Engineering, Procurement & Construction For Well Pad 4 & 9 at West Qurna (Phase 2) Contract Area

ENGINEERING, PROCUREMENT &
CONSTRUCTION FOR WELL PAD 4 & 9 AT

WEST QURNA (PHASE 2) CONTRACT AREA
ITP
FOR FIELD JOINT COATINGS & REPAIRS
APPROVED
01 27-Sep-2021 AFU A MANZERRA M. DI CROCE F. CAMILLETTI
FOR USE
APPROVED
00 08-Feb-2021 AFU A MANZERRA S. PEACOCK F. CAMILLETTI
FOR USE
ISSUED FOR
C 02-Feb-2021 IFA A MANZERRA S. PEACOCK F. CAMILLETTI
APPROVAL
ISSUED FOR
B 12-Jan-2021 IFR A MANZERRA S. PEACOCK F. CAMILLETTI
REVIEW
INTERNAL
A 30-Nov-2020 IDC DISCIPLINE S. PEACOCK L. PASSANITI F. CAMILLETTI
CHECK
ISSUE
REV DATE STATUS PURPOSE ISSUED BY CHECKED BY APPROVED BY
COMPANY DOCUMENT ATTRIBUTES:

Company Contract Originator Facility System Sequence
Discipline DocType Lang
Code Territory Code Code Code Code Number
8015 0151 SC02 00 000 QC IP 00001 E
This document is property of the COMPANY and it shall not be disclosed to third parties, or reproduced, without permission of the COMPANY.
This document is tracked by Integrated Document Management System (IDMS). When it is printed, it shall be considered as “For information
only”. The controlled copy is the IDMS version, and thus, it is the document holder’s responsibility to make sure that the latest version is in
use.
THE WEST QURNA (PHASE 2) CONTRACT
AREA
INSPECTION & TEST PLAN FOR FIELD JOINT COATINGS &

Rev.: 01 Status: AFU
REPAIR
COMPANY No: 8015-0151-SC02-00-000-QC-IP-00001
Page: Page 2 of 15
Contractor No: IQ075-00-0812-SC-0001
DOCUMENT REVISION HISTORY SHEET
REV STATUS DATE ISSUED UPDATE / AMENDMENT DETAILS
A IDC 30/11/2020 INTERNAL DISCIPLINE CHECK
B IFR 12/01/2021 ISSUED FOR REVIEW
C IFA 02/02/2021 ISSUED FOR APPROVAL
00 AFU 08/02/2021 APPROVED FOR USE
01 AFU 27/09/2021 APPROVED FOR USE
Uncontrolled copy, if printed or saved

AREA

REPAIR
Page: Page 3 of 15
CONTENT
1. INTRODUCTION .......................................................................................................... 4
1.1. Purpose ............................................................................................................................... 4
1.2. Scope .................................................................................................................................. 4
1.3. Abbreviations ..................................................................................................................... 5
2. REFERENCE DOCUMENTS ...................................................................................... 5
3. INSPECTION AND TEST PLAN ................................................................................ 7
A. Document review before start works ............................................................................. 8
B. Personnel qualification .................................................................................................. 8
C. In-coming materials ....................................................................................................... 9
D. Inspection equipment check ......................................................................................... 9
E. Steel surface check ..................................................................................................... 11
F. Field Joint Coating Check ........................................................................................... 11
G. Repair of parent coating .............................................................................................. 13
H. FINAL CHECKS .......................................................................................................... 14
4 ATTACHMENTS......................................................................................................... 15

