0032 50 l sp 015 a4 specification for insulating joint

Contract Package No.3B Cikande – Bitung Distribution Pipeline

REVISION HISTORICAL SHEET

Rev. Date Page Description

A 27 January 2012 All Issued for Review

B 14 JUNE 2012 AllIssued for Review based on ERR no.0032-00-G-ES-064-A dated 8 February 2012

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PT. PROMATCON TEPAT GUNA 0032-50-M-SP-015-A4 Specification for Insulating Joint


C 05-JULY-2012 All Issued for Review based on ERR no.0032-00-G-ES-395-A dated 20 June 2012

D 13-JULY-2012 All Issued for Review based on ERR no.0032-00-G-ES-395-A dated 20 June 2012

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Table of Content

1. INTRODUCTION...........................................................................................................................3

1.1. General................................................................................................................................31.2. Scope...................................................................................................................................3

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2. DEFINITIONS................................................................................................................................3

3. REFERENCE DOCUMENTS.........................................................................................................3

3.1. Code and Standard..............................................................................................................3

4. ENVIRONMENTAL CONDITION...................................................................................................4

5. TECHNICAL REQUIREMENTS AND DESIGN DATA..................................................................4

5.1. Main Pipe Line.....................................................................................................................45.2. Material Selection................................................................................................................4

6. DESIGN.........................................................................................................................................5

7. FABRICATION...............................................................................................................................6

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8. TESTING AND INSPECTION........................................................................................................6

8.1. Radiography........................................................................................................................68.2. Magnetic Particle Inspection or Ultrasonic Inspection.........................................................68.3. Hydrostatic Pressure Test...................................................................................................68.4. Leak Test.............................................................................................................................68.5. Dimensional Inspection.......................................................................................................68.6. Visual Inspection..................................................................................................................68.7. Electrical Resistant Test......................................................................................................7

9. PAINTING......................................................................................................................................7

10. MARKING AND PACKING.........................................................................................................7

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10.1. Marking.............................................................................................................................710.2. PACKING.........................................................................................................................7

11. PREPARATION FOR SHIPMENT..............................................................................................8

12. DOCUMENTATION....................................................................................................................8

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1. INTRODUCTION

1.1. General

The design of the Insulation Joint shall be based on the provision of a safe and reliable supply of insulation joint and accessories as per design life of pipeline. Safe condition shall be ensured under all operating conditions, including those associated with start-up and shut-down of plant and equipment, and throughout the intervening shut down periods.

The design of insulation joint system and equipment shall ensure that all operating and maintenance activities can be accessed and performed safely and conveniently.

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1. System design studies and calculations shall be completed during the course of the detail engineering design to demonstrate the adequacy of the insulation joint system design and to confirm insulation joint/equipment rating for the total facility.

1.2. Scope

This specification covers the requirements for design, fabrication, performance, inspection, testing, painting, and preparation for shipment of Insulation Joints to be supplied for the South Sumatra - West Java Gas Pipeline Project CP3B, Cikande-Bitung Onshore Distribution Pipe Line in Indonesia for PT. Perusahaan Gas Negara (Persero) Tbk.

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2. DEFINITIONS

Employer PT Perusahaan Gas Negara (Persero) Tbk. (PGN)

Engineer Japan Oil Engineering Co., Ltd in association with PT Connusa Energindo.

Contractor PT Promatcon Tepatguna

Purchaser PT Promatcon Tepatguna

Subcontractor The party(s) that carry out all or part of the design, procurement, installation and testing of the systems as specified by Contractor

Vendor The party which materials, equipments, technical

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documents/drawings and services to perform the duties specified by the purchaser.

MIGAS Direktorat Jendral Minyak dan Gas Bumi

3. REFERENCE DOCUMENTS

3.1. Code and Standard

2. ASME B16.9

Factory-made Wrought Buttwelding Fittings

3. ASME Gas Transmission and Distribution Piping Systems

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B31.8

4. ISO 15589-1

Cathodic Protection of Pipeline Transportation System

5. NACE RP 0177

Mitigation of Alternating Current and Lightning Effect on Metallic Structures and Corrosion Control System

6. IEC 60167

Method of test for the determine of the insulating of Solid Insulating Material

7. API 5L Specification For Line Pipe

8. ASTM Test Method and Definitions for Testing of Steel Product

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A370

9. ASTM A 694

Standards for Forgings, Carbon and Alloy Steel, For Pipe Flanges, Fitting, Valve, andparts for High Pressure Transmission System.

