Concrete Weight Coating
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PETRONAS CARIGALI SDN BHD
PROVISION OF FRONT END ENGINEERING DESIGN (FEED) AND ENGINEERING, PROCUREMENT, CONSTRUCTION, INSTALLATION & COMMISSIONING (EPCIC) OF SK316 DEVELOPMENT PROJECT
(CONTRACT NO. CHO/2012/D316/1000) TABLE OF CONTENT 1
PROJECT INTRODUCTION ............................................................................................................ 5
1.1
SCOPE OF DOCUMENT ....................................................................................................................... 7
1.2
DEFINITION ......................................................................................................................................... 7
1.3
ABBREVIATION ................................................................................................................................... 7
2
REFERENCES ................................................................................................................................ 8
2.1
PROJECT DOCUMENTS ....................................................................................................................... 8
2.2
COMPANY STANDARDS ...................................................................................................................... 8
2.3
CODES AND STANDARDS .................................................................................................................... 8
2.4
SYSTEM OF UNITS ............................................................................................................................... 9
3
GENERAL REQUIREMENTS ......................................................................................................... 10
4
CONCRETE COATING MATERIALS .............................................................................................. 11
4.1
CEMENT ............................................................................................................................................ 11
4.2
AGGREGATES .................................................................................................................................... 11
4.3
WATER .............................................................................................................................................. 12
4.4
ADDITIVES ......................................................................................................................................... 12
4.5
REINFORCING STEEL ......................................................................................................................... 12
4.6
WELDED STEEL WIRE MESH.............................................................................................................. 13
4.7
STEEL CAGE TYPE .............................................................................................................................. 13
5
RECEIPT, HANDLING AND STORAGE OF BARE PIPES ................................................................... 14
6
CONCRETE COATING APPLICATION ........................................................................................... 15
6.1
VISUAL AND HOLIDAY INSPECTION OF 3‐LAYER PE COATED PIPES ................................................. 15
6.2
PLACEMENT OF REINFORCEMENT STEEL ......................................................................................... 15
7
APPLICATION OF COATING MATERIALS ..................................................................................... 16
7.1
PREPARATION OF THE CUTBACK AREA ............................................................................................ 16
7.2
FINISHING OPERATIONS WITHIN CONCRETE COATING PLANT ........................................................ 16
7.3
CURING ............................................................................................................................................. 17
7.3.1
WATER CURING ............................................................................................................................... 17
7.3.2
STEAM CURING ................................................................................................................................ 18
7.3.3
CURING BY SEALING COMPOUNDS ................................................................................................. 18
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PETRONAS CARIGALI SDN BHD
PROVISION OF FRONT END ENGINEERING DESIGN (FEED) AND ENGINEERING, PROCUREMENT, CONSTRUCTION, INSTALLATION & COMMISSIONING (EPCIC) OF SK316 DEVELOPMENT PROJECT
(CONTRACT NO. CHO/2012/D316/1000) 7.3.4
CURING UNDER POLYETHYLENE WRAPPING ................................................................................... 18
7.3.5
FOG CURING .................................................................................................................................... 19
8
INSPECTION AND TESTING ........................................................................................................ 20
8.1
STACKING OF 3‐LAYER PE COATED PIPES ......................................................................................... 21
8.2
CONTROL, IDENTIFICATION AND SEGREGATION OF 3‐LAYER PE COATED PIPES ............................. 22
8.3
DELIVERY AND STORAGE OF CONCRETE COATING RAW MATERIALS .............................................. 22
8.4
TEST TO BE PERFORMED ON CONCRETE COATING MATERIAL UPON RECEIPT ............................... 23
8.4.1
SIEVE ANALYSIS AND CLEANLINESS CONTROL OF AGGREGATES .................................................... 23
8.4.2
STEEL REINFORCEMENT WIRES DIMENSIONAL CONTROL .............................................................. 23
8.4.3
MIXING WATER CHEMICAL ANALYSIS ............................................................................................. 23
8.5
VERIFICATION OF CALIBRATION OF THE TEST INSTRUMENTS ......................................................... 24
8.5.1
HOLIDAY DETECTOR ........................................................................................................................ 24
8.5.2
PIPE WEIGHING SCALES ................................................................................................................... 24
8.6
VISUAL AND HOLIDAY INSPECTION OF THE 3‐LAYER PE COATED PIPES .......................................... 24