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REPAIR
Page: Page 4 of 15
1. INTRODUCTION
1.1. Purpose
This document contains the details of the Quality Control activities to be performed during
the execution of the works for the FJC & Repairs of the two Flowlines on the project.
This document is issued, at Project level, as Inspection & Test Plan complete with Project
information’s, Project requirements and contractual obligations.
1.2. Scope
This Inspection and Test Plan (ITP) is for the Pipeline Field Joint Coating & Repair works
to be performed during this activity for construction of well pad 4 & 9 at West Qurna
(phase 2) contract Area. This affects all sub-CONTRACTOR’s and lower tier Sub-
contractors engaged in construction activities at site.
This work scope is specifically related to development of two new Well Pads 04 and 09
along with associated gathering lines. With this aim, two Trunk lines will be installed to
connect Well Pads 04 and 09 to the CPF. A resume is reported below:
Flowline Length [m]

from WP4 to CPF 5974
from WP9 to CPF 10330

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REPAIR
Page: Page 5 of 15
1.3. Abbreviations
AT Air Temperature
DFT Dry Film Thickness
DP Dew Point Temperature
FJC Field Joint Coating
ITP Inspection & Test Plan
MFR Manufacturer
MS Method Statement
MSDS Material Safety Data Sheet
MTDS Material Technical Data Sheet
PPT Procedure Production Testing
PQT Procedure Qualification Testing
PROD Production
QC Quality Control
RH Relative Humidity
ST Surface Temperature
2. REFERENCE DOCUMENTS
ISO 21809-3 External coatings for buried or submerged pipelines used in pipeline
transportation systems -- Part 3: Field joint coatings
ISO 2808 Paints and varnishes - Determination of film thickness
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 grades of uncoated steel substrates and of steel
substrates after overall removal of previous coatings

AREA

REPAIR
Page: Page 6 of 15
products – Tests for the assessment of surface cleanliness
products – Tests for the assessment of surface cleanliness: Guidance
on the Estimation of the Probability of Condensation Prior to Paint
Application
products – Tests for the assessment of surface cleanliness: extraction
of soluble contaminants for analysis-The Bresle method
products – Tests for the assessment of surface cleanliness: Field
method for conductometric determination of water-soluble salts
products — Surface roughness characteristics of blast-cleaned steel
substrates — Part 5: Replica tape method for the determination of the
surface profile Preparation of steel substrates before application of
paints and related products – Surface roughness characteristics of blast-
cleaned surfaces
SSPC guide 15 Field Methods for Extraction and Analysis of Soluble Salts on Steel
and Other Nonporous Substrates
8015-0151-SC02-00-000-QC-PN-00001 Project Quality Management Plan
8015-0151-SC02-00-000-HS-PP-00001 HSE Plan
8015-0151-SC02-60-000-PL-SP-00014 Specification for Field Joint Coatings
8015-0151-SC02-00-000-CN-MS-00004 Method Statement for Field Joint

Coatings & Repair

AREA

REPAIR
Page: Page 7 of 15
3. INSPECTION AND TEST PLAN
ITP FOR FIELD JOINT COATINGS & REPAIR
DEFINITION OF INSPECTION AND TEST PLAN SYMBOLS
R/V: Review/ Verify- Verify satisfactory completion of activity by review of

documentary evidence.
W: Witness- Verify satisfactory completion of activity by witnessing,

manufacturing will continue if inspector is not present.
H: Hold- Verify satisfactory completion of activity by witnessing,

manufacturing will not proceed until witness is complete, or inspection is
waived in writing by Company
S: Surveillance Inspection- To check site activities without notice to Contractor
M: Monitor- To monitor work in progress
I: Inspection/ Perform- Inspection during site activities
REMARKS:
NB. The Activities are not necessarily in the order of actual operational
sequence on site

ENGINEERING, PROCUREMENT & CONSTRUCTION
FOR WELL PAD 4 & 9 AT THE WEST QURNA (PHASE 2)
CONTRACT AREA
ITP For Field Joint Coatings and Repair Rev.: 01 Status: AFU
COMPANY NO.: 8015-0151-SC02-00-000-QC-IP-00001 Page: 8 of 15
CONTRACT NO.: IQ075-00-0812-SC-0001
# Activity Description Reference Document Acceptance Criteria Record Frequency / Extension Inspection Requirement
Form PQT PPT PROD. CC CQ COMPANY
A. Document review before start works
Document review before 8015-0151-SC02-60-000-PL- 8015-0151-SC02-60-000-
A.1 start works: Method of SP-00014- Specification for PL-SP-00014- Specification MS Once - - I H H
Statement (MS) FJC for FJC
Document review before 8015-0151-SC02-00-000-CN- 8015-0151-SC02-60-000-

