ISO 21809-11:2019
Petroleum and natural gas industries — External coatings for buried or submerged pipelines used in pipeline transportation systems — Part 11: Coatings for in-field application, coating repairs and rehabilitation
This document specifies the criteria and requirements for the in-field application of coatings, coating repair and coating rehabilitation on buried pipelines.
This document specifies:
— coating assessment (new and existing);
— removal of degraded coatings;
— surface preparation;
— on site or in situ application of external coatings.
It is applicable to petroleum or natural gas pipelines, with or without a cathodic protection system.
The pipelines could be operational during the removal, preparation and application process.
This document states qualification/testing for field contractors and site applied coatings to all of the pipeline components, including bends, tees, fittings, valves and interfaces between different coatings in soil-to-air pipeline sections.
Technical and performance characteristics of the repair and rehabilitation coating materials are referenced to ISO 21809-3.
The coating of field joints is outside the scope of this document. Field joint coatings are dealt with in ISO 21809-3.
This document excludes the application of coatings when the pipeline is immersed (submerged).
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Foreword
Introduction
1 Scope
2 Normative references
3 Terms and definitions
4 Abbreviations
5 General requirements
5.1 Responsibility of the purchaser
5.2 Rounding
5.3 Conformity to requirements
6 Information to be supplied by the purchaser
6.1 General information
6.2 Additional information
7 Qualification processes and application procedures
7.1 General
7.1.1 Coating material qualification, by the manufacturer (coating materials qualification)
7.1.2 Qualification of the coating system, by the applicator (coating system qualification)
7.1.3 Procedure Qualification Trials (PQT) if requested by the purchaser
7.1.4 Pre-Production Trial (PPT)
7.1.5 Production test
7.2 Application Procedure Specification (APS)
7.3 Procedure Qualification Trial (PQT)
7.4 Pre-Production Trial (PPT)
7.5 Inspection and Testing Plan (ITP)
7.6 Coating materials
7.7 Qualification of coating and inspection personnel
7.7.1 General
7.7.2 Qualification of coating operatives
7.7.3 Documentary evidence of applicator’s coating operatives’ qualification
7.7.4 Requalification
7.8 Production testing and inspection
7.8.1 Inspection documents and traceability
8 Safety requirements
8.1 General
8.2 Safety precautions in flammable atmosphere
8.3 Safety precautions in confined space
8.4 Safety precautions for coating removal
8.5 Safety precautions for surface preparation and coating application
8.6 Positive isolation and ventilation
9 Requirements for quality management and quality assurance
9.1 General
9.2 Test during work execution
10 Criteria for the condition assessment of an existing coating
10.1 General — Evaluation of coating condition
10.2 Applicable inspection techniques
10.2.1 In Line Inspection (ILI)
10.2.2 Direct Current Voltage Gradient Surveys (DCVG)
10.2.3 Alternating Current Voltage gradient Survey (ACVG)
10.2.4 Current density
10.2.5 Direct assessment and visual inspection
10.2.6 Exploratory excavations
10.2.7 Testing of the existing coating system
11 Selection of the rehabilitation coating
11.1 Selection of the pipeline rehabilitation coating system
11.1.1 Contamination by soluble salts
11.1.2 Dust contamination of the substrate
11.1.3 Substrate contamination by oil, grease, and other petroleum-like products
11.1.4 Soil properties and soil stress
11.1.5 Additional mechanical protection
11.1.6 Compatibility with existing coating
11.1.7 Fittings
11.1.8 Feasibility of surface cleaning
11.1.9 Space availability for surface preparation and coating application
11.1.10 Backfilling time constraints
11.1.11 Condensation and water/moisture on the substrate
11.1.12 Substrate temperature
11.1.13 Product and applied coating temperature
11.1.14 Ambient temperature
11.1.15 Relative humidity
11.1.16 Backfill material
11.2 Additional mechanical protection
12 Removal of the existing coating and surface preparation
12.1 General
12.2 Removal of existing coating
12.3 Surface preparation
12.3.1 Hand Tools
12.3.2 Power tools
12.3.3 Abrasive blast cleaning
12.3.4 Water cleaning/jetting
12.3.5 Abrasives
12.3.6 Surface profile
12.3.7 Rust back (flash rust)
12.4 Inspect the pipe after coating removal
13 Functional requirements for extensive field coating application
