AMERADA HESS (INDONESIA - PANGKAH) LIMITED

UJUNG PANGKAH DEVELOPMENT PROJECT

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FABRICATION AND INSTALLATION FRP PIPE 1 of 13

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1. INTRODUCTION 2
1.1 Scope 2
1.2 Definition 2

2. REFERENCE 2
2.1 General 2
2.2 Codes and Standards 3
2.3 Project Specifications 3

3. HANDLING, STORAGE AND INSPECTION 3

3.1 Handling 3
3.2 Storage 4
3.3 Inspection 4

4. ASSEMBLY 5
4.1 Assembly of Pipe and Fitting 5
4.2 Assembly of Flange 10

5. TESTING 10
5.1 Preparation for testing 10
5.2 Safety 11
5.3 Hydrostatic Pressure Testing 12
5.4 Flushing 13

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1. INTRODUCTION

1.1 Scope

This procedure covers the requirements Fabrication and Installation FRP Pipe for Ujung
Pangkah Development Project.

1.2 Definition

a) “COMPANY” means Amerada Hess ( Indonesia-Pangkah ) Limited or its

successors or assigness who are the end user of the facilities.

b) “MIGAS” means Indonesia Government Body responsible for issuing

approvals and licenses for oil and gas facilities

c) “CONTRACTOR” is IKPT specifying / purchasing the equipment for and

on behalf of the “ COMPANY”.

d) “ VENDOR” ( OR “SUBCONTRACTOR”) is the party, which

manufactures or supplies the equipment and services to perform the duties
specified by “CONTRACTOR”.

2. REFERENCE

2.1 General

The requirements contained in the latest edition of the following applicable codes,
standards, and construction specifications. The intent of this procedure is not superseding
those codes, standards, and project specifications, but to supplement them as necessary
and stress their importance by reciting their major requirements.

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2.2 Codes and Standards

API 15LR Specification for Low Pressure Fiberglass Line

Pipe
API 15HR Specification for High Pressure Fiberglass Line
Pipe

2.3 Manufacturer’s Standard

Ameron Fiberglass Pipe Installation Manual

3. HANDLING, STORAGE AND INSPECTION

3.1 Handling

1. Let the factory arrangement of the pipe be your guide for connect supporting and
spacing when rearranging for transport. Do not let pipe or fittings rest on the bed of
the truck where nails, studs and other objects might damage them. Wherever pipe or
fittings come in contact with wood or metal, padding such as excelsior, carpet or
foam should be used.

2. The pipe should be securely fastened directly over the dunnage with tiedowns
consisting of nylon straps or manila rope. Avoid overtightening which may cause
excessive localized deformation in the pipe.

3. Do not allow the pipe to extend more than 3 feet ( 900 mm ) beyond the truck or
trailer bed as permanent damage can result from excessive flexing.

4. Pipe and fittings should never be thrown or dropped under any circumstances.

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5. If load is irregular and cannot be reliably moved by fork truck, or proper equipment
is not available, the pipe should be carefully loaded and unloaded by hand one length
at a time.

3.2 Storage

1. Supports should be spaced in maximum 10 ft intervals and approximately 6 ft from

each end.

2. A pipe stack should not exceed 10 ft in height and should have side supports or
blocks to prevent rolling or slipping in the stack.

3. If it is necessary to stack pipe directly on the ground, make sure that the ground
surface is level, soft and free of rocks or sharp objects.

4. Protective end coverings should be left in place until time of installation to protect
the pipe ends and to prevent dirt or other materials from entering the pipe.

5. Fittings, adhesives and tools should be stored in their shipping boxes under cover
and protected from water, mud and extreme heat or cold.

3.3 Inspection

Since pipe and fittings may be subjected to rough treatment during transportation,
storage and handling, it is imperative that they be fully inspected for possible impact
damage, cracking or manufacturing defects.

