TABLE OF CONTENT

1 PROJECT OVERVIEW....................................................................................................2
2 GENERAL........................................................................................................................ 2
3 DEFINITIONS.................................................................................................................. 2
4 REFERENCE DOCUMENTS...........................................................................................3
5 SAFETY & HEALTH........................................................................................................3
6 ROLES AND RESPONSIBILITIES..................................................................................4
6.1 SUPERVISOR.............................................................................................................4
6.2 COATING APPLICATOR...............................................................................................4
6.3 HOLIDAY DETECTOR OPERATOR................................................................................4
6.4 ABRASIVE BRUSHER..................................................................................................4
6.5 QC INSPECTOR.........................................................................................................4
6.6 SAFETYMAN...............................................................................................................4
6.7 HELPERS...................................................................................................................5
6.8 DRIVER.....................................................................................................................5
7 ENVIRONMENTAL.......................................................................................................... 5
8 PERMIT........................................................................................................................... 5
9 LIAISON OFFICER.......................................................................................................... 5
10 MANPOWER................................................................................................................... 5
11 EQUIPMENTS................................................................................................................. 6
12 WORKING TIME.............................................................................................................. 7
13 MATERIAL OF FJC......................................................................................................... 7
14 PRE-CONSTRUCTION WORKS.....................................................................................7
15 MATERIAL STORAGE....................................................................................................7
16 ENVIRONMENTAL CONDITION.....................................................................................8
17 HSS FJC APPLICATION.................................................................................................8
17.1 CLEANING SURFACE..................................................................................................8
17.2 SURFACE PREPARATION............................................................................................8
17.3 PRIMER APPLICATION.................................................................................................9
17.4 WRAPPING – HEAT SHRINKING SLEEVES....................................................................9
18 INSPECTION AND TESTING........................................................................................10
18.1 MOCK UP TEST........................................................................................................12
18.2 EPOXY PRIMER AND SLEEVE INSTALLATION INSPECTION...........................................12
18.3 HOLIDAY INSPECTION...............................................................................................12
18.4 PEEL TEST..............................................................................................................12
19 DOCUMENTATION.......................................................................................................13
20 ATTACHMENT.............................................................................................................. 13
1 PROJECT OVERVIEW

xxxx

2 GENERAL

xxxx

3 DEFINITIONS

PROJECT - xxxx
COMPANY - xxxx
CONTRACTOR - xxxx
CONSULTANT - xxxx
VENDOR - The party which supply materials, equipments, technical
documents/drawings and services to perform the duties specified
by CONTRACTOR.
DITJEN MIGAS - Representatives from the Indonesia Goverment which is
responsible for issuing licences and permits oil and gas facilities.

4 REFERENCE DOCUMENTS

PGTB-HSE-PLN-001 Project HSE Plan

PGTB-HSE-PR-001 Work Permit Procedure

PGTB-HSE-PR-002 Job Safety Analysis (JSA) Procedure

PGTB-HSE-PR-003 Emergency Response Plan Procedure

PGTB-PL-SPC-004 Specification for Field Joint Coating

PGTB-PL-DTS-003 Data sheet for Field Joint Coating

5 SAFETY & HEALTH

 All personnel shall receive safety induction prior to entry into site.
 All HSE issues in every work location will be coordinated by the Safety Man.
 All personnel shall be provided with and shall use the appropriate personal protective
equipment (PPE) (e.g. hard hat, safety goggle, dust masks, safety shoes, hand gloves,
rubber boot, reflector vest, etc.).
 All tools and equipment shall be checked daily by supervisor and/or safety man person
prior to use.
 Any damaged equipment or tools shall be not used. They shall be tagged, removed
from site and replaced by equipment or tools in proper condition.
 All personnel involved in operations in close proximity shall be made aware of the
conditions & hazards around them. High voltage power line, excavation landslide, lifting
work and all hazard indication shall be included in the JSA.
  A Job Safety Analysis (JSA) shall be prepared by safetyman and be attached to the
Permit to Work (PTW) for COMPANY site representative approval. JSA shall be
developed in accordance with Risk Assessment.
 The JSA shall be clearly explained to all workers by the safetyman/supervisor during the
tool box meeting. Supervisor shall make sure that all personnel understand all the risks
and hazards identified in the JSA.
 All personnel shall be made familiar with the Emergency Response Plan (ERP), see
document Number PGTB-HSE-PR-003 Emergency Response Plan Procedure.
 All required warning signs, barriers and protection shall be installed prior to the start of
construction activity by HSE department.
 Any operations carried out where there is public access or a thoroughfare such as a
road, shall be closely monitored by the Site Safety Man.