13.1 Rehabilitation of in service pipeline
13.2 Environmental condition
13.3 Steel preheat
13.4 Surface preparation
13.5 Coating application
13.6 Over the ditch rehabilitation
13.7 Testing and burying the pipe
14 Functional requirements for Local Repairs of coating damage
14.1 General
14.2 Coating damage not exposing bare steel
14.3 Coating damage exposing bare steel
15 Soil-to-air interface
15.1 Distances
16 Documentation and reporting
Annex A (informative) Test programs for procedure Qualification Trials, Pre-Production Trials or Production Testing
Annex B (informative) Excavations
Annex C (informative) Excavation priority matrix for coating assessment activities
Bibliography
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Foreword
Introduction
1 Scope
2 Normative references
3 Terms and definitions
4 Abbreviations
5 General requirements
5.1 Responsibility of the purchaser
5.2 Rounding
5.3 Conformity to requirements
6 Information to be supplied by the purchaser
6.1 General information
6.2 Additional information
7 Qualification processes and application procedures
7.1 General
7.1.1 Coating material qualification, by the manufacturer (coating materials qualification)
7.1.2 Qualification of the coating system, by the applicator (coating system qualification)
7.1.3 Procedure Qualification Trials (PQT) if requested by the purchaser
7.1.4 Pre-Production Trial (PPT)
7.1.5 Production test
7.2 Application Procedure Specification (APS)
7.3 Procedure Qualification Trial (PQT)
7.4 Pre-Production Trial (PPT)
7.5 Inspection and Testing Plan (ITP)
7.6 Coating materials
7.7 Qualification of coating and inspection personnel
7.7.1 General
7.7.2 Qualification of coating operatives
7.7.3 Documentary evidence of applicator’s coating operatives’ qualification
7.7.4 Requalification
7.8 Production testing and inspection
7.8.1 Inspection documents and traceability
8 Safety requirements
8.1 General
8.2 Safety precautions in flammable atmosphere
8.3 Safety precautions in confined space
8.4 Safety precautions for coating removal
8.5 Safety precautions for surface preparation and coating application
8.6 Positive isolation and ventilation
9 Requirements for quality management and quality assurance
9.1 General
9.2 Test during work execution
10 Criteria for the condition assessment of an existing coating
10.1 General — Evaluation of coating condition
10.2 Applicable inspection techniques
10.2.1 In Line Inspection (ILI)
10.2.2 Direct Current Voltage Gradient Surveys (DCVG)
10.2.3 Alternating Current Voltage gradient Survey (ACVG)
10.2.4 Current density
10.2.5 Direct assessment and visual inspection
10.2.6 Exploratory excavations
10.2.7 Testing of the existing coating system
11 Selection of the rehabilitation coating
11.1 Selection of the pipeline rehabilitation coating system
11.1.1 Contamination by soluble salts
11.1.2 Dust contamination of the substrate
11.1.3 Substrate contamination by oil, grease, and other petroleum-like products
11.1.4 Soil properties and soil stress
11.1.5 Additional mechanical protection
11.1.6 Compatibility with existing coating
11.1.7 Fittings
11.1.8 Feasibility of surface cleaning
11.1.9 Space availability for surface preparation and coating application
11.1.10 Backfilling time constraints
11.1.11 Condensation and water/moisture on the substrate
11.1.12 Substrate temperature
11.1.13 Product and applied coating temperature
11.1.14 Ambient temperature
11.1.15 Relative humidity
11.1.16 Backfill material
11.2 Additional mechanical protection
12 Removal of the existing coating and surface preparation
12.1 General
12.2 Removal of existing coating
12.3 Surface preparation
12.3.1 Hand Tools
12.3.2 Power tools
12.3.3 Abrasive blast cleaning
12.3.4 Water cleaning/jetting
12.3.5 Abrasives
12.3.6 Surface profile
12.3.7 Rust back (flash rust)
12.4 Inspect the pipe after coating removal
13 Functional requirements for extensive field coating application
13.1 Rehabilitation of in service pipeline
13.2 Environmental condition
13.3 Steel preheat
13.4 Surface preparation
13.5 Coating application
13.6 Over the ditch rehabilitation
13.7 Testing and burying the pipe
14 Functional requirements for Local Repairs of coating damage
14.1 General
14.2 Coating damage not exposing bare steel
14.3 Coating damage exposing bare steel
15 Soil-to-air interface
15.1 Distances
16 Documentation and reporting
Annex A (informative) Test programs for procedure Qualification Trials, Pre-Production Trials or Production Testing
Annex B (informative) Excavations
Annex C (informative) Excavation priority matrix for coating assessment activities
Bibliography