Beruflich Dokumente
Kultur Dokumente
RECORD OF REVISION
Rev. Incorporated
Section Page Company Comment Contractor Response
No. (Y/N)
TABLE OF CONTENT
1. INTRODUCTION .................................................................................................................................. 4
1.1 General ....................................................................................................................................... 4
1.2 Objective ..................................................................................................................................... 5
1.3 Definition of Terms ...................................................................................................................... 5
1.4 Abbreviation ................................................................................................................................ 5
2. REFERENCE, CODE AND STANDARDS ............................................................................................ 7
2.1 Indonesian Codes, Standard and Regulations ............................................................................ 7
2.2 International Codes and Standards ............................................................................................. 7
2.3 Conflicting Requirement .............................................................................................................. 8
3. GENERAL REQUIREMENTS............................................................................................................... 9
3.1 General ....................................................................................................................................... 9
4. MATERIAL REQUIREMENTS .............................................................................................................. 9
4.1 General ....................................................................................................................................... 9
4.2 HSS Coating Material ................................................................................................................ 10
4.3 HDPU Infill Material ................................................................................................................... 10
5. FIELD JOINT COATING APPLICATION ............................................................................................ 11
5.1 Surface Preparation .................................................................................................................. 11
5.2 Application of HSS .................................................................................................................... 12
5.3 Application of HDPU.................................................................................................................. 13
6. INSPECTION AND TESTING............................................................................................................. 14
6.1 Procedure Qualification Test (PQT) ........................................................................................... 14
6.2 Pre-Production Test (PPT) ........................................................................................................ 15
6.3 Visual Inspection ....................................................................................................................... 15
6.4 Coating Thickness Inspection.................................................................................................... 15
6.5 Holiday Inspection ..................................................................................................................... 16
6.6 Peel Strength Test .................................................................................................................... 16
6.7 Cathodic Disbondment .............................................................................................................. 17
6.8 Hot Water Immersion Test......................................................................................................... 17
6.9 Impact Test ............................................................................................................................... 17
6.10 Indentation Resistance .............................................................................................................. 18
6.11 Lap Shear Strength ................................................................................................................... 18
6.12 Thermal Aging Resistance ........................................................................................................ 18
7. FIELD JOINT COATING REPAIR ...................................................................................................... 18
8. MARKING .......................................................................................................................................... 19
9. HANDLING, SHIPPING AND STORAGE ........................................................................................... 20
10. DOCUMENTATION............................................................................................................................ 20
1. INTRODUCTION
1.1 General
SAKA Indonesia Pangkah Limited/SIPL (herein referred as COMPANY) has been commissioned to
undertake the operator of Ujung Pangkah Block in East Java since January 2014 from HESS. The
Ujung Pangkah field is located offshore off the north coast of East Java approximately 35 km north of
Gresik, East Java, Indonesia; lies adjacent to the Bengawan Solo river delta.
WHP-A currently producing natural gas and crude oil and then the fluid is transported to CPP near
WHP-B for separation and compression/pumping process. WHP-B producing oil and gas, then the
produced fluid are transferred to CPP for separation and compression/pumping process. The outlet of
oil and gas separation process at CPP will be transported via 16” Export Pipeline to WHP-A, and
continued with 18” Export Pipeline from WHP-A to Onshore Processing Facility (OPF) in Gresik.
COMPANY intends to proceed with Development of the West Pangkah Field which is part of the
Ujung Pangkah Block. West Pangkah Field lies on a transition zone with water depth variation
between 0 to -5 meter and around 5 km away from COMPANY WHP-B/CPP existing facilities. The
development plan of West Pangkah Field is to construct one (1) onshore well pad facility with six (6)
well slots as well as production and utility facilities. The production from West Pangkah Field will be
commingled with Pangkah's production facility at WHP-B/CPP then delivered to COMPANY Onshore
Processing Facility (OPF) in Gresik for further processing.
In summary, West Pangkah Field Development FEED consists of the following major components:
a) Onshore wellsite facility
b) Production pipeline & gas lift pipeline
c) Modification of the existing facilities (WHP-B & AUP) to accommodate West Pangkah’s
production and support West Pangkah’s production systems
In the OPF all product will continue further process to separate oil, gas, LPG and water. The oil
product will be transferred via pipeline to Maspion Jetty ready for shipping. The further process is
liquefaction to convert heavy fraction becomes LPG and the low fraction becomes Sales Gas. The
Sales Gas will be transported to PLN at PJB via 20” Onshore Sales Gas Pipeline.
