Doc.

No : MEP-P-ES-007
CORROSION PROTECTION COATINGS
FOR BURIED IN-PLANT PIPING Rev 0 page 1 of 11
Rev Date : 25 July 2005

PT. MEDCO E&P INDONESIA

STANDARD SPECIFICATION
FOR
CORROSION PROTECTION COATINGS FOR BURIED IN-PLANT PIPING

MEP-P-ES-007, Inspection And Testing Of Valves, rev 0, 25 July 2005

Custodian: Surface Engineering
 Doc. No : MEP-P-ES-007
CORROSION PROTECTION COATINGS
FOR BURIED IN-PLANT PIPING Rev 0 page 2 of 11
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TABLE OF CONTENTS

PAGE

1 SCOPE 3

2 APPLICABLE CODES, STANDARDS AND SPECIFICATIONS 3

3 GENERAL REQUIREMENTS 4

4 POLYETHYLENE TAPE WRAP SYSTEM 5

4.1 General 5
4.2 Materials 6
4.3 Equipment 7
4.4 Surface Preparation 7
4.5 Priming 8
4.6 Installation 9
4.7 Repair 9

5 INSPECTION AND TESTING 10

6 PIPE IDENTIFICATION AND MARKING 11

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CORROSION PROTECTION COATINGS
FOR BURIED IN-PLANT PIPING Rev 0 page 3 of 11
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1 SCOPE

This Specification defines the minimum requirements for field applied anti-corrosion
coatings for buried steel and cast iron pipe for in-plant piping systems. This specification
shall be applicable for all buried in-plant ferrous piping systems except for the following:

a) Nominal pipe diameters larger than 10", or

b) Pipe with 10" or smaller nominal pipe diameter, which is buried for a length in
excess of 100 meters.

In either of these two cases, the corrosion protection coatings shall comply with the
requirements of COMPANY specifications MEP-L-ES-003 and MEP-L-ES-004.

2 APPLICABLE CODES, STANDARDS AND SPECIFICATIONS

The latest edition of the following codes, standards, specifications and technical
publications shall form a part of this Specification, except as modified herein:

AWWA - American Water Works Association

AWWA C-209 Cold - Applied Tape Coatings for Special Sections, Connections, and
Fittings for Steel Water Pipelines.

COMPANY Specifications

MEP-L-ES-003 Machine Applied Anti-Corrosion Coatings for Buried Pipe.

MEP-L-ES-004 Hand Applied Anti-Corrosion Coatings for Buried Pipe.

MEP-G-ES-010 Storage, Handling and Transportation of Steel Pipe.

NACE - National Association of Corrosion Engineers

NACE-RP-02-74 High Voltage Electrical Inspection of Pipeline Coatings Prior to

Installation.

NACE-TM-01-70 Visual Standard for Surfaces of New Steel Airblast Cleaned with
Sand Abrasive.

NACE-TM-01-74 Laboratory Methods for the Evaluation of Protective Coatings Used

as Lining Materials in Immersion Service.

NACE-TM-01-75 Visual Standards for Surfaces of New Steel Centrifugally Blast

Cleaned with Steel Grit and Shot.

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CORROSION PROTECTION COATINGS
FOR BURIED IN-PLANT PIPING Rev 0 page 4 of 11
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SSPC - Steel Structures Painting Council

SSPC-SP1 Solvent Cleaning

SSPC-SP2 Hand and Tool Cleaning
SSPC-SP3 Power Tool Cleaning
SSPC-SP6 Commercial Blast

SIS - Swedish Standards Institute

SIS 05 59 00 Pictorial Surface Preparation Standard for Painting Steel Surface.

3 GENERAL REQUIREMENTS

3.1 Throughout this Specification, the following definitions are applicable:

a) COMPANY - MEDCO E&P INDONESIA

b) CONTRACTOR - The CONTRACTOR and all of his

subCONTRACTORs, if any, which are
responsible for shop or yard application of anti-
corrosion coatings to steel and cast iron pipe.

c) Responsible Government Authorities - All national, regional, local and

municipal organizations with jurisdiction over matters applicable to buried,
in-plant piping systems.

3.2 All coating materials and application operations shall be in accordance with the
requirements of the responsible Government authorities, BPMIGAS, Migas and
others with jurisdiction over buried, in-plant piping systems. COMPANY will not
accept ignorance of these requirements as cause for delay or as basis for a claim
against COMPANY.

