1. Concrete Weight Coating Plant “Aladja”
PetroGas FZE

2. Applying Of Concrete Coating Using Gunnite Method By Means Of CRC Machine

3. - Range of Pipes Diameters for Applying Concrete Coating
TECHNICAL CAPABILITIES OF THE PLANT
- Range of Pipes Diameters for Applying Concrete Coating
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

4. Technical Base of the Company “PetroGas FZE” Provides
Steady Supply of Materials

5. “Aladja” Weight Coating Plant Material and Technical Base Allows Any Complexity Operations Execution

6. Ability to Perform Operations 24/7

7. Particularly Developed Winter Period Procedure Allows High Quality Concrete Production In Temperatures Lower Than +5 °С Degrees. Plant Fully Operational 12 Month Per Year

8. Storage Yard Area – m²

9. CWC Plant Is Located In 700 meters Away From “Aladja” Port, Which Decreases The Time and Cost in Pipes & Materials Transferring

10. Quality Control Is Performed At All Stages Of Production And Guaranteed By TPI.

11. Laboratory And All Certified Tools Required For Destructive Testing (DT) And Non-Destructive Testing (NDT) Controls Are Available On Site

12. 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 Method for Making Test Cubes from Fresh |Concrete; - BS Method for Determination of Density of Hardened Concrete Cubes; - BS Method for Determination of Density of Hardened Concrete Cores; - NACE RP High Voltage Electrical Inspection of Pipeline Coating to Installation.

13. Technological Process of Concrete Coating Applying

14. Feeding Pipe To The Racks For Anti-Corrosion Coating Control & Repair If Any

15. 2. Installation Of Pipes On Transfer Cart And Application Of Concrete Coating

16. 3. Pipes Weighing & Simultaneous Negative Buoyancy Calculation

17. 4. Transportation To Storage Area

18. 5. Damaged Concrete Coating Repair By Means Of Manual Gunnite Machine

19. 6. Installation Of Anode Protection

20. THREE LEVEL QUALITY ASSURANCE

21. 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

22. 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

23. 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

24. 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)

25. 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

26. Concrete Weight Coating Plant “Aladja”
Plant Qualified Engineers and Operating Personnel Are Minded To Implement Projects Of Any Complexity
Concrete Weight Coating Plant “Aladja”
PetroGas FZE, 2010