BREDERO PIPELINE SERVICES LIMITED

BNCL

CLIENT:
PROJECT:

SHELL PETROLEUM DEVELOPMENT COMPANY LTD

TBA
QUALITY PROCEDURE
THREE LAYER COATING FINAL INSPECTION IN PLANT

Clause
1
1.1
2

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QP073
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12 April 13
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Description

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SCOPE
This document describes the procedure to be followed during the final in-plant inspection
of applied polyethylene coating. Adherence to this procedure by the relevant personnel is
mandatory.
REFERENCES

2.1

DEP 31.40.30.31-GEN February 2011

2.2

ISO 21809-1 : 2009

RESPONSIBILITIES

3.1

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

3.2

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

3.3

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

3.4

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

PROCESS DESCRIPTION

4.1

FINAL INSPECTION RACK

4.1.1

Pipes are kicked off the coating conveyor and on to the inspection racks. These racks
are lined with rubber or plastic to prevent damage to the applied coating. An hydraulic
ram moves the pipes along the rack to a set of rotation wheels.

4.1.2

These wheels lift the pipe such that it can be freely rotated for inspection. At this stage,
the coupling is removed from the lead end of the pipe and a flow of cooling water
directed up the bore as the pipe rotates.

4.1.3

A visual inspection is made of every pipe, and the coating thickness is measured and
recorded. The pipes unique identity is confirmed and recorded. The pipe is lowered and
passed to the end brushing station.

4.1.4

After brushing, the pipe remains in the same station for electrical holiday inspection. A
detection wand comprising either a phosphor-bronze brush or carbon-impregnated
rubber and forming an arc of 180 degrees is connected to a holiday detector fitted with
an audible warning device. After one pass, the pipe is rotated half a turn and the second
half of the surface is inspected in the same way.

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

BREDERO PIPELINE SERVICES LIMITED

BNCL

CLIENT:
PROJECT:

SHELL PETROLEUM DEVELOPMENT COMPANY LTD

TBA
QUALITY PROCEDURE
THREE LAYER COATING FINAL INSPECTION IN PLANT

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

QP073
00
th
12 April 13
2 of 3

Clause

Description

4.1.5

Power wire brushes remove coating material from the bevel ends and cutback areas of
each pipe as it rotates on a fixed set of wheels. The brushing mechanism has an
adjustable end-stop fitted such that the correct cutback dimension is formed
automatically. Where pipes have been rejected from the previous station, end brushing
will not normally be performed.

4.1.6

Any pipe noted as having defects which cannot be rectified in the plant will be clearly
marked in accordance with the provisions of Clause 5.4 of procedure QP001.

5
5.1

Revision

QUALITY REQUIREMENTS
VISUAL INSPECTION
100% visual inspection on each pipe. Any repairs which can be made inline will be made
in accordance with the requirements of procedure QP075. Any other repairs will be
clearly marked with yellow tape and an NCR raised.
Acceptance Criteria: Coating free from breaks, blisters, pinholes or other irregularities.

5.2

COATING THICKNESS
Six thickness readings to be taken 90 degrees apart with one on the weld seam
(if available) at each of three locations along the pipe length approximately one metre
from each end and at the midpoint of the pipe length using a calibrated elcometer
thickness gauge. Record for every pipe.
Acceptance Criteria: Minimum thickness over body of pipe as per ITP07.

5.3

COATING CUTBACK
Check each end of every pipe using a steel rule or a purpose made jig.
Acceptance Criteria: Cutback 150 +/- 20mm

5.4

HOLIDAY DETECTION (ELECTRICAL INSPECTION)

100% coverage of each pipe using a fixed holiday detector set at 5kV/mm of thickness or
a maximum of 25kV.
Acceptance Criteria: No holidays.

5.5

FBE PRIMER AND ADHESIVE THICKNESSES

At the start of each shift, and following any break in production, the first part of the first
coated pipe will be coated with FBE only, followed by a short length with FBE and
adhesive only. The thickness of the FBE will be measured using a calibrated elcometer
thickness gauge, and a further reading taken over the combined FBE and adhesive
layers.

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

BREDERO PIPELINE SERVICES LIMITED

BNCL

CLIENT:
PROJECT:

SHELL PETROLEUM DEVELOPMENT COMPANY LTD

TBA
QUALITY PROCEDURE
THREE LAYER COATING FINAL INSPECTION IN PLANT

Clause

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

QP073
00
th
12 April 13
3 of 3

Description

Revision

Acceptance Criteria: FBE thickness 500 microns minimum. Adhesive thickness 500
microns minimum.
5.6

PIPE IDENTIFICATION
The pipe unique numbers will be recorded in sequence during production. Any pipe
which cannot be identified will be placed in quarantine pending further investigation and
may not be processed further until identified. To aid tracking, the coating date, shift and
sequence number may be marked on the pipe bore using paint crayon.
Acceptance Criteria: All pipes uniquely identified. NCR raised to cover any
unidentifiable pipes.

5.7

PERIODIC PRODUCTION TESTS

Impact and adhesion testing is covered by procedure QP074.

6
6.1

CALIBRATION
THICKNESS GAUGE
Thickness gauges will be calibrated at the start of each morning and afternoon shift, or in
the case of continuous production not less than twice per ten hours. Calibration is
performed by means of a certified test shim close to the nominal coating thickness of
2.7mm placed over the surface of a blast cleaned pipe.

6.2

HOLIDAY DETECTOR
The holiday detection equipment will be checked at the start of each morning and
afternoon shift, or in the case of continuous production not less than twice per ten hours.
A high tension voltmeter will be used to verify that the set voltage is correct.

DOCUMENTATION
The following documents will be completed as required:

7.1

QF012 Coating Thickness Inspection Report

7.2

QF046 Coating Repair Inspection Report

7.3

RF002 Nonconformance Report

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