3.3 CONTRACTOR shall furnish all materials, labor and equipment required for
application of anti-corrosion coatings to steel and cast iron pipe, unless specifically
stated otherwise by COMPANY in writing.

3.4 All surface preparation and coating operations shall be done in accordance with
the written instructions of the coating manufacturer.

3.5 CONTRACTOR shall when requested by COMPANY and at no cost to

COMPANY, secure the services of the coating manufacturer's representative to
approve the surface preparation and application of all coating materials.

3.6 All surface preparation and coating operations shall be performed by and under the
supervision of personnel skilled in the application of the anti-corrosion materials
specified. CONTRACTOR shall provide all the skilled personnel required for
execution of this work.

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3.7 CONTRACTOR shall be responsible for handling, transportation and storage of the
pipe in accordance with COMPANY Specification MEP-G-ES-010.

4 POLYETHYLENE TAPE WRAP SYSTEM

4.1 General

a) All tape and primer materials shall be kept out of direct sunlight during
transportation and storage. Tape and primer materials shall be stored in a
clean, cool and dry warehouse until required. Only sufficient quantities for
one day’s work shall be removed from the warehouse.

b) The Polyethylene Tape Wrap System shall consist of primer applied to

bare steel or cast iron, one or more layers of polyethylene inner wrap tape
and one layer of polyethylene outer wrap coating.

c) COMPANY has approved two Polyethylene Tape Wrap Systems as

defined in the following:

i) Standard System - This system consists of primer, a single layer of

inner wrap tape and a single layer of outer wrap tape.

ii) Double Wrap System - This system consists of primer, two layers of
inner wrap tape and a single layer of outer wrap tape.

d) The following table defines the minimum coating system requirements for
various underground piping systems:

SERVICE STANDARD DOUBLE WRAP

SYSTEM SYSTEM
All cast iron piping, all sizes Required ----
All carbon steel piping, all ---- Required
sizes, up to 10" maximum

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4.2 Material

a) The primer shall be certified to be in accordance with the requirements of

the tape manufacturer. The following products have been approved by
COMPANY for use on in-plant piping system:

APPLICATION ACCEPTABLE
SERVICE METHOD PRODUCTS
POLYKEN
All services except where Hand Brush or 927
non-flammable primers are Spray
required
All carbon steel piping, all Hand Brush 929
sizes, up to 10" maximum

b) The inner wrap tape shall be polyethylene tape backed with a butyl based
adhesive. The following products have been approved by COMPANY for
both the Standard and the Double Wrap Tape coating systems:

APPLICATION ACCEPTABLE PRODUCTS

SERVICE METHOD
POLYKEN
Pipe 3" nominal diameter Tapester-54 960-13
and smaller (See Note 1)
Pipe 4" nominal diameter Tapester-212 980-15
up to and including 10" (See Note 1)
Fittings, ells, tees, valves, Hand 930-25
etc.
Fill voids around fittings, Hand 931
ells, valves, etc.
Patch, repair damaged tape Hand 934
coatings
Outer wrap tape Tapester-54 or 955-15
212

Note 1- Tapester is a tape wrapping machine manufactured by Midwestern

Manufacturing COMPANY. This machine or a COMPANY
approved equal must be used for application of the tape where
indicated.

Other products of the same manufacturer and products of other

manufacturer's may be acceptable but must be approved in writing by
COMPANY after completion of a technical evaluation of the proposed

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product.
4.3 Equipment

a) All tools and equipment for preparation and application of the tape shall be
supplied by CONTRACTOR, shall be of good quality, shall be maintained
in good operating condition and shall be suitable for use to apply materials
required by this Specification.

b) When the tape manufacturer recommends particular equipment, that

equipment shall be used. All equipment shall be subject to approval of
COMPANY.

c) All cleaning, priming and coating machines shall be equipped with rubber
wheels or hard fiber overlayed wheels to prevent marking or denting the
pipe.

4.4 Surface Preparation

a) All surfaces shall be cleaned of all visible oil, grease and other detrimental
materials by steam and solvent cleaning in accordance with SSPC-SP-1.
The surface shall be dry to the touch before any additional surface
preparation is performed.

b) As a minimum requirement, all the exterior surface of the pipe shall be

abrasive blasted in accordance with the requirements of SSPC-SP-6
(NACE No.3). Experienced operators using silica shall perform all blasting
or flint based sand with grit size 16-30. Soft sand shall not be used. Care
shall be taken to protect pipe ends and bevels during abrasive blasting
operations.

c) The abrasive blast material shall be free of impurities, water and oil. All
abrasives shall be removed by brush-off blast or vacuum type cleaner prior
to applying coatings.

d) The compressed air for blasting shall be free of water and oil. Separators
and traps shall be provided at the compressor and blasting station.
Separators and traps shall be checked daily for effective moisture removal
during coating operations.

e) Blast cleaning operations shall not be conducted on surfaces that are less
than 5oF above Dewpoint or when the relative humidity is greater than
85%. Blast cleaning under these conditions may be performed but the pipe
shall be warmed to a temperature (not to exceed 125oF) at least 5oF above
the Dewpoint prior to initiating the blasting operation.

