petrobras n-2911

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N-2911 ENGLISH 12 / 2010

PROPERTY OF PETROBRAS 30 pages and WG

Inspection and Repair of External Anticorrosive Pipe Coatings During

Construction and Installation of Onshore Pipelines

Procedure

This Standard replaces and cancels its previous revision.

The CONTEC - Authoring Subcommittee provides guidance on the interpretation of this Standard when questions arise regarding its contents. The Department of PETROBRAS that uses this Standard is responsible for adopting and applying the sections, subsections and enumerates thereof.

CONTEC Comissão de Normalização

Técnica

Technical Requirement: A provision established as the most adequate and which shall be used strictly in accordance with this Standard. If a decision is taken not to follow the requirement (“non-conformity” to this Standard) it shall be based on well-founded economic and management reasons, and be approved and registered by the Department of PETROBRAS that uses this Standard. It is characterized by imperative nature.

Recommended Practice: A provision that may be adopted under the conditions of this Standard, but which admits (and draws attention to) the possibility of there being a more adequate alternative (not written in this Standard) to the particular application. The alternative adopted shall be approved and registered by the Department of PETROBRAS that uses this Standard. It is characterized by verbs of a nonmandatory nature. It is indicated by the expression: [Recommended Practice].

SC - 14

Copies of the registered “non-conformities” to this Standard that may contribute to the improvement thereof shall be submitted to the CONTEC - Authoring Subcommittee.

Proposed revisions to this Standard shall be submitted to the CONTEC - Authoring Subcommittee, indicating the alphanumeric identification and revision of the Standard, the section, subsection and enumerate to be revised, the proposed text, and technical/economic justification for revision. The proposals are evaluated during the work for alteration of this Standard.

Painting and Anticorrosive Coatings

“The present Standard is the exclusive property of PETRÓLEO BRASILEIRO S.A. - PETROBRAS, for internal use in the Company, and any reproduction for external use or disclosure, without previous and express authorization from the owner, will imply an unlawful act pursuant to the relevant legislation through which the applicable responsibilities shall be imputed. External circulation shall be regulated by a specific clause of Secrecy and Confidentiality pursuant to the terms of intellectual and industrial property law.”

Introduction

PETROBRAS Technical Standards are prepared by Working Groups - WG

(consisting specialized of Technical Collaborators from Company and its Subsidiaries), are

commented by Company Units and its Subsidiaries, are approved by the Authoring Subcommittees -

SCs (consisting of technicians from the same specialty, representing the various Company Units and

its Subsidiaries), and ratified by the Executive Nucleus (consisting of representatives of the Company

Units and its Subsidiaries). A PETROBRAS Technical Standard is subject to revision at any time by its

Authoring Subcommittee and shall be reviewed every 5 years to be revalidated, revised or cancelled.

PETROBRAS Technical Standards are prepared in accordance with PETROBRAS Technical

Standard N-1. For complete information about PETROBRAS Technical Standards see PETROBRAS

Technical Standards Catalog.

../link.asp?cod=N-0001

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Summary

1 Scope................................................................................................................................................... 4

2 Normative References......................................................................................................................... 4

3 Terms and Definitions.......................................................................................................................... 6

4 General Conditions.............................................................................................................................. 7

5 Inspection ............................................................................................................................................ 8

5.1 Receiving Inspection at the Warehouse of the Job Site ........................................................ 8

5.2 Inspection During Pipeline Assembly..................................................................................... 9

6 Technical Characteristics of Repair Materials ................................................................................... 10

6.1 Repairs on 3LPE Coating..................................................................................................... 10

6.1.1 Three-Layer Polyethylene Coating (3LPE) .................................................................. 10

6.1.2 Elastomeric Filler Mastic System Combined with Polyethylene Laminate (Patch)...... 10

6.1.3 Heat-Shrinkable Sleeves ............................................................................................. 12

6.2 Repairs on 3LPP Coating..................................................................................................... 12

6.2.1 Three-Layer Polypropylene Coating (3LPP)................................................................ 12

6.2.2 Polypropylene Filler Adhesive Combined with Polypropylene Laminate (Patch) ........ 12

6.2.3 Heat-Shrinkable Sleeves ............................................................................................. 14

6.3 Repair on FBE Coating ........................................................................................................ 14

7 Receiving, Storage, Handling and Transportation of Repair Materials ............................................. 16

7.1 Receiving.............................................................................................................................. 16

7.2 Storage................................................................................................................................. 16

7.3 Handling and Transportation................................................................................................ 16

8 Classification of Damages and Selection Guide for Repair of Pipes Coated with 3LPE e 3LPP ..... 17

9 Classification of Damages and Selection Guide for Repair with Liquid Epoxy of FBE-Coated Pipes20

10 Repair Application ........................................................................................................................... 21

10.1 Environmental Conditions .................................................................................................. 21

10.2 General Application Conditions........................................................................................... 21

11 Specific Application Conditions ....................................................................................................... 23

11.1 Polyethylene or Polypropylene Coating ............................................................................. 23

11.2 Elastomeric Filler Mastic Combined with Polyethylene Laminate (Patch) ......................... 23

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11.3 Polypropylene Filler Adhesive Combined with Polypropylene Laminate (Patch) .............. 24

11.4 Heat-Shrinkable Sleeve ..................................................................................................... 24

12 Inspection and Tests ....................................................................................................................... 24

12.1 Thickness Measurement .................................................................................................... 24

12.2 Visual.................................................................................................................................. 24

12.3 Holiday Detector Test......................................................................................................... 25

Annex A - Application Procedure (PA) .................................................................................................. 26

Annex B - Qualification .......................................................................................................................... 27

Annex C - Adhesion Test - Dynamometer Method - Polyethylene Laminate or Irradiated Polypropylene with Adhesive (Patch) - Test in Region Overlapping Pipe Coating...................................... 29

Figure

Figure C.1 - Adhesion Test on Patch - Dynamometer Method ............................................................. 30

Tables

Table 1 - Properties of Three-Layer Polyethylene Coating ................................................................... 10

Table 2 - Requirements for Repair Applied with Three-Layer Polyethylene Coating............................ 10

Table 3 - Properties of Elastomeric Filler Mastic................................................................................... 11

Table 4 - Properties of Hot Melt Adhesive of Patch .............................................................................. 11

Table 5 - Properties of External Irradiated Polyethylene Film of Patch ................................................ 11

Table 6 - Requirements for Repair Applied with Irradiated Polyethylene Alaminate Complemented with Hot Melt Adhesive.................................................................................................................. 12

Table 7 - Properties of Triple Layer Polypropylene Coating ................................................................. 12

Table 8 - Properties of Polypropylene Filler Adhesive .......................................................................... 13

Table 9 - Properties of Polypropylene Adhesive ................................................................................... 13

Table 10 - Properties of External Polypropylene Film of Patch............................................................. 13

Table 11 - Requirements for Repair Applied with Irradiated Polypropylene Laminate Complemented with Polypropylene Adhesive .............................................................................................. 14

Table 12 - Dry Film Requirements ........................................................................................................ 15

Table 13 - Requirements for Applied Coating ....................................................................................... 15

Table 14 - Classification of Damages and Repair Methods for 3LPE and 3LPP Coatings................... 18

Table B.1 - Tests and Inspections for Qualification of Applicators and Inspectors ............................... 28

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Foreword

This Standard is the English version (issued in 12/2011) of PETROBRAS N-2911 12/2010, (including its Amendment - 05/2011). In case of doubt, the Portuguese version, which is the valid document for all intents and purposes, shall be used. 1 Scope 1.1 This Standard specifies the conditions required for repair work to be done during construction and installation on pipes coated with polyethylene (3LPE) or polypropylene (3LPP) or fusion-bonded epoxy (FBE), intended for pipelines after the performance of the following field inspections:

a) receiving of pipes at the warehouse of the job site; b) pipeline construction and installation.