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4. ASSEMBLY

4.1 Assembly of Pipe and Fitting

4.1.1 Cutting of Pipe

1. Scribe the pipe using a pipe fitter’s wrap-around

2. When holding the pipe in a vice, use rubber padding or similar to

protect the pipe from damage

3. Contaminated pipe surfaces should be cleaned prior to machining the

pipe ends

4. Use a hacksaw or an abrasive wheel when cut the pipe

5. Ensure that cut ends remain within the tolerances

6. These tolerances can be checked by using e.g the arbor of the shaver
flush with the cut end of the pipe

7. Various types of shavers are avalaible for shaving the pipe ends,
subject to the pipe size

4.1.2 Shaving

1. Prevent the pipe from being damaged

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2. Fix the arbor to the inside of the pipe by turning the central tensioning
bolt clockwise

3. Be sure to use the correct taper angle

4. Take care when shaving the first layer, because the pipewall may be
not be equally thick on all sides

5. Maximum shaving depth/ feed is 2 mm

4.1.3 Preparing for bonding

1. Thoroughly sand within 2 hours from assembly

2. Use flapper wheel sanders with a small drilling machine ( 1700-2000

rpm ) or emery cloth with a grid of 60

3. Bonding surfaces must be dry and clean before sanding

4. Sanded surface must have a dull, fresh finish, not a polished look

5. Check the assembly length and mark pipe and fitting for alignment of
elbows, flanges, etc

6. Measure back from the edge of the spigot the required insertion depth
plus 50 mm and scribe a line. After assembly by pulling the joint
together the scribe on the pipe should be 50 mm from the end of the
bell.

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7. During final assembly the spigot may slip approximately 5 mm further

into the bell, therefore the dry fitted assembly should be
approximately 5 mm longer per joint.

8. If the relative humidity is higher than 75% or if the bonding surfaces

are wet they should be dried

9. If the sanded surfaces have been contaminated, or if initial sanding

took place more then 2 hours before assembling, the surface should be
re-sanded

10. Use a clean dry cloth or brush to remove sanding dust etc

11. Do not touch the sanded surfaces after sanding and cleaning

4.1.4 Preparing the Adhesive

1. Add the curing agent to the resin

2. Stir thoroughly until no streaks are visible and the mixture has an even
colour ( after 2 to 3 minutes )

3. Make sure that before mixing the adhesive, all preparations have been
done and all parts to be bonded are ready for assembly, because mixed
adhesive has a limited potlife subject to the ambient temperature.

4. Apply the adhesive immediately after mixing

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5. Never use adhesive that has started to cure. This is case when the
mixture gets clotted and toughens

6. Use a spatula or an adhesive scraper for applying the adhesive

7. All surfaces to be bonded ( sanded area’s ) must be completely

covered with adhesive, approximately 0.5 mm in the bell and 1 mm on
the spigot

8. A too thick layer of adhesive may result in flow restrictions

9. Make sure that also sufficient adhesive is applied on the cylindrical

end of the spigot that will be covered by the bell

4.1.5 Assembling the adhesive bonding joint

1. When inserting the spigot pay attention to the marks and position and
keep the joint together. Letting the spigot slip back or turning the
spigot after complete insertion may result in a bad joint

2. Hook the 2 winches in the band clamps and start pulling the joint
further together in a smooth movement until the joint is firmly fixed
together and there is 50 mm between the bell end and the mark

3. Do not remove the winches until the adhesive has fully cured

4. For removing excessive adhesive, also from the inside if possible

( flanges ), a spatula may be used

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4.1.6 Curing of the adhesive

1. Wrap the required size Ameron heating blanket around the joint
keeping the power supply cable free from the blanket

2. Make sure the voltage is correct

3. The blanket should be tied down using heat resistant wire

4. Good blanket to pipe surface contact is essential for proper curing of

the adhesive

5. When the temperature is below 10ºC or the wind has a cooling effect,
insulation material should cover the heating blanket. Insulation
material should overlap the sides of the blanket with at least 100 mm
and should match to the pipe. It should not cover the thermostat

6. Curing time is mainly subject to the distance ( = wall thickness )

between blanket and adhesive

7. Apply electrical power to the heating blanket and check if it heats up

8. Write down on the pipe next to the heating blanket the starting time

9. During the time of curing the functioning of the heating blanket

should be checked regularly; if a cold heating blanket is found,
remedy the problem and start the complete curing cycle again

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10. During curing the joint should not be moved, vibrated or otherwise
disturbed

4.2 Assembly of Flanges

1. Finger tighten all nuts. Bolt threads must be clean and lubricated. Use lubricated
washer under both nuts and bolt heads to protect flange backfacing.