6 ROLES AND RESPONSIBILITIES

6.1 Supervisor
The Supervisor will be responsible for the overall coordination and supervision of the
activities. Supervisor will provide the necessary information and liaise with PTW Coordinator
and responsible for applying the correct work permits prior to commencement of works. The
Supervisor shall also be responsible for the overall implementation of the Project HSE Plan
and safety regulations that govern.

6.2 Coating Applicator

The coating applicator is responsible for the safe and qualified application of the coating as
per approved procedure and VENDOR recommendation.

6.3 Holiday Detector Operator

Holiday detector operator is responsible to perform the coating inspection using a holiday
detector prior to lowering the pipe onto the trench.

6.4 Abrasive Brusher

The brusher team is responsible to perform safe surface preparation activities on the steel
surface. The brusher is also responsible for the cleaning the steel surface until acceptance
criteria.

6.5 QC Inspector
The QC Inspector is responsible for the quality of the pipe bend. The QC Inspector will
ensure that the bending operation is performed in accordance with the approved bending
procedure. The QC Inspector will perform all required inspection during and after the
bending operation and provide a report to COMPANY.
6.6 Safetyman
The Safetyman will be responsible for the implementation of the HSE Plan and in
compliance with all statutory regulations that govern on all the activity commenced at his
assigned spread. The safetyman will be assisted by a supervisor at every construction
spread to help supervise the HSE aspect of the work undergone and also to conduct safety
briefings.

6.7 Helpers
The Helpers are responsible for performing all work ordered by supervisor correctly and
safely. Work will consist of unskilled activities such as: preparing the hand tool, perform
manual handling, etc.

6.8 Driver
The Drivers are responsible for driving the vehicle safely. Drivers shall have valid driving
license. The Drivers are also responsible for cleaning the vehicle that they drive.

7 ENVIRONMENTAL

 Workers shall keep the working area clean and tidy. Waste shall be disposed of in
disposal bins.
 Smoking at working area is strictly prohibited.

8 PERMIT

Permit to Work (PTW) shall be prepared by Supervisor and approved by COMPANY

representative and A permit-to-work coordinator will be provided to ensure each permit are
filled out correctly with necessary attachment (certificates, JSA, drawing etc).

9 LIAISON OFFICER

The CONTRACTOR Liaison officer shall inform the village chief minimal 1 weeks before
start of construction activities at the area. All local land owners beside the ROW shall also be
informed at the same time or prior to the start of work.

10 MANPOWER

CONTRACTOR will mobilize the following manpower to perform Clearing & Grading Activity.
Each team will consist of the following persons:
Table-1 Manpower List
 No Description Pax

1 Supervisor 1 person
2 Abrasive Brusher 2 person
3 FJC applicator 2 person
4 Holiday Detector Operator 1 person
5 QC Inspector 1 person
*Share
6 Safetyman* 1 person
for per
7 Helpers 1 person
spread
8 Mini Bus/Van Driver 1 person
Un-
skilled manpower or workers (helper) will be as much close to 100% to be recruited from
local community. All workers shall be given a safety induction by the Safety Man and shall
be educated about working hazards and risks prior to being assigned to a working area.