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f) Where abrasive blasting is not possible, all bare steel surfaces shall be
power tool cleaned in accordance with SSPC-SP-3. Prior to initiating any
surface preparation other the abrasive blasting, CONTRACTOR shall
obtain written authorization from COMPANY.

g) Hand tool cleaning is only permitted in tightly spaced areas where it is not
possible to operate power tools. COMPANY shall witness all hand tool
cleaning. Hand tool cleaning shall be done in accordance with
SSPC-SP-2.

h) In no case shall more surface area be prepared in one day than can be
satisfactorily coated in the same day. All prepared surfaces shall be coated
prior to sundown on the same day it was cleaned. If any flash rusting
occurs, the affected surface must be prepared again in accordance with
this Specification.

i) CONTRACTOR shall obtain written permission from COMPANY prior to

surface preparation inside oil and gas processing facilities because of the
hazards associated with sparking caused by surface preparation
operations.

4.5 Priming

a) Prior to any primer application, the pipe shall be cleaned to remove any
wetness or other contamination.

b) Primer shall be kept at a warehouse and only the daily requirements shall
be brought to the job site. Only the amount of primer required for
immediate use shall be emptied from the drums into open containers. After
obtaining the quantity required, bungs shall be immediately replaced in the
drums to prevent the loss of solvents by evaporation. Care shall be taken
that the contents of the drum have been properly agitated to ensure that
there has been no separation of solids from solvents prior to filling the open
containers.

c) Primer that has become contaminated with foreign matter or has thickened
because of evaporation of solvents shall not be used.

d) The primer shall be thoroughly agitated in its container before application to

the pipe.

e) Primer shall be either brush or spray applied to the cleaned pipe surface. A
uniform, thin film of primer is required over all exposed pipe surfaces.
Minimum coverage shall be as recommended by manufacturer or as
recommended in this Specification, which ever is greater. The primed
surface must be kept free of dust, dirt, rust and other foreign substances.

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f) Primer must be tacky at the time the primary tape coating is applied.

4.6 Installation

a) Both the inner and outer tape shall be applied with proper mechanical
equipment, approved in writing by COMPANY and by the tape coating
manufacturer. The machine operator within the limits specified by the tape
manufacturer shall control the tension of the tape. No wrinkling will be
permitted.

b) Polyethylene tapes shall be machine applied to straight runs of pipe. Hand

application is permitted only for ells, fittings, tees, valves, etc. where
machine wrapping is not possible.

c) The inner wrap tape shall be spirally wrapped over the primed pipe
surface. The tape shall be wrapped to provide a minimum overlap of
30 mm. Sufficient tension shall be applied to ensure that the tape conforms
to the surface of the pipe with no gaps or wrinkles.

d) If a Double Wrap System is specified, a second layer of inner wrap tape

shall be applied to provide a minimum overlap of 30 mm. The seam for this
second layer of tape shall overlap the seam of the first layer of inner wrap
tape by a distance equal to the width of the inner tape.

e) The outer wrap tape shall be spirally wrapped over the inner wrap tape to
provide a minimum overlap of 30 mm. The seam for the outer wrap tape
shall overlap the exposed seam of the inner wrap by a distance of the width
of the inner wrap tape for a Standard system. For a Double Wrap system,
the seam of the outer wrap shall overlap the seam of the inner wrap tape
by a distance equal to of the width of the inner wrap tape.

f) The end of each new roll of either inner or outer wrap tape shall overlap the
end of the preceding roll by a minimum of 300 mm. The splice shall be
applied in such a manner to provide a wrinkle free splice. The spiral angle
for each new roll of tape shall parallel the spiral angle of the previous roll.

g) After tape wrapping operations have been completed, the tape coating
shall be cut back with a cutting device, guided from the end of the pipe, to
produce a straight, uniform cutback at a distance of 225 mm from the end
of the pipe, if a field weld is required on the pipe end.

h) The outer wrap tape shall be completely bonded with the inner wrap.