1.2 Suppliers of the repair materials proposed by this Standard shall present an Application Procedure (Annex A), which shall be qualified according to the requirements of Annex B. 1.3 The repairs contemplated by this Standard cover the following materials:

a) polypropylene filler adhesive filler combined with irradiated polypropylene laminate complemented with polypropylene adhesive (Patch) for 3LPP;

b) polyethylene or polypropylene filler (Melt Stick); c) liquid epoxy; d) heat-shrinkable sleeve; e) elastomeric filler mastic combined with irradiated polyethylene laminate complemented

with hot melt adhesive (Patch) for 3LPE. NOTE The order of the repairs indicated does not indicate priority of use. They are in alphabetical

order. 1.4 It is not permitted, under any circumstances whatsoever, to apply sleeves over sleeves or the “fish scale” type process. 1.5 Such materials and the selection guide for repair of each one of them are described in Sections 6, 8, and 9, respectively, of this Standard. 1.6 This Standard is not applicable to repairs of the thermal insulation system of the pipeline. 1.7 This Standard is applicable as of its date of issuance. 1.8 This Standard contains Technical Requirements and Recommended Practices. 2 Normative References The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document applies.

PETROBRAS N-2328 - Revestimento de Junta de Campo para Duto Enterrado;


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ABNT NBR 10443 - Tintas e Vernizes - Determinação da Espessura da Película Seca sobre Superfícies Rugosas; ABNT NBR 14847 - Inspeção de Serviços de Pintura em Superfícies Metálicas; ABNT NBR 15158 - Limpeza de Superfície de Aço por Compostos Químicos; ABNT NBR 15185 - Inspeção de Superfícies para Pintura Industrial; ABNT NBR 15239 - Tratamento de Superfícies de Aço com Ferramentas Manuais e Mecânicas; ABNT NBR 15877 - Pintura Industrial - Ensaio de Aderência por Tração; ABNT NBR ISO 9001 - Sistema de Gestão de Qualidade - Requisitos; ISO 8501-1 - Preparation of Steel Substrates before Application of Paints and Related Products-Visual Assessment of Surface Cleanliness - Part 1: Rust Grades and Preparation of Grades of Uncoated Steel Substrates and of Steel Substrates After Overall Removal of Previous Coatings; ASTM B 117 - Standard Practice for Operating Salt Spray (Fog) Apparatus; ASTM D 149 - Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies; ASTM D 257 - Standard Test Methods for DC Resistance or Conductance of Insulating Materials; ASTM D 570 - Standard Test Method for Water Absorption of Plastics; ASTM D 638 - Standard Test Method for Tensile Properties of Plastics; ASTM D 790 - Standard Test Methods for Flexural Properties of Unreinforced and Reinforced Plastics and Electrical Insulating Materials; ASTM D 870 - Standard Practice for Testing Water Resistance of Coatings Using Water Immersion; ASTM D 1000 - Standard Test Method for Pressure - Sensitive Adhesive-Coated Tapes Used For Electrical and Electronic Applications; ASTM D 1002 - Standard Test Method for Apparent Shear Strength of Single-Lap-Joint Adhesively Bonded Metal Specimens by Tension Loading (Metal-to-Metal); ASTM D 1238 - Standard Test Method for Melt Flow Rates of Thermoplastics by Extrusion Plastometer; ASTM D 1525 - Standard Test Method for Vicat Softening Temperature of Plastics; ASTM D 2240 - Standard Method Test for Rubber Property - Durometer Hardness; ASTM D 2247 - Standard Practice for Testing Water Resistance of Coatings in 100 % Relative Humidity; ASTM D 2370 - Standard Test Method for Tensile Properties of Organic Coatings; ASTM D 2671 - Standard Test Method for Heat-Shrinkable Tubing for Electrical Use; ASTM D 4541:2009 - Standard Test Method for Pull-off Strenght of Coatings Using Portable Adhesion Testers;

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ASTM E 28 - Standard Test Methods for Softening Point of Resins by Ring-and-Ball Apparatus; ASTM E 96 - Standard Test Methods for Water Vapor Transmission of Materials; ASTM G 14 - Standard Test Method for Impact Resistance of Pipeline Coatings (Falling Weight Test); CAN/CSA-Z245.20: 2006 - External Fusion Bonded Epoxy Coating for Steel Pipe; DIN 30672 - Wrappings of Corrosion Protection Tapes and Heat Shrinkable Material for Pipelines for Continuous Operating Temperatures of Up to 50 °C; NACE Nº2/SSPC-SP10 - Joint Surface Preparation Standard Near-White Metal Blast Cleaning; NACE RP 0274 - High Voltage Electrical Inspection of Pipeline Coating; NACE SP 0188 - Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates; AFNOR NF A49-711 - Steel Tubes. External Coating with Three Polypropylene Layers Coating. Application by Extrusion; SSPC SP 11 - Power Tool Cleaning to Bare Metal.

NOTE For documents referred in this Standard and for which only the Portuguese version is

available, the PETROBRAS department that uses this Standard should be consulted for any information required for the specific application.

3 Terms and Definitions For the purposes of this document, the following terms and definitions apply. 3.1 applicator professional responsible for applying the repair 3.2 conformity certificate document issued by the manufacturer or applicator, referring to each material supplied, where the tests required in this Standard are recorded, with the respective typical values in accordance with the limit values 3.3 quality certificate document issued by the manufacturer or applicator, referring to each lot of material supplied, where the tests required in this Standard are recorded, with the respective values found 3.4 manufacturer company that manufactures raw materials

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3.5 supplier company that provides the repair 3.6 holiday detector equipment used to detect discontinuities on the surface of the anticorrosive coating when it is subjected to a particular potential difference 3.7 irradiated polyethylene laminate with hot melt adhesive (patch) it is comprised of a non-heat shrinkable irradiated and cross-linked polyethylene laminate coated on one of the sides with heat-activated hot melt adhesive 3.8 lot (batch) typical produced quantity of a given material or product defined by the manufacturer, which shall inform the methodology used for its definition. This information shall be submitted to the client in a separate document only once, unless changes are made to systematic procedure adopted for defining the lot or if the typical quantity is modified 3.9 elastomeric filler mastic it is comprised of a heat-activated elastomeric mass 3.10 heat-shrinkable sleeve it is comprised of an external cross-linked polyethylene film by the electronic irradiation process, complemented with hot melt adhesive on one of the sides, or an external polypropylene film by an electronic irradiation process, complemented with polypropylene adhesive. In both cases an anticorrosive epoxy primer is necessary (provided by the sleeve manufacturer) and a closure seal or butt strap 3.11 anticorrosive liquid epoxy coating coating applied by means of an airless gun, roller, brush or spatula, comprised of a solvent-free liquid epoxy, 100 % solids by mass, cured with polyamine at ambient temperature 4 General Conditions 4.1 The receiving inspection at the warehouse of the job site and during pipeline assembly shall be performed according to an Inspection Procedure prepared by the pipeline construction company for each of these 2 items, according to Section 5 of this Standard and previously approved by PETROBRAS. 4.2 The repair shall be applied in accordance with an Application Procedure (PA) prepared by the manufacturer of the respective material, according to Annex A of this Standard. The PA shall be qualified by PETROBRAS according to Annex B of this Standard before the beginning of field repair activities. In those cases in which the manufacturer’s PA has already been qualified by PETROBRAS (see B.1.6) the PA number shall be informed in the technical bid presentation phase.

