.3.6 All pipe

inspection
Salt contamination prior to 3.1.1 10% of pipe
blasting

Page 16 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

Table 2- Surface preparation

Test frequency for

Property Standard section
production
Environmental 2pipes/shift and after
condition during 3.3.3 changes in weather
blasting conditions
After every
Cleanliness of
3.3.5 compressor start-up
compressed air
and every 10 pipes
4pipes per shift and
Pipe temperature after changes in
3.1.3
during blasting environment
conditions
Surface cleanliness 3.1.2 All pipe
First 5 pipes after
Surface profile 3.1.2 every start up and
then every 10th pipe
Dust contamination 3.1.2 All pipe
Conductivity of blast 4pipes per shift or
3.3.7
media after every 10 pipes
Salt
contamination 3.3.6 Every 10th pipe
following blasting
Pipe damage 3.3.4 All pipe

Page 17 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

Table 3 – Coating application

Property Standard section Test frequency
2 test /shift and after
Environmental conditions
3.3.3 changes in weather
during coating application
conditions
Pipe temperature prior to
3.3.7 All pipe
coating application
Pipe temperature during
3.3.7 All pipe
coating application
Lance operation 3.2 At start -up
Coating thickness 3.3.9 All pipe
Cut back 2.2 All pipe

Table 4 – Non – destructive testing

Property Standard section Test frequency

Coating appearance 3.3.8 All pipe
Coating thickness 3.3.9 All pipe
Holiday detection 3.3.10 All pipe
Hardness Test 3.3.11 All pipe

Table 5 –Destructive testing

Test frequency
Property Standard section Test frequency
for qualification
Appendix A.1.0.1 2 pipes
Flexibility ≥ 2 per shift
Table 6, Appendix B5
Appendix A.1.0.1 2 pipes
Hot water soak ≥ 2 per shift
Table 6, Appendix B6
Appendix A.1.0.1 2 pipes
Adhesion (pull off Table 6, ASTM
≥ 2 per shift
and knife tests) D4541 and Appendix
B.2.0
NACE PR0394-2002 2 pipes
Cross-section and
(refer to Appendix G- ≥ 2 per shift
interface porosity
Figurer 2)
Appendix A.1.0.1 2 pipes
DSC Test Table 6, ASTM ≥ 1 per shift
E1356 – 08

Page 18 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

4.0 Coating system qualification

4.1 Coating Materials

Applicator shall obtain from the manufacturer copies of their most recent technical data sheets
describing the product, its general performance, and application requirements.

Applicator shall obtain from manufacture certification for each batch used to coat company line
pipe and piping.

The certification shall include:-

 Product name , designation and batch number

 Product quality control test results

Coating materials acceptable for use shall be:-

1. contained in manufacturer original, unopened containers

2. stored in a dry, clean location, controlled at or below manufacturer’s

recommended temperature

3. clearly marked with batch number and date of manufacturer

4. applied six months or less from the date of manufacture and before any expiry
date

4.2 Coating System Qualification

Qualification shall be carried out according to this specification. The coating applicator shall show
that samples of the coating system applied on pipes and panels as required by this specification
have been successfully subjected to the tests as specified in Table 6; appendix A.1.0.1. The tests
shall be carried out in a Company approved independent and specialized test laboratory as listed in
section 4.4. The company or its representative shall witness the application and shall witness the
tests.

The tests that are required are detailed in Table 6, Appendix A.1.0.1

4.2.1 Preparation of test panels

The tests specified in Table 6, Appendix A.1.0.1. Shall be conducted on coating applied to the
required film thickness specified in Section 3.3.9 by spraying onto the steel test panels and pipes.
Coating shall be applied by the candidate applicator.

Page 19 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

All test panels shall be cut from 5 mm hot rolled ASTM -A 36 or equivalent steel plate. Panel Size
shall be in accordance with the test requirements of the relevant test method.

The steel panels shall be grit blasted to achieve a surface preparation standard meeting ISO 8501-
1 SA 2 ½. The surface profile shall be measured in accordance with ISO 8503-2 or ISO 8503-4
and shall be between 50 – 75 µm for coatings with a dry film thickness of up to 600 µm. For
coatings above 600 µm dry film thickness the surface profile shall be 75 – 100 µm unless
otherwise agreed. Both the preparation grade and the surface profile of the test panels shall be
included in the qualification test report.

Samples shall be checked using a Shore D hardness test (ASTM D2240-05), the result of which
shall meet manufacturer’s reported figures.

Apply the coating in accordance with the instructions of the coating manufacturer and in
accordance with application procedures to be used during the project. Test panels shall be
attached to the pipe ends.

4.2.2 Conditioning of test panels

The test panels shall be air dried for 10 days at 25°C, followed by 24 h drying in a circulating- air
oven at 50 °C. Relative humidity during the drying shall not exceed 80%.

After completing the schedule of conditioning outlined above, panels may be stored at room
temperature until needed for testing, but shall not be for longer than 90 days.