4.7 Repairs

a) If the outer wrap is damaged and a holiday is not detected in the damaged

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area, the outer wrap shall be removed from the damaged area taking care
not to damage the inner wrap. Before the outer wrap is replaced, the
exposed inner wrap shall be inspected with a holiday detector to determine
if it has been damaged during removal of the outer wrap.

If no holidays are detected, the outer wrap shall be replaced in accordance

with the manufacturer's instructions to provide a minimum overlap of
75 mm of original, sound coating. If a holiday is detected in the inner wrap,
the coating shall be repaired in accordance with Section 4.7. (b) of this
Specification.

b) If the outer and inner wrap are damaged or a holiday is detected, the
damaged area shall be repaired by removing the damaged coating,
cleaning the exposed steel, repriming and reapplying inner and outer wrap
tape in accordance with the manufacturer's repair instructions.

c) CONTRACTOR shall repair all holidays and damaged coating at no

expense to COMPANY.

5 INSPECTION AND TESTING

5.1 All records of inspection and testing of material received by CONTRACTOR and all
manufacturers’ material certificates shall be submitted to COMPANY.

5.2 All stages of the work shall be subject to full time inspection by COMPANY. Such
inspection shall not relieve the CONTRACTOR of his responsibility to provide
materials, workmanship and inspection in accordance with this Specification.

5.3 For quality control of the coating and wrapping of the pipe, CONTRACTOR shall
employ qualified inspectors. The qualification of the inspectors shall be verified
and approved by COMPANY before the work begins. COMPANY shall determine
final acceptance of all coating and wrapping work.

5.4 Pipe which has been cleaned and primed, or cleaned, primed, coated and
wrapped without having been inspected and approved by the COMPANY, shall be
rejected. COMPANY shall inspect the prepared surface prior to any application of
primer or other coating materials. The prepared surface will be inspected by
comparing the actual clean surface with the photographs in SIS-05-59-00. Any
surface, in the opinion of COMPANY, which is not satisfactory, shall be further
cleaned at no expense to COMPANY.

5.5 CONTRACTOR shall furnish high voltage electronic holiday detectors of a type
acceptable to COMPANY and shall test all coating immediately after application.
The holiday detector shall be a low impedance, high voltage holiday detector such
as Spy Model S-120 or equivalent. Testing for coating flaws shall be in
accordance with NACE Standard RP-02-74. The minimum detector voltage shall
be 12,500 volts for that determined by the formula, whichever is greater:

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V = 7850 (t)½

Where "t" is the specified minimum coating thickness expressed in mm.

5.6 The crest voltage of the holiday detector shall be set as high as practicable and
operating voltage shall be set in accordance with AWWA C-203, Section
2.13.12.4. CONTRACTOR shall provide necessary devices for calibrating the
holiday detector.

5.7 All coated pipe under test shall be positively grounded by a means satisfactory to
COMPANY. The detector electrode shall be periodically cleaned to continuously
provide full contact with the surface of the coating. The approved electronic
holiday detector shall be passed over the coated pipe as coating progresses.

5.8 Any defective part of the coating shall be clearly marked by CONTRACTOR
immediately after it is detected.

5.9 All pinholes, voids, holidays, air bubbles, cracks and other breaks shall be carefully
marked. Repairs may be made immediately following the coating and wrapping
operation or may be deferred, but in any case, shall be repaired and reinspected
prior to back filling of the trench. The following shall be classed as defects that
CONTRACTOR shall repair:

a) All holidays detected by the high voltage electronic holiday detector.

b) Cuts or abrasions visible at the surface of the coating which penetrate the
outer wrap.

c) Cracks, pinholes, voids, air bubbles or wrinkles.

6 PIPE IDENTIFICATION AND MARKING

6.1 CONTRACTOR shall mark onto each length of pipe the nominal pipe size,
material, grade and the wall thickness. This marking shall be made in waterproof
paint, not closer than 1 meter from the end of the pipe and shall be in letters at
least 40 mm high.

6.2 CONTRACTOR shall also mark each length of pipe with the identification of the
coating material. CONTRACTOR shall label each length with either STANDARD
or DOUBLE WRAP as applicable.

6.3 If the final coating on the pipe is black, then white letters shall be used. Conversely,
if the final coating is white, black letters shall be used.

MEP-P-ES-007, Inspection And Testing Of Valves, rev 0, 25 July 2005

Custodian: Surface Engineering