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4.3 PETROBRAS may carry out field tests on pipelines already in operation whose coating repairs are those listed in the PA in order to check the quality of their performance. A new qualification may be required in the event the tests prescribed in the PA used present flaws. 4.4 Before the beginning of field repair activities, the applicators of the pipeline construction company shall be evaluated by PETROBRAS according to B.2. 4.5 Qualification of the PA and the tests mentioned in 4.2 and 4.4 shall be performed by the repair material supplier and the repair applicator of the pipeline construction company, respectively, at their own expense and with follow-up by PETROBRAS technicians or professionals designated by the latter. 5 Inspection 5.1 Receiving Inspection at the Warehouse of the Job Site 5.1.1 Check if the coating is in accordance with the purchase documents and design specifications, recording the identification of pipes in such a manner as to allow their traceability to the material quality certificate.

5.1.2 The coating shall be inspected according to 5.1.4 of this Standard right after it is received, observing the following:

a) the devices and instruments used in the tests shall be duly identified and adjusted; b) all defects or damages detected shall be marked on the surface of the coating by means

of paint, crayon or other similar materials; c) pipes to be inspected shall rest on appropriate supports in such a manner as to allow

access to 100 % of their surface. If possible, the area intended for the inspection shall be covered;

d) inspection results shall be presented through previously prepared spreadsheets. 5.1.3 The damages found shall be classified according to Sections 8 or 9 and the respective repair work shall be done according to the instructions of this Standard. 5.1.4 The inspection shall include the following items:

a) visual inspection of coating: — it shall be performed on the entire surface of all coated pipes; — non-uniform color and appearance, bubbles, notches, tears, cracks, holes, cuts, pulled

off parts, disbondment or any indication of deterioration are unacceptable; — damage and/or onset of corrosion process in the collar region; — surface defects such as wrinkles and protrusions shall be corrected;

b) holiday test on coating: — the holiday detector test shall be performed on the entire surface of all pipes; — each pipe shall be inspected using a pulsating current holiday detector according to

recommended practice NACE RP 0274 along the full length of the pipe. The test voltage shall be 12 kV per millimeter of total coating thickness, limited to 25 kV (in the case of FBE-coated pipes, the device shall be of the dry, full rectified wave direct current type and the voltage shall be from 3 kV to 3.5 kV). The device shall be adjusted to its sensitivity at least once every 8 working hours, according to Section 8 of the above-mentioned Standard;

— the contact electrode shall be made of conductive rubber or a square-wire spring, and shall travel over the pipe at a maximum speed of 18 m/min.

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5.1.5 If the coated pipes are stored in an area exposed to the weather for more than 12 months, visual, impact, and melt flow index tests shall be performed. The melt flow index test is not applicable to FBE-coated pipes. 5.1.6 Impact and melt flow index tests shall be performed as described below:

a) impact test: — it shall be performed on 1 pipe from each stack for every 100 pipes. For less than 100

pipes, at least one pipe shall be tested; — select the pipe that is exposed the most to the sun; — perform the impact test on the side of the pipe exposed to the sun; — tests shall be performed at 3 points of the pipe at least 30 mm from each other; — the energy used for the impact tests shall be 7 J per millimeter in thickness for 3LPE

and 10 J per millimeter in thickness for 3LPP. For FBE the total energy applied is 1.5 J;

— after the impact test, the coating shall be subjected to the holiday test according to 5.1.4 b) for 3LPE and 3LPP coatings. For FBE coatings, the voltage used in the test shall be 2.5 kV ± 0.2 kV;

— no holes shall appear on the coating; — impact points on non-rejected pipes coated with 3LPE and 3LPP shall be repaired

according to Table 14 and Section 12; for FBE-coated pipes, follow the provisions in Sections 9 and 12;

b) melt flow test:

— it shall be performed on a pipe from each stack for every 100 pipes. For less than 100 pipes, at least one pipe shall be tested;

— select the pipe that is exposed the most to the sun; — remove the polyethylene or polypropylene samples from the side exposed to the sun

and on the diametrically opposite side; — the thickness of the polyethylene or polypropylene layer of the samples shall be the

largest possible, taking care not to reach the adhesive layer; — determine the melt flow index according to ASTM D 1238 (190 ºC / 2.16 kg for

polyethylene and 230 ºC / 2.16 kg for polypropylene); — the difference in melt flow indices on the exposed side and on the side not exposed to

the sun shall not be smaller than 25 %; — in case any flaw is found, the pipe shall be rejected and a verification procedure shall

be started in order to delimit the irregularity; — if rejection does not occur, all areas damaged by the tests shall be repaired as

prescribed in Section 8. 5.2 Inspection During Pipeline Assembly 5.2.1 It shall be performed on all pipes immediately before the pipeline is laid in the ditch. 5.2.2 It shall comply with the provisions in 5.1, and only the visual inspection and holiday test are required to be performed on the coating.

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6 Technical Characteristics of Repair Materials 6.1 Repairs on 3LPE Coating 6.1.1 Three-Layer Polyethylene Coating (3LPE) 6.1.1.1 It comprises a heat-activated polyethylene-based adhesive. It is recommended for small coating repairs, as described in Table 14. 6.1.1.2 The three-later polyethylene coating for a design temperature up to 80 ºC shall comply with the requirements of Tables 1 and 2.

Table 1 - Properties of Three-Layer Polyethylene Coating

Properties Units Limit Values Test methods

Shear strength (23 ºC 2 ºC) (see Note 2) N/cm2 min. 235 ASTM D 1002

Dielectric strength (23 ºC 2 ºC) kV/mm min. 10 ASTM D 149

Tensile strength (23 ºC 2 ºC) MPa min. 5 ASTM D 638

Elongation at rupture (23 ºC 2 ºC) % min. 350 ASTM D 638

Softening point ( see Note 2) °C min. 100 ASTM E 28

Hardness (23 ºC 2 ºC) Shore D min. 30 ASTM D 2240

Dimensions:

- Length (see Notes 1 and 2) mm - ASTM D 1000

- Diameter (see Notes 1 and 2) mm - ASTM D 1000 NOTE 1 According to material manufacturer’s standard. NOTE 2 To be informed by manufacturer in the Material Quality Certificate.