The West Pangkah Field location as part of the Ujung Pangkah Block is shown on Figure 1.1.
1.2 Objective
This specification covers the minimum standards of quality and technical requirements governing
materials, surface preparation, application of the coating materials, inspection and testing of field joint
coating and joint filler material systems which use heat shrinkable wraparound sleeves with HDPU
(High Density Polyurethane) as infill material on concrete coated pipeline section and heat shrinkable
wraparound sleeves for non-concrete coated pipeline section of the offshore pipelines and spool.
In the event MANUFACTURER is unable to comply with this project specification or any part thereof,
then all MANUFACTURER exceptions to this project specification shall be notified to COMPANY in
writing subjected for approval.
3. GENERAL REQUIREMENTS
3.1 General
The pipelines shall use manufacture Heat-Shrinkable Sleeves (HSS) or other COMPANY approved
system for anticorrosion coating for field joint area of pipeline.
MANUFACTURER shall submit to COMPANY for approval field joint coating application procedures.
Procedures shall incorporate actual equipment, materials, surface preparation, coating application,
repairs and time required to complete each application using the procedure submitted. COMPANY
may request and witness a demonstration test performed prior to mobilization.
MANUFACTURER shall demonstrate that the proposed heat shrink sleeve provides good adhesion to
and is compatible with the adjacent main line pipe coating.
MANUFACTURER shall furnish all materials, labour, equipment and incidentals required to meet this
Specification. All equipment to be used for the work shall be in good condition and suitable for the
work and shall be equipped with working and calibrated pressure regulators and gauges. All
equipment shall be subject to inspection and approved by COMPANY prior to its use on the work.
COMPANY shall have the right to undertake additional inspection or testing of raw materials during
any stage of manufacture. Materials not complying with this Specification shall be rejected.
All coating materials shall be applied in accordance with the material MANUFACTURER written data
sheets and application instructions.
4. MATERIAL REQUIREMENTS
4.1 General
The properties of all materials shall meet the functional requirements and properties of the joint
coating system as described in this Specification. Only COMPANY approved materials or
combinations of materials shall be used. The selected systems/material shall be suitable for a 15
years design life.
The field joint coating system shall be fielding proven and shall be selected to ensure compatibility
with the anti-corrosion coating system (3LPE and Neoprene).
The field joint coating system shall provide a level of mechanical protection equal to that of the
adjacent anti-corrosion coating. The field joints shall be resistant to tensioner and stinger damage
during pipe laying and shall not crack or degrade as a result of pipeline bending during installation.
Testing of field joint system shall be performed to ensure that joint integrity is maintained when
subject to the most severe anticipated installation loads.
The material and grade of field joint coating shall be confirmed by the MANUFACTURER in
accordance with test requirements as provided in Section 6 of this Specification. The
MANUFACTURER shall prove to the satisfaction of COMPANY that the selected coating is suitable
for the intended work and provides a continuous high integrity contact with the anti-corrosion coating
of the parent line pipe.
MANUFACTURER shall blend the ingredients so that foam having the following minimum
requirements is produced: All filler material components shall be non-carcinogenic.
Table 4-1 Properties of Injected Moulded HDPU
Prior to surface cleaning, the surfaces shall be completely dry. The surface shall be carried out by
abrasive cleaning to grade St 3 in according with ISO 8501-1, by power-tool cleaning as described in
ISO 8504-3. Surface roughness profile shall be measured using an approved profile comparator in
accordance with ISO-8503-1 and shall be calibrated prior to the start of the work in accordance with
ISO-8503-3 or ISO 8503-4. The blast cleanliness shall be checked on every joint and roughness
profile shall be checked once every 10 joints.
Dust or foreign matter shall be removed from the cleaned surface by an industrial vacuum cleaner.
The dust contamination allowed shall be of a maximum grade 3 as per ISO 8502-3. The frequency of
checking for dust contamination shall be once every 10 joints.
Blast cleaned field joints shall be coated within 2-4 hours according to the conditions below:
Relative humidity (RH) > 80% 2 hours
Relative Humidity (RH) 70 – 80% 3 hours
Relative Humidity (RH) < 70% 4 hours
Pipes delayed beyond this point or pipes showing any visible rust stain, shall be re-blast cleaned
again.
