1. UMM AL DALAK FIELD EARLY PRODUCTION SCHEME (EPC)
RESPONSE TO ADNOC OFFSHORE COMMENTS ON
Documents Title (XXXXXXXXXXXXXXXXX)
CLIENT : ADNOC-OFFSHORE NPCC ADNOC-OFFSHORE
PROJECT TITLE : UMM AL DALAK FIELD EARLY PRODUCTION SCHEME (EPC) Prepared: Prepared: Page No. 1 of 2
NPCC/ADNOC JOB
No. :
2136 / E1279 Checked: Checked: Rev. No. Last Rev.
NPCC DOC. No. : 2136-XXXXAC-XXX-XXX- Rev. xx Approved: Approved:
AO Ref. No. : Transmittal from AO: XX-NPCC-XXX Date: XX-XX-20X
Form No. E-030 (Proj.2136)
CRS for WP
ITEM
NO.
SECTION
NO.
ADNOC-OFFSHORE COMMENTS VENDOR / NPCC RESPONSE
ADNOC-OFFSHORE
RESPONSE
SITE COMMENTS
1
Page 3 –
section 2.1.5
Maximum design temperature of the projects shall be
included
Added as per requirement
2 Page 3 –
section 2.1.1
Pre-Inspection Meeting (PIM) section to be added Added as per requirement
3
Page 4 –
section 3.1
Table 1
Hot seawater resistance to be changed to less than 3.0% Revised as per requirement
4
Page 4 –
section 3.1
Table 1
Abrasion loss and Water absorption
ADNOC’s latest Neoprene coating standard (attached
in last page of MTP) has been referred for the
testing standards. can be discussed during PIM.
Noted & closed
2. UMM AL DALKH EARLY PRODUCTION SCHEME EPC PROJECT
CONTRACT No: 798586
COMPANY PROJECT No. E1279 / CONTRACTOR PROJECT No. 2136
A4 29.06.2022 Issued for review/comments
Meenu Baby(DC) Meenu Baby(DC) Joseph Richard
(AGM QHSE)
A3 26.05.2022 Issued for review/comments
Meenu Baby(DC) Meenu Baby(DC) Joseph Richard
(AGM QHSE)
A2 24.05.2022 Issued for review/comments
Meenu Baby(DC) Meenu Baby(DC) Joseph Richard
(AGM QHSE)
A1 29.04.2022 Issued for review/comments
Meenu Baby(DC) Meenu Baby(DC) Joseph Richard
(AGM QHSE)
Rev Date Description
Prepared
By
Reviewed
By
Approved
By
C
NPCC Purchase Order Number : 2136-PRJ-SEC-2021/872/A
Equipment / Material : Neoprene Coating of Riser & Clamps
Equipment Tag No. :
MANUFACTURING/TEST PROCEDURE FOR NEOPRENE COATING
DOCUMENT CLASS D2
CONTRACTOR Doc. No. : 2136-872A-X003-001
COMPANY Doc. No.: XXX-XXXX-XX-X
VENDOR Doc. No. ORF-4001-MTP-0002
3. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
1 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
TABLE OF CONTENTS
Nr. Description Page. Nr.