Table 2 - Requirements for Repair Applied with Three-Layer Polyethylene Coating

Properties Units Limit values Test methods

Visual - passes / fails (see Note 1)

Discontinuity of repair kV 12 KV/mm

limited to 25 KVNACE RP 0274

Impact resistance (23 ºC to 30 ºC) (see Note 2)

J min. 15 ASTM G14

NOTE 1 It shall present a uniform surface without fissures and holes. NOTE 2 At least 2 impact points 30 mm apart from each other shall be made.

6.1.2 Elastomeric Filler Mastic System Combined with Polyethylene Laminate (Patch) 6.1.2.1 The coating is comprised of the application of elastomeric filler mastic combined with irradiated polyethylene laminate complemented with hot melt adhesive (patch). 6.1.2.2 It is recommended for filling spaces and recomposing thicknesses, and is used together with a patch as described in Table 14.

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6.1.2.3 Elastomeric filler mastic with polyethylene laminate (patch) shall be used on pipes coated with triple later polyethylene for a maximum temperature of 80 ºC. It shall comply with Tables 3 to 6. 6.1.2.4 The total thickness of the polyethylene laminate shall be, at least, 1 mm.

Table 3 - Properties of Elastomeric Filler Mastic

Properties Units Limit Values Test Methods

Water absorption (23 ºC 2 ºC) % max. 1,00 ASTM D 570

Softening Point (see Note 2) °C min. 100 ASTM E 28

Shear strength (23 ºC 2 ºC) (see Note 3) MPa min. 0,01 ASTM D 1002

Length (see Notes 1 and 2) mm - ASTM D 1000

Width ( see Notes 1 and 2) mm - ASTM D 1000

Thickness ( see Notes 1 and 2) mm - ASTM D 1000 NOTE 1 As informed by the material manufacturer. NOTE 2 To be informed by the manufacturer in the Material Quality Certificate. NOTE 3 The thickness of the test plate shall be 0.045 in.

Table 4 - Properties of Hot Melt Adhesive of Patch

Properties Units Limit Values Test methods

Softening point oC min. 100 ASTM E 28

Shear strength (23 VºC 2 ºC) MPa min. 1,00 ASTM D 1002

Water Absorption % max. 0.30 ASTM D 570

Table 5 - Properties of External Irradiated Polyethylene Film of Patch

Properties Units Limit Values Test Methods

Elongation at rupture (23 ºC 2 ºC) (see Note 2)

% min. 350 ASTM D 638

Tensile strength (23 ºC 2 ºC) (see Note 2) MPa min. 15 ASTM D 638


Volumetric resistivity (23 ºC 2 ºC) .cm min. 1012 ASTM D 257

Dielectric strength - voltage rise (23 ºC 2 ºC) at 500 V/s

kV/mm min. 12 ASTM D 149

Heat shock (4 hours at 225 ºC) - (1) ASTM D 2671 Procedure C

Heat aging 168 hours at 150 ºC 2 ºC, followed by

- Tensile stress MPa min. 14 ASTM D 638

- Elongation at rupture % min. 300 ASTM D 638 NOTE 1 No cracks. NOTE 2 To be informed by the manufacturer in the Material Quality Certificate.

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Table 6 - Requirements for Repair Applied with Irradiated Polyethylene Alaminate

Complemented with Hot Melt Adhesive



Holiday on repair kV 12 kV/mm

limited to 25 kV NACE RP 0274

Adhesion (23 ºC to 33 ºC) mm/min min. 80 Annex C Impact Resistance (23 ºC to 33 ºC) (see Note 2)

J min. 4 ASTM G14

NOTE 1 It shall present a uniform surface, without fissures and holes. NOTE 2 At least, 2 impact points shall be provided 30 mm from each other.

6.1.3 Heat-Shrinkable Sleeves PETROBRAS N-2328 shall be followed. 6.2 Repairs on 3LPP Coating 6.2.1 Three-Layer Polypropylene Coating (3LPP) 6.2.1.1 It is comprised of a heat-activated polypropylene-based adhesive. It is recommended for small repairs on the coating as described in Table 14. 6.2.1.2 For a design temperature up to 110 ºC, the coating shall comply with the requirements of Tables 2 and 7.

Table 7 - Properties of Triple Layer Polypropylene Coating


Shear strength (23 ºC 2 ºC) (see Note 2) N/cm2 min. 240 DIN 30672

Dielectric strength (23 ºC 2 ºC) kV/mm min. 10 ASTM D 149

Tensile strength (23 ºC 2 ºC) MPa min. 8 ASTM D 638

Elongation at rupture (23 ºC 2 ºC) % min. 350 ASTM D 638

Softening Point (see Note 2) °C min. 135 ASTM E 28


Dimensions:

- Length (see Notes 1 and 2) mm - ASTM D 1000

- Diameter (see Notes 1 and 2) mm - ASTM D 1000

NOTE 1 According to the material manufacturer’s standard. NOTE 2 It shall be informed by the manufacture in the Material Quality Certificate.

6.2.2 Polypropylene Filler Adhesive Combined with Polypropylene Laminate (Patch) 6.2.2.1 The coating is comprised of the application of polypropylene filler adhesive combined with irradiated polypropylene laminate complemented with polypropylene adhesive.


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6.2.2.2 It is used for filling spaces and recomposing thicknesses together with the patch as described in Table 14. 6.2.2.3 Polypropylene adhesive combined with 3LPP laminate (Patch) shall be used on pipelines coated with triple layer polypropylene for a maximum temperature of 110 ºC. The requirements set out in Tables 8 to 11 shall be met. 6.2.2.4 The total thickness of the polypropylene laminate shall be, at least, 2 mm.

Table 8 - Properties of Polypropylene Filler Adhesive

Properties Units Limit values Test methods Shear strength at 23 °C (1 cm/mm) (see Note)

min. 200

Shear strength at 120 °C (1 cm/mm)

N/cm2

min. 17 ASTM D 1002

Softening point (ring and ball) (see Note) oC min. 140 ASTM E 28

NOTE To be informed by the manufacturer in the Material Quality Certificate.

Table 9 - Properties of Polypropylene Adhesive

Properties Units Limit values Test methods Shear strength at 23 °C (1 cm/mm) (see Note)

min. 450

Shear strength at 120 °C (1 cm/mm) N/cm2

min. 60 ASTM D 1002

Softening point (ring and ball) (see Note 1) oC min. 140 ASTM E 28

NOTE To be informed by the manufacturer in the Material Quality Certificate.

Table 10 - Properties of External Polypropylene Film of Patch


Tensile strength at 23 °C (see Note 1) MPa min. 20 ASTM D 638 Elongation at rupture at 23 ºC (see Note 1)

% min. 350 ASTM D 638

Dielectric strength at 23 °C V/mm min. 12,000 ASTM D 149

Volumetric resistivity at 23 °C .cm min. 1016 ASTM D 257 Elongation at 23 °C after heat aging (150 ºC / 7 days)

% min. 220 ASTM D 638

Water absorption (23 °C / 24 hours) % max. 0,4 ASTM D 570 Water vapor transmission (38 °C / 90 % UR)

g/h/m² max. 0,052 ASTM E 96

Low temperature flexibility (1” dia. mandrel) oC max. - 20 ASTM D 2671 Procedure C

Flexural Modulus MPa min. 750 ASTM D 790

Hardness Shore D min. 63 ASTM D 2240 Heat Aging (flexibility without fissures, 2 000 hours / 150 °C)

passes / fails

passes AFNOR NF A 49-711

Heat aging (elongation variation) 168 hours at 150 °C

% max. 35 ASTM D 638

Softening point (VICAT) ºC min. 129 ASTM D 1525 NOTE 1 To be informed by manufacturer in the Material Quality Certificate. NOTE 2 Tests performed on film with incorporated adhesive.