The field joint surface shall be inspected immediately after blast cleaning and any feature of the steel
surface such as weld spatter, scabs, laminations or other imperfections considered injurious to the
coating integrity, made visible during blast cleaning, shall be reported to the COMPANY
representative and on permission.
From COMPANY representative, such defects shall be removed by filing or grinding. Pipes affected in
this manner shall be re-blasted if the defective area is larger than 50 mm in diameter.
The ends of the existing pipe protective coating shall be inspected and chamfered. Unbounded
portions of the coating shall be removed and then suitably trimmed. Portions where the parent coating
is removed shall be thoroughly cleaned as specified. The adjacent chamfered areas of the pipeline
coating shall be cleaned and abraded, to expose a clean uniform fresh surface of uncontaminated
factory applied coating.
thermometer (digital pyrometer with flat probe type contact). Temperature indicating crayons shall not
be used. Pre-heat temperature shall be checked on every joint. Care shall be taken to ensure that the
entire pipe surface is heated evenly. Temperature measuring instruments shall be calibrated
immediately before the start of work and thereafter at intervals recommended by the
MANUFACTURER of the instrument.
The heat shrink sleeve shall be applied to the filed joint in accordance with the sleeve
MANUFACTURER’s written instructions. The wraparound sleeve shall be of a size such that a
minimum overlap of 50 mm is ensured (after shrinking) on both the sides of the yard applied corrosion
coating of pipes.
In case where the carrier pipe is installed by direct boring/jacking, the overlap on the mill coating for
the leading edges of the joints shall be minimum 200 mm. When this extra overlap is achieved by
providing an additional of heat shrink tape/wraparound, it shall be applied in such a manner that the
square of the patch on the joint coating is in direction opposite to the direction of boring / jacking.
Upon pre-heating, the pipe surface shall be applied with two pack epoxy primer of wet film thickness
150 microns or as per MANUFACTURER’s recommendation whichever is higher, to cover the
exposed bare metal of the welded field joint and 10 mm minimium onto the adjacent pipe coating if
recommended by the MANUFACTURER. The wet film thickness of the primer shall be checked on
every joint with a wet film thickness gauge prior to installation of sleeve. Thickness gauge shall be
calibrated once per shift.
Immediately after application of epoxy primer, the wraparound sleeve shall be applied in a single
continuous wrap, centered on the line of the girth weld under firm, even, hand tension, ensuring no air
is trapped to provide a smooth, wrinkle free and bubble free surface. Within the stipulated time as
recommended by the MANUFACTURER, sleeve shall be positioned such that the closure patch is
located to one side of the pipe in 10 or 2 O’clock position, with the edge of the undergoing layer facing
upward and an overlap of minimum 50 mm.
A heat shrinking procedure shall be applied to shrink the sleeve in such a manner to start shrinkage of
the sleeve beginning from the center of the sleeve and heat circumferentially around the pipe.
Continue heating from the center towards one end of the sleeve until recovery is completed. In a
similar manner, heat and shrink the remaining side. Shrinking has been completed when the adhesive
begins to ooze at the sleeve edges all around the circumference.
The complete shrinking of the entire sleeves shall be obtained without undue heating of the existing
pipe coating and providing due bonding between pipes, sleeve and pipe coating. The installed sleeve
shall not be disturbed until the adhesive has solidified.
The finished coating shall be of uniform, free from wrinkles, voids and pin holes. Particular attention
shall be paid to the finish over weld seams. In the event of uneven application, voids, wrinkles,
entrapped air etc. then the heat shrink sleeve shall be completely removed; the area shall be wire
brushed again and a replacement sleeve applied in accordance with the approved procedure.
Field joint material during pipeline installation shall be installed using the same equipment and
procedures as used for the demonstration.
The material dispensing equipment shall be the minimum injection capacity (determined with
MANUFACTURER’s recommendations and submitted with procedures prior to pipelay operations) to
obtain required material. The injection rates used in pipelay shall not be less than those values
submitted in the procedures.
Mold shall remain in position until curing of the joint material has occurred. The mold shall be of the
reusable tape type and/or High Density Polyethylene (HDPE) molding material. HDPE molding
material shall remain on the field joint upon completion.
