SOUTH EAST SUMATRA GAS PROJECT FEED

JOB No: 1335

CNOOC South East Sumatra BV

PIPELINE WEIGHT COATING SPECIFICATION

DOCUMENT NUMBER: 028120-SPL-004

REV DATE DESCRIPTION PREP’D CHK’D APP’D CLIENT.

A 10-02-2003 ISSUED FOR INTERNAL REVIEW FPM WB
B 14-02-2003 ISSUED FOR CLIENT REVIEW FPM VB WB
C 27-02-2003 ISSUED FOR FEED FPM
 CNOOC SOUTH EAST SUMATRA BV
SOUTH EAST SUMATRA (SES) GAS PROJECT
FRONT END ENGINEERING DESIGN

PROJECT SPECIFICATION
PIPELINE WEIGHT COATING SPECIFICATION

TABLE OF CONTENTS

Page
1.0 SCOPE 3
2.0 CODES AND COMPANY SPECIFICATIONS............................................................................3
3.0 DEFINITIONS...............................................................................................................................3
4.0 GENERAL REQUIREMENTS......................................................................................................4
5.0 CONCRETE WEIGHT COATING................................................................................................4
6.0 GUARANTEE..............................................................................................................................11

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SOUTH EAST SUMATRA (SES) GAS PROJECT
FRONT END ENGINEERING DESIGN

1.0 SCOPE
This Specification covers the material, application, inspection and testing of weight coating of line
pipe for onshore and offshore use.

2.0 CODES AND COMPANY SPECIFICATIONS

The requirements and recommendations of the latest revisions of the following listed codes,
standards and COMPANY's Project Specifications shall apply :
2.1 Codes
ASTM A615 Standard Specification for Deformed Billet-Steel Bars for Concrete
Reinforcement
ASTM C31 Standard Method of Making and Curing Concrete Compressive and
Flexural Strength Test Specimens in the Field
ASTM C33 Standard Specifications for Concrete Aggregates
ASTM C39 Standard Method of Test for Compressive Strength of Molded Concrete
Cylinders
ASTM C42 Standard Method of Obtaining and Testing Drilled Cores and Sawed
Beams of Concrete
ASTM C150 Standard Specification for Portland Cement
ASTM C518 Steady-State Thermal Transmission Properties by Means of the Heat
Flow Meter
2.2 Project Specifications
028120-SPL-007 Protective Coatings - Pipelines
028120-SPL-006 Line Pipe and Riser Handling

3.0 DEFINITIONS
CONTRACTOR is the independent party awarded a contract by COMPANY for the supply of
material, application, inspection and testing of insulation and weight coating of linepipe for
onshore and offshore pipelines.
Manufacturer is the supplier of the raw materials for insulation and weight coating for the
CONTRACTOR.

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 CNOOC SOUTH EAST SUMATRA BV
SOUTH EAST SUMATRA (SES) GAS PROJECT
FRONT END ENGINEERING DESIGN

4.0 GENERAL REQUIREMENTS

The purpose of this Specification and its referenced codes, standards and General Specifications is
to establish a minimum level of acceptable quality. Alternate standard designs of equal or superior
quality may be proposed, provided all exceptions are listed and written approval for all exceptions
is obtained from COMPANY.
In the case of conflict between documents, CONTRACTOR shall submit the discrepancy
immediately to COMPANY for final resolution.
The material covered by this Specification shall be complete in all details and ready for installation.
The material supplied shall be of a type, model or series in regular production at the Manufacturer's
facilities.
The allowable time lapse between the date of manufacture of all materials to be used and the
intended date of use shall be determined and submitted to COMPANY for approval prior to
purchase of any material.
In case of breakdown of the coating application equipment, CONTRACTOR shall guarantee the
availability of spare equipment or spare parts which are available to be installed in a reasonably
short time period, to ensure minimum delays to schedule any spare equipment shall be required to
produce coatings of equal or better quality or finish to that produced by the primary equipment.