11 EQUIPMENTS

CONTRACTOR will mobilize the following equipment to perform construction survey

activities, consist of the following:
Table-2 Equipment List

No Description Pax

1 Temperature probe 1 Unit

2 Dew point tester 1 Unit
3 Humidity Tester 1 Unit
4 Gas Tank, hose, torch and regulator 1 set
5 Abrasive Brushing equipment set 2 set
6 Surface profile gauge As required
7 Wet film thickness gauge 1 unit
8 Hand tools (scissor, knife, cutter) As required
9 Measuring tape 1 unit
10 Hand Roller Rubber 2 Units
11 Wiper cloth/duster 2 Units
12 Mini Bus As required
13 Peel test Equipment 1 Unit
14 Holiday Detector 1 Unit

All Heavy equipment must be inspected by CONTRACTOR and COMPANY HSE Personnel
and have valid certificates.
12 WORKING TIME

Working times will start at 7.00 WITA, after a Pre-Job meeting and a check that all
equipment and tools are in good condition prior to use. 11.45 WITA to 12.00 WITA is time
designated to clean-up the working area and tidy the equipment or tools up prior to lunch
time. Break is 12.00 WITA to 13.00 WITA include time to pray. Working continues at 13.00
WITA until 17.30 WITA, and 17.45 WITA to 18.00 WITA is time designated to
clean-up/house keeping the working area and equipment. Prior to leave the working area, all
equipment and tools shall be tidied up and the working area shall be cleaned. No work
during rainy and risky weather.

13 MATERIAL OF FJC

Material of wrapping for Buried Pipe (mainline) and Induction Bend Pipe Body application
HSS GTS 65 or equivalent and DDX-80 type or equivalent for HDD pipes as per
specification and data sheet.

14 PRE-CONSTRUCTION WORKS

Prior to start the field joint coating application, following activities shall be performed:
1. Ensure that PPE is worn correctly.
2. Pre-job meeting attended by all the personnel involved.
3. The supervisor shall clearly explain the work permit and JSA to all personnel involved.
4. Check the equipment and tools to be used, any damaged equipment and/or tools shall be
repaired prior to use or replaced.
5. Install barriers, signage, and warning signs at the working areas.
6. Ensure the weld joint has been tested (NDE) and approved
7. Ensure that PQT for FJC material and applicator has been performed and accepted by
COMPANY

15 MATERIAL STORAGE

All Field joint coating material shall be stored at the following storage term as per
MANUFACTURING recommendation:
1. Keep product in dry and ventilated area
2. Keep product sealed in original cartons
3. Avoid exposure to direct sunlight, rain, snow, dust or other adverse environmental
elements
4. Avoid to prolonged storage at temperatures 23° C (73° F), out of direct sunlight (Shelf life
will be lesser at higher temperatures) and minimum curing temperature 10° C (50° F).
16 ENVIRONMENTAL CONDITION

The application of the shrink sleeves shall be performed only when the environmental
conditions meet following requirements:

 The outside metal surface shall be clean, dry and free from foreign matter prior to apply
liquid epoxy primer.
 The metal temperature shall be a minimum of 3o C above the dew point and be free of
visible moisture or ice.
 The relative humidity shall not exceed 85% during the application of the epoxy primer.

17 HSS FJC APPLICATION

The field application shall begin once the field weld is complete and all NDT is accepted and
released by QC for coating. The proper step of field joint coating to be implemented,
including:

17.1 Cleaning Surface

Prior to apply Heat Shrink Sleeves, the surface shall be cleaned of dust, oil, moisture,
grease, dirt, varnish and other contaminants by a clean dry air. Surface preparation for
cleaning shall comply with SSPC-SP-03 or SP-11. After cleaning, the metal surface shall be
thoroughly checked; any deposits, weld spatter etc. shall be removed. The surface profile of
1.0 – 30 mils shall be achieved.
Surface profile shall be check using surface profile gauge i.e. Pre-O-Film TESTEX shall be
done every 1 KM or at least one sample daily per crew production whichever is lesser.