All testing shall be performed on test panels conditioned according to this clause.

4.2.3 Coating thickness test

The coating thickness shall be measured according to 3.3.9. The acceptance criteria shall be as
stated in SP1246 part 4 for internal coating (The 90-10 Rule).

4.2.4 Pinhole/holiday detection Test

The method of holiday detection shall be as per 3.3.10. The number of holidays shall be reported
per pipe joint. Excessive holidays (more than 5 pins per pipe joint) shall require applicator to review
the application process.

4.2. 5 Cathodic disbondment Test

The cathodic disbondment test, in accordance with Appendix B.3.0 is used to determine the
maximum service temperature for a given pipeline coating material. At the maximum service
temperature, the coating’s CD shall pass the performance acceptance criteria in, Table 6,
Appendix A.1.0.1

Page 20 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

4.2. 6 Adhesion Testing

4.2. 6.1 Pull-off test

For qualification purposes, the adhesion strength of the coating shall be tested by a pull-off test
according to ASTM 4541-02

4.2.6.2 Knife test

The adhesion of the coating on a pipe shall be determined at a random location by the following
method:

Using a sharp and pointed knife, two incisions of approximately 15 mm in length shall be made
through to the steel surface to form an ‘X’ with an angle of intersection of approximately 30°.
Commencing at the intersection, an attempt shall be made to lift the coating from the steel
substrate using the blade of the knife.

An adhesive breakaway from the point of intersection of more than 2 mm, or brittle breakaway of
flakes of more than 2 mm constitutes a failure.

Cohesive failure caused by voids in the coating leaving a honeycomb structure on the steel surface
also constitutes a failure.

4.2.2.6.3 Pull off Adhesion after water immersion

After the water immersion, the coating shall be examined visually and by a pull off adhesion test.
The coating shall show no blistering and no disbondment. Pull off adhesion strength determined as
per ASTM D4541 shall be more than 17 MPa with less than 10% adhesive failure to substrate.

4.2. 7 Hot water resistance

The hot water resistance shall be carried out at 85° C ±2° C test temperature. The duration of the
test for coating qualification shall be 28 days. After the exposure; the coating shall show no
significant evidence (less than 25 % of the test area) of blistering or disbonding and shall show no
failure of adhesion. Tests shall be carried out at 23°C after the panels have been dried and within
24 hours of removal from the immersion test. The pull off adhesion strength shall be more than
75% of 17 MPa.

4.2. 8 Penetration test

Penetration test is used to determine the maximum service temperature for a given pipeline
coating material. The penetration resistance is determined in accordance with ASTM G 17. This
test uses a blunt rod for pipeline coating, however, for the purpose of the screening exercise, flat
coated panels shall be used instead of pipe samples .

Page 21 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

Triplicate tests shall be carried out at room temperature, 23°C and at 85°C. The maximum
penetration shall be not greater than 10%.

4.2. 9 Impact resistance test

Impact resistance shall be determined in accordance with ASTM G 14. Visual examination and
holiday detection in accordance with Section 3.3.10 shall be used to determine breaks in the
coating. Flat panels can be used for the screening tests. The test shall be carried out with test
panels at both room temperature and at the minimum design temperature of the pipe. There shall
be no breaks in the coating after 10 repeats impacts on the same panel.

4.2. 10 Abrasion test

Abrasion test shall be determined in accordance with ASTM D4060. The maximum mass loss shall
be less than 20mg per 1000 cycles

4.2. 11 Water vapour permeability test

Water vapor permeability shall be determined using the wet cup test in accordance with ASTM D
1653 at 23°C and 85 °C over 90 days, with measurements made at 30 day intervals. The Water
vapour permeability shall be less than 300 g/m² at 23°C and less than 1500 g/m² at 85 °C.

4.2. 12 Water absorption test

The water absorption of coated panels shall be determined at room temperature and at 85°C after
immersion for 90 days, in accordance with ASTM D 870. The water adsorption shall be no greater
than 70 g/m².

4.2.13 Flexibility test

The flexibility test is carried out to assure the coating has adequate flexibility for field bending or
reeling and shall be determined in accordance with a modified NACE RP0394-2002 (Appendix H,
procedure A) test at 2.5 /PD minimum, total strain (arc matching) The specimen shall not have any
crack, fissure or delaminatiom of the coating after testing.

4. 2.14 Salt spray test (salt fog )

The resistance to salt spray shall be determined in accordance with ASTM B117. The test shall be
carried out for 1000 hours. The coating shall be free from any sign of deterioration, including
blistering cracking and staining except from the area within a radius of 2.0 mm from the center of
the X cut. There shall be no loss of adhesion.

Page 22 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

4.2. 15 DSC Test for Glass Transition Temperatures

The DSC test is run in accordance with ASTM E1356–08 and measures glass transition
temperatures and exotherms from the coating system. Coating chips of suitable size are to be cut
from the pipe for this test. These are both fingerprint characteristics of the coating system and also
show the degree of cure of the coating.