5.0 CONCRETE WEIGHT COATING

5.1 Equipment
CONTRACTOR shall provide mechanical equipment capable of applying coating utilizing
the "high velocity impingement" method to the specified degree of uniformity with respect to
thickness, density and strength. CONTRACTOR equipment shall provide for either the
batching of materials by weight or continuous mixing where all feeds are accurately
controlled and percentages of mix are calibrated by weight. Batching scales shall be
maintained in good condition to + 2% accuracy. A water gauge accurate to within + 3% of
the indicated values shall be used for adding water to the mix. Any equipment that tends to
separate the ingredients shall not be used.
All equipment, tools and supplies furnished by CONTRACTOR must be of good quality,
adequate design, must be maintained in good condition during use and shall be subject to the
approval of COMPANY. Equipment shall be capable of coating joint lengths up to 42 feet.
5.2 Weight Coating Materials
Cement shall conform to ASTM C150 Type I. The cement shall be stored in a manner that
will satisfactorily protect it from the elements. Cement that has hardened, partially hardened,
become lumpy or become contaminated with foreign materials shall not be used.
Sand shall be of the silica type and well graded from fine to coarse. It shall be clean and free
from injurious amounts of salt, alkali, harmful substances, or organic impurities.
Sand shall conform in all respects to ASTM C33. COMPANY reserves the right to reject any
sand not deemed acceptable by virtue of either source or quality.
Heavy aggregate shall be crushed and graded to the following sieve sizes :
Sieve Passing
3/8 in. 100%
No. 4 80 - 90

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No. 16 40 - 70
No. 50 10 - 30
No. 100 2 - 10
The heavy aggregate shall be free of clay and injurious amounts of salt, alkali, deleterious
substances, and organic impurities that may affect the strength of the concrete. COMPANY
reserves the right to reject any aggregate not deemed acceptable by virtue of either source or
quality.
Reinforcing steel shall be made from best quality billet-steel, formed into welded galvanized
wire fabric type reinforcing. The wire fabric shall be minimum 14 gauge (.08"). The
chemical and physical properties of the billet-steel shall conform to ASTM A615 Gr. 40.
One layer of 1.5"x1.5"x17 gauge (.054") galvanized hexagonal wire netting shall be used.
Two layers of reinforcing steel shall be used for concrete thicknesses of 2" and above.
Water shall be clean and free from injurious amounts of oil, acid, alkali, salt, or organic
material and shall be of potable quality.
5.3 Mix Design
The concrete mix shall be designed to yield the specified density on the drawings immersed
in sea water and with maximum water absorption of 3%. CONTRACTOR shall design its
mixes using the components approved and shall determine the proportions which will give
the required densities and strength. All mix designs are to be agreed with the COMPANY
prior to commencement of the Work.
Full details shall be provided by CONTRACTOR with regard to :
(a) the proportion and weights of the respective materials used in the mix
(b) the water/cement ratio
(c) the gradings of the various aggregates with combined grading curves as necessary.
5.4 Application of Reinforcing Steel
Reinforcing steel may be applied by any method that will provide for the continuity of
reinforcing. When reinforcing is spooled on, a lap of approximately 1 inch shall result.
A minimum of one reinforcing wrap shall be used, and it shall be placed as close as possible
to the center of the concrete coating. If more than one layer of reinforcing is used, the layers
shall be evenly distributed throughout the concrete thickness. The reinforcing wire shall not
contact the pipe corrosion coating or be exposed on the external coating surface.
5.5 Application of Concrete Coating
No concrete shall be applied if the surrounding temperature at the curing station is outside
the parameters of the approved procedure.
If kraft paper has been placed on the joint to protect the corrosion coating, the paper shall be
completely removed before the joint is concrete coated.
The dry materials shall be mechanically batch mixed in a paddle mixer or equal with
sufficient water to make homogeneous grout. The concrete shall then be applied to the pipe
within 30 minutes after the water is first added to the mix and then only provided there has
been no additional water added to the mix to return the concrete to the original slump.
Each joint of pipe shall be coated in a continuous operation. If more than one application is
required to produce a coating of the specified thickness, then the time allowed between
successive applications shall not exceed 30 minutes. If the time between coats does exceed

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FRONT END ENGINEERING DESIGN