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Table 11 - Requirements for Repair Applied with Irradiated Polypropylene Laminate

Complemented with Polypropylene Adhesive



Holiday on repair kV 12 kV/mm

limited to 25 kV NACE RP 0274

Adhesion (23 °C to 33 °C) mm/min min. 80 Annex C Impact resistance (23 °C to 33 °C) (see Note 2)

J min. 4 ASTM G14

NOTE 1 It shall present a uniform surface without fissures and holes. NOTE 2 At least, 2 impact points shall be provided 30 mm apart.

6.2.3 Heat-Shrinkable Sleeves PETROBRAS N-2328 shall be followed. NOTA For 3LPP coated pipes polypropylene sleeves shall be used. 6.3 Repair on FBE Coating 6.3.1 Use shall be made of liquid epoxy applied in the field in the repair region and it shall comply with the requirements of Tables 12 and 13. 6.3.1.1 The product shall be applied by a specific painting process on the substrate at ambient temperature.

6.3.1.2 The dry film thickness required for the coating is 15050450 µm.

6.3.2 Dry Film Characteristics The tests to be conducted to evaluate the performance of the dry film are those contained in Table 12.


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Table 12 - Dry Film Requirements


Pull-off Strength (see Note 1) MPa min. 12

ABNT NBR 15877:2010, Annex 2

or ASTM D 4541:2009, Method D - Equipment Type IV

Salt spray resistance at 35 °C (see Notes 2 and 3)

h 2 000 ASTM B 117

Resistance at 100 % relative humidity at 40 °C (see Note 3)

h 2 000 ASTM D 2247

Resistance to immersion in distilled water at 40 ºC (see Note 3)

h 2 000 ASTM D 870

Cathodic disbondment (28 days) at -1.5 V at 23 ºC (see Note 4)

mm max. 10 CAN/CSA

Z245.20:2006 Water absorption (24 hours) % max. 0.1 ASTM D 570

Tensile Strength MPa min. 42 ASTM D 2370

Elongation % min. 9,0 ASTM D 2370

Dielectric strength kV/mm 16 ASTM D 149 NOTE 1 After the adhesion test, the nature of the flaw may not be of the types: adhesive between

the substrate and the coating (AB), or cohesive on the paint layer for breaking stress values lower than 12 MPa. However, the occurrence of a cohesive type flaw on the paint layer is acceptable if the breaking stress value is 12 MPa or above.

NOTE 2 For salt spray resistance tests the test specimens shall be cut 7 cm in length by 1 mm in width parallel to their largest dimension and 50 mm from the top edge of the plate. After 2 000 hours of testing, the maximum corrosion progress from the incision shall be 3 mm.

NOTE 3 At the end of the tests to verify the salt spray resistance, the resistance at 100 % relative humidity and the immersion resistance in distilled water at 40 °C, anomalies such as bubbles, fissures or corrosion spots shall not be observed.

NOTE 4 The coating shall not present cracks, disbondment or holidays when tested according to Section 8, but with a potential difference of 2.5 kV ± 0.2 kV.

Table 13 - Requirements for Applied Coating


Hardness after testing for one second Shore D min. 75 ASTM D 2240

Pull-off strength on steel MPa min. 12

Pull-off strength on FBE MPa min. 12

ASTM D 4541:2009, Method D - Equipment Type IV or ABNT NBR 15877:2010, Annex 2

Impact at 0 °C J min. 1.5

Impact at 25 °C J min. 1.5 CAN/CSA Z245.20:2006

Section 10.12

Cathodic disbondment 28 days @ 23 ± 2 °C @ - 1.5 V

mm max. 10.0 CAN/CSA Z245.20:2006

Section 10.8

Immersion in hot water for 28 days Degrees, 1

to 5 max.1 CAN/CSA Z245.20:2006

Electrical volume resistivity Ω cm min. 1014 ASTM D 257 NOTE The chemical resistance of the coating to chemical agents that come into contact with the

coating during pipeline operation shall be checked.

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7 Receiving, Storage, Handling and Transportation of Repair Materials 7.1 Receiving 7.1.1 The materials comprising the repair system shall be inspected upon receipt, including verification of the integrity of their packing and packaging. They shall be in accordance with the purchase documents, design specifications and under normal conditions for application. 7.1.2 Each lot shall be perfectly characterized, under normal conditions for application and accompanied by the quality certificate and its packaging shall contain the following information:

a) product type; b) reference standard; c) product name and brand; d) technical and dimensional characteristics of product; e) identification number or sign of manufacturing lot; f) product expiration date.

7.1.3 The receiving inspection shall include at least the following:

a) check if the materials to be used have been produced by manufacturers included in PETROBRAS’ vendor list and are accompanied by the respective conformity certificates according to this Standard;

b) check the Quality Certificates, which shall attest conformity to the requirements of Tables 1 to 13. The requirements are those indicated by the Notes “to be informed by the manufacturer in the material quality certificate” in the respective Tables;

c) check the expiration dates of the components of the anticorrosive coatings and the integrity of the packaging;

d) check for the presence of moisture inside the packaging; if moisture does occur, packaging items shall be segregated and the manufacturer shall be consulted concerning the possibility of the materials losing their properties and the measures which shall be taken.

7.2 Storage 7.2.1 All materials needed for the coating shall be stored in a sheltered and ventilated location where the ambient temperature shall not exceed 45 °C, at least, 10 cm from the ground, so as to prevent damages, away from occasional heat sources and in their original packaging. 7.2.2 All materials shall be stored in such a manner as to ensure that those manufactured first are used first, provided their period of validity has not expired. 7.2.3 Storage conditions shall comply with the material manufacturer’s instructions. 7.3 Handling and Transportation 7.3.1 All materials required for coating shall be handled and transported in such a way as to prevent damages to their packaging.

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7.3.2 During transportation, packaging with the components of the anticorrosive coatings shall not be left exposed to weathering. 8 Classification of Damages and Selection Guide for Repair of Pipes Coated with

3LPE e 3LPP 8.1 The classification of damages and the repair method for each type are described in Table 14.

