JOB NO. DOCUMENT NO.

REV. 0
E14005 TSB-40-SP-205-A4
DATE OCTOBER 2020 PAGE 1 OF 10

SPECIFICATION FOR INSULATION JOINT

FEED PIPANISASI PADALARANG – SUKABUMI BARU

DAN PEMBANGUNAN TBBM SUKABUMI BARU

DIREKTORAT PEMASARAN & NIAGA

0 OCT 2020 ISSUED FOR BID IMN FI AS

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED CLIENT
 FEED Pipanisasi Padalarang - Sukabumi Baru Dan Pembangunan TBBM Sukabumi Baru

REVISION HISTORICAL SHEET

Rev. No. Date Page Description

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TABLE OF CONTENTS

1.0 GENERAL................................................................................................................... 4
2.0 DEFINITIONS ............................................................................................................. 4
3.0 CODES, STANDARDS, AND REFERENCES ............................................................ 4
3.1 Local Laws & Regulation .................................................................................... 4
3.2 Project Specification ........................................................................................... 5
3.3 International Codes & Standards ....................................................................... 5
4.0 DESIGN AND MANUFACTURE ................................................................................. 6
5.0 MATERIALS ............................................................................................................... 7
6.0 INSPECTION AND TESTS ......................................................................................... 8
7.0 SURFACE PREPARATION AND PAINTING ............................................................. 9
8.0 MARKING ................................................................................................................... 9
9.0 PREPARATION FOR SHIPMENT .............................................................................. 9
10.0 DOCUMENTATION .................................................................................................. 10
11.0 WARRANTY ............................................................................................................. 10
12.0 HANDLING &STORAGE .......................................................................................... 10

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1.0 GENERAL

This specification covers the minimum requirements for design, fabrication, performance,
inspection, testing, painting, and preparation for shipment of Insulation Joints to be supplied for
FEED of Pipanisasi Padalarang – Sukabumi Baru dan Pembangunan TBBM Sukabumi Baru
project of PT Pertamina (Persero).

2.0 DEFINITIONS

Definitions used in this document will not violate other definitions used in other documents
which is:
Company PT. Pertamina (Persero) Direktorat Pemasaran & Niaga, the
owner of the Project FEED Pipanisasi Padalarang – Sukabumi
Baru Dan Pembangunan TBBM Sukabumi Baru.

Contractor All Contractors to be appointed by Company.

Third Party Inspector A third party inspector to be appointed by Company to
inspect the
works of Contractor.
Vendor The party which supply materials, equipment, technical
document/ drawing, and service to perform the duties by the
Contractor.
Site The right-of-way and places provided by Company where the
works are to be executed and any other places as may be
specifically designated in the Contract as forming part of the
Site.
Issuer The person/party who develop and release the document and
correspondence.
Project Documents All documents which are prepared, revised, and issued for
accelerating the project execution, such as correspondence,
drawings, specifications, requisitions, purchase orders,
vendor prints, etc.

3.0 CODES, STANDARDS, AND REFERENCES

Insulation Joint covered by this specification shall comply with the requirements of the
applicable provisions of the latest edition of the following codes, standards and specifications.

3.1 Local Laws & Regulation

No 300K/38/M.PE/199 : Decree of the Minister of Mining and Energy

Regarding Working Safety of Oil and Gas Pipeline
SNI 3473:2011 : Sistem Transportasi Pipa Penyalur Untuk Cairan
Hidrokarbon dan Cairan Lainnya

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3.2 Project Specification

TSB-40-SP-003-A4 : General Specification for Painting and Protective

Coating
TSB-40-BD-201-A4 : Pipeline Design Basis Padalarang – Sukabumi
Baru
TSB-00-BD-001-A4 : Basic Engineering Design Data (BEDD)

3.3 International Codes & Standards

Insulation Joint shall comply with the following codes and standards.