30 minutes all previous coatings shall be removed and the entire joint recoated at no expense
to COMPANY.
5.6 Coating Joints with Anodes
Anodes shall be installed at the specified location on a certain number of the pipe joints.
After proper curing of the anode attachment coating repairs, the concrete weight coating may
be applied.
5.7 Curing
During curing, the concrete coated pipe shall be stacked on sand ridges or on a flat earth
surface free of obstructions.
If the joints are placed on sand ridges they should be so placed as to eliminate any injurious
deflection in the pipe. The concrete may be cured by water spray or by application of a
curing membrane. The concrete coated pipe shall cure for not less than 4 days after
application of concrete, and shall not be handled or loaded out from the yard until so cured.
No deviation from this requirement shall be permitted.
Water curing shall commence no later than 6 hours after coating. It shall consist of keeping
the concrete continuously moist for the curing period by means of intermittent watering.
During this treatment, pipe joints shall be kept continuously moist by means of either manual
or mechanical watering.
Membrane curing shall be of the white pigmented compound or plastic membrane type. It
shall be applied by mechanical apparatus to the coated surface in quantity to provide
complete coverage in accordance with manufacturer's recommendations. The application of
this curing compound or sheet shall take place immediately after coating is completed and
preferably before the pipe is removed from the concrete coating apparatus. A slight spray of
water applied after concrete application and before applying the curing agent shall be
required for the curing compound method.
5.8 Cutbacks
The concrete shall be square cut or tapered back from 10 1/2” from the pipe end at a
minimum two-to-one slope, until the required thickness of coating is reached.
The uncoated portion of the pipe and the bevels and lands shall be kept clean and free from
concrete spatters, oil, grease, etc.
5.9 Concrete Inspection and Testing
5.9.1 General
All testing shall be at CONTRACTOR's expense. The testing methods to be used
are outlined below.
Pipe coating not meeting the requirements, as outlined herein, shall be rejected and
recoated by CONTRACTOR at no expense to COMPANY. Coatings shall be
rejected for the following reasons :
(a) improper placement of reinforcing steel
(b) unfinished coatings which have been allowed to remain unfinished for a
period of 1/2 hour or more
(c) concrete strength below the specified values
(d) concrete density outside the specified range
(e) individual coated joint weight outside the specified range, or joint
average below the specified coated pipe weight.
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FRONT END ENGINEERING DESIGN

5.9.2 Tolerances
The minimum compressive strength of the as placed concrete, as determined from
tests, shall not be less than 3,500 psi after 7 days and 4,650 psi after 28 days.
The density of concrete, as determined from tests, shall be no more than 5 pcf
above or 0 pcf below the specified density as given in the individual submarine
pipeline specifications.
In addition, the average weight per foot (negative buoyancy) of five successively
coated joints shall be greater than or equal to the required weight per foot.
The nominal weight coating thickness and approximate length of pipe to be coated
will be specified for each pipe O.D. in the individual pipeline specification. The
concrete coating thickness shall be concentric and uniform around the
circumference of the pipe, and shall not vary more than 1/4" along the length of a
coated pipe joint.
5.9.3 Compressive Strength
Compressive strength of each mix, as applied during the coating operation, shall be
determined from samples prepared at the jobsite in cylindrical molds obtained in
accordance with practices outlined in ASTM C31. A minimum of two (2) test
cylinders shall be taken in the morning, and two (2) in the afternoon for each day
of production. These cylinders shall be tested according to procedures obtained in
ASTM C39 to determine the 7 day and 28 day compressive strengths of the
concrete.
Six core samples shall be taken and tested from each day’s production. The cores
shall be taken as close to 7 days after impingement as possible, but not less than 4
days after impingement. The cores shall be taken from coated pipes representing
three equally spaced periods of that day’s production. For this purpose three pipes
shall be selected, marked, and joint numbers noted at the time of impingement. The
cores shall be taken and tested in accordance with ASTM C42 to determine the 7
and 28 day compressive strengths of the concrete. Repair of the coating where the
cores were taken shall be per the repair section of this Specification.
If the average compressive strength obtained for the 7 day test for the cylinder or
core falls below the minimum, CONTRACTOR has the option to recoat all the
pipes coated during the days production when the samples were taken or,
alternatively, wait for the results of the 28 days tests.
5.9.4 Dry Density and Water Absorption
From one pipe out of every fifty or at least two per 24 hour period, a piece of
concrete is to be removed and weighed. Repair of the coating where the section
was removed shall be as per this Specification. After 24 hours curing, this concrete
sample is to be weighed. The sample shall then be immersed in a tank of fresh
water for not less than 24 hours. The volume of the sample is to be determined
from the volume of water displaced. The concrete dry density shall then be
calculated using this weight and volume.
After saturation the sample is reweighed immediately on removal from the tank
after surface water has drained off.
For a given length or pipe, weight of sea water absorbed is given by :
Wabs1 = Vc (Wsat - Wcs) 64/62.4 Vs
Where :
Vc = Volume of concrete per ft of pipe length (theoretical)
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FRONT END ENGINEERING DESIGN