MANUFACTURER shall include as a part of procedure, suitable method of storage of the infill
material. Storage method will prevent contamination or deterioration of the material.
MANUFACTURER shall propose a suitable mould to fit around the pipe and contain composite infill
material. Infill material shall have the ability to cure sufficiently to ensure sufficient strength to support
the pipe prior to moving the field joint over any rollers. MANUFACTURER shall provide curing curve
(strength vs time) to demonstrate this application.
Using the blade and starting from the transverse incision, the end of the strip thus formed shall be
lifted. The peel test shall be performed using a hand held dynamometer device fixed and pulled at 90°
angle trying to maintain the constant peeling speed of 10 mm/min.
The adhesion test shall be considered as passed if only backing peeled from the testing area and at
the minimum value of 3 N/cm leaving visible only the adhesive layer on 100% of the test area.
In case the acceptance criteria have not been met, the work procedure shall not be considered
qualified until the test is successfully passed on three consecutively applied heat shrink sleeves
during the Pre-Qualification Test.
Stop the field coating works until remedial measures are taken against the cause of such
faults, to the entire satisfaction of the COMPANY.
MANUFACTURER shall replace all joint coating found or expected to be unacceptable as per Section
5 of this specification. MANUFACTURER shall repair all areas where the coating has been removed
for testing by the COMPANY.
After the coating work on field joints and repairs to the coating have been completed the coating as a
whole shall be tested with spark-tester before lowering the pipeline.
COMPANY shall be entitled to check the coating on buried pipelines or parts of pipelines with
equipment such as the Pearson Meter and the resistance meter. If the coating defects are
established, the MANUFACTURER shall be responsible for excavation at such points, repairing the
coating, spark testing and backfilling the excavations.
8. MARKING
The identity of all field joints shall be noted and recorded on an appropriate tally sheet. The field joint
number shall be unique and shall be traceable to the unique pipe number. The field joint identity shall
be maintained by marking on either the concrete coating adjacent to the field joint or on the field joint
infill area itself. A tracking and identification procedure shall be submitted for COMPANY approval
prior to commencement of field coating.
All materials used for the coating work shall be clearly marked and stored in sealed containers under
the temperature and humidity conditions dictated by the MANUFACTURER. Any damaged containers
shall be rejected. The containers shall be marked as follows:
MANUFACTURER’s name
Project name
Material type, name and complete identification of material, including plant of origin
Batch number
Date of manufacture and date of expiry
Storage requirements
Safety instructions
Surface defects such as slivers, sharp notches, gouges, scores, pits, and severe machining marks,
etc., shall be considered injurious defects and in need of repair.
Surface imperfections not classified as injurious shall be repaired by grinding. Providing the thickness
is not reduced locally below the minimum specified thickness. The machined or ground area shall be
examined for defects using wet MPI. If a defect is indicated, the area shall be examined around
further until a defect-free indication is obtained. UT shall be performed on areas after all grounding is
complete to ensure that minimum section thickness is maintained.
Weld repairs are not permitted.
Flanges and fittings containing large defects shall be rejected.
Minor cosmetic grinding shall be permitted, subject to COMPANY review and approval.
10. DOCUMENTATION
All documents and correspondence related to the activities described by this Specification shall be
written in English Language. All documents shall be prepared in the format approved by COMPANY.
MANUFACTURER shall furnish the following information to COMPANY for pre-qualification.
Complete information for the material type, properties along with descriptive catalogues.
Test certificates and results of previously conducted tests, for all material properties.
Reference lists of previous supplies, in last 5 years, of the similar material indicating the
project details such as diameter, quantity, operating temperature, year of supply and project
name.
MANUFACTURER shall furnish the following documents for COMPANY review and approval, prior to
the shipment.
Test certificates/results as per MANUFACTURER’s quality control procedure for each batch of
materials.
MANUFACTURER’s technical data sheets for the coating materials.
Field joint coating inspection and test reports.
Specific application instructions with pictorial illustrations.
Specific handling, transportation and storage instructions.
Procedure for repair of the factory applied coating.
MANUFACTURER shall ensure that all materials are supplied in sealed, damage-free, clearly marked
containers with documentation detailing the following:
MANUFACTURER’s name.
The unique product identification and grade of the product contained.
The batch number of the product.
The date and place of manufacture of the product.
Material Safety Data Sheets (MSDS)
Expiry date for use