4.2. 16 Linear Thermal Expansion

The Linear Thermal Expansion of the cured coating shall be determined using a Push-Rod
Dilatometer in accordance with ASTM E228. The thermal expansion is important as differences
between the expansion characteristics of the coating and the steel pipe can lead to cracking and/or
reduced adhesion of the coating.

4.3 Test results

Color photographs of all test plates before and after the testing shall be presented as an appendix
to the test report, with captions and explanatory notes describing each photograph. The following
information shall be included as part of the caption.

Coating system

Coating supplier

Applicator and facility

Date the panel was coated and to include a unique identification mark/number

Test Procedure

Date testing started

Date evaluation test carried out

Test results in accordance with standards

Photographs of evaluated samples

Observations and comments

Testing Laboratory name & location

4.4 Approved Laboratories

Manufacturers may utilize the following company approved Independent Laboratories for testing
materials in accordance with this specification.

 Charter Coating Service (2000) Ltd., Calgary, Canada

Page 23 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

 COT, Haarlem, the Netherlands

 Marintek, Oslo, Norway

 Bodycote, Houston, Texas, USA

 Shell Global Solution, SGSI

The Coating manufacturers and applicator may propose an alternative independent laboratory. The
alternative laboratory shall be approved by the company prior to commencement of any testing.
Cost of approval shall be paid by the coating manufacturer and /or as appropriate.

4.5 Product Fingerprinting

Following qualification, all company accepted products shall be fingerprinted at the manufacturer’s
cost. The wet samples utilized in the test program shall be fingerprinted in accordance with the
following test methods:-

 Infra Red Fingerprint

 Volume Solids

 Viscosity @ 23°C

 Pot life @ 40°C

 PVC (Pigment Volume Concentration)

 VOC (Volatile Organic Compounds) limits where appropriate.

The manufacturer shall also supply to the company the relevant acceptance Production Tolerance
as a range associated with each test.

All information released to the company under the fingerprinting test will be kept confidential by the
company..

Page 24 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

5.0 Applicator Qualification

5.1 Genaral

Before qualification, an applicator shall be subjected to an assessment audit in accordance with the
company GU 398. All high and medium rated non conformances identified during the audit must be
rectified before qualification.

Applicator qualification shall take place using the production equipment required to apply an
approved coating. The qualification shall be carried out according to the following procedures:-

5.2 Coating process and applicator selection

The contractor shall submit to the company information on the required coating process and
recommended applicators. The information shall include:

- Description of the coating process for the line pipe, bends, fittings, and internal girth weld if any.

- Pipe cleaning and surface preparation (cleanliness, profile, chemical pre-treatment, etc.)

- Required surface and material application temperatures if applicable

- Recommended applicators

5. 3 Coating plant

In order to demonstrate that the available equipment is capable of applying the specified coating
according to the requirement of this specification , each recommended applicator shall submit full
details of their coating plant , including :-

- Layout diagram of the coating plant and work flow scheme

- General description of the equipment available to carry out the coating process

- Details of process control and inspection equipment required for the coating process, such as
temperature control, thickness control, holiday testers, laboratory equipment, etc.

- Details for the pipe marking, handling, storage and transport equipment and procedures

-applicator’s quality control procedures

Page 25 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

5. 4 Qualification

After approval of the process and plant details and before production starts, the applicator shall
submit evidence that he successfully applied the coating system before on pipes of the specified
material, and that the applied coating system complied with the requirements of this specification
given in Appendix A.1.0.1.Table 6.

The applicator shall coat at least 2 pipes with the coating system and shall subject samples from
these pipes to the tests given in Appendix A.1.0 Table 6. The quality control tests may be carried
out in the applicator’s own laboratory, or by an approved independent laboratory. The company
shall witness the application and the tests. The results of the tests shall be reported to the
company, signed by the head of the laboratory and the witnessing TPI.

When application is going to include coating of bends and/ or fittings, the applicator shall coat at
least one fitting or bend as agreed with the company and subject this coated sample to the same
qualification tests.

5.5 Quality plan, inspection and test plan, manufacturing plan

Contractor shall operate and maintain a quality system (e.g. ISO 9001 or ISO9002) or approved
equivalent. Internal coating shall constitute part of the scope.

A quality plan (QP) in compliance with ISO 10005 or equivalent approved by the company, shall
consist of an inspection and test plan (ITP) and manufacturing plan (MP), as a minimum , and shall
be developed specifically for all aspects of work and shall be approved prior to commencement of
manufacturing operations. The ITP shall provide columns or spaces for the company to indicate
company’s and/or company’s third party inspector inspection requirement , for example the
monitor, witness, hold points, etc. for the operation to be undertaken .

The MP shall clearly define the sequence of operations and process controls to be implemented at
each stage of coating operation. All procedures, processing parameters, requirements, etc.
stipulated in this technical specification shall be applied. Deviation s are only permitted if approved
by the company CFDH for material integrity .Alternatively one combined document consisting of an
ITP and MP is acceptable provided the guidelines stated above are followed.