A.2 start works: Inspection and MS-00004 PL-SP-00014- Specification ITP Once - - I H H
Test Plan (ITP) for FJC
HSE Approved documents

Ordinary Work Permit release
for ordinary works (e.g. Ordinary: 1 per
rules
access to area) week
Document review before
A.3 HSE WP Forms Once Once I H H
start works: Work Permits
HSE Approved documents
Specific Work Permit release
for Specific works (e.g. hot Specific: 1/day
rules
works)
B. Personnel qualification
PASS the qualification
Personnel qualification: 8015-0151-SC02-00-000-

8015-0151-SC02-60-000-PL- CN-MS-00004 Personnel
B.1 Coating operator - training Once Once Once I H W
SP-00014 Certificate
and qualification 8015-0151-SC02-00-000-
QC-IP-00001
VALID CERTIFICATE
Personnel qualification: Min 5 years of experience
NACE I or FROSIO I or Personnel
B.2 Painting Inspector - and holder of NACE I or Once Once Once I H R
equivalent certificate Certificate
certification FROSIO I or equivalent
certificate

ENGINEERING, PROCUREMENT
& CONSTRUCTION FOR WELL
PAD 4 & 9 AT THE WEST QURNA
(PHASE 2) CONTRACT AREA
VALID CERTIFICATE
Min 5 years of experience
Personnel qualification: NACE I or FROSIO I or
and holder of NACE I or Personnel
B.3 Painting Supervisor - equivalent certificate Once Once Once I H R
FROSIO I or equivalent Certificate
certification
certificate
C. In-coming materials
MFR batch
In-coming materials: LME approved abrasive Certificate,
Purchase Order
C.1 abrasive - Quantity and type 8015-0151-SC02-00-000- MTDS, MSDS Every batch Every batch Every batch I H W/R
Delivery note
check CN-MS-00004 SC02-QC-CI-
019
MFR batch
LME approved coating mat.
Certificate,
In-coming materials: coating 8015-0151-SC02-00-000-
C.2 Purchase Order MTDS, MSDS Every batch Every batch Every batch I H W/R
- Quantity and type check CN-MS-00004
SC02-QC-CI-
Shelf life valid
019
In-coming materials: Storage & packaging of
Receipt, storage and MFR instruction, MTDS, abrasive & coating materials SC02-QC-CI-
C.3 Every package Every package Every package I H W/R
handling of the FJC materials MSDS according MFR instruction, 061
(abrasive and coating) MTDS; MSDS
D. Inspection equipment check
Measuring &
Inspection equipment check: Calibration: MFR
Test Equipment
ST & RH, AT Calibration certificate
D.1 MFR instruction Calibration Once Once Once I H W/R
Pyrometer & hygro-
Certificate
thermometer Accuracy: ISO 8502-4
Register

MFR instruction Calibration: MFR Measuring & Cal.: MFR Cal.
Inspection equipment check: 8015-0151-SC02-00-000-QC- Calibration certificate Test Equipment Cert. check,
D.2 roughness PP-00004 Inspection Calibration Once Once once I H W/R
Replica tape Gauge Measuring and Test Equipment Accuracy: ± 2 µm or MFR Certificate Accuracy:
Procedure instruction Register 1/day
MFR instruction Measuring & Cal.: MFR Cal.
Calibration: MFR
Inspection equipment check: 8015-0152-SC01-00-000-QC- Test Equipment Cert. check,
Calibration certificate
D.3 Soluble salt check PP-00004 Inspection Calibration Once Once once I H W/R
Conductivity meter Measuring and Test Equipment Certificate Accuracy:
Accuracy: ± 3 µS/cm
Procedure Register 1/day
MFR instruction Measuring &
Inspection equipment check: Calibration: MFR Cal.: MFR Cal.
8015-0152-SC01-00-000-QC- Test Equipment
Coating continuity Calibration certificate Cert. check,
D.4 PP-00004 Inspection Calibration Once Once I H W/R
High Voltage Holiday once
Measuring and Test Equipment Certificate
Detector Accuracy: ±10% Acc.: 2/day
Procedure Register
Calibration: MFR Cal.: MFR Cal.
Inspection equipment check: 8015-0152-SC01-00-000-QC- Test Equipment
Calibration certificate Cert. check,
D.5 Adhesion PP-00004 Inspection Calibration Once Once I H W/R
once
Spring Balance Measuring and Test Equipment Certificate
Accuracy: ± 5% Acc.: 1/week
Procedure Register
Calibration: MFR
Inspection equipment check: 8015-0152-SC01-00-000-QC- Test Equipment
Calibration certificate
D.6 Impact PP-00004 Inspection Calibration Once Once NR I H W/R
Accuracy: total required
Impact standard mass Measuring and Test Equipment Certificate
mass ± 5%
Procedure Register
MFR instruction Calibration: MFR Measuring & Cal.: MFR Cal.
Inspection equipment check: 8015-0152-SC01-00-000-QC- Calibration certificate Test Equipment Cert. check,
D.7 Coating Thickness PP-00004 Inspection Calibration Once Once once I H W/R
DFT Gauge Measuring and Test Equipment Accuracy: total DFT ± 3% - Certificate Accuracy: min
Procedure ISO2808 Register 2/shift