17.2 Surface Preparation

Surface preparation for the installation of shrink sleeves to pipe joints shall be accordance to
MANUFACTURE’s recommendation.
Cleaning of pipe surface area by using wire brush/hand and power tools must comply with
minimum St 2 is covered by BS EN ISO 8504-3/SSPC-SP3/SSPC-SP11. Cleaning is done
in the area to be coated and added/added approximately 100 mm on each side (overlap
joint on 3LPE).
After the surface cleansing then do the preheat. If environmental temperature more than
20°C then Preheat done until the temperature of 70°-80°C. If the environmental
temperature is less than 20° C then Preheat done until the temperature 70°-80° C.

17.3 Primer Application

All cleaned surface shall be protect from environmental condition such as high humidity,
radial rainfall surface moisture.
The primer shall be applied to all exposed metal surface and onto the line pipe coating
3LPE
 The liquid epoxy primer shall be mixed using the proper component ratio and an
appropriate mechanical mixer until uniform and free of lumps.
Preheat the joint area 40º C up to 50º C by heating distribution evenly surrounding and
check the temperature by using a digital or pyrometer by equipped with flat temperature
sensor.
After preheating, the primer shall be applied in a uniform coat by brush or roller to obtain
minimum dry film thickness 4 mils. The primer shall be extended two 150mm over the
3LPE external coating. Overlap Sleeve to the external coating is 100mm.
The primed surface shall be kept clean and free of contamination and moisture prior to
application of shrink sleeve.
The mixing ratio by volume of Epoxy Primer Base to Epoxy Primer Cure is 4:1. Bulk epoxy
is available in US gallon quantities (1 US Gallon = 3.79 L).
The Typical Thickness of Epoxy is 4-6 mils (100-150 microns).
For detail of mixing ratio shall refer to material installation guide from manufacture, and for
detail material specification and data sheet for mainline and HDD, see document no.
PGTB-PL-SPC-004 Specification for Field Joint Coating and PGTB-PL-DS-003 Data Sheet
for Field Joint Coating.

17.4 Wrapping – Heat Shrinking Sleeves

Preheat the epoxy coating to 90ºC +/-5 by heating distribution evenly surrounding and
check the temperature by using a digital or pyrometer by equipped with flat temperature
sensor.
The shrink sleeve shall be applied immediately after the primer application without waiting
so as to ensure that the heat shrink sleeve is applied on the wet epoxy, and the underlap
approximately 150 mm (6”) from edge of 3LPE.
Wrap the shrink sleeve centrally around the girth weld. Position the leading edge of the
sleeve onto the pipe between the 10 and 2 o’clock position. Preheat the underside of the
leading edge of the sleeve with a LPG flame and press firmly down onto the top of the joint
area.
Using 2 torches begin at center of the sleeve and heat circumferentially around the pipe.
Applicator should work opposite sides pipe.
The sleeve should be wrapped around the joint leaving a small gap between the bottom of
the joint and sleeve. Sleeve overlap onto itself should be a minimum of 75 mm length
Use a small hard hand roller on the sleeve, working from the centre to an edge to push out
trapped air. The installed shrink sleeve shall be smooth, free of dimples, bobbles,
puncture, and burn holes and tightly adherent to the pipe joint area.
Repair shall be performed by removing the existing shrink sleeve and installation a new
shrink sleeve except as follow:
 Wrinkles, bubbles, areas with entrapped air and similar defects may be repaired, when
approved by COMPANY in advance, by cutting out the defect to tightly adhered adjacent
shrink sleeve material. Prepare the substrate and sound adjacent shrink sleeve. Apply
primer, whenever required to the prepared substrate. Fill the cut-out with moldable sealant
so that the filled surface is flush with the adjacent sleeve surface. Cover the filled defect
with approved linked HDPE backed repair patch in accordance with the shrink sleeve
manufacturer’s latest printed instruction.
Pin holes and holidays, detected by final coating inspection, may be repaired when
approved by COMPANY by using melt stick material or in accordance with above
paragraph instruction.