Page 26 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

6.0 Documentation
The contractor shall keep accurate records of all relevant data of the coating process. This
documentation shall, as a minimum, consist of:

 Copies of coating system information as specified in section 4.0

 Copies of qualification information as required in Appendix A.1.0 table 6

 Copies of, or reference to , all procedures for coating of the pipe

 Serial numbers of all pipes as given by the pipe manufacturer (e.g. by copy of the pipe mill
data sheets)

 Serial numbers as given by the coating applicator (if applicable ) correlated with the
manufacture’s serial numbers )

 The order of pipe coating, and the day and shift each pipe was coated.

 The batch numbers of the coating materials. The day and time of loading each batch.

 Serial numbers of rejected pipes and reasons for rejection.

 The results of quality control testing in accordance with section 3.3 of this specification.

 Names and signatures with dates of responsible persons for the coating process and
quality control

This documentation shall be submitted to the company after completion of the coating work,
together with the testing and inspection instruments’ calibration certificates.

Page 27 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

7.0 Storage and Handling

Coated pipe shall be stored and handled in such a manner as to prevent damage to the pipe, pipe
ends, bevels and applied coating.

All pipes shall be stored in a manner to provide for safe stacking and unstacking operations.

Pipe without external coating shall be stacked off the ground on berms covered with a plastic
sheeting material, or on timbers with a minimum width of 6 in (15cm ) wide bearing surface. The
berms or timbers shall be of sufficient height to prevent the pipe ends from coming into contact
with the ground and to keep pipe clear of any localized surface water.

All pipes shall be stored at an angle to allow water to drain from the interior. Exposure of internally
coated pipe to water should be minimized.

Externally coated pipe shall be handled in accordance with the requirement of the relevant DEP for
the external coating

Internally coated pipe shall be stored so that debris, oil or other contamination detrimental to the
internal pipe coating does not come in contact with the internal surface.

Page 28 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

Appendix A 1.0

A 1.1 Testing Methods

The testing methods and duration are shown in Table6.

Table 6: Performance Tests

Test Acceptance Limits Test Frequency Test

Panels/Sample method
s
Thickness 90-10 rule all ISO 2808
PDO SP-
1246
Holiday Holiday free all NACE
detection RP0188-90

Hardness Test Shore D value to meet manufacturer’s all ASTM

requirements D2240-05

Cathodic 8mm maximum arithmetic mean and 10 3 per test Appendix B

Disbondment mm max. radius at 85°C for the 28 days temperature 3
test. The 48 hour production test shall be
established during qualification test for
each system and applicator.
Pull Off 17 MPa min, less than 10% adhesive 3 ASTM
Adhesion * failure to substrate D4541
note 1
Knife No adhesive breakaway from the 3 Appendix B
Adhesion test intersection of more than 2 mm, or brittle 2
breakaway of flakes of more than 2 mm
Hot water Test at 85°C. No blisters or disbondment and 3 Appendix B 6
resistance pass pull off adhesion test (this table) after 48
hours (production) or 90 days (qualification).
Penetration Less than 10% of DFT at 85°C 2 ASTM G17

Impact 1.70 J minimum for both 0°C and 20°C. No 3 per test ASTM G14
holiday at 67.5V temperature

Abrasion ≤ 20mg per 1000 cycles, CS-17 wheels, 1 3 ASTM

kg, at least 1000 cycles of test to be D4060
conducted
Water vapour ≤ 300g/m at 23 °C; ≤ 1500g/m2 at 85°C
2
3 ASTM D
permeability after 90 days (measure every 30 days) 1653
Water 90 days at 23 ±3°C and 85°C. Absorption ≤ 3 per test ASTM D 870
absorption 70 g/m2 temperature

Page 29 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

Chemical 90 days at 23 ±3°C without blistering, to 2 each Appendix B 4 and B

resistance be followed by autoclave test medium 1
Autoclave Free of blisters, cracks, delaminations, or 3 Appendix B 1
other defects exposing the steel substrate NACE TM01-85
to corrosive media ASTM D 714
Flexibility 2.5 °/PD bend at 23 °C. The specimen 3 Appendix B 5
shall not have any crack, fissure, or
delamination of the coating
Cross section ≤ 10% contamination on back of coating 3 NACE RP0394-2002
and interface and through-film and across-film porosity (Appendix G-figure
porosity ratings ≤ 1 G2)
Gas pressure To be specified by the company 3 Appendix B 7
variation

Salt fog No blistering; no loss of adhesion after 3 ASTM B117 (for

1000 hours 1000 hr)

DSC Tg values max. ± 2°C of those stated by 2 ASTM E1356

the manufacturer. Cure ≥ 96%.
Tg shall be ≥ 10°C higher than max.
Operating temp.
Linear Thermal Measure from -10°C to + 90°C 3 ASTM E228
Expansion

* Note 1: The pull off fixture may have to be shaped to fit the curvature of the pipe.

Page 30 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

A.1.2 Roles and Responsibilities

Table 7.