Calibration: MFR
8015-0152-SC01-00-000-QC- Test Equipment
Inspection equipment check: Calibration certificate
D.8 PP-00004 Inspection Calibration Once Once NR I H W/R
Digital Scale
Measuring and Test Equipment Certificate
Accuracy: ± 1g
Procedure Register
E. Steel surface check
Steel surface check: prior to 8015-0151-SC02-00-000-CN- SC02-QM-ME-
E.1 Visual - No contaminants 3 joints 3 joints Each joint I H W/R
abrasive blasting, cleanliness MS-00004 050
Visual
FBE tail length = 5-50 mm
from PP bevel
Steel surface check: prior to 8015-0151-SC02-00-000-CN- PP angle = 15 - 30° SC02-QM-ME-
E.2 3 joints 3 joints Each joint I H W/R
abrasive blasting, cut-back MS-00004 PP coat back length = 150 050
mm
If not, cut-back dimensions
to restore
Steel surface check: prior to
8015-0151-SC02-00-000-CN- RH < 85% SC02-QM-ME-
E.3 abrasive blasting: 3 joints 3 joints Each joint I H W/R
MS-00004 & ISO 8502-4 ST > 3°C above the DP 050
Atmospheric Cond.
Steel surface check: after to 8015-0151-SC02-00-000-CN- As per manufacturer SC02-QM-ME- 3 times per
E.4 3 joints 3 joints I H W/R
abrasive blasting, profile MS-00004 & ISO 8503-5 requirements - TBD 050 shift
8015-0151-SC02-00-000-CN-
Steel surface check: after to SC02-QM-ME- 3 times per
E.5 MS-00004 & ISO 8502-6&9 or < 2 µg / cm2 (20 mg / m2) 3 joints 3 joints I H W/R
abrasive blasting, chlorides 050 shift (notes a,b)
SSPC guide 15
Steel surface check: after 8015-0151-SC02-00-000-CN- SC02-QM-ME-
E.6 A Sa 2 ½ or B Sa 2 ½ 3 joints 3 joints Each joint I H W/R
abrasive blasting, cleanliness MS-00004 & ISO 8501-1 050
Steel surface check: after
8015-0151-SC02-00-000-CN- SC02-QM-ME-
E.7 abrasive blasting, dust Size and Q.ty max rating 2 3 joints 3 joints 3 time per shift I H W/R
MS-00004 & ISO 8502-3 050
contamination
F. Field Joint Coating Check