18 INSPECTION AND TESTING

Surface preparation shall be compared with SSPC-SP1 and SP11(or other method has
been tested, witnessed & approved by Company).
Test shall be made at the end of surface preparation with surface profile gauge to indicate
roughness of surface. If oil is evident, the contaminated surface shall be cleaned and
retested or replaced.
All of testing equipment for inspection shall be certified and calibrated accordingly prior to
use.
The surface roughness shall meet the manufacturer’s requirement to achieve the
maximum result.
A visual test shall be carried out after the field joint coating application finished. The
applied shrink sleeve shall be free of air pockets, tenting, edge lifting, bubbles, wrinkles
and other visible defects.
18.1 Mock up Test
Mock up test shall be performed at CONTRACTOR’s and shall be informed to COMPANY
for witnessed. CONTRACTOR shall prepare MPS, ITP and Procedure Qualification Test
Report and signed by CONTRACTOR and COMPANY. This qualification test also for
Coating Applicator and all Coating Applicator shall be qualified before working.

18.2 Epoxy Primer and Sleeve Installation Inspection

The primer thickness shall be determined using a wet film thickness gauge minimum every 1
KM or at least one sample per crew per day whichever lesser. The primer thickness shall
meet the requirements of the manufacturer’s recommendation, here in 4 mills.

18.3 Holiday Inspection

 Direct current holiday detection of 100% of the wrapped joint and repaired area shall be
carried out.
 The electrode ring used coating holidays shall be designed to ensure direct contact with
the coating and complete coverage of the coated surface with no gaps.
 The holiday detector output voltage shall be regularly controlled and shall be min 12.000
volts. Check any defective location shall be clearly marked with the paint marker
immediately, and ensure any defective shall be repaired and re-holiday test immediately.
 The travel rate of holiday detector ring maximum 0.5 m/s

18.4 Peel Test

Peel test shall be done in the one sleeve per 1 KM or daily production at least one sample a
day whichever is lesser, shall be destructively tested. Peel test location shall be random
sampling.
Peel test shall e accordance to ASTM D 1000. Strips of 25 x 200 mm shall be cut
perpendicular to the pipe axis, either at 9 or 3 o’clock position in the area between the
circumferential weld bead and the line coating and on the line coating.
Manual remove of the leading edge of the strip by using a screwdriver or chisel, ensure that
the initial adhesive bond line cut is essential center within the adhesive layer or towards the
epoxy primer layer.
Attach the peel gauge to leading edge of the test strip and fasten clamp. Holding the test
gauge with both hands exert a steady force with a pulling speed of approximately 100
mm/min and an angel of 90º to the circumference of the pipe.
Peel test result shall exceed 2.5 kg/cm or accordance to acceptance value from manufacture
recommendation.
Peel test unit si N/cm as per manufacture recommended. Accaptance criteria For GTS-65
HP, the value of peel test shall be a performed at a temperature 23° to 30°C. The minimum
acceptance values shall be 60 N/cm. Accaptance criteria peel test for DDX, the value of peel
test shall be a minimum 100 N/cm at temperature 30°.
 After peel test, the damage coating surface shall be repaired. The repair procedure shall
follow the requirement mentioned in section 17.4 of this document.

19 DOCUMENTATION

QC Inspector shall maintain record of all material qualifications testing and all quality control
check performed during installation. The information shall be supplied to COMPANY as the
job progress, and shall be formally submitted for review and acceptance within seven (7)
working days of the project completion.

20 ATTACHMENT
 Attachment-1: FJC Inspection Report

 Attachment-2: Peel Test Report

 Attachment-3: Coating Damage Report

 Attachment-4: Holiday Test Inspection Report

ATTACHMENT-1: FJC INSPECTION REPORT
ATTACHMENT-2: PEEL TEST REPORT
ATTACHMENT-3: COATING DAMAGE REPORT
ATTACHMENT-4: HOLIDAY TEST INSPECTION REPORT