ROLE RESPONSIBILITY

Coating Supplier/manufacturer or Propose a suitable coating system and if applicable

applicator an applicator and facility

Coating Supplier/manufacturer or
Use the company approved laboratory
applicator

Coating Supplier/manufacturer or
Propose Third Party Inspection Agency (TPA)
applicator

Perform test program, including test plate

preparation and coating application (If
Laboratory manufacturer/applicator chooses to apply the
coating this shall be witnessed by Test Laboratory
and the TPA)

Prepares and endorses all reports including

Laboratory
photographs and finger printing.

Witness all the test applications and check final result

TPA interpretation, compile and endorse full report
including photographs.

Review the test result and update the list of approved

CFDH for Materials and Corrosion
coating systems and/or applicator as appropriate.

A.1.3 Execution of the Procedure

This specification shall be used for any proposed coating system to be applied for pipe coating
work that has not been previously approved by the company and is not listed in the approved
coating system (Appendix A.2.0), or when the product finger printing has changed.

Page 31 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

A.1.4 Related Business Control Documents

The related CMF Documents can be retrieved from the Corporate Business Control Documentation
Register TAXI.

Doc. ID Document Title

SP-1246
DEP-30.48.00.31-Gen

A.1.5 Review and Improvement

This procedure shall be reviewed every three years, the review and improvement shall be
authorized by the CFDH for material integrity. Appendix A2 of this procedure shall be updated to
incorporate newly approved coating systems as and when required, this shall also be authorized by
the CFDH for material integrity.

Page 32 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

Appendix A 2.0 PDO Approved Coating Systems for Internal

protection of Pipelines
No. Type Trade Name Manufacturers Manufacturing Approved by Date of
Plant CFDH approval

Page 33 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

APPENDIX B.1 AUTOCLAVE TEST METHOD

1.0 SCOPE

To determine compatibility of the coating with a given environment.

2.0 EQUIPMENT

The autoclave vessel should be rated for a minimum working pressure of 2,000 psi and a
temperature of 200°F with adequate pressure gauges, indicating temperature controllers and a
rupture disc pressure relief system. Suitable materials to withstand the corrosive test media shall
be used. The rupture disc vent and all other vents shall be piped to a caustic scrubber designed to
neutralize H2S discharges.

3.0 TEST SPECIMEN

The test specimen shall be 1 in. [25 mm] x 6 in.[152 mm] x 0.25 in. [6 mm] thick. The steel
substrate shall be left exposed on the 6 in. [152 mm] x0.25 in, [6 mm] faces. Specimens shall be
prepared and coated in accordance with manufacture recommendations. Test specimens shall be
inspected for runs, pinholes, blisters, and coating thickness recorded before testing. Multiple
coating systems should be Included and compared in a single test run. A control sample with
known performance in the test environment should be included in each test.

4.0 PROCEDURE

4.1 Water with 5% NaCI by weight should cover approximately 50% of the surface of the coated
specimen. A gas mixture of 0.5% (by volume) H 2S, 5% CO2, and 94.5% CH4 (methane) should be
used to pressurize the autoclave. Where expected service conditions may have a higher H 2S or
CO2, concentration, the gas composition should be altered accordingly.

4.2 The autoclave is filled to the middle of the test specimens with 5% brine, sealed, flushed with
CO2, pressurized with the gas mixture, and heated to 200 °F/93 °C. Gas should be vented to the
scrubber to prevent pressures over 2,000 psi [I4 MPa] as the autoclave is heated. The pressure
and temperature shall be maintained for 48hours before the heaters are turned off. The gases shall
be vented rapidly, pressure release in less than two minutes, after four hours of cooling.

4.3 The coatings are rated in the vapor and fluid zones. They are rated for color change, swelling,
softening, blisters, cracks, delamination, and loss of adhesion using the latest edition of NACE

Page 34 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

Test Method TM-01-85, Evaluation of Plastic Coatings by Autoclave Testing. A blister rating can be
developed following the latest edition of ASTM D714.
5.0 REPORT

a. Batch number and date tested.

b. Download temperature and duration
c. Ratings in both fluid and vapor zones for color change, swelling, softening, blisters,
cracks, delamination, and loss of adhesion especially noting defects exposing the steel
substrate.

Page 35 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

APPENDIX B.2 KNIFE TEST

The adhesion of the coating on a pipe shall be determined at a random location by the following
method:

Using a sharp and pointed knife, two incisions of approximately 15 mm in length shall be made
through to the steel surface to form an ‘X’ with an angle of intersection of approximately 30°.
Commencing at the intersection, an attempt shall be made to lift the coating from the steel
substrate using the blade of the knife.

An adhesive breakaway from the point of intersection of more than 2 mm, or brittle breakaway of
flakes of more than 2 mm constitutes a failure.

Refusal to peel, or a cohesive break less than 2 mm long entirely within the coating, constitutes a
pass.

Cohesive failure caused by voids in the coating leaving a honeycomb structure on the steel
surface also constitutes a failure.