1.0 Revision Control Sheet 2
2.0
2.0 Reference standards, project specifications and documents
2.1 Scope
2.2 Quality Assurance and Plan
2.3 Pre-qualification Test
3
3
3
3
3.0 Materials
3.1 Summary of PCP properties
3.2 Equipment for testing PCP properties
4
4
5
4.0 Elastomer Preparation 6
5.0 Application Procedure
5.1 Preliminary Measurement Inspection
5.2 Surface Preparation
5.3 Priming and coating
5.4 Coating of Riser pipes
5.5 Coating application on Clamps
5.6 Vulcanization
5.7 Repair of applied coating after vulcanization
5.8 Field joint coating
6
6
7
7
10
10
11
12
6.0 Inspection and Testing of coating on, clamps 13
7.0 Treatment of rejected pipe joints, clamps and coatings 14
8.0 Handling, Storage and Delivery 14
9.0 Data sheets of Neoprene raw material & Bonding Agents. 15-21
10.0 Health, Safety and Environment Policy
10.1 Occupational Health Policy
22
23
11.0 List of Risers and clamps under scope of Ocean Rubber 24
12.0 Approved drawings showing coating thickness for Risers and clamps (Typical) 25-28
13.0 Material properties sheet from doc. A0-IG-P-SP-009 rev.0 29
4. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
2 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
1.0 - REVISION CONTROL SHEET
Rev. # Date
Page
#
section Description
A1 23.05.2022 All
pages
Project # 2136 removed from title
Comments incorporated
A2 26.05.2022 3
4
section
2.3.4
table
3.1
Cathodic disbondment test and Ozone test revised as
mandatory requirement and to be conducted
Cathodic disbondment test and Ozone test revised as
mandatory requirement and to be conducted
A3 22.05.2022 3
4
2.1.5
2.2.1
3.1
Maximum design Temperature added
PIM section added
Table-1 – hot seawater resistance changed to less than
3%
5. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
3 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
2.0 Reference Standards, Company specifications and documents
The elastomer coating shall be firstly in accordance with these Specification and secondly in accordance with the
latest edition at the time of actual work for the following:
E1279-TS-PLW-L-0010 rev.E1 - ADNOC project Specification for Neoprene coating for Risers & Riser clamps
SP-1040 rev.0 - Engineering Specification for Neoprene corrosion protective coating of Riser Pipes and Clamps
A0-ENG-S-SP-105 rev.0 - ADNOC specification for Riser clamp
A0-IG-P-SP-009 rev.0 - ADNOC offshore tech. standard – Specification for Neoprene & EPDM coating of Risers & Clamps
2.1 Scope The scope includes Polychloroprene (Neoprene) coating of Risers, Clamps and field joints. The
specification covers the minimum requirement for riser coating materials, surface preparation, coating
application in the plant and in yard, quality control, handling, storage and certification by OCEAN RUBBER
FACTORY LLC, U.A.E. for the external protection from corrosion of the relevant carbon steel riser line. The
elastomeric anti-corrosion and mechanical protective coating of non-conductive grade has very good adhesion to
steel and meets the following requirements and the specification given in this manual:
1. Suitable for coating of pipes, clamps & field joints
2. Design life of minimum 40 years.
3. Suitable for Surface temperature of -100
C to +920
C
4. See attached list of pipes and clamps which will be under scope of Ocean Rubber – page 24
5. Maximum design temperature for the project will be +600
C
2.2 Quality Assurance and Quality Plan
Ocean Rubber Factory LLC, is certified to ISO 9001:2015 with Certificate number: 33368. Inspection & Test
Plan (ITP) document format number QF-QC-024 is submitted for every project with an identification number
which lists all the logical sequential activities to be undertaken to complete the work. Internal Quality formats
[eg. QF-PUR-001, 002,003 etc.] will be made available to the client on request.
2.2.1 PRE-INSPECTION meeting (PIM)
PIM will be held between Ocean Rubber, NPCC and CPY, prior to start of work, to review the ITP & work
procedure and discuss any points which require clarification.
2.3 Prequalification Test
1. Test certificates / Data sheets of Primer, Polychloroprene and Bonding agent will be submitted.
2. Neoprene application Process and final inspection PQT for riser pipe coating and field joint coating will be
conducted on a 8 inches x 3 metres length pipe provided by NPCC.
3. Clamps coating procedure process PQT will be conducted on the first production clamp.
4. Neoprene material PQT will be conducted in Ocean Rubber’s laboratory in the presence of NPCC/ADNOC/TPIs.
Total of 11 tests are required as per project specification. 8 tests will be completed in a period of 2 to 3 days.
(Hardness, Tensile strength, Elongation at break, Tear resistance, Abrasion loss, compression set, Specific
gravity and water absorption ). 1 Test (hot seawater resistance Test) will be completed in a period of 30 days.
For the balance 2 Tests (Ozone resistance test and Cathodic disbondment test ), Ozone Test Will be conducted
in USA Lab (7 days test with cycle time of 6 to 7 weeks ) and Cathodic Disbondment Test will be conducted in
Element Lab in Abu Dhabi.( 28 days test with cycle time of 6 to 7 weeks )
6. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
4 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
3.0 Materials
Elastomeric protective coatings based on Polychloroprene ( PCP/Neoprene) is applied to pipeline risers, clamps
and field joints. The required properties of the elastomeric coating are given below. The coating will withstand
exposure to oxidation and ozone, and surface temperature range [-100
C and 920
C ]. The coating will have good
resistance to mechanical damage, exhibit strong adhesion to steel and cathodic disbondment resistance. The
design life will be minimum (40) years.
Nominal thickness of the PCP lining for the riser pipes of 8 inches will be 15mm (+3/-0 mm).
