PetroGas FZE

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PetroGas FZE
Concrete Weight Coating PlantAladja
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Applying Of Concrete Coating Using Gunnite Method
By Means Of CRC Machine
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- Range of Pipes Diameters for Applying Concrete
Coating
TECHNICAL CAPABILITIES OF THE PLANT
10 40
- Concrete Coating Reinforcement
Galvanized Wire Mesh from 1 to 4 Layers
- Thickness of Concrete Cover
Up to 210 mm
- Obtainable Concrete Density For Concrete
Weight Coating
Up to 3100 kg/m³
- CWC Plant Capacity
0,47 m³/min
- Batching Plant Capacity
0,6 m³/min
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Technical Base of the Company PetroGas FZE
Provides Steady Supply of Materials
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Aladja Weight Coating Plant Material and
Technical Base Allows Any Complexity Operations
Execution
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Ability to Perform Operations 24/7
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Particularly Developed Winter Period Procedure
Allows High Quality Concrete Production In
Temperatures Lower Than 5 ? Degrees. Plant
Fully Operational 12 Month Per Year
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Storage Yard Area 900 000 m²
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CWC Plant Is Located In 700 meters Away From
Aladja Port, Which Decreases The Time and Cost
in Pipes Materials Transferring
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Quality Control Is Performed At All Stages Of
Production And Guaranteed By TPI.
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Laboratory And All Certified Tools Required For
Destructive Testing (DT) And Non-Destructive
Testing (NDT) Controls Are Available On Site
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Concrete Coating Application Operations Are
Performed in Accordance With Approved Procedures
Developed On The Basis Of The Following Standards
- DNW-OS-F101 Offshore standard- ASTM C33
Standard Specification for Concrete
Aggregates- ASTM C94 Standard Specification
for Ready-Mixed Concrete- ASTM A82 Standard
Specification for Steel Wire, Plain, for Concrete
Reinforcement- ASTM C642 Standard Test Method
for Specific Gravity, Absorption and Voids in
Hardened Concrete- ASTM A810 Standard
Specification for Zinc-Coated (Galvanized) Steel
Pipe Winding Mesh- API-RP 5LW Recommended
Practice for Transportation of Line Pipe on
Barges or Marine Vessels- API RP
5L1 Recommended Practice for Transportation of
Line Pipe- BS 1881-108 Method for Making Test
Cubes from Fresh Concrete- BS 1881-114 Method
for Determination of Density of Hardened Concrete
Cubes- BS 1881-120 Method for Determination of
Density of Hardened Concrete Cores- NACE RP
02-74-1974 High Voltage Electrical Inspection of
Pipeline Coating to Installation.
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Technological Process of Concrete Coating
Applying
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1. Feeding Pipe To The Racks For
   Anti-Corrosion Coating Control Repair If Any

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2. Installation Of Pipes On Transfer Cart And
Application Of Concrete Coating
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3. Pipes Weighing Simultaneous Negative
Buoyancy Calculation
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4. Transportation To Storage Area
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5. Damaged Concrete Coating Repair By Means Of
Manual Gunnite Machine
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6. Installation Of Anode Protection
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THREE LEVEL QUALITY ASSURANCE
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1 Pipe and Raw Materials Receipt
- Receipt Inspection of Raw Materials
a) Condition, Packing Markings
b) Testing of Concrete Materials
- Cement Portland Cement
a) Test Certificate
b) Batch Date of Manufacture
c) Physical Condition of Cement, i.e. Lumps
Contamination
- Iron Ore Delivery Testing
a) Test Certificate
b) Packing List Country of Origin
c) Check for moisture content
- Water
a) Certificates Issued by Local Water Authority
Tested 3rd Party
b) Cleanliness
- Wire Reinforcement
a) Test Certificates
b) Conditions of Rolls
c) Dimensional checks
d) Markings
e) Packaging Storing
- 3-LPE Coated Pipe Stacking (Temporary Storage)
a) Stacking of 3-LPE Coated Pipe
b) Check if Number of Tiers is Per the Approved
Calculation
c) Check That separators are Intact no Pipe
Surfaces are Adhering to Each Other
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2 CWC Coating Qualification (PQT)
- Concrete Mix Design
- Concrete Weight Design
- 3-LPE Coated Pipe Reception
- Temperature (Ambient, Water, Sand, Iron Ore)
- Aggregate Gradation (Iron Ore)
- Aggregate Gradation (Sand)
- Pipe Weight Scale Calibration
- Holiday Detector Voltage Check
- Visual Inspection Holiday Detection
- 3-LPE Coating Repairs (If Any)
- Concrete Mix Temperature
- Concrete Moisture Content
- Reinforcement Required (Wire Mesh Control)
- Reinforcement Placement, Overlap, Reinforcement
Concrete Cover
- Concrete Girth Measurements
- Concrete Cut-Back Control
- Visual Inspection of Applied Concrete
- Weight of Freshly Concrete Coated Pipe
- Calculation of Negative Buoyancy
- Electrical Isolation Between Reinforcement/Pipe
- Concrete Repairs (If Any)
- Compressive Strength (Cubes)
- Compressive Strength (Cores)
- Density
- Water Absorption
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3 Concrete Coating Production
- 3-LPE Coated Pipe Stacking (Temporary Storage)
- CWC Plant, 3-LPE Coated Pipe Reception
- Holiday Detector, Voltage Check
- Visual Inspection Holiday Detector
- Pipe Weight Scale Calibration
- 3-LPE Coating Repairs (If Any)
- Ambient Temperature
- Concrete Mix Temperature, Concrete Mix Content
- Concrete Application
- Reinforcement Required (Wire Mesh Control)
- Reinforcement Overlap
- Reinforcement Placement
- Reinforcement Concrete Cover
- Concrete Cut-Back Control
- Reclaimed Concrete
- Visual Inspection of Applied Concrete
- Concrete Girth Measurements
- Weighing of Freshly Concrete Coated Pipe
- Calculation of Negative Buoyancy
- Pipe Markings
- Anodes Slotting
- Concrete Repairs (Cracks)
- Surface Damage
- Electrical Isolation Between Reinforcement and
Pipe
- Colour Coding Concrete Coated Pipe
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4 Laboratory Productions Tests
- Concrete Moisture Content
- Aggregate Gradation (Iron Ore)
- Aggregate Gradation (Sand)
- Compressive Strength (Cubes)
- Compressive Strength (Cores)
- Density
5 Handling Stacking of Coated Pipe
- Handling of Coated Pipe
- Stack Heights
- Load-Out
6 Records Documentation
- Documentation Record (All Reports on a Daily
Basis)
- Final Documentation (Data Books)
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Completed Projects
Epic of new 30" Trunk Line and Infield Lines
Pipeline 30 29 km. Concrete Thickness 80, 105
152,4 mm
Pipeline 20 5 km. Concrete Thickness 65 75 mm
Pipeline 18 5 km. Concrete Thickness 40 mm
GARAGOL DENIZ DEVELOPMENT PROJECT
Pipeline 14" 74 km. Concrete Thickness 40 mm,
45 mm, 95 mm
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Plant Qualified Engineers and Operating Personnel
Are Minded To Implement Projects Of Any Complexity
Concrete Weight Coating Plant Aladja
PetroGas FZE, 2010