8.7
CONCRETE COATING MIX CONTROL ................................................................................................ 25
8.8
CONCRETE COATING MIX TEMPERATURE MEASUREMENT ............................................................. 25
8.9
WATER‐CEMENT RATIO CHECK ........................................................................................................ 25
8.10
REINFORCING WIRE POSITION CONTROL ......................................................................................... 26
8.11
CONCRETE COATING APPLICATION CONTROL ................................................................................. 26
8.12
MEASUREMENT OF EXTERNAL DIAMETER OF APPLIED CONCRETE ................................................. 26
8.13
CUTBACK CONTROL .......................................................................................................................... 27
8.14
WEIGHING OF FRESHLY CONCRETE COATED PIPE............................................................................ 27
8.15
CALCULATION OF NEGATIVE BUOYANCY ......................................................................................... 27
8.16
VISUAL INSPECTION OF APPLIED CONCRETE .................................................................................... 28
8.16.1
SURFACE FALL‐OUTS (SPALLING) OF FRESHLY CONCRETE COATED PIPES ...................................... 29
8.16.2
CONCRETE COATING DAMAGES ON FRESH AND HARDENED CONCRETE ....................................... 29
8.16.3
CRACKS ............................................................................................................................................ 29
8.17
ELECTRICAL RESISTANCE BETWEEN STEEL REINFORCEMENT AND THE PIPE ................................... 30
8.18
CONTROL OF CURING PROCESS ....................................................................................................... 30
8.19
CONTROL OF STACKING OF PIPES DURING THE CURING PROCESS .................................................. 30
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PETRONAS CARIGALI SDN BHD
PROVISION OF FRONT END ENGINEERING DESIGN (FEED) AND ENGINEERING, PROCUREMENT, CONSTRUCTION, INSTALLATION & COMMISSIONING (EPCIC) OF SK316 DEVELOPMENT PROJECT
(CONTRACT NO. CHO/2012/D316/1000) 8.20
CONTROL OF MARKING ON CONCRETE COATED PIPES ................................................................... 30
8.21
CONTROL OF MARKING ON CONCRETE COATING REPAIR ............................................................... 31
8.22
DETERMINATION OF FACTOR ALPHA IN THE FORMULA FOR CALCULATION OF NEGATIVE BUOYANCY ....................................................................................................................................... 31
8.23
COMPRESSION STRENGTH TEST CUBES ........................................................................................... 31
8.24
COMPRESSION STRENGTH CORE SAMPLES ...................................................................................... 32
8.25
DETERMINATION OF THE TIME FOR STACKING OF PIPES IN MORE THAN ONE LAYER ................... 33
8.26
WATER ABSORBTION TEST ............................................................................................................... 34
8.27
ADHESION BETWEEN THE 3‐LAYER PE COATING AND CONCRETE COATING ................................... 34
8.28
IMPACT TESTING .............................................................................................................................. 35
8.29
STACKING OF CURED CONCRETE COATED PIPES.............................................................................. 36
8.30
LOAD OUT INSPECTIONS .................................................................................................................. 37
9
3‐LAYER PE COATING REPAIR .................................................................................................... 38
10
CONCRETE COATING REPAIR AND STRIPPING OF CONCRETE COATED PIPES .............................. 40
11
PIPE MARKING .......................................................................................................................... 42
12
STORAGE, HANDLING AND TRANSPORTATION OF CONCRETE COATED PIPES ............................ 43
13
DOCUMENTATION .................................................................................................................... 45
13.1
GENERAL REQUIREMENTS ................................................................................................................ 45
13.2
TECHNICAL DOCUMENTATION TO BE SUBMITTED DURING THE BIDDING PHASE .......................... 45
13.3
TECHNICAL DOCUMENTS TO BE SUBMITTED AFTER AWARD OF THE CONTRACT TO SUBCONTRACTOR ............................................................................................................................ 46
13.4
FINAL TECHNICAL DOCUMENTATION .............................................................................................. 47
13.5
CONTENT OF PARTICULAR TECHNICAL DOCUMENTS ...................................................................... 48
13.5.1
CONCRETE COATING APPLICATION PROCEDURE ............................................................................ 48
13.5.2
INSPECTION AND TEST PLAN ........................................................................................................... 49
13.5.3
DAILY PRODUCTION REPORT ........................................................................................................... 49
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PETRONAS CARIGALI SDN BHD
PROVISION OF FRONT END ENGINEERING DESIGN (FEED) AND ENGINEERING, PROCUREMENT, CONSTRUCTION, INSTALLATION & COMMISSIONING (EPCIC) OF SK316 DEVELOPMENT PROJECT
(CONTRACT NO. CHO/2012/D316/1000)
1
PROJECT INTRODUCTION
NC3 and NC8 are gas fields located in Block SK 316, approximately 180km North of Bintulu, Sarawak with water depth ranging approx. between 70m – 105m. NC8 field is located approximately 7km South East on NC3 field. The nearby riser facility E11RC is located approximately 80 km South West of NC3. The existing trunk line connecting E11RC to shore TL 6 is available and provisioned for in this gas field development. The locations of NC3, NC8 and nearby facilities are illustrated in Figure 1‐1 below.