Riser Clamps will be coated with thickness as per project drawings with 12mm(+2/-0mm) thick Ribbed inside the
clamps and 8mm (±2mm) thick plain Neoprene on hanger clamp top flange as specified in drawings.
Brace clamps will be coated with thickness as per project drawings with 12mm(+2/-0mm) thick Plain Neoprene.
Field joint coating thickness will be 15mm ( +3mm/-1mm). Company approved drawings showing thickness of
coating on risers, riser flange, riser clamps attached in pages 25-28 of this document. The PCP coating shall be in
accordance with the requirements listed in table 1.
All material will be issued and used on “First in First out" basis.
3.1 Table 1 – Summary of Polychloroprene Properties
Un-aged Material Properties Test Frequency
Hardness 65 ± 5 Shore A
ISO 868 for field and ISO 48-4(*)
for laboratory Test
Each batch and every
joint
Ozone Resistance No cracks ISO 1431-1 (40 ° C, 50 pphm 168
hrs 20%applied strain) (*)
One batch in Ten. (One
Test Minimum)
Tensile Strength 14 N/mm
2
minimum ISO 37 or ASTM D412(*) 1 per 5 batches
Elongation at Break Greater than 350 % ISO 37 or ASTM D412(*) 1 per 5 batches
Tear Strength 45 N/mm minimum ISO 34-1 or ASTM D624(*) 1 per 5 batches
Hot seawater
resistance
Less than 3.0% by volume change with no blistering
ISO 1817 (*)
(30 days @ 70° C in seawater)
One batch in five. (One
Test Minimum)
Cathodic
disbondment 5mm max.
ASTM G8 ( 28 days, 25
0
C, at –
1.5V potential )
One batch in five. (One
Test Minimum)
Abrasion Loss 260 mm
3
max. ISO 4649 (*) One batch in five. (One
Test Minimum)
Compression Set 30 % maximum ISO 815-1, 22 Hrs at 70°C(*) One Test Minimum
Specific Gravity 1.33 ± 0.03 ISO 2781(*) Each batch
Water Absorption 3.0 % max. by volume change ISO 1817, 22 Hrs at 70°C(*) Each batch
(*) – Test standards marked with (*) are taken from ADNOC standard A0-IG-P-SP-009 ( Rev.0)-relevant page attached
(page 29)
7. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
5 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
3.2 Equipment for testing PCP Properties
Rubber Hardness Testing Equipment Rheometer and Viscometer
Electronic Densimeter Computerised Universal Testing Machine
Compression Set equipment Abrasion Resistance equipment
8. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
6 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
4.0 Elastomer preparation
Quality control shall be carried out on the base products, and the independent certificates forwarded to
client in the close-out documentation. Rheometric values and viscometer values of the PCP will be
forwarded to the Client on request.
5.0 Application Procedure
5.1 Preliminary Measurement and Inspection
a) Check for the serial number, measured length in meters and all the information marked on the pipe joint
and clamps and record the same in Customer Supplied Products Report. Before start of any activity, all
traceability marking shall be transferred in non-coated area of pipe/clamp.
b) Carry out visual inspection on the pipes and clamps for any indentations or other external damage
including corrosion damage and record if any, against the pipe joint serial number and inform the
customer for further action. Any damage found is to be rectified after Client approval.
c) Arrange for removal of bevel protectors, end caps if any, and refit the same after coating.
d) Clamps and field joint sections will also be inspected and results recorded as above.
5.2 Surface Preparation
a) Remove grease and oil if any, using approved solvents which do not leave residue.
b) Following degreasing all surfaces shall be detergent washed with 5% Biprox or equivalent, rinse repeatedly
with high pressure (3000 psi) potable water with less than 200ppm total dissolved solids and less than
50ppm chlorides and allow to dry. Check by quantitative chemical analysis (Salt meter using Bresle method)
for soluble salt contamination, if present, salt contamination should be removed from the pipe spool
surface by rinsing with high pressure fresh potable water. The acceptable limit for the salt on the pipe is 20
mg/m2
max., after blasting.
c) Approved grit (Garnet) shall be used to provide the required anchor profile. Check blasting air for oil and
moisture contamination.
d) Blast the pipes, clamps or field joint sections as per the following conditions :
The pipe surface temperature shall be at least 30
C above the Dew point. Pipe surface will be heated if
required.
Relative humidity : Less than 85% Temperature : 10 to 50 degree C.