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Table 14 - Classification of Damages and Repair Methods for 3LPE and 3LPP Coatings

Pipe coating

Type Dimensions of damages

Polyethylene orpolypropylene

coating Adhesive

Primer (FBE)

Steel Repair method Holiday test

I A 100 cm2 remaining thickness 75 %

not reached

not reached

not reached

no repair required no holidays

detected

II any length withwidth 15 mm

remaining thickness 25 % and

< 75%

not reached

not reached

not reached

polyethylene or polypropylene filler

holidays not detected

1st layer: adhesive (polypropylene) or

mastic (polyethylene) III

A 100 cm2

c 50 cm l 1/4 P

remaining thickness 25 % and

< 75%

reached / not

reached

not reached

not reached

2nd layer: patch

holidays not detected


mastic (polyethylene)

IV A 25 cm2

c 50 cm l 1/4 P

reached reached reached reached

2nd layer: patch

holidays detected

1st layer: primer

2nd layer: adhesive (polypropylene) or

filler mastic (polyethylene)

V

25 cm2 < A < 100 cm2

c 50 cm l 1/4 P

reached reached reached reached

3rd layer: patch

holidays detected


mastic (polyethylene)

VI.a reached reached /

not reached

not reached

not reached 2nd layer:

Heat-shrinkable sleeve with hot melt

or polypropylene adhesive

undetected holidays

1st layer: primer

VI.b (see

Note1)

A > 100 cm2

and/or c > 50 and/or l >

1/4 P

reached reached reached reached2nd layer:

heat-shrinkable sleeve with hot

melt or polypropylene

adhesive

detected holidays

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Table 14 - Classification of Repair Damages and Methods for 3LPE and 3LPP Coatings (Continued)

Where:

A is the area; c is the damage length; l is the damage width; P is the pipe perimeter ( D, where D is the pipe outside diameter).

8.2 The minimum overlap of repair material over the original pipe coating shall be 100 mm. The original pipe coating shall be sanded with sandpaper with a maximum grit size of 36 in the overlapping area within a region between 120 mm and 150 mm around the repair area. 8.3 The coating of the entire repaired area shall be subjected to holiday testing according to 12.3. 8.4 During the inspection of pipelines the defective area shall be marked with paint, crayon or a similar material, thereby facilitating the location of areas with defects. 8.5 The maximum number of repairs permitted shall comply with the following criteria:

a) type II damage - 10 repairs; b) type III damage - 5 repairs; c) type IV damage - 5 repairs; d) type VI.a damage- 1 repair; e) type VI.b damage - 1 repair.

Pipe coating Type

Dimensions of damages PE or PP

coating Adhesive

Primer (FBE)

Steel Repair method Holiday test

NOTE 1 For making Type II, III, and VI repairs, the following shall be observed: a) the surface to be repaired shall be sandpapered, using an electric rotary sander or by cross hand

sanding with a sandpaper having a maximum grit size of 36 in order to obtain a uniform and rough anchor profile;

b) before applying the repair material, the area shall be cleaned with the aid of dry compressed air, rags or paintbrushes, which shall be dry and free of contaminants, thereby eliminating all remaining residues;

c) the repair shall then be made according to Section 10. NOTE 2 For making Type IV, V, and VI.b repairs, the following shall be observed:

a) remove the loose coating and the adhesive from the damaged areas; b) treat the metal surface by abrasive blasting according to NACE

No. 2/SSPC-SP 10 to grade Sa 2 1/2 of ISO 8501-1. As an alternative, in the event it is not possible to use abrasive blasting, and provided this is approved by PETROBRAS, mechanical treatment with a rotary tool shall be used according to SSPC SP 11;

c) the region to be repaired shall be cleaned with the aid of dry compressed air, a rag or a paintbrush, which shall be dry and free of contaminants, thereby eliminating all remaining residues (loose coating, dust, and other contaminants);

d) the repair shall then be made according to Section 10. NOTE 3 If any of the dimensions of the damaged area is smaller than 20 cm, after primer application, fill the

area with filler adhesive so that the sleeve fits the surface perfectly.

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9 Classification of Damages and Selection Guide for Repair with Liquid Epoxy of FBE-

Coated Pipes 9.1 After the inspection, the damaged area shall be marked with paint, chalk, crayon or a similar material, thereby facilitating the location of the areas to be repaired. 9.1.1 Damages subject to repairs are classified into 2 types:

a) type I damage: spot damage detected in the holiday test or with an area equal to or smaller than 1 mm2;

b) Type II damage: non-spot type damage smaller than 100 cm2, with the largest length not greater than 3 cm.

9.1.2 Pipes with more than 3 Type II damages or with an area larger than 100 cm2 shall be rejected. 9.1.3 The repair material to be used shall be of the 2 component liquid epoxy type (solvent free) and be compatible with the powder epoxy used for the pipe coating, or thermoplastic materials. 9.1.4 The repair material shall be prepared according to the instructions provided in the technical bulletin of the product to be used. 9.1.5 Right after mixing together the 2 components, the product shall be applied over the area to be repaired with the aid of a putty knife, thereby covering the entire region previously prepared. 9.1.6 The maximum thickness of the repairs shall be 50 % larger than the nominal thickness of the original pipe coating. 9.1.7 After the material has been cured, the entire repaired area shall be inspected through a holiday detector according to 12.3. 9.2 Repair on Type I Damages The surface shall be prepared as described below:

a) the damaged coating shall be removed by means of sharp-edged instruments (knife, pocket knife or retractable knife) or a bastard file, until the metal substrate is reached, resulting in a countersunk area;

b) after the damaged coating is removed, the region to be repaired shall be cleaned with a rag or a brush, which shall be dry and free of contaminants, thereby eliminating all remaining residues (coating, dust etc.) and shall be free of moisture;

c) if the substrate presents signs of oxidation a sandpaper having a grit size of 80 or a bastard file shall be used to fully remove these signs and then a clean and dry rag or brush shall be used for cleaning the area to be repaired.

9.3 Repair on Type II Damages 9.3.1 Remove all the damaged coating by means of a bastard file until the substrate is reached, eliminating any traces of oxidation that may possibly exist.

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9.3.2 After the damaged coating is removed, a 10 mm wide strip surrounding the area to be repaired shall be reamed to ensure overlapping of the repair material over the original coating. 9.3.3 The surface of the filed region shall then be sanded, using sandpaper having a grit size of 80 in the overlapping area in a strip between 120 mm and 150 mm around the repair area in order to allow anchoring of the repair to be applied. 9.3.4 The area to be repaired shall be delimited by applying adhesive tape on the undamaged region. 9.3.5 Before the repair material is applied, the area shall be cleaned with the aid of a rag or brush, which shall be dry and free of contaminants, thereby eliminating all remaining residues, and it shall be free of moisture. 10 Repair Application 10.1 Environmental Conditions 10.1.1 At the beginning of each workday or when changes occur in weather conditions, the ambient temperature, the pipeline temperature and the relative air humidity shall be measured. 10.1.2 In unsheltered locations, the application shall not be made on rainy days or days in which rain is expected if it is not possible to install proper covering. 10.1.3 The ambient temperature, during the application of the anticorrosive coating, shall be between 10 °C and 50 °C. 10.1.4 The temperature of the pipeline where the anticorrosive coating shall be applied shall be equal to or greater than the temperature corresponding to the dew point temperature plus 3 °C and not above 50 °C. 10.1.5 The relative humidity, when the anticorrosive coating is applied, shall not exceed 85 %. 10.1.6 The anticorrosive coating may be applied with a relative air humidity between 85 % and 95 %, provided one of the following conditions is satisfied: [Recommended Practice]

a) pipeline surface temperature 3 °C above the dew point temperature; b) pipelines are preheated between 45 °C and 50 °C.