API 5L : Specification for Pipeline

API RP 5L1 : Recommended Practice for Railroad Transportation
of Line Pipe
API RP 5LW : Recommended Practice for Railroad Transportation
of Line Pipe on Barges and Marine Vessels
API 1104 : Welding of Pipelines and Related Facilities
ASME Section V : Non-Destructive Examination
ASME Section VIII Div. 1 : Boiler and Pressure Vessel Code – Rules for
Construction of Pressure Vessels.
ASME Section IX : Boiler and Pressure Vessel Code – Welding and
Brazing Qualifications.
ASME B16.9 : Factory-Made Wrought Steel Butt Welding Fittings
ASME B31.4 : Pipeline Transportation Systems for Liquids and
Slurries
SSPC – SP10 : Surface Preparation Standard - Near White Blast
Cleaning
SSPC – SP1 : Surface Preparation Standard – Chemical Cleaning
SSPC – VIS 1 : Guide and Reference Photographs for Steel
Surfaces Prepared by Dry Abrasive Blast Cleaning
ASTM A370 : Standard Test Methods and Definitions for
Mechanical Testing of Steel Products
ASTM A149 : Standard Specifications for High Tensile Strength
Carbon-Steel Plates for Pressure Vessels (Plates 2
In. and Under In Thickness)
ASTM D149 : Standard Test Method for Dielectric Breakdown
Voltage and Dielectric Strength of Solid Electrical
Insulating Materials at Commercial Power
Frequencies
MSS SP-75 : Specification for High Test Wrought Butt Welding
Fittings
IEC 60167 : Method of test for determination of insulating of solid

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insulating material
IEC 60167 – 2 : Equipment for testing, measuring and monitoring of
protective measures, Part 2: Insulating Resistance
ASME B36.10 : Welded and Seamless Wrought Steel Pipe
ASTM D257-07 : Standard Test Methods for DC Resistance or
Conductance of Insulating Materials
MSS-SP-25 : Standard Marking System for Valves, Fittings,
Flanges and Unions
MSS-SP-53 : Quality Standard for Steel Castings and Forgings for
Valves, Flanges, Fittings, and Other Piping
Components
MSS-SP-55 : Quality Standard for Steel Castings for Valves,
Flanges, Fittings, and Other Piping Components -
Visual Method for Evaluation of Surface Irregularities
NACE MR 0175 : Sulfide Stress Corrosion Cracking Resistant
Metallic Materials for Oil Field Equipment
BS EN 10204 : Metallic Products - Types of inspection Documents
ASME B16.25 : Buttwelding Ends
IEC 60529 : Degrees of Protection Protection Provide by
Enclosures IP (Code)
ISO 15598-1 : Petroleum and Natural Gas Industries – Cathodic
Protection of Pipeline Transportation Systems

4.0 DESIGN AND MANUFACTURE

a. Insulation Joint and connecting lugs shall be designed in accordance with ASME
Section VIII Div.1.

b. The Insulation Joint shall be designed in accordance for 20 years design life.

c. Insulation Joint shall be of the “Monolithic” (boltless) type for onshore application, fully
prefabricated, seamless or Longitudinal Submerged Arc Welding (LSAW) construction
with 100% radiograph test result shall be provided.

d. The design shall be such that under maximum working conditions, stress in any part
and joint shall not exceed the specified minimum strength of the part. The Insulation
joint shall be designed to withstand the above conditions without leakage or breakdown
of Insulation properties.

e. The design of Insulation joint shall be such that the completed and assembled unit is
capable of resisting a moment producing a longitudinal stress of 72 % SMYS
(Specified Minimum Yield Strength) in the adjacent pipe pups while operating at the
maximum operating pressure without leakage or breakdown of the Insulation
properties. The allowable calculation shall be submitted for review.