Blast cleanliness : SA 3.0 of ISO 8501–1 or ASTM D2200 A Surface amplitude : 75 to 100 microns
e) Use the cellulose tape and check for presence of any dust and if found, clean with dry, clean air. The
allowable dust presence will be Class1.
f) Within 30 minutes of completion of blasting, apply primer on the the blasted items and complete within
four (4) hours.
9. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
7 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
5.3 Priming and Coating
A). Materials used All material will be issued and used on " First in First out" basis.
1. Primer layer – Chemlok 205 (grey colour). – Applied by roller or brush
2. Bonding Agent Layer- Chemlok 6224 (black colour). – Applied by roller or brush
3. Tack cement rubber solution ( PCP Compound Solution) – Applied by roller or brush
4. Elastomeric coating material [eg. PCP from Denka/Dupont Chloroprene, Japan, Bayprene].
B) Primer and bonding cement
1. The application of the primer will begin within 30 minutes of completion of blasting and completed
within four (4) hours of blast cleaning. Stripe coating will be done on welded joints, edges and holes.
Apply one coat of primer at a coating thickness of 10 to 30 microns DFT and allow it to dry completely.
Thickness is checked using thickness Gauge.
2. Apply one coat of bonding agent at coating thickness of 15 to 30 microns and allow it to dry completely.
Ensure clean surface prior to coating.
3. Within 2 hours of bonding agent coating, apply a coat of tack cement rubber solution and allow it to dry
completely.
4. Bonding agents are coated on the pipes by leaving maximum 150mm cutback from the end of the pipes.
5. During the bonding system application and curing, ensure the steel surface is at least 50
C above the dew
point and the relative humidity is below 75%. If necessary, the pipe surface will be warmed but will not
be raised above 450
C.
5.4 Coating of Riser Pipes using automatic machine and
Hot vulcanizing Technique
Elastomeric material shall be coated on the riser pipe using automatic coating machine.
The time gap for each operation is as follows:
Primer application – start within 30 minutes of blasting and complete within 4 hours
Bonding agent application – start within 4 hours of priming
Tack cement rubber solution – start within 2 hours of bonding agent application
PCP/Neoprene coating application – start within 15 hours of tack cement rubber solution application
10. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
8 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
Coating of Riser Pipes using Automatic Pipe Coating machine
Riser Pipe being coated in an Automatic Coating Plant
The PCP will be extruded into a tape and applied by pressure sticking. The pipe to be coated will be
fixed between the headstock and tailstock. The tape extruder unit / pressure sticker will be carriage
mounted and will run parallel on rails.
The cold feed extruder with variable pitch screw will produce a continuous strip of fresh, warm
compound which will be spirally wound on the rotating pipe joint and is then firmly stuck using a
pressure roller.
The dimensions of the extruded strip are checked and the required thickness of coating as per project
specification is achieved by repeating the process.
11. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
9 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
Visual check and holiday detection
(1.7 KV per mm thickness) is carried out. Any minor
filling up of PCP is carried out by stitching the
uncured PCP using roller ensuring there is no air
entrapment. Holiday test is repeated.
Pressure Roller of Automatic Coating Plant
Nylon tape (75mm—100mm width) will also be machine applied to attain uniform tension and not manually
applied. Nylon tape is wound on a spool mounted on the traversing carriage of the automatic coating
machine.
Nylon tape being wound automatically by machine under uniform tension
The tape will be wound initially by hand around the bare ends of the pipe and then wrapped around the
coating with a 50% overlap automatically by the machine. The tape tension and overlap is adjusted to
uniform wrapping. The nylon tape is wrapped until it covers about 150mm of the other bare end. The
coating is double-wrapped for a length of 300mm to maintain tension. Adhesive tapes are used to secure
the nylon tape ends.
12. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
10 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
5.5 Coating of Clamps
Clamps will be internally coated using calendared Neoprene sheets applied and stitched manually as per
standard rubber lining process. Calendared rubber sheets of the required size with allowance for trimming
are measured and cut. The side to be bonded is cleaned with solvent and applied on the pipe by stitching the
sheet manually starting from one edge to the other, gradually removing any air entrapments. 100% of the
area to be coated will be stitched. The number of layers of sheets will depend on the final thickness
requirement. Recommended thickness of each layer of sheet is 1mm to 5mm. Where Ribbed Neoprene is to
be applied premoulded ribbed sheet will be used.
The coated area is spark tested and any holidays detected will be repaired. Any repair is carried out by stitching
the uncured rubber using roller ensuring there is no air entrapment. Holiday test is repeated.