ASTM D 709 Standard Specifications For Laminated Thermosetting Materials

ASME Section VIII

Pressure Vessel

IEC 61557-2 Electrically Safety in Low Voltage Distribution Systems

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4. ENVIRONMENTAL CONDITION

Ambient Temperature

Relative Humidity Rainfall

Maximum :92°F

Maximum : 84.2% Average Anual : 1684.2 mm/year

Minimum : 72°F Minimum : 76.1% Design Value : 200 mm/hour

Average : 78°F Average : 80%

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5. TECHNICAL REQUIREMENTS AND DESIGN DATA

5.1. Main Pipe Line

Specifications of the main pipeline in which Insulation Joints are installed are as follows:

Table 5.1 - Specifications of Main Pipeline

Nominal Line

Size24” O.D.

Distance 33230 mm

Rating ANSI 300

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Design

Pressure720 psig

Operating

Pressure536 psig

Design

Temperature130°F

FluidNatural gas (refer to Fluid

Data)

The Insulation Joint shall comply with the above conditions

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5.2. Material Selection

The Insulation Joints shall be designed, fabricated, inspected and tested in accordance with the following requirements;

The Insulation Joints shall be designed in accordance with ASME B31.8 considering design factor of 0.5. No corrosion allowance shall be considered.

Isolating spacing ring shall made of ageing resistant, epoxy glass laminate according to ASTM D 709. It compressive strength shall be above 350 n/mm2

The sealing gasket shall be composed of a polymeric material ( e.g. fluorinated rubber or butadiene – acrylonitrile copolymer ), classified according to ASTM D200.

.The filling material shall be an adhesive sealant elastomer or low viscosity, cold

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curing thermosetting resin having a compressive strength above 130 N/mm2

The spacing ring, sealing gasket, and filling material shall not allow any absorpsion of moisture and shall be able to maintain their required compressive strength and insulating properties over the entire 20 year service live of pipeline.

6. DESIGN

The Insulation Joint shall be of the “monobloc type”, fully prefabricated, seamless or all-welded construction.

Insulation joint shall be suitable for pipeline design condition as specified in the Data Sheet for Insulation Joint 0032-50-L-DS-004-A4, which shall include design pressure,

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design temperature and expected external loads such as bending, torsion and possible load cycling. The Data Sheet for insulation joint, as specified in Appendix –A shall be suitable for service under sour conditions as defined by NACE MR 0175.

The insulation joint shall be of the “monobloc type”, fully prefabricated, seamless or welded construction. Pipe pups on the ends of the insulation joint shall be the same material as matching line pipe. The pipe pups shall be manufactured in accordance with the above referenced line pipe specification.

The Insulation Joints shall be no bolt monobloc type.

Electrical resistance at 1,000 V DC shall have minimum value of 60 Mega Ohm. Maximum current leakage acceptable shall be 5 mA at 5,000V AC for 1 minute.

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The pipeline thickness, where the Insulation Joints will be connected to, is 0.5 inches.

The Insulation Joints shall be designed to withstand design conditions without leakage or breakdown of the insulation properties.

The Insulation Joints shall be designed such that it will be possible to pass intelligent pigs through them.

The Insulation Joints body shall be made of forged steel. The grade of material shall be matched and compatible to the line pipe material (API 5L X-65).

Allowable bending moment shall be proposed by the Vendor. The Vendor shall provide calculation of allowable bending moment. The calculation shall be subject to approval by the Purchaser.

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Test pieces shall be provided at both ends. Test pieces shall be designed allowing for terminating 25 mm2 stranded copper cable.

Ends shall be beveled in accordance with ASME B16.9 Figure 1.

Surge Arrestor and spark gap terminals shall be installed at insulation joints for safety reason.

7. FABRICATION

Welding procedures and welders shall be qualified accordance with ASME Section IX for the specific materials and configuration of welding used in the fabrication.

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Repairs to defective welds shall be in accordance with ASME Section IX. Removal of defective material shall be finished by grinding to bright sound metal. Prior to repair welding, material shall be preheat of 203oF or the preheat specified in the welding procedure.

The completed insulation joint shall be supplied with a jumper cable attached to pre-installed lugs for use during its installation into the pipeline

8. TESTING AND INSPECTION

The Insulation Joints shall be inspected and tested in accordance with the following requirements.

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8.1. Radiography

All butt welds required for the fabrication of the insulation joint shall be radiographic using a fine grain film, lead screens, and suitable source of radiation. Longitudinal seam welds shall meet the limits of acceptability standard in ASME Section VIII – Unfired Pressure Vessel.