10.2 General Application Conditions 10.2.1 The coating shall be applied based on an application procedure (Annex A).

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10.2.2 All paint, varnish, old coating, corrosion products, oil, grease, dust, and any foreign materials found on the surface of the pipeline shall be inspected according to ABNT NBR 14847 and ABNT NBR 15185 and removed according to ABNT NBR 15158 and ABNT NBR 15239. 10.2.3 Solvents recommended by the supplier of the repair to be applied shall be used. 10.2.4 The end of the original coating shall be beveled to an angle smaller than 30º in relation to the pipeline surface. 10.2.5 The repair shall be applied on the same workday in which the surface treatment is performed. If, when the repair is applied, the surface presents signs of corrosion, the surface treatment shall be repeated. 10.2.6 Primer is not used for the following types of coatings: epoxy, polyethylene or polypropylene. 10.2.6.1 Immediately after the surface is prepared, a uniform coat of primer shall be applied on the pipeline. The thickness of the primer film after drying shall be at least 20 μm. 10.2.6.2 The primer shall not extend over the original coating in case it is triple layer polyethylene or polypropylene, and its application shall be restricted to the metal substrate. 10.2.6.3 In the case of heat-shrinkable sleeves, the primer shall have a minimum thickness of 100 μm. 10.2.6.4 Primer application shall be free of flaws and may be made by spraying or by using a roller or brush, except on weld seams where a brush shall be obligatorily used. 10.2.6.5 Material contaminated by foreign substances or displaying settling preventing primer from being properly homogenized shall not be used. 10.2.6.6 The contents of each primer container shall be completely homogenized before used. 10.2.6.7 The solution shall be diluted according to the instructions provided by the coating manufacturer. 10.2.6.8 The primer film shall present a uniform thickness and shall be free of flaws such as dripping, blistering, bubbles and impregnation of solid particles. 10.2.6.9 The repair shall only be applied after the primer has dried tack free. If the primer has been completely cured, it shall be removed and primer shall once again be applied on the surface. 10.2.6.10 When the spraying method is utilized, suitable air filters shall be used to remove all the oil and moisture from the compressed air. Mechanically or pneumatically agitated pressurized tanks shall be used.

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10.2.6.11 For regions in which the solution has already been applied and which have incorporated dust during drying, the solution shall be removed and a new application shall be made. 11 Specific Application Conditions 11.1 Polyethylene or Polypropylene Coating Preheat the area to be repaired and then heat the coating at one of the ends preferably with hot air or another method indicated by the supplier in the “Qualified Application Procedure (PA)” and make the application in the area to be repaired so as to uniformly fill it. Then continue to apply heat with hot air or another method indicated by the supplier in the qualified PA, so as to simultaneously heat the deposited product and the repaired area. Using a putty knife, render the surface uniform, checking if the product is perfectly adhered to the pipe coating. 11.2 Elastomeric Filler Mastic Combined with Polyethylene Laminate (Patch)

11.2.1 Preheat the surface to be repaired as indicated in the qualified PA, remove the protective paper from the mastic and manually mold it so as to fill the entire area to be repaired. Then apply heat by means of propane or LPG torches with a moderate flame on the product deposited on the damaged area. Using a heated putty knife, render the surface of the mastic on the pipe coating uniform. After removing excess material, if any, apply the patch for its mechanical protection.

11.2.2 The area prepared as described in the Notes of Table 14 (metal and adjacent coating) shall be preheated as indicated in the qualified Application Procedure (PA). In the area from which the coating has been removed, primer and a suitable adhesive shall be applied, if necessary, as indicated in Table 14. 11.2.3 Cut a apiece of polyolefin sleeve (patch) so as to allow the damaged area to be covered and its corners to be rounded (see Annex C) overlapping at least 100 mm to each side of the damaged region. 11.2.4 Provision shall be made to prevent pieces of adhesive from being attached between the surface of the original coating and the patch. 11.2.5 The polyolefin patch shall have its adhesive preheated by means of a propane or LPG torch with a moderate flame until it acquires a glossy appearance. The area to be repaired shall also be preheated as indicated in the qualified Application Procedure (PA). 11.2.6 After its centered application on the air to be repaired, the external film of the patch shall be once again uniformly heated and pressed against the piping to prevent the occurrence of roughness or air bubbles and ensure proper adhesion. 11.2.7 Provision shall be made to prevent the filler mastic from flowing and penetrating between the patch and the surface of the original pipe coating. 11.2.8 No edges shall be allowed to be raised over the original coating. Provision shall be made to ensure that after the repair is cooled down the adhesive has flowed through the edges of the patch.

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11.2.9 The repair shall be completely conformed to the original coating. Repair patches may not be placed one on top of the other. 11.3 Polypropylene Filler Adhesive Combined with Polypropylene Laminate (Patch)

11.3.1 Preheat the surface to be repaired as indicated in the qualified PA, cut a piece of the adhesive that is large enough to cover the entire area to be repaired. Then apply heat preferably with hot air or by means of propane or LPG torches with a moderate flame on the product deposited on the damaged area. Using a heated putty knife, render the surface of the adhesive to the pipe coating uniform. After removing the excess material, if any, apply the patch for its mechanical protection, when applicable.

11.3.2 Follow the procedures described in 11.2.2 to 11.2.9, considering that in 11.2.7 the filler material is polypropylene adhesive. 11.4 Heat-Shrinkable Sleeve Heat-shrinkable sleeves shall comply with the provisions in PETROBRAS N-2328. 12 Inspection and Tests During the repair application phase, provision shall be made for at least the tests described in 12.1 to 12.3. All repaired areas that come into contact with pipe handling accessories shall be re-inspected and, if necessary, the repair work shall be redone. 12.1 Thickness Measurement 12.1.1 Four measurements uniformly distributed along the repair area shall be made using an electromagnetic, magnetic or ultrasonic device. All values measured shall be recorded and the dry film

thickness required shall be 15050450

μm.

12.1.2 Before the measurements are made, calibration procedures according to ABNT NBR 10443 shall be followed. Repeat these procedures at least once every 8 hours. NOTE This test applies only to epoxy repairs. 12.2 Visual 12.2.1 A visual examination shall be performed in the entire surface of the repaired section. 12.2.2 A non-uniform color and appearance, bubbles, notches, wrinkles, protrusions, contaminants, and other defects jeopardizing the performance of the repair are not acceptable and shall be corrected.


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12.2.3 For repairs with polyethylene or polypropylene laminate (patch), the visual inspection shall contemplate the following requirements:

a) the patch shall be fully in contact with the surface of the original pipe coating; b) the minimum overlapping over the original pipe coating shall be at least 100 mm; c) the patch shall present fluid adhesive on its edges; d) the surface of the patch shall be in sound conditions, with no cracks caused by

overheating; e) the entire surface of the repair shall be smooth, with no traces of air bubbles or raised

edges; f) if any of the conditions mentioned in the previous items are not satisfied (except

overheating), the patch may be reheated in order to satisfy all of the conditions. If this does not occur, the repair shall be removed and remade.