Vulcanisation is carried out as per Section 5.6.
PCP coated clamp being checked for holiday prior to vulcanisation
5.6 Vulcanisation
The applied elastomer coating is vulcanised in a steam pressure autoclave at a pressure of
4±0.3kg/cm2
(150±10°C ) for a period of 3.5 to 4 hours. The coated pipe and clamp is to be
placed in the autoclave within a period of 24 hours (maximum) after completion of coating.
13. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
11 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
5.7 Repair of Applied coating after vulcanisation
Any repair to the coating will be carried out only after approval from the Owner.
Any damaged areas to the coating will be informed to to the contractor/owner for approval
prior to repairs. Standard guidelines for repairs are classified below into A,B & C
A) Surface flaws of less than 3 mm depth shall be repaired using a self-curing mixture
compound A & B. The repair area shall be lightly abraded and cleaned with solvent. Mix
equal quantities of compound A and B thoroughly, and apply on the area to be repaired.
Allow to cure for 48 hours at a room temperature and the hardness shall be 60±5 shore A
when fully cured. This is allowed for ≤ 20 mm2
.
B) Generally repairs shall be carried out to the areas of diameter less then or equal to
100mm2
. The maximum area of repair can be 10mm x10mm.
Cut the faulty coating and taper the edges with a sharp knife to angle of about 200
to 300.
The chamfered edges are then roughened abrading with a power wire brush or suitable hand
tool.
The exposed steel surface shall be cleaned and roughened by using a grinding disc.
Prime the to be repaired area.
Apply bonding and rubber solutions (after each one is dried completely) to the primer coated
area and the tapered edges.
Cut rubber sheet to the size of to be repaired area and stitch the same using the special
tools.
Trim the excess compound, if any.
A 50mm wide by 2mm thick strip of rubber shall be stitched over the joint.
The repaired area plus at least 150mm either side shall be wrapped tightly with Nylon tape .
Using the spot vulcaniser, (electrically heated) Vulcanise the repaired area.
Arrange for inspection for hardness, thickness, visual and spark test and no leaks are
permitted.
14. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
12 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
5.8 Field Joint Coating Procedure
a) Cut the edges of the present PCP coating to 30o
angle and make it rough by grinding. Carry out this for
both sides.
b) Follow the surface preparation, primer coating after taking into consideration all requirements as
stated in section 5.2 and 5.3 of this procedure
c) Coat the required thickness as per the
customer’s requirement in layers of 1
mm to 5mm thick sheets of uncured
PCP Sheets.
d) Use Aluminum Foil, if necessary, and
Vulcanize with Field joint press-
electrically Heated Press with
Temperature Control Panel, for joining.
e) Set the temperature between 130 to
1500
C and allow curing for a period of
time as mentioned in the respective
Job Card. Arrange for testing the joints
for visual, hardness, holidays,
dimension and thickness. Coated Field Joints
15. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
13 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
6.0 Inspection & Testing of coated riser pipes, clamps and field joints
6.1 Visual Inspection – All coated items will be visually checked 100% for surface imperfections, lack of bond at
joints and ends, blisters, delaminations, cuts, indentations, excessive tape marking and other apparent
irregularities and marked clearly and informed to client/TPI.
6.2 Coating Thickness Testing – Calibrated instruments such as vernier calipers, measuring tape and digital
coating thickness gauge will be used at equally spaced 4 locations around the coated item at different locations.
6.3 Hardness - Use calibrated hand held Hardness meter- Shore A, and take the readings at equally spaced 4
locations around the coated item at different locations.
6.4 High Voltage Holiday Detection - Carryout the Holiday test at 1.7 kV per mm ( to be at least 30 KV capacity).
1.7KV/mm based on allowable electric strength of 3.4 KV/mm of the material derived from Ocean Rubber’s past
experience and tests on the coating material. 100% Holiday voltage detection test is to be carried out and
coating and lining shall be free of holidays. The holiday detection will be calibrated at field prior to use using high
voltage voltmeter.
6.5 Adhesion Test
a) Prepare a test coupon at the same time and
same autoclave as the coated items like
Clamps. Or cut 25mm wide strip of elastomer
coating in a coated pipe joint or bend and test
using load cell with digital display. The
adhesive strength of the coating shall be a
minimum of 12 N/mm. Exposure of bare or
primed steel beneath the pull off sample
shows poor bonding.