Page 36 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

APPENDIX B.3 CATHODIC DISBONDING RESISTANCE

1.0 SCOPE

This test provides an accelerated adhesion assessment of the coating.

2.0 EQUIPMENT
-D. C. Power supply unit
-Platinum or platinum-coated anode wire
-Electrolyte solution consisting of 3% by weight sodium chloride (NaCl) in distilled water
-Plastic tubes 3% in. [90 mm] diameter, 4 in. [l00mm
-High resistance volt/amp meter
-Hot Plate or oven capable of maintaining ±5° F (±3°C)
-Calomel reference electrode
-Utility knife

3.0 TEST SPECIMEN

3.1 QUALIFICATION SPECIMEN

The test specimen shall be 4 in. [100 mm] square by 0.250 in. [6 mm] thick, prepared and coated
in accordance with the manufacturer recommendation.

3.2 TEST RING SPECIMEN

The test specimen shall be 4 in. [100 mm] square segment cut from the test ring.
Drill a 0.250 in. [6 mm] hole through the coating to expose the substrate, ensuring that the hole
does not go through the substrate. This holiday should be drilled at the center of specimen.
Glue plastic tube onto specimen with holiday at center of tubing

4.0 PROCEDURE

The cathodic disbonding resistance of the coating shall be tested as follows: the test sample shall
be free of holidays when tested in accordance with (4.2.2.4). A sample of coated pipe shall be
taken of sufficient length and with approximately the same diameter as the production pipe. A
6 mm hole shall be drilled in the coating, using a flat-faced mill. The hole shall penetrate not more
than 0.5 mm into the pipe steel. The hole shall be at least 50 mm from any weld. The sample shall
be placed inside an electrolytic cell or an electrolytic cell shall be attached on the pipe surface. All
metallic parts other than the test defect shall be sealed from the electrolyte using a resin or other

Page 37 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

suitable compound. The volume of the cell shall be at least 250 ml. The cell shall be filled with a 3
% sodium chloride solution. An inert auxiliary electrode (e.g., platinum wire or mesh) shall be
placed in the electrolyte, remote from the test defect. A saturated calomel reference electrode
(SCE) shall be placed in the electrolyte with the tip 10 mm from the test defect. By means of a
potentiostat, the electrochemical potential of the steel shall be polarised to -1500 mV ± 10 mV with
respect to the SCE. This potential shall be maintained throughout the test. The current required to
maintain the potential shall be checked and recorded daily. The duration of the test shall be 28
days, after which the sample shall be removed from the cell and examined.

For quality control purposes, the duration of the test shall be 48 hours. For tests at elevated
temperatures, the temperatures shall be controlled as follows:

 When the sample is immersed in the cell, the solution, including the sample, shall be kept
at the test temperature by placing a thermostatically controlled heater in the electrolyte
solution or by placing the cell and sample in a thermostatically controlled convection
oven which does not communicate with the test cell.

 When the cell has been attached on the pipe sample, the steel sample shall be placed in
a thermostatically controlled furnace or sand bath that also covers the top surface of the

sample with at least 1 cm of sand. The oven or sand bath shall be adjusted to
maintain the required test temperature on the pipe surface in the test defect.

 During tests at elevated temperatures, suitable reflux coolers shall be used to prevent
evaporation of the test electrolyte or the test cells will be constantly topped up with
distilled water and the electrolyte changed out after 7 days.

At the end of the test period, the sample shall be rinsed with fresh water and wiped dry. The
sample will be inspected for blistering (ASTM D714) and this shall be recorded. Two cuts shall be
made through the coating in the longitudinal direction of the pipe and two similar cuts made in the
circumferential direction, each pair of cuts being 5 mm apart and approximately following the
tangent of the test defect. The length of the cuts shall extend to approximately 20 mm each side of
the defect; see Figure 1. By means of a knife, the strips of coating between the cuts shall be
peeled from the pipe surface as far as possible, starting at the test defect. The distance over which
the coating is detached and the metal is exposed, measured from the edge of the original test
defect, shall be recorded in all four directions. The radius of disbonding shall be the arithmetic
mean of the four measurements.

5.0 REPORT

A photograph of the test sample after testing, showing the disbondment area, shall be included in
the test report. Report the average disbonded radius and any blistering.

Page 38 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

FIGURE 1 Determination of the radius of disbonding

Page 39 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

APPENDIX B.4 CHEMICAL RESISTANCE TEST

1.0 SCOPE
To evaluate the resistance of coating to various reagents.

2.0 EQUIPMENT
Quart [1liter] Glass Jars and Vented Lids
MEDIUM CONCENTRATION pH VALUE
HCl in water 2.5-3.0
HF in water 2.5-3.0
H2SO4 in water 2.0
NaCl + H2SO4 in water 100,000 ppm 3.0
chlorides
NaCl in water 10.0%
Distilled water 100%
Toluene

3.0 TEST SPECIMEN

Each test specimen shall be 1 in. [25 mm] x 8 in.[200 mm], 0.25 in. [6 mm] thick. All sides of the
test specimen shall be coated. Specimens shall be prepared and coated in accordance with the
manufacturer recommendations.