Figure 1‐1 Location of Project Gas from NC3 and NC8 fields are the main feed gas supplier into the PETRONAS LNG Complex Train 9 near Bintulu which is expected to be ready for start‐up in December 2015.The scope demarcation between upstream and downstream facilities is as described below in Figure 1‐2.
Figure 1‐2 Upstream and Downstream Scope Demarcation
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PETRONAS CARIGALI SDN BHD
PROVISION OF FRONT END ENGINEERING DESIGN (FEED) AND ENGINEERING, PROCUREMENT, CONSTRUCTION, INSTALLATION & COMMISSIONING (EPCIC) OF SK316 DEVELOPMENT PROJECT
(CONTRACT NO. CHO/2012/D316/1000) The development of NC3 and NC8 fields is envisaged to be in complex‐type configuration. NC3 will become a hub comprising of a Central Processing Platform (CPP) with living quarters and a bridge‐linked Wellhead Platform (WHP). Another WHP is to be installed at NC8; it will be tied‐back to NC3 via an inter‐field subsea pipeline. Though compression may not be required at the beginning of production, the need for gas compression is anticipated after approximately four (4) years. Hence the provision for future compression facilities and mercury removal facilities shall be considered as part of this FEED work for the NC3 CPP.
Figure 1‐3 Overall Development Concept A new subsea pipeline connecting NC3 and E11RC will be installed to deliver the processed gas and the spiked dehydrated condensate. Due to incompatibility of this gas quality with the existing gas supply at the riser, a dedicated manifold at E11RC may be required to accommodate this tie‐in. This is to ensure that the gas from NC3 and NC8 fields do not contaminate the entire network to shore. As such, modification will be required to convert the existing TL 6 to be dedicated for gas from NC3 and NC8. The future trunk line (TL 7) may be required in the future should TL 6 no longer be fit for service. The processed gas and dehydrated condensate will be separated at onshore receiving facilities prior to being introduced into LNG Plant Train 9.
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PETRONAS CARIGALI SDN BHD
PROVISION OF FRONT END ENGINEERING DESIGN (FEED) AND ENGINEERING, PROCUREMENT, CONSTRUCTION, INSTALLATION & COMMISSIONING (EPCIC) OF SK316 DEVELOPMENT PROJECT
(CONTRACT NO. CHO/2012/D316/1000)
1.1 SCOPE OF DOCUMENT The purpose of this document is to define the minimum requirements for concrete weight coating to be used for the following offshore rigid pipeline in the SK316 Development Project: 32” Offshore pipeline from NC3 WHP to E11RC Platform 32” Offshore pipeline from E11RC Platform to Onshore Beach Valve Location 20” Offshore pipeline from NC8 WHP to NC3 WHP (Diameter to be confirmed) 1.2 DEFINITION COMPANY
PETRONAS Carigali Sdn Bhd
CONTRACTOR
SAIPEM
SUBCONTRACTOR
Party selected by COMPANY/CONTRACTOR responsible for application of the concrete weight coating on PROJECT pipes in accordance with this specification and other contractual documents
MANUFACTURER
Supplier of the raw materials or inspection and testing equipment required to perform the work
PROJECT
FEED for SK316 Facilities ‐ Development of the NC3 and NC8 Gas Fields
1.3
ABBREVIATION
FBE
Fusion Bonded Epoxy
N/A
Not Applicable
No.