6.6 Hammer (Sounding ) Test
Carry out the Hammer ( 1 Kg hammer ) test at vertical height of at least 500mm every 150mm in equal four
planes in the coated items (north, south, east and west) at 150mm intervals. Locate where change of sound is
noticed.
7.0 Treatment of Rejected Pipe Joints and Coating
Procedure for removal of rubber from rejected joints/coatings shall be submitted to Client before
commencing the work. In case of Blasting surface rejection arrange for reblast and incase of coating
rejection, remove the coating and arrange to recoat after repeating surface preparation. Pipe joints
which have been quarantined due to the presence of an excessive number of steel surface defects are to
be returned to client. In case of any conflict of requirements and acceptance criteria between project
specifications, procedures and ITP’s, the most stringent requirement will apply.
Load Cell with digital display for Adhesion Test
16. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
14 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
8.0 Handling, Storage and Delivery
Pipe and Clamp handling :
1. The handling of Pipes and clamps are by using crane, forklift or trolleys in a safe manner
preventing damage to the items and its coated surfaces.
2. The items shall not be dragged. The items shall be picked up bodily using End hooks suitable
radii lined with Plastic or similar approved material. A spreader Bar is used between the lifting
lines.
3. Pipes (bare and Coated) shall be safely stacked on level yards, free from foreign materials of a
Proven load bearing capacity. No contact with ground is allowed and min. space of 150mm from
ground level is maintained.
4. Delivery of Riser Pipes and Clamps shall be by means which ensure protection of the quality of
the product after final inspection and test. Where contractually specified, this protection shall be
extended to include delivery to destination.
5. Delivery shall be by means of Delivery note indicating product description and quantity and
signed by authorized delivery personnel. On receipt of goods customer/ representative shall sign
the delivery note evidencing receipt of the goods.
6. Materials used for coating will have distinct Product identification and Traceability with batch
numbers, date of manufacturing and Quantity.
7. All the Pipes are identified with marks, before commencement of Surface preparation.
9.0 Data Sheets of Neoprene raw material & Bonding Agents - As attached in following pages
117. LORD TECHNICAL DATA
LORD TECHNICAL DATA
Description
LORD Chemlok®
205 adhesive is a heat-activated
adhesive designed for use as a substrate primer under
other Chemlok covercoat adhesives, or as a one-coat
adhesive for bonding unvulcanized nitrile elastomer
compounds. It is composed of a mixture of polymers,
organic compounds and mineral fillers dissolved or
dispersed in an organic solvent system.
Features and Benefits
Versatile – can be used as a primer under a wide variety
of Chemlok covercoat adhesives such as the Chemlok
220 series, Chemlok 230 series, Chemlok 250 series or
Chemlok 6000 series adhesives.
Convenient – can be used as a one-coat adhesive to
bond some nitrile rubber compounds to rigid substrates
during vulcanization.
Easy to Apply – applies easily by brush, dip, spray or
roll coat methods; suitable for existing production lines.
Durable – provides rubber tearing bonds and excellent
environmental resistance when used in combination with
Chemlok covercoat adhesives.
Chemlok
®
205 Adhesive and/or Primer
Application
Surface Preparation – Thoroughly clean metal surfaces
prior to adhesive application. Remove protective oils,
cutting oils and greases by solvent degreasing or
alkaline cleaning. Remove rust, scale or oxide coatings
by suitable chemical or mechanical cleaning methods.
• Chemical Cleaning
Chemical treatments are readily adapted to auto-
mated metal treatment and adhesive application
lines. Chemical treatments are also used on metal
parts that would be distorted by blast cleaning or
where tight tolerances must be maintained. Phos-
phatizing is a commonly used chemical treatment for
steel, while conversion coatings are commonly used
for aluminum.
• Mechanical Cleaning
Grit blasting is the most widely used method of
mechanical cleaning. However machining, grinding
or wire brushing can be used. Use steel grit to blast
clean steel, cast iron and other ferrous metals. Use
aluminum oxide, sand or other nonferrous grit to blast
clean stainless steel, aluminum, brass, zinc and other
nonferrous metals.
Typical Properties*
Appearance Gray Liquid
Viscosity, cps @ 25°C (77°F) 85 -165
Brookfield LVT
Spindle 2, 30 rpm
Density
kg/m3
920.0 - 970.0
(lb/gal) (7.7 - 8.1)
Solids Content by Weight, % 22 - 26
Flash Point (Seta), °C (°F) 14 (57)
Solvents Methyl Isobutyl Ketone (MIBK), Methyl Ethyl Ketone (MEK), Xylene
*Data is typical and not to be used for specification purposes.