f. The Insulation Joint and pipe pup piece shall be designed for scraper and instrumented
pigs where the inside diameter not less than the internal diameter of the adjoining pipe
or line pipe. The Inside of Insulation Joints shall be free from foreign object and have
smooth surface.
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g. The Joint between pup-pieces at pipe and main forging at Insulation joints shall be full
penetration butt weld type. Welding procedures and the welders must be qualified to
the ASME Sect. IX including weld repair procedure, removal of defect parts/welds is
done using a grinder. Before repair is done, the material must be pre-heated until the
temperatures exceeds 200⁰F or to temperature stated in welding procedures.

h. The Insulation Joint shall be equipped by factory with two terminal connecting lugs with
fully penetrated welding on the outer surface of each pup piece on both sides. Welding
between connecting lugs and pup pipe shall be done at manufacturer shop with fully
penetration multilayer fillet welding and shall have enough mechanical strength.

i. The insulation joint shall be designed to withstand the design service and
environmental conditions for the design life of the pipeline. Design conditions are
detailed in the Data Sheet.

j. Insulation Joints shall be possible to pass intelligent pigs through them.

k. No Repair by weld is allowed.

l. Bevelled area and all machined area shall be protected.

m. Surge arrester (or surge diverter, surge protector, spark gap) shall be installed to each
Insulation joint in accordance with TSB-30-SP-202-A4 “Cathodic Protection System
Specification”.

n. Vendor shall submit detailed longitudinal cross section drawings of the Insulation Joints
showing all parts, material, dimensions, surface finished & tolerance and ITP
(Inspection Test Plan) documents for manufacture and inspection of Insulation Joint
and shall be approved by Company.

5.0 MATERIALS

a. Insulation joint body must be made of forged steel with normalized condition by the
electric arc furnace or basic oxygen process.

b. The pup pieces for fabrication of Insulation Joints shall be provided by Vendor. The pup
pieces material shall be the same material or equivalent as the matching pipeline for
material and its grade. And as well as the forged components shall be equivalent
material to the matching pup pieces. Material for connecting lugs shall be equivalent
with pup piece and informed to the Company for approval.

- Maximum Carbon content of welded ends (pipe pup piece) shall conform to mating
pipe. Vendor shall be followed minimum requirements of API 5L Grade B.

c. Insulation joint and Insulation ring material as of Insulations parts shall have resistance
to corrosion inhibitors.

d. Seal gasket and Insulation filling material shall have permanent residual elasticity to
ensure leak testing.

e. Detail of Insulation material, including dielectric strength, compressive strength,

dimensions and suitability for use at the design temperature shall be included in Vendor
proposal.

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f. Insulation material shall have a dielectric resistance for at least 2.5 kV/mm with
maximum current leakage will be 5 mA as per ASTM A149.

g. Elastomer material shall have AED (Anti-Explosive Decompression) Certificate.

h. Full record and information of all raw materials shall be available and provided.

i. Grounding lug at each terminal connection of Insulation Joint shall be provided with
shop weld method, full penetration weld.

6.0 INSPECTION AND TESTS

The Insulation Joints shall be visual inspected and tested in accordance with MSS-SP-55.

a. All welds shall be subjected to 100% radiographic examination, unless impossible for
reasons of weld geometry, and shall comply with the acceptance standard in ASME
Section IX.

b. Magnetic particle and/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 VII.

c. Hydrostatic pressure test

1) Insulation joints to be proceeded complete with pup piece installed on Insulation

joint for hydrostatic test with test pressure of 1.25 times the design pressure with
holding time not less than 2 hours.

2) No evidence of leakage during test

d. Leak test using helium gas at 0.5 MPa for 10 minutes with no evidence of leakage
during test. Gas detector shall be used on the outside of the Insulation joint to detect
any helium leakage (Helium Sniffer).

e. Dielectric and megger test shall be performed out before and after the hydrostatic test.

f. The Electrical resistance of the joint shall be checked before and after hydrostatic
testing in accordance with ASTM D149. The final testing shall be as follows:

1) Electrical resistance in air at room temperature shall be measured with a 1000V DC

mega tester under stable voltage to ensure that the electrical resistance of the
Insulation joint is greater than 10 Mega-Ohms.