Field Joint Coating 8015-0151-SC02-00-000-CN- According to spec and MFR
F.1. - 3 joints 3 joints Each joint I H W/R
application criteria check MS-00004 requirements
Pre-heating check: acc. to
spec and MFR requirements
Primer: no exposed steel or
Field Joint Coating check: 8015-0151-SC02-00-000-CN- FBE SC02-QM-ME-
F.2 3 joints 3 joints Each joint I H W/R
visual MS-00004 Coating: no wrinkles, 050
creases, air entrapment, etc.
Overlap on parent coating =
50 mm
three measures three measures at three measures
at each of 3, 6, each of 3, 6, at each of 3, 6,
9 & 12 o’clock 9 & 12 o’clock 9 & 12 o’clock
Field Joint Coating check: 8015-0151-SC02-00-000-CN- SC02-QM-ME- positions positions positions
F.3 21809-3 annex B I H W/R
Thickness check MS-00004 & ISO 2808 50 per joint – 2 per joint – 2 per joint – 2
measures on measures on measures on
body sleeve 1 body sleeve 1 on body sleeve 1
on weld cap weld cap on weld cap
Energy = > 10 J/mm
ST = 23 ± 2 °C
Punch weight = TBD
Drop height = 1 m
8015-0151-SC02-00-000-CN-
Field Joint Coating check: no breakdown at impact SC02-QM-ME- 3 joints - 2 hits 3 joints - 2 hits
F.4 MS-00004 & ISO 21809-3 - I H W/R
impact resistance areas when tested by HVHD 050 per joint per joint
annex D
at proper Voltage
Impacts to do on body pipe
(not on overlap area, not on
girth weld).

V = 5 kV/mm + 5kV; max
25kV
8015-0151-SC02-00-000-CN- Speed = max 300 mm/s
Field Joint Coating check: SC02-QM-ME-
F.5 MS-00004 & ISO 21809-3 100 % FJC without pinholes, 3 joints 3 joints Each joint I H W/R
holiday test 050
annex C if pinhole is found the HSS
shall be stripped, reapplied
and retested
Test Temperature = Tmax
8015-0151-SC02-00-000-CN-
Field Joint Coating check: Pressure = 10 N/mm2 SC02-QM-ME- 3 joints - 1 test
F.6 MS-00004 & ISO 21809-3 - - I H W/R
indentation Residual Thickness > 0.6 050 per joint
annex E
mm
1 joint each
3 joints – per 3 joints – per 100 coated
Field Joint Coating check:
8015-0151-SC02-00-000-CN- > 4.0 N/mm at 23 ± 2 °C each joint each joint joints – per
Peel strength on steel surface SC02-QM-ME-
F.7 MS-00004 & ISO 21809-3 refusal to peel at pull rate of 1 test FJC on 1 test FJC on each joint I H W/R
and plant coating at ambient 050
Annex H2 10 mm/min steel; 1 test FJC steel; 1 test FJC 1 test FJC on
temperature
at overlap at overlap steel; 1 test
FJC at overlap
3 joints – per
Field Joint Coating check:
8015-0151-SC02-00-000-CN- > 2.0 N/mm at Tmax ± 2 °C each joint
Peel strength on steel surface SC02-QM-ME-
F.8 MS-00004 & ISO 21809-3 refusal to peel at pull rate of 1 test FJC on - - I H W/R
and plant coating at ambient 050
Annex H2 10 mm/min steel; 1 test FJC
temperature
at overlap
G. Repair of parent coating
Repair of parent coating: 8015-0151-SC02-00-000-CN- Average DFT > 3 mm, SC02-QM-ME-
G.1 Each repair Each repair I H W/R
Total DFT check MS-00004 minimum value 2,5 mm. 050

V = 25 kV
Speed = max 300 mm/s
Repair of parent coating: 8015-0151-SC02-00-000-CN- 100 % repaired area without SC02-QM-ME-
G.2 Each repair Each repair I H W/R
Holiday detection MS-00004 pinholes, if pinhole is found 050
the repair shall be completed
and retested for pinholes
H. FINAL CHECKS
V = 5 kV/mm + 5kV; max
Holiday detection after 8015-0151-SC02-00-000-CN-
25kV SC02-QM-ME-
H.1 lowering of pipeline: holiday MS-00004 & ISO 21809-3 - - 100% I H H
Speed = max 300 mm/s 050
test annex C
100 % FJC without pinholes
Notes
Testing of the soluble salt level during production may be reduced or omitted, by agreement between SICIM and LUKOIL, if a PPT has demonstrated that the application procedure ensures a salt level below
a
these requirements.
b A shift is defined as the time period when a crew of workers is at work.
c All Inspections and Testing related to PQT & PPT are Hold Point for Company
Parties involved Legend
CC = CONTRACTOR CONSTRUCTION I = Inspection/ Perform
CQ = CONTRACTOR QUALITY R = Record Review
COMPANY = LUKOIL REPRESENTATIVE W = Witness Inspection (notification required (RFI), presence not mandatory)
S = Surveillance Inspection
H = Hold Point (notification required (RFI), presence mandatory)
M = Monitor
V = Verify