118. LORD TECHNICAL DATA
2
For further detailed information on surface preparation of
specific substrates, refer to Chemlok Adhesives appli-
cation guide. Handle clean metal surfaces with clean
gloves to avoid contamination with skin oils.
Apply Chemlok 205 adhesive to stainless steel,
aluminum, brass or other nonferrous substrates within
one-half hour after cleaning. For ferrous substrates such
as steel, a longer layover can be tolerated if no rust is
formed.
Mixing – Thoroughly stir adhesive before use, and
agitate sufficiently during use to keep dispersed solids
uniformly suspended.
Chemlok 205 adhesive is normally used full strength
for brush, dip and roll coat applications. For spray
application, dilute adhesive to a Zahn Cup #2 viscosity
of 18-20 seconds. Chemlok 205 adhesive may be diluted
with ketone-type solvents such as MEK and MIBK without
adverse effects on handling and application. The diluent
must be slowly added to the adhesive while stirring.
Careful attention should be given to agitation since
dilution will accelerate settling. Refer to the Chemlok
Adhesives application guide for further information.
Applying – Apply adhesive by brush, dip, roll coat, spray
or any method that gives a uniform coating and avoids
excessive runs or tears.
Normally the dry film thickness of Chemlok 205 adhe-
sive should be 5.1-10.2 micron (0.2-0.4 mil). When using
Chemlok 205 adhesive over grit blasted substrates,
when using it in conjunction with Chemlok 220 series
covercoats or when using Chemlok 205 adhesive as a
nitrile adhesive, apply a dry film thickness at the high end
of the range. For all other applications (i.e., swaging or
smooth substrates), apply Chemlok 205 adhesive at the
low end of the film thickness range.
Drying/Curing – Thoroughly dry parts coated with
Chemlok 205 adhesive before applying the covercoat
adhesive. This will take approximately 30-45 minutes
at room temperature. It is best to use temperatures
of 65-93°C (150-200°F) and abundant circulating air;
however, forced air drying is possible at temperatures up
to 149°C (300°F) for short periods of time. Maximum air
flow at minimum temperatures will give the best results.
After parts have dried, apply Chemlok covercoats using
similar application methods.
Dried films of Chemlok 205 adhesive are non-tacky;
therefore, coated parts may be piled into tote pans
for subsequent processing. Wear clean gloves when
handling coated parts and cover the tote pans to prevent
contamination by dirt, grease, oil, etc. If coated parts are
properly protected, they can be stored for at least one
month before applying covercoat or bonding.
Chemlok 205 adhesive can be used to bond nitrile
rubber by compression, transfer, injection or other
molding procedures used to make bonded parts. As
with other Chemlok adhesives, maximum adhesion is
obtained when the rubber has completely cured. Ideal
bonding conditions exist when both the adhesive and the
rubber cure at the same time. To accomplish this, load
the adhesive coated metal parts in the mold and quickly
fill the cavity with rubber.
Dry films of Chemlok 205 adhesive remain firm at
molding temperatures. During transfer or injection
molding operations, the adhesive shows minimal
tendency to wipe or sweep. During multiple-cavity
loading, the prebaking begins with the first loaded metal
parts. Keep mold loading cycles to a minimum to prevent
adhesive and rubber from pre-curing. However, Chemlok
205 adhesive will resist moderate prebaking times
without affecting bond performance. Transfer or injection
molds need properly designed runners and sprues, as
well as adequate pressures. This prevents rubber pre-
curing before the mold cavities are completely filled.
Cleanup – Clean areas with a rag as soon as possible
using MEK.
119. Chemlok® 6224 Adhesive
Technical Data Sheet
Chemlok®
6224 adhesive is a high-performing covercoat
adhesive that bonds a wide variety of elastomers to various
metals. It is composed of a mixture of polymers, organic
compounds and mineral fillers dissolved or dispersed in an
organic solvent system.
Chemlok 6224 adhesive displays improved prebake
resistance and is highly resistant to boiling water, salt spray,
high temperatures and other harsh environments.
Features and Benefits:
Versatile – bonds a variety of elastomers and metals when
used in combination with Chemlok 205 primer.
Environmentally Resistant – provides superior resistance
to heat, water, salt spray, chemicals, oils, solvents and
corrosive atmospheres.