Number
OD
Outside diameter (external pipe diameter)
PQT
Pre‐Qualification Test
3LPE
3‐Layer Polyethylene
3LPP
3‐Layer Polypropylene
CWC
Concrete Weight Coating
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PETRONAS CARIGALI SDN BHD
PROVISION OF FRONT END ENGINEERING DESIGN (FEED) AND ENGINEERING, PROCUREMENT, CONSTRUCTION, INSTALLATION & COMMISSIONING (EPCIC) OF SK316 DEVELOPMENT PROJECT
(CONTRACT NO. CHO/2012/D316/1000)
2
REFERENCES
Unless otherwise stated, the latest issue of the below listed PTS COMPANY Specifications, Codes, Standards and Regulations shall apply. Equivalent alternatives may be offered; these shall be identified and mutually agreed on. 2.1
PROJECT DOCUMENTS
DOCUMENT
NAME
/1/ 05‐SSPL‐BOD‐U‐0001
Pipeline And Riser Design Basis
/2/ TBC
Input for Pipeline Study
/3/ 05‐GEN‐BOD‐B‐0001
Process Design Basis
/4/ 05‐SSPL‐REP‐U‐0001
Steady State Pipeline Simulation Report
/5/ 05‐GEN‐BOD‐Z‐0002
Corrosion Study Memorandum
/6/ 05‐SSPL‐REP‐U‐0002
Pipeline Transient Analysis Report
/7/ 05‐SSPL‐REP‐U‐0003
Pipeline Route Selection Report
2.2
COMPANY STANDARDS
DOCUMENT
NAME
/8/ 31.40.00.20
Pipeline & Riser Engineering
/9/ 31.40.30.30
Concrete coating of linepipe
2.3
CODES AND STANDARDS
DOCUMENT
NAME
/10/ ISO 21809‐1
Petroleum and Natural Gas Industries ‐ External Coatings for Buried or Submerged Pipelines Used in Pipeline Transportation Systems ‐ Part 1: Polyolefin Coatings (3‐Layer PE and 3‐Layer PP).
/11/ BS EN 10288
Steel Tubes and Fittings for Onshore and Offshore Pipelines ‐ External Two Layer Extruded Polyethylene Based Coatings
/12/ ASTM C 150
Standard Specification for Portland cement
/13/ ASTM C 33
Standard Specification for Concrete Aggregates
/14/ ASTM A 810‐01
Standard Specification for Zinc‐Coated (Galvanized) Steel Pipe Winding Mesh
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PETRONAS CARIGALI SDN BHD
PROVISION OF FRONT END ENGINEERING DESIGN (FEED) AND ENGINEERING, PROCUREMENT, CONSTRUCTION, INSTALLATION & COMMISSIONING (EPCIC) OF SK316 DEVELOPMENT PROJECT
(CONTRACT NO. CHO/2012/D316/1000)
/15/ ASTM A 615 M
Standard Specification for Deformed and Plain Carbon Steel Bars for Concrete Reinforcement
/16/ ASTM 185‐01
Standard Specification for Steel Welded Wire Reinforcement, Plain, for Concrete
/17/ ASTM A 82‐01
Standard Specification for Steel Wire, Plain, for Concrete Reinforcement
/18/ ASTM C 309‐98 A
Standard Specification for Liquid Membrane‐ Forming Compounds for Curing Concrete
/19/ ASTM C 171
Standard Specification for Sheet Materials for Curing Concrete
/20/ ASTM C 39/C39 M‐01
Standard Test Method for Compressive Strength of Cylindrical Concrete Specimens
/21/ ASTM C 617‐98
Standard Practice for Capping Cylindrical Concrete Specimens
/22/ BS EN 197‐1
Cement ‐ Part 1: Composition, Specifications and Conformity Criteria for Common Cements
/23/ BS EN 1008
Mixing Water for Concrete ‐ Specification for Sampling, Testing and Assessing the Suitability of Water, Including Water Recovered from Processes in the Concrete Industry, as Mixing Water for Concrete
/24/ BS 4482
Cold Reduced Steel Wire for the Reinforcement of Concrete Products‐ Specification
/25/ BS 4483
Steel Fabric for the Reinforcement of Concrete ‐ Specification
/26/ BS EN 12390‐2
Testing Hardened Concrete ‐ Part 2: Making and Curing Specimens for Strength Tests
/27/ BS EN 12390‐3
Testing Hardened Concrete ‐ Part 3: Compressive Strength of test Specimens
2.4
SYSTEM OF UNITS
The International Unit System (SI) shall be utilized throughout the project, unless otherwise highlighted. Any conversion shall be provided in parenthesis where applicable.