Radiographic test shall be applied to all butt welds.

8.2. Magnetic Particle Inspection or Ultrasonic Inspection

Magnetic particle or ultrasonic for all fillet welds and all other welds where it is impractical to use radiographic examination. The limits of acceptability shall be according to ASME Section VIII.

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8.3. Hydrostatic Pressure Test

The insulation joint shall be hydrostatically tested with a test pressure to the minimum 1.75 x design pressure but the resultant hoop stress shall not exceeds 95% of SMYS of the weakest component. Test holding time shall be two (2) hours. Ends caps may be welded to both ends for the pressure test. However, after completion of the test, these caps shall be cut off and the end bevels replaced on the insulation joint.

(a) Minimum duration after test pressure has been stabilized.

(b) Reduce to zero

(c) Repeat above procedure twice

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8.4. Leak Test

Leak test using helium gas at 75 psig after hydrostatic test. Gas detector shall be used on the outside of the insulation joint to detect any helium leakage. This test may be replaced by pneumatic leakage test at 1.1 times of design pressure upon the Purchaser’s approval.

8.5. Dimensional Inspection

The Manufacturer shall perform dimensional inspection on a step-by-step basis during manufacture. The ultimate dimension s will be inspected after completion of hydrostatic, leak and electrical test.

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8.6. Visual Inspection

The various procured materials are to be visually inspected with regards to their compliance with requirements, tolerances, etc. The same inspection is to be repeated after the various steps of manufacture, since some failure or other defect not visible in the material raw conditions, could be revealed after machining.

8.7. Electrical Resistant Test

The electrical resistance of the joint shall be checked before and after hydrostatic test. Final testing shall be as follows:

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Electrical resistance in air at room temperature shall be measured by Mega Ohm at 1000 Volts battery type and hand operated type. The guarantee for the insulation joint is 60 Mega Ohm.

For resistance to the applied voltage, the guarantee for the insulation joint is 5000 V, with the voltage being applied for one minute. The maximum current leakage acceptable is 5 mA

The dielectric strength of the insulation joint shall be higher than 2.5 KV

Dielectric and resistance tests shall also be carried out before and after the hydrostatic test.

The Vendor shall submit to the Purchaser all tests and quality certificates.

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9. PAINTING

The insulation joint shall be externally painted in the shop up to 50 mm from the bevel ends. The paint coating system shall accordance to project painting specification..

10. MARKING AND PACKING

10.1. Marking

A stainless steel label shall be affixed to the outside of the insulation joint.

The insulation joint shall be marked with a durable identification tag providing the following data:

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1. Tag number or Equipment name2. Material, grade and thickness of pipe pups3. Design pressure and temperature4. Nominal size5. Purchase order number6. Design Code7. Weight8. Year of fabrication and acceptance testing mark

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10.2. PACKING

Before shipment, the insulation joint shall packed according to procedure prepared by SUPPLIER / VENDOR and approved by PMC / PGN.

Particular care shall be taken in order to avoid damage to the insulation joint and coating.

The joints shall be wrapped in waterproof material with adequate end protectors and mounted in wooden crates to prevent movement during shipment

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11.PREPARATION FOR SHIPMENT

All items shall be properly packed and protected from damage during shipment.

Exposed-machined surface shall be coated with easily removal rust preventive.

The Vendor shall be solely responsible for the adequacy of the preparation for shipment

provisions employed in respect of materials and applications to insure that materials will

arrive at their destination as exactly same ex-works condition.

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12. DOCUMENTATION

The following documents shall as a minimum be submitted after completion of production to PMC / PGN for review and approval:

Assembly drawings showing dimensions, material used for construction, weight and external and internal coating systems.

Check calculations, according to code and design data

Welding Procedure Specification (WPS) and Welding Procedure Qualification Record (WPQR)

Assembly procedure

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Reproducible copy of final construction drawings approved by PGN

Certificates of the chemical analysis and mechanical test carry out on the material used

Material certificates for all materials included in the finished product according to BS EN 10204.

Non-destructive examination report of all verification, check and test performed

Statement of guarantee on heat treatments carry out (records)

All calculations and drawings

Certificates of inspections and tests in accordance with the requirements of this specification including a document showing the recording of hydraulic test.

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Hydrostatic and leakage test record with charts

Non-destructive inspection record

Record of visual and dimensional inspection

Electrical test reported

10.

11.

1.2.

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0032 50 l sp 015 a4 specification for insulating joint

Documents