2) Manufacturer shall conduct Insulation joint test at the applied voltage for one minute
up to 5000V AC 50Hz. The maximum current leakage acceptable is 5mA.

3) The dielectric strength test shall be performed by applying an AC sinusoidal current

with a frequency at 50 – 60 Hz to joint.

4) The current shall be applied gradually, starting from an initial value not exceeding
1.2 kV increasing to 2.5kV inline no longer than 10 seconds and shall be
maintained at peak value for 60 seconds.

5) The measurement of the electrical resistance shall be performed on each Insulation

joint kept in vertical position using mega ohm meter of a suitable range.
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g. Inspection certificate shall be in accordance with BS EN 10204 Type 3.2.

h. Lamination test & check shall be performed after beveling and 100mm over it ends.

The Vendor shall submit to the Purchaser all tests and quality certificates. Company reserves
the right to witness all phases of the Insulation Joint manufactures and test at
Manufacturer/Vendor workshop in accordance with this specification.

7.0 SURFACE PREPARATION AND PAINTING

After completion of non-destructive inspection, hydrostatic testing and leak testing, all metal
surfaces preparation before blasting shall be as per SSPC-SP1. After all metal surface cleaned
it shall be blasted with dry abrasive blasting to achieve minimum near white metal (SSPC-
SP10) and paint shall be internally and externally coated to limit possibility of over stray voltage
between two spool accordance to General Specification for Painting and Protective Coating,
doc. no. TSB-40-SP-003-A4.

8.0 MARKING

The following information shall be clearly marked on the Insulation Joints in accordance with
MSS-SP25 requirement.
- Project Name
- Company Name
- Manufacturer’s Logo/Name
- Purchase Order Number
- Tag Number
- Nominal and Internal Diameter
- Design Pressure
- Test Pressure
- Design Temperature
- Service
- Weight
- Date of Manufacturer
- ANSI Rating/ Pressure Rating
- Material, Grade and Thickness of Pipe
- Design Code
- Country of Origin
- Final Acceptance Testing Mark

9.0 PREPARATION FOR SHIPMENT

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

b. Open ends shall be protected and blanketed to avoid damage and ingress of any
foreign materials during transportation and testing. All threaded, bevel, and machined
surfaces subject to corrosion shall be well protected by a coat of grease or other
suitable material.

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c. 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.

d. All procedures for pipe and fitting transportation, handling and storage shall be based
on the requiremens of API RP 5L1 for rail and in land transportation and API 5LW for
sea transportation.

10.0 DOCUMENTATION

The following documents shall be submitted after completion of production.

- Mill certificates of the Insulation Joint (including pipe pup piece) materials used for
construction as per this specification requirements.
- Hydrostatic and leakage test record with charts
- All Non-destructive inspection records, complete with procedures
- Record of visual and dimensional inspection
- Electrical resistance, dielectric resistance, and maximum current leakage test record
- All raw material records
- Helium leak test records

11.0 WARRANTY

The Vendor must provide warranty for 12 months after the Insulation Joints is installed on the
pipeline or not more than 18 months after it is delivered to the field. The warranty mentioned is
related to defects in raw material, workmanship, in accuracy to design, in accuracy of material
and procedures. Any wear out or fail part of Insulation Joint during warranty period shall be
changeable and replace by Vendor.

12.0 HANDLING &STORAGE

a. Insulation Joint shall be handled in a manner that prevents damage to the coatings
and beveled ends during transportation. Adequate strapping and padding shall be
provided when loading.

b. Foreign substances, dirt, steel shot and other debris shall be removed from inside the
Insulation Joint before stockpiling or shipping.

c. Insulation Joint transportation by rail and in land transportation shall be in accordance

with API RP 5L1.

- Insulation Joint transportation by sea shall be in accordance with API RP 5LW

- Vendor shall responsible for any damages during transportation, handling,
storage at stockpile area and to the site, etc.

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