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PETRONAS CARIGALI SDN BHD
PROVISION OF FRONT END ENGINEERING DESIGN (FEED) AND ENGINEERING, PROCUREMENT, CONSTRUCTION, INSTALLATION & COMMISSIONING (EPCIC) OF SK316 DEVELOPMENT PROJECT
(CONTRACT NO. CHO/2012/D316/1000)
3
GENERAL REQUIREMENTS
For testing purposes specified in this Specification, the production shift shall be considered of maximum 12 hours depending on the SUBCONTRACTOR’s internal organization. In case SUBCONTRACTOR intends to work more than 12 hours per day, COMPANY/CONTRACTOR shall consider that the work is performed in more than one shift and the relevant testing frequency shall be respected as per this Specification. All SUBCONTRACTOR’s documents shall comply with the limitations of this Specification. SUBCONTRACTOR shall promptly inform COMPANY/CONTRACTOR of any need to make changes to these documents, which shall have to be specifically accepted by COMPANY, who has the right to require additional testing without additional costs. Any technical deviations to this Specification shall be obtained by SUBCONTRACTOR only through a concession request format. In any case it is not allowed to insert any deviation from this Specification in any SUBCONTRACTOR’s document prior that this deviation has not been previously presented separately to COMPANY/CONTRACTOR and approved in written by COMPANY/CONTRACTOR. Concession requests require COMPANY’s review and approval prior to implementation of the proposed changes. Pipes coated by implementing the technical changes prior to the COMPANY’s approval shall be rejected. Prior to the commencement of the production and during the production, COMPANY shall reserve the right to perform audits in the SUBCONTRACTOR’s facilities. COMPANY and COMPANY’s representatives shall be permitted by SUBCONTRACTOR the unlimited access to all SUBCONTRACTOR’s facilities related to the SUBCONTRACTOR’s scope of work for the PROJECT starting from the moment the work has been awarded to SUBCONTRACTOR until SUBCONTRACTOR has completed all of the obligations related to his scope of work in the PROJECT. It is mandatory requirement for SUBCONTRACTOR’s coating facilities that all of the inspection activities according to the action points specified in inspection and test plans can be performed by inspectors from all involved Parties in safe manner for all personnel involved in these activities. In case the inspection activities cannot be safely performed for all persons involved in inspection (CONTRACTOR, SUBCONTRACTOR’s, COMPANY’s and Third Party’s personnel), SUBCONTRACTOR shall stop all of the activities at that particular inspection point and shall organize the work space in a manner that all activities can be performed in safe manner. All costs due to such stoppages shall be borne only by SUBCONTRACTOR.
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PETRONAS CARIGALI SDN BHD
PROVISION OF FRONT END ENGINEERING DESIGN (FEED) AND ENGINEERING, PROCUREMENT, CONSTRUCTION, INSTALLATION & COMMISSIONING (EPCIC) OF SK316 DEVELOPMENT PROJECT
(CONTRACT NO. CHO/2012/D316/1000)
4
CONCRETE COATING MATERIALS
The concrete coating applied on line pipes shall have the following nominal dry and cured concrete density of 3044 kg/m3. 4.1 CEMENT Unless otherwise specified in the Purchase Order, all cement used for the preparation of the concrete shall be “Portland Cement” conforming to the requirements of one of the following standards depending on the availability at the location where the concrete coating application shall be carried out:
ASTM C 150 Type II and V;
MS 522 standard;
BS EN 197‐1 standard.
All batches of cement shall be supplied to SUBCONTRACTOR with test certificate stating the compliance either with the ASTM C 150 (Type II and V) or BS 12 or EN 197‐1 standard which shall then SUBCONTRACTOR submit to COMPANY for review prior to its use. The certificates must be presented to COMPANY’s review to verify that also the following mandatory requirements are met:
that the content of alkali is
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