4.0 PROCEDURE

4.1 Pour enough medium into the jar so half the length of the test specimen is immersed in the
medium and half the specimen is in the vapor phase of the medium & ambient temperature.
4.2 Place the vented lid on the jar and ensure the medium level remains constant for 90 days.
4.3 After 90 days immersion, examine the test specimen for bleaching, swelling, softening, blisters,
cracks, delamination and loss of adhesion.
5.0 REPORT
The condition of the sample after 90days immersion of both the liquid and vapor phase-portions of
the sample.

Page 40 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

APPENDIX B.5 FLEXIBILITY TEST

1.0 SCOPE
To assure the coating has adequate flexibility for field bending.

2.0 EQUIPMENT
Hydraulic Press
Bending Mandrels of Fixed Radii
Freezer
Microscope

3.0 TEST SPECIMEN

3.1 QUALIFICATION SPECIMEN

Each test specimen shall be 1 in. [25 mm] x 8 in, [200 mm] x 0.25 in. [6 mm] thick. The specimen
shall be prepared and coated in accordance with manufacturer recommendations and the
procedure to be used on the project.

3.2 TEST RING SPECIMEN

Each specimen shall be 1 in. [25 mm] x 8 in. [200mm] x pipe wall thickness, with the 8 in. [200
mm] dimension parallel to the axis of the pipe.

4.0 PROCEDURE

4.1 Ensure the test specimen edges have all stress raisers removed. Place the test specimens into
the freezer and cool them to 32 °F [0°C] and hold for one hour.
4.2 Calculate the required mandrel radius with the following formula:

R = mandrel radius
t = substrate thickness (see diagram)
s = strain (deflection) in degrees per pipe
diameter length (°/PD)

4.3 Where a mandrel of the calculated radius is not available, the mandrel of next smaller radius
shall be used.

Page 41 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

4.4 Bend the test specimens over the radius with the coating on the outside of the bend. Complete
the bend within 30 seconds of removal from the conditioning chamber/freezer and bend the sample
in approximately 10 seconds.

4.5 Visually inspect the specimens under 40 power magnifications for cracking and disbonding
after the specimens have warmed to room temperature.

5.0 REPORT

5.1 Specimen thickness, mandrel radius, and deflection:

5.2 Whether the specimen has any crack, fissure, or delamination of the coating; the presence of any
such defect within 0.1 in. [2.5 mm] of the strap edge does not constitute failure.

Page 42 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

APPENDIX B.6 HOT WATER TEST

A coated sample of 200 mm x 100 mm machined from a ring of the coated pipe shall be immersed in
tap water at the test temperature specified in Table 6. For qualification testing the exposure time shall
be 90 days and for quality control it shall be 48 hours.

The bare edges of the sample shall be coated to prevent ingress of moisture beneath the coating.

Immediately after the exposure, the coated sample shall be removed from the water bath and allowed
to cool to ambient temperature. The coating shall then be examined visually and the pull off adhesion
shall be tested. The coating shall show no blistering and no disbondment. Pull off adhesion strength
conducted as per ASTM D4541 shall be more than 17 MPa with less than 10% adhesive failure to
substrate.

Page 43 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

APPENDIX B.7 Resistance to gas pressure variations

1.0 Scope
The test consists of verifying, by evaluation of visual appearance and determination of the
adhesion, the behavior of the applied coating after it has been subjected to pressure variations in a
gaseous environment (N2).

2.0 Apparatus and materials

2.1 Sealed chamber, capable of resisting the test pressures during the whole of the test.
2.2 Nitrogen, as pressurizing gas.
2.3 Pressurizing system, capable of increasing the pressure by 1 bar per minute.

3.0 Test specimens

Substrates can be of two types:
 Approximately 100mmx 50mmx 1mm steel panels
 Length of steel pipe approximately 100mm long with a diameter small enough to fit into the
test chamber or, if the diameter is too large for the pipe to fit into the chamber, specimens
cut from the pipe or fitting.
 The surfaces of the test panels or lengths of pipe shall be prepared and coated at the
same time and in the same way as the corresponding production surfaces

4.0 Procedure
4.1 General
Unless otherwise specified by the coating material manufacturer, wait a month after the coating
has been applied to the test panels or lengths of pipe before carrying out any tests.

4.2 Cyclic pressure test

This test is carried out only as a qualification test on the inside coating.
Put the specimen in the chamber and subject it to the set of 10 test cycles shown schematically in
Figure C.1, as Follows:
— Progressively increase the pressure in the chamber to 100bar
— keep the specimen under pressure for a fixed period of time to allow the pressurizing gas to
penetrate into the Coating:
• 20 h for the 1st to 4th cycles and the 6th to 9th cycles,
• 68 h for the 5th and 10th cycles;
• release the pressure rapidly over a few minutes (not more than 5 minutes);

Page 44 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

• leave the coating at atmospheric pressure for to permit the development of any blisters on the
coating, so that a cycle lasts either 24 h or 72 h (this latter period corresponds to the weekend, i.e.
from Friday to Monday).