12.3 Holiday Detector Test 12.3.1 It shall be performed on 100 % of the repair surface. The test voltage shall be indicated by the repair supplier, but it shall not be less than 1.5 kV. A dry type full rectified wave DC holiday detector shall be used according to NACE SP 0188. The measuring device shall be adjusted to its sensitivity before each test starts. NOTE As a safety measure, it is not permitted to use holiday detectors on days in which there is

risk of lightning. All safety requirements prescribed in NACE SP 0188 shall be met before the test is released.

12.3.2 The contact electrode shall be comprised of a copper brush, conductive rubber or square wire spring and shall travel over the pipeline at a maximum speed of 18 m/min. 12.3.3 If holidays are detected, the repair shall be fully replaced.

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Annex A - Application Procedure (PA)

A.1 The PA of the manufacturer of the repair system shall comply with all of the requirements of this Standard and contain, at least, the following items:

a) technical document on which the PA was based; b) qualified repair materials to be used, with commercial reference and physical and

chemical characteristics according to Section 6; c) repair identification, indicating the application temperature and the maximum pipeline

operating temperature; d) characteristics of measuring equipment and instruments to be used; e) repair material receiving, storage, and transportation plan; f) repair application method, contemplating:

— proper type of solvent for cleaning the surface to be repaired; — environmental conditions; — cleaning of steel pipeline and its original coating, mentioning the preparation grade of

the steel pipeline surface in the repair region and how to prepare the original coating in the overlapping area;

— repair application; g) requirements of repair applied; h) inspection and test methods of the items listed below, contemplating frequency of

inspections, dimensions, and number of test specimens and their acceptance or rejection criteria: — in the repair material; — in the repair applied;

i) handling of repaired pipe; j) entity responsible for tests.

A.2 There shall be a specific PA for each repair material listed in 1.3.

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Annex B - Qualification B.1 Qualification of PA B.1.1 PETROBRAS or professionals designated by the latter shall witness all qualification tests and inspections mentioned in Annex A, that is, the raw materials comprising the repair and the requirements of the repair applied, as mentioned in Section 6. B.1.2 Before this qualification starts, the repair supplier shall present the PA approved by PETROBRAS, as well as the respective material quality certificates containing at least the commercial reference and the physical and chemical characteristics according to Section 6. NOTE Final qualification of the PA of the repair supplier is contingent upon full compliance with the

requirements of Section 6 and the other requirements specified by PETROBRAS, such as, for example, the implementation of a quality system in accordance with ABNT NBR ISO 9001.

B.1.3 Tests shall be performed on repairs applied as described below:

a) create 3 types of damages of each of types II to VI of Table 14, for which the repair is applicable, in pipes coated with triple layer polyethylene or polypropylene and 3 damages of each of types I and II of Section 9 for FBE-coated pipes, with a minimum diameter of 8” and at least 40” long, for each operating temperature and type of repair to be applied;

b) in the sequence, damages on pipes coated with polyethylene, polypropylene or FBE shall be repaired in accordance with the PA indicated for each repair and, in each one of them, all tests and inspections defined in Sections 6 and 12 shall be performed and recorded according to the limit temperature of the repair to be applied.

B.1.4 The dimension and number of test specimens, the acceptance and rejection criteria, the location and the time schedule for the performance of qualification tests shall be attached to the PA.

NOTE Qualification of the PA shall be interrupted when any test or inspection performed presents

an unacceptable result, and the entire qualification process shall be restarted. During a new qualification, the raw materials comprising the repair that have already satisfied B.1.3 will not be required to undergo new lab tests. The PA shall be considered qualified when all tests and inspection are in accordance with the requirements set forth in this Standard.

B.1.5 Qualification tests are valid for the specific conditions that were used for applying the repair. NOTE In case any of the raw materials comprising the repair are modified, a new qualification shall

be undertaken, and, for heat-shrinkable sleeves, the provisions in PETROBRAS N-2328 shall be performed.

B.1.6 Upon completion of qualification works, the supplier shall issue, for final approval of PETROBRAS and before the beginning of field production activities, a duly identified qualification file in digital form, containing at least the following information and/or documents:

a) manufacturers of raw materials comprising the repair; b) specification of raw materials with their respective temperature limits; c) raw material quality certificate; d) application procedure; e) measuring equipment and instruments with the respective calibration certificates of the

application process; f) thickness and other repair dimensions; g) treatment of steel pipe surface and original coating in the area to be repaired;


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h) results of the inspections and tests of raw materials and repair applied, with the respective entities that performed the tests;

i) list of application agents and inspectors trained by the repair supplier. B.2 Qualification of Coating System Applicators and Inspectors B.2.1 Before field repair application services are started and in the presence of PETROBRAS or professionals designated by the latter, each applicator previously trained by the repair supplier shall proceed as described below:

a) apply 3 repairs for type II, V and VI.b damages of Table 14 on pipes coated with polyethylene or polypropylene or 3 repairs for type I and II damages of Section 9 in case pipes are coated with FBE;

b) all the tests and inspections defined in Table B.1 shall be performed, recording the results obtained.

Table B.1 - Tests and Inspections for Qualification of Applicators and Inspectors

Type of repair Tests and inspections

Liquid epoxy Section 12 and Adhesion Test of Table 13

Heat-shrinkable sleeve Section 12 and Adhesion Test - dynamometer method of PETROBRAS N-2328

Elastomeric mastic combined with polyethylene laminate

Section 12 and Annex C of this Standard

Polypropylene adhesive combined with polypropylene laminate

Section 12 and Annex C of this Standard

B.2.2 Applicators whose tests and inspections mentioned in B.2.1 comply with the acceptance criteria of the Application Procedure are qualified to apply the repair in the field. Inspectors shall take part in the entire coating inspection training program and shall provide evidence that they are qualified to inspect the repairs applied according to the supplier’s recommendations. If the applicator or inspector has already been qualified for a type of repair on a particular PETROBRAS project within the past two years, he/she will not be required to undergo this qualification phase. B.2.3 Applicators and inspectors should be qualified during the PA qualification phase with follow-up by the supplier.[Recommended Practice]


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Annex C - Adhesion Test - Dynamometer Method - Polyethylene Laminate or Irradiated

Polypropylene with Adhesive (Patch) - Test in Region Overlapping Pipe Coating

a) mark the surface of the patch in the area overlapping the original steel pipe coating with

25 mm wide and 125 mm long strips in the direction crosswise to the pipe centerline; b) cut the demarcated strips until the surface of the pipe coating is reached; c) raise one of the ends of the strip to attach the dynamometer yoke, ensuring that the

adhesive is removed from the original coating and not only the polyethylene or polypropylene film from the adhesive, since this would mask the test results;

d) apply loading increasing from 1.0 kgf/s to 4.0 kgf; e) keep this load for 60 seconds, always in the direction orthogonal to the pipe centerline; f) after the testing period, the maximum pull-off shall be 80 mm.

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Pipeline

A

A

Defectpatch

Start of test

End of test

Section A-A

100

25

80 mm(Max.)

P = 4,0 kgf(see Note 2)

125

100

100

100

Note 1: Dimensions in millimeters, unless otherwise indicated. Note 2: Keep a force of P = 4.0 kgf in the radial direction for 60 seconds.

Figure C.1 - Adhesion Test on Patch - Dynamometer Method

petrobras n-2911

Documents

water vapor

electronic

salt spray

material quality

equipment

raw materials

relative air

dew point