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1、TECHNICAL SPECIFICATION CONCRETE COATING OF LINEPIPE DEP 31.40.30.30-Gen. November 1991 DESIGN AND ENGINEERING PRACTICE USED BY COMPANIES OF THE ROYAL DUTCH/SHELL GROUP This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prio
2、r written consent of Shell Internationale Petroleum Maatschappij B.V., The Hague, the Netherlands. The copyright of this document is vested in Shell Internationale Petroleum Maatschappij B.V., The Hague, the Netherlands. All rights reserved. Neither the whole nor any part of this document may be rep
3、roduced, stored in any retrieval system or transmitted in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owner. PREFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of pub
4、lication, of: Shell International Oil Products B.V. (SIOP) and Shell International Exploration and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, and other Service Companies. They are based on the experience acquired during their involvement with the
5、design, construction, operation and maintenance of processing units and facilities, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice. The objective is t
6、o set the recommended standard for good design and engineering practice applied by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any other such facility, and thereby to achieve maximum technical and economic benefit from sta
7、ndardization. The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each locality. The system of DEPs is expected to be sufficien
8、tly flexible to allow individual operating companies to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they shall be solely responsible for the quality of work and the attainment of the required design and engin
9、eering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, witho
10、ut detracting from his own responsibility, consult the Principal or its technical advisor. The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies of the Royal Dutch/Shell Group and other companies receiving technical advice and services
11、 from SIOP, SIEP or SIC. Consequently, three categories of users of DEPs can be distinguished: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by these Operating companies is subject in all respects to the terms and conditions of the re
12、levant Service Agreement. 2)Other parties who are authorized to use DEPs subject to appropriate contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2) which requires that tenders for projects, materials supplied or -
13、generally - work performed on behalf of the said users comply with the relevant standards. Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and SIC disclaim any liability of whatsoever nature for any damage (including injury or death) s
14、uffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this disclaimer shall inure in all respects to SIOP, SIEP, SIC and/or any company affiliated to these companies
15、that may issue DEPs or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent of SIOP and SIEP, be disclosed by users to any company or person whomsoever and the DEPs sh
16、all be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of SIOP and SIEP. The copyright of DEPs vests in SIOP and SIEP. Users shall arrange f
17、or DEPs to be held in safe custody and SIOP or SIEP may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be directed to the DEP Administrator in SIOP. NOTE: In addition to DEP publications there are Sta
18、ndard Specifications and Draft DEPs for Development (DDDs). DDDs generally introduce new procedures or techniques that will probably need updating as further experience develops during their use. The above requirements for distribution and use of DEPs are also applicable to Standard Specifications a
19、nd DDDs. Standard Specifications and DDDs will gradually be replaced by DEPs. DEP 31.40.30.30-Gen. November 1991 Page 2 TABLE OF CONTENTS 1.INTRODUCTION.5 1.1SCOPE 5 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS5 1.3DEFINITIONS 6 1.4ACTION ITEMS. 6 1.5CROSS-REFERENCES6 2.MATERIALS 7 2.
20、1LINEPIPE. 7 2.2CEMENT 8 2.3SAND/AGGREGATES.8 2.4WATER 8 2.5REINFORCEMENT STEEL.9 3.EQUIPMENT.11 4.COATING PROCESS12 4.1PROPORTIONING OF MATERIALS12 4.2APPLICATION OF CONCRETE COATING12 4.3CURING. 13 5.INSPECTION AND TESTING.15 5.1GENERAL 15 5.2MISCELLANEOUS INSPECTIONS/TESTS16 5.3STRENGTH AND DENSI
21、TY TESTING.18 5.4DETERMINATION OF SUBMERGED WEIGHT.20 5.5WATER ABSORPTION TEST 21 5.6IMPACT TESTING22 6.REPAIRS. 24 6.1GENERAL 24 6.2DAMAGED AREAS.24 6.3CRACKS 24 6.4CORE HOLES/INSPECTION AREAS.25 7.INSTALLATION OF ANODES26 7.1UNLOADING, HANDLING, STORAGE AND CLEANING.26 7.2INSTALLATION.26 7.3ELECTR
22、ICAL CONNECTIONS.26 7.4INSPECTION AND TESTING.27 7.5STACKING 28 8.PIPE IDENTIFICATION.29 8.1GENERAL 29 8.2MARKING 29 8.3PIPE TALLY. 29 9.DOCUMENTATION AND APPROVALS.30 9.1DOCUMENTATION.30 9.2PROCEDURE SPECIFICATIONS.30 9.3QUALIFICATION TESTING30 9.4SUMMARY OF REQUIRED PRINCIPALS APPROVALS31 10.SUMMA
23、RY OF INSPECTIONS/TESTS32 11.SCOPE OF WORK CHECKLIST33 12.REFERENCES34 FIGURES. 36 APPENDICES APPENDIX 1SOME IMPORTANT DESIGN ASPECTS38 DEP 31.40.30.30-Gen. November 1991 Page 3 DEP 31.40.30.30-Gen. November 1991 Page 4 1.INTRODUCTION 1.1SCOPE This DEP gives minimum requirements for the application
24、of reinforced concrete coating to the exterior surface of steel linepipe (which has been coated previously with anti-corrosion coating) for use in marine environments, estuaries, rivers, wadis, swamps, etc. This DEP is written on the assumption that it will be used as the technical specification inc
25、orporated into a coating contract. It could, however, be used as an attachment to a purchase order. (P)The concrete is classified as either strength Grade A or B, as specified by the Principal in the contract Scope of Work. The choice of grade shall be made during the detailed design stage of the pi
26、peline project, based on the external forces it will be subjected to during installation and operation, e.g. related to water depth, required tensions etc. Grade A is intended for more arduous in-service and/or installation conditions than Grade B coating, e.g. Grade B is intended for estuaries, riv
27、ers, wadis, swamp use. This DEP includes the installation of anodes (including thermit welds) but excludes the design or purchase of anodes. The scope of this DEP does not include: -specific design requirements (these would be established in the pipeline design) -the choice of anti-corrosion coating