4 ATTACHMENTS
Attachment 1 SC02-QC-CI-019 MATERIAL RECEIPT INSPECTION REPORT

Attachment 2 SC02-QC-CI-061 CONSUMABLE LOG REPORT
Attachment 3 SC02-QC-ME-050 FIELD JOINT COATING REPORT

Engineering, Procurement & Construction For Well Pad 4 & 9 at West Qurna (Phase 2) Contract Area

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ENGINEERING, PROCUREMENT &

CONSTRUCTION FOR WELL PAD 4 & 9 AT

COMPANY DOCUMENT ATTRIBUTES:

8015 0151 SC02 00 000 QC IP 00001 E

INSPECTION & TEST PLAN FOR FIELD JOINT COATINGS &

DOCUMENT REVISION HISTORY SHEET

REV STATUS DATE ISSUED UPDATE / AMENDMENT DETAILS

A IDC 30/11/2020 INTERNAL DISCIPLINE CHECK

B IFR 12/01/2021 ISSUED FOR REVIEW

C IFA 02/02/2021 ISSUED FOR APPROVAL

00 AFU 08/02/2021 APPROVED FOR USE

01 AFU 27/09/2021 APPROVED FOR USE

Uncontrolled copy, if printed or saved

INSPECTION & TEST PLAN FOR FIELD JOINT COATINGS &

Uncontrolled copy, if printed or saved

INSPECTION & TEST PLAN FOR FIELD JOINT COATINGS &

Flowline Length [m]

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INSPECTION & TEST PLAN FOR FIELD JOINT COATINGS &

Uncontrolled copy, if printed or saved

INSPECTION & TEST PLAN FOR FIELD JOINT COATINGS &

8015-0151-SC02-00-000-QC-PN-00001 Project Quality Management Plan

8015-0151-SC02-00-000-HS-PP-00001 HSE Plan

8015-0151-SC02-60-000-PL-SP-00014 Specification for Field Joint Coatings

8015-0151-SC02-00-000-CN-MS-00004 Method Statement for Field Joint

Uncontrolled copy, if printed or saved

INSPECTION & TEST PLAN FOR FIELD JOINT COATINGS &

3. INSPECTION AND TEST PLAN

ITP FOR FIELD JOINT COATINGS & REPAIR

DEFINITION OF INSPECTION AND TEST PLAN SYMBOLS

R/V: Review/ Verify- Verify satisfactory completion of activity by review of

W: Witness- Verify satisfactory completion of activity by witnessing,

H: Hold- Verify satisfactory completion of activity by witnessing,

S: Surveillance Inspection- To check site activities without notice to Contractor

M: Monitor- To monitor work in progress

I: Inspection/ Perform- Inspection during site activities

Uncontrolled copy, if printed or saved

COMPANY NO.: 8015-0151-SC02-00-000-QC-IP-00001 Page: 8 of 15

CONTRACT NO.: IQ075-00-0812-SC-0001

Document review before 8015-0151-SC02-00-000-CN- 8015-0151-SC02-60-000-

HSE Approved documents

Personnel qualification: 8015-0151-SC02-00-000-

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CONTRACT NO.: IQ075-00-0812-SC-0001

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CONTRACT NO.: IQ075-00-0812-SC-0001

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CONTRACT NO.: IQ075-00-0812-SC-0001

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CONTRACT NO.: IQ075-00-0812-SC-0001

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CONTRACT NO.: IQ075-00-0812-SC-0001

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