Immediately at the end of the 10th test cycle, open the chamber and examine the appearance of
the coating, noting all modifications (corrosion, spots or blisters). In addition, carry out an adhesion
test in accordance with section 4.2.2.6
Repeat the appearance examination after 24h and after 48h, noting all modifications.

5 Results
Record any degradation observed immediately on removing the specimen from the chamber and
indicates any further changes after 24 h and 48 h.
Record the adhesion of the coating measured in the adhesion test.

Page 45 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

Appendix C.1 User Comment Form

User Comment Form

If you find something that is incorrect, ambiguous or could be better in this Procedure, write your
comments and suggestions on this form. Send the form to the Document Control Section (DCS).
They make a record of your comment and send the form to the correct CFDH. The form has spaces
for your personal details. This lets DCS or the CFDH ask you about your comments and tell you
about the decision.
Procedure Details Title: Issue Date:

Number:

Page Number: Heading Number: Figure Number:

Comments:

Suggestions:

User’s personal details

Name: Ref. Signature: Date:

Ind.:

Phone:
Document Control Section Actions
Comment Date: CFDH

Page 46 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

Number: Ref. Ind.:

Recd.: To CFDH:
CFDH Actions

recd. Decision: Inits.: Ref. Date:

Date: Reject:  Ind.

Accept, revise at next issue: 

Accept, issue temporary amendment
Comments:

Originator Date: Inits.: Document Date: Inits.:

Advised: Control

Advised.

Page 47 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

Appendix-D - Glossary of Definitions, Terms and Abbreviations

Definitions

Company The term Company shall refer to Petroleum Development Oman L.L.C.

Contractor The party which carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project,
or operation or maintenance of a facility.

Inspection and Test PlanThe term Inspection and Test Plan (ITP) is used to identify activities
that are to be controlled, the controlling specification and the control
mechanisms.
Manufacturer /supplier is the party which manufactures or supplies pipeline coatings to perform
the duties as specified by the company.

Approved laboratories are the parties which carry out all of the tests as stipulated in Appendix
A.2.0 of this document
Third party agency (TPA) is the party which may be assigned by the company to oversee
implementation of the test programmer in accordance with this document
and to certify completion of the testing. This includes coating inspectors
Applicator is the party that applies the coating to the line pipe or piping spools in its
coating plant.

Shall The word 'shall' used throughout this specification indicates a Contract
requirement.

Should The word 'should' used throughout this specification indicates a

recommendation.

User The Company or Supplier who uses this Specification.

CFDH Corporate Functional Discipline Head

TA Technical Authority

NACE National Association of Corrosion Engineers

ISO International Organization for Standardization.

ASTM American Society for Testing Materials

TPA Third Party Inspection Agency

VOC Volatile Organic Compounds

PVC Pigment Volume Concentration

pv Volume Resistivity

DIN Deutsches Institut Fur Normung

Page 48 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

Appendix-E – References
In this specification, reference is made to the following publications. Unless specifically
designated by date, the latest edition of each publication shall be used together with any
amendments
PDO Specifications and Procedures
Specification for painting and coating of Oil and Gas production SP1246
facilities.

Shell
Specification
s
Protective Coatings For Onshore Facilities. DEP 30.48.00.31-Gen

International
Standards
ASTM A 36 Specification for Structural Steel

ASTM D 870 Standard Practice for Testing Water Resistance of Coatings Using Water
Immersion

ASTM D 1653 Standard Test Method for Water Vapour Permeability of Organic Coating Films

ASTM G 6 Standard Test Method for Abrasion Resistance of Pipeline Coatings

ASTM G 14 Standard Test Method for Impact Resistance of Pipeline Coatings (falling
weight test)

ASTM G 17 Standard Test Method for Penetration Resistance of Pipeline Coatings (Blunt
Rod)

ASTM G 42 Standard Test Method for Cathodic Disbonding of Pipeline Coatings Subjected
to Elevated Temperatures

ASTM E1356–08 Standard Test Method for Assignment of the Glass Transition
Temperatures by Differential Scanning Calorimetry

ASTM E228 Standard Test Method for Linear Thermal Expansion of Solid Materials
With a Push-Rod Dilatometer
ASTM 4541-02 Standard Test Method for Pull-Off Strength of Coatings Using Portable
Adhesion Testers
DIN 50907 Cycling Salt Spray/Dry Corrosion Test

ISO 4624 Paints and Varnishes Pull-off test

Page 49 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.
 Revision: approved
Petroleum Development Oman LLC Effective: Sep-09

This page was intentionally left blank

Page 50 Internal Liquid Coating Systems for Carbon Steel Piping and Line pipes Printed 01/09/09
The controlled version of this CMF Document resides online in Livelink®. Printed copies are UNCONTROLLED.