28、 or its application -the design, purchase and installation of buckle/crack arresters -the use of intermediate coatings (e.g. anti-slip coatings) -slotting of the concrete to reduce bending stiffness -concrete coating thicknesses less than 25 mm NOTE:Important aspects of these excluded items are brie
29、fly discussed in Appendix 1. 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorised by SIPM, the distribution of this DEP is confined to companies forming part of or managed by the Royal Dutch/Shell Group, and to Contractors nominated by them (i.e. the distribution c
30、ode is “C“, as defined in DEP 00.00.05.05-Gen.). This DEP is intended for use primarily in exploration and production applications but may also be applied, where appropriate, in oil refineries, chemical plants, gas plants and supply/marketing installations. If national and/or local regulations exist
31、 in which some of the requirements may be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent and which combination of requirements will be acceptable as regards safety, environmental, economic and legal aspects. In all
32、 cases the Contractor shall inform the Principal of any deviation from the requirements of this document which is considered to be necessary in order to comply with national and/or local regulations. The Principal may then negotiate with the Authorities concerned with the object of obtaining agreeme
33、nt to follow this document as closely as possible. DEP 31.40.30.30-Gen. November 1991 Page 5 1.3DEFINITIONS For the purposes of this DEP, the following definitions apply: The Contractor is the party which carries out all or part of the design, engineering, procurement, and concrete coating applicati
34、on for the project. The Principal may sometimes undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the party which initiates the projec
35、t and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant, authorised to act for the Principal. The word shall indicates a requirement. The word should indicates a recommendation. Scop
36、e of Work is the section of the coating contract which describes the scope of work relating to the concrete coating of linepipe. 1.4ACTION ITEMS Where the Principal is required to make a decision or give a particular design value of a parameter, this is shown by the use of a (P) in the margin NOTE:A
37、 summary checklist of these and other relevant items is given in (11). Where the Principals approval is only required under certain circumstances, this is not shown by a margin marker. Where the Contractor is required to obtain the Principals approval for a particular action or procedure, this is sh
38、own by the use of a (C) in the margin. NOTE:It is intended that most, if not all, of these approvals would be part of the qualification testing which is required prior to the start of full concrete production. Details of the requirements for procedure specifications, qualification testing and a summ
39、ary listing of approvals are given in (9). It is assumed that the Contractors quality systems and procedural details will have been screened prior to contract award and that the referenced approvals merely need finalizing and formalizing. 1.5CROSS-REFERENCES Where cross-references are made within th
40、is DEP, the number of the cross-referenced section/sub-section is shown in brackets. All referenced standards invoked by this DEP are listed in (12). DEP 31.40.30.30-Gen. November 1991 Page 6 2.MATERIALS 2.1LINEPIPE The Contractor shall unload, receive and store either bare or anti-corrosion coated
41、pipe (or both). 2.1.1Unloading/receipt of linepipe The Contractor shall unload all pipes using slings, spreader bars and protected lifting hooks which have current test and insurance certificates. The equipment shall be proposed by the (C)Contractor for approval by the Principal prior to use. A pipe
42、 tally shall be made at the time of offloading and stacking; recording mill number, pipe length, pipe weight, heat number, contract number, steel grade and any further information (P)that the Principal considers to be relevant or required. (P)The Principal shall provide the Contractor with a copy of
43、 the pipe specification, against which the Contractor shall inspect each pipe at the time of receipt. Inspection shall consist of visual inspection of outer and inner surfaces and coating damage (if applicable), the end bevels for mechanical damage or manufacturing defects, and pipe end ovality. Any
44、 such damage or defects noted shall be recorded by the Contractor and reported in writing to the Principal within three working days. Any damaged area noted shall be marked on the pipe surface using marking material compatible with proposed coating system(s). Pipes which are out of specification or
45、have an identification anomaly shall be clearly marked with the word “HOLD“ on the outer surface of the pipe. Any damage to pipes after receipt by the Contractor shall be brought to the attention of the Principal within three working days. The Principal shall instruct the Contractor on the method to
46、 be used by the Contractor to correct the damage. 2.1.2Handling and storage of linepipe The Contractor shall stockpile all pipes received at the Contractors coating yard. Pipes shall be handled and stockpiled in such a manner as to prevent damage to pipe or coating. For safety reasons, the pipe shal
47、l not be stacked more than 4 m high. The Contractor shall store the pipe by laying out on prepared sand rows. Sand rows shall be kept clean and clear of vegetation, large and injurious aggregates, or any other deleterious substances. Pipe for long term storage (in excess of 2 months) shall be laid o
48、n prepared sand rows having a covering of polyethylenesheeting. The bottom layer of pipes, as a minimum, shall be secured with wedges or clips to prevent collapse of the stockpile. (C)The Contractor shall submit a description of the stockpiling and storing method, which shall require the approval of
49、 the Principal prior to use. 2.1.3Handling, stockpiling and loading out of concrete coated pipe Pipes shall be handled at all times in a suitable manner to avoid damage to pipe, attachments, coating or concrete. The Contractor shall clean the end cutback of coated pipes, to remove all concrete spatter (C)and any deleterious material, prior to load out. The Contractor shall propose a method of cleaning, for approval by the Principal. The Contractor shall rebevel pipe ends only when specifically instructed to do so by the Principal. The procedure for rebevelling shall be agreed with the Pri
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