Prebake Resistant – coated parts can achieve quality
adhesion after 7-10 minute prebake in certain application
and bonding processes.
Easy to Apply – applies easily by brush, dip, spray, or roll
coat methods.
Elastomers:
• Natural Rubber (NR)
• Polyisoprene (IR)
• Styrene-butadiene (SBR)
• Polychloroprene (CR)
• Nitrile (NBR)
Application:
Surface Preparation – Thoroughly clean metal surfaces
prior to primer application. Remove protective oils, cutting
oils and greases by solvent degreasing or alkaline cleaning.
Remove rust, scale or oxide coatings by suitable chemical or
mechanical cleaning methods.
Allow primer to thoroughly dry before applying Chemlok
6224 adhesive.
For further detailed information on surface preparation of
specific substrates, refer to Chemlok Adhesives application
guide.
Mixing – Thoroughly stir adhesive before use, and agitate
sufficiently during use to keep dispersed solids uniformly
suspended. If dilution is needed, use xylene or toluene. Note
proper dilution for the various application methods is best
achieved by experience. Give careful attention to agitation
since dilution will accelerate settling.
Applying – Apply adhesive by brush, dip, spray or roll coat
methods.
Regardless of application method, the dry film thickness of
Chemlok 6224 adhesive should be 12.7-25.4 micron (0.5-
1.0 mil). Note optimum film thickness for a particular bonded
part is dependent on the rubber formulation and the level of
adhesion required.
Typical Properties*
Appearance Black Liquid
Viscosity, cps @ 25°C (77°F)
Brookfield LVT
Spindle 2, 30 rpm
100 - 300
Density
kg/m3
(lb/gal)
982 -1006
(8.15 - 8.35)
Solids Content by Weight, % 25.5 - 28.5
Flash Point (Seta), °C (°F) 27 (80)
Solvents Xylene
*Data is typical and not to be used for specification purposes.
121. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
22 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
10.0 Health, Safety and Environment Policy
The Health, Safety and Environment Policy of OCEAN RUBBER FACTORY L.L.C is to keep all employees safe
and healthy and to provide safe working environment by adopting effective Accident Preventive Practices
based on International codes and rules as well as local policies and practices.
In accordance with these policies in OCEAN RUBBER FACTORY L.L.C, we are committed to:
Pursue the goal of accident free work place.
Promote healthy and safe work procedures and methods in the company.
Protect the environment to control hazards and risks to health and safety of all employees.
Promote and implement hygienic work conditions and practices at every level.
Award HSE matters equal importance with any other critical business activity.
Use available resources to efficiently promote HSE policy.
Promote a culture in which all company employees share this commitment.
122. Issued to :
National Petroleum
Construction Co.(NPCC)
For ADNOC project
UMM AL DALKH EPS EPC PROJECT
ORF internal doc. RL-778-AD
Work Procedure for Neoprene coating of Risers, Clamps
and Field joint
ISSUE DATE COMPANY Doc No. : XXXXXXXXXXXXXX Sheet No. Rev
28.06.2022
NPCC Doc. No. : 2136-872A-X003-001
23 of 29 A4
Vendor Doc. No. : ORF-4001-MTP-0002
QF-QC-032;.Rev.0
10.1 Occupational Health Policy of OCEAN RUBBER FACTORY (ORF)
Management deems ORF’s responsibility to endeavor to the best of its ability and knowledge to
provide a working environment free from recognized hazards that may cause death or serious physical
harm to employee.
ORF shall observe the rules formulated by the country regarding employee’s Health and Safety.
ORF shall provide and maintain all equipment required for implementing the company’s HSE policy and
to effect effective House-Keeping.
ORF shall propagate HSE requirements through posters and sign boards.
ORF shall educate employees on their rights and responsibilities regarding HSE.
ORF shall apprise employees of Safe Operating Procedures for each job to enable them to follow
practices required to ensure Safety and Health.
Education of employees on Operating Procedures shall be a continuous process.
First Aid Kits will be located in easily accessible places in the factory.
At least two operators trained in administering First Aid shall be present in each shift.
T ORF shall as a matter of policy, have standing arrangements with established medical facilities and
recognized medical institutions for attending medical treatment needs including emergencies.
A vehicle and a driver shall be made available in case of an emergency.
Statutory Rules and Regulations.
Rules and Regulations of the United Arab Emirates shall be observed in to.
ORF shall appoint and empower a HSE Engineer to deal with HSE and liaise with Government authorities
in cases where necessary.