2. Tighten all nuts following the sequences shown under tightening sequence.

5. TESTING

5.1 Preparation for Testing

1. All vent and other connections, which can serve as pressure test vents shall be open
during filling so that all air can be vented prior to applying test pressure to the
system

2. Lines that are spring or counterweight supported shall be temporary blocked up

during test in order to sustain the hydrostatic load

3. Before pressure testing, all lines or systems shall be inspected to ensure that all
connected parts to be excluded from the test are isolated by blinds

4. Instruments shall be excluded from hydrotest of piping system

5. Adequate temporary supports should be used where volume and weight of water
may cause line deflection

6. Hydrostatic test loops shall have all high points in the piping with a vent and all low
points with a drain, regardless of whether or not they are specifically shown on the
drawings. When filling, the test fluid shall be introduced at the lowest point of the
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system to minimize the risk of entrapped air and all vents shall be opened. Vents and
drains shall be closed once a continuous flow of fluid is obtained through the vent or
drain.

7. Hydro testing shall be performed via a manifold. The test pump shall be isolatable
from the system with its own pressure gauge. Valves, hoses used in tests shall be
suitably rated.

8. At least 2 gauges shall be installed in the test system, one near the pressure generator
( at the lowest point ) and the other at the highest point, both of which to be
positioned so that they can be easily reached and observed

9. When testing underground systems, the line should be partially backfilled and
temporarily blocked at directional changes to prevent excessive movement during
the test

10. Care should be taken to prevent above ground systems from buckling or moving
excessively during test or in case of sudden depressurization

5.2 Safety

1. Qualified and experienced personnel should operate pressurizing equipment

2. Do not make any adjustments on pressurized fittings under pressure. For example, if
an adapter or flange joint is leaking, take the pressure off the line before attempting
to tighten

3. The test operation should be well planned and carried out with all due precautions. It
is always best for one man to be in charge of the operation so that all other persons
on the job take their direction from him

4. The working area shall be roped off and sign positioned

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5. This work shall be carried out in open space or shelter with sufficient ventilation

6. The installer’s supervisor shall be responsible for safety provisions

5.3 Hydrostatic Pressure Testing

1. Care shall be exercised to avoid increase in pressure due to temperature

variation during the test

2. Hydrostatic testing shall not be done against closed valves

3. Vents shall be open during filling of water so that air is vented prior to applying
pressure to the system. Vents will then be closed to permit pressurization to
commence

4. The pressure shall be brought up slowly and gradually to allow for equalizing
for strain during the test, and in stages to allow checking for leaks and
inspection of the system

5. Once attained, the test pressure shall be held for a period of two hours or such
time as required for a full visual inspection of the system to be made. During
the first half hour of hydrotest, if pressure drops it is necessary to bring up to
test pressure and test for two hours or such times as required for a full visual
inspection of the system. A ±4% pressure change during hydrotest is
acceptable.

6. Temperature changes have a definitive effect on the pressure in the line. In

closed systems, where a pipe is directly exposed to the sun, pressure increases
up to 25% may occur. Take necessary precautions to prevent over

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pressurization. An overnight decrease in pressure from afternoon to early

morning is normal due to temperature changes and does not necessarily
indicate a leak.

7. After completion of hydrostatic test, the pressure shall be released gradually in

steps. All the vents and drains shall be kept open until the lines are fully
drained. All temporary facilities installed to facilitate pressure test shall be
removed.

6. Flushing

1. Flushing to be conducted by “ end to end “ method and carried out after hydrotest

2. All in line valves and ball valves shall be flushed in fully open position

3. All instrument leads shall be disconnected prior to flushing. Soft seated valves should be
removed before flushing

4. Water shall run through the piping for 15 minutes

5. Blind off all pipe ends if they are not connected yet to prevent ingression of debris or foreign
material.

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