Wsat = Weight of saturated concrete sample (fresh water)

Wcs = Weight of sample immediately after impingement
Wabs1 = Weight of sea water absorbed in lb/ft from lab. test
Vs = Volume of concrete sample used in saturation test.
For checking purposes, water absorption tests shall also be carried out on concrete
coated pipes of the same frequency as specified above. Water absorption tests are
to be carried out not less than 24 hours after impingement by completely
immersing a length of concreted pipe in a tank of fresh water for at least 24 hours
and weighing the pipe on removal from the tank, immediately after surplus water
from inside the pipe has been drained off. If CONTRACTOR can show to the
satisfaction of COMPANY that the 24 hour period is not necessary to obtain full
saturation, then the period may be reduced by mutual agreement.
For a given length of pipe, weight of sea water absorbed is given by :
Wabs2 = (WPsat - Wc) 64/62.4 (L-CB)
Where :
WPsat = Weight of saturated concrete coated pipe (fresh water)
Wc = Weight of each concrete coated pipe in lbs. immediately after
impingement
Wabs2 = Weight of sea water absorbed in lb/ft from pipe joint test
L = Length of steel pipe in feet
CB = The concrete coating cutback at each end added together.
Wabs1 and Wabs2 shall be correlated and averaged to obtain an acceptable average
daily estimate of water absorption Wabs in lb/ft.
5.9.5 Coated Pipe Dimensional Inspection
Each joint of pipe shall be weighed in air immediately after impingement on
CONTRACTOR's scales having a certified accuracy of + 1.0%. The length of each
pipe joint shall be measured to the nearest 0.01 foot. The concrete coating cutback
on each end shall be measured from the end of the pipe to the approximate center
of the beveled end of the concrete. The average diameter of each corrosion and
insulation coated pipe is to be taken as determined by girth tape measurements
equally spaced along the pipe with two end measurements being made
approximately 2 ft. from the ends of the concrete coating.
The above values and the negative buoyancy shall be recorded and tabulated for
each joint against an agreed upon joint numbering system.
5.9.6 Negative Buoyancy
The negative buoyancy of each joint shall be calculated and tabulated. The
diameter (DA) to be used for evaluating the uplift/foot run in sea water is to be the
arithmetic mean of the five diameters given by the girth measurements of the
concrete coating.
Uplift/foot is to be taken as :
B = 16 PiDA2
Where Pi = 3.14
Net down weight/foot is to be taken as :
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FRONT END ENGINEERING DESIGN

Wd = ((Wc-WCB)/(L-CB)) + Wabs
Where W = API standard weight/foot of line pipe.
For every fifty pipe production period the value of Wabs to be used is that
determined from the absorption test for that same period.
The negative buoyancy/foot in seawater for each length of pipe is then determined
and defined by:
NB = Wd - B
The theoretical value of negative buoyancy shall be calculated using the same
above formula's using the theoritical values of DA, Wc, L, CB and Wabs, and
compared to the computed NB for each coated joint. The actual average negative
buoyancy of successive coated joints shall be within -0 +10% of the theoretical
value, and -0 +15% for individual pipes.
Should a number of pipe lengths in a fifty pipe production period not satisfy the
negative buoyancy requirements using the value of Wabs1 obtained in the test, then
the contractor can select three further pipes from the same fifty pipe period and
subject samples from each of these to a water absorption test; the average value of
Wabs1 for the four must be used for checking negative buoyancy requirements.
If CONTRACTOR wishes to use an alternative method for calculating negative
buoyancy then this must be submitted in writing to COMPANY or its
representative for approval.
5.9.7 Moisture Content Inspection
The moisture content of the aggregate being used shall be checked at least once per
shift or more frequently if it is shown to be necessary in order to maintain a
satisfactory control on the water/cement ratio of the concrete mix.
5.9.8 Wire Mesh Inspection
CONTRACTOR shall be prepared with an ohmmeter or a 12v. light bulb to test
concrete coated joints to ensure that there is no contact between the wire
reinforcement and the pipe.
On the center of the first pipe of each day's production a water jet shall be used to
clear away the freshly placed concrete down to the corrosion coating for an area 1"
wide and 9" long in the longitudinal direction. This exposed area shall be used to
confirm that the mesh is positioned and overlapped within the concrete as
specified.
If the wire is not positioned correctly the pipe shall be rejected and recoated. Each
pipe in succession shall be inspected in this manner until the position of the mesh is
accepted.
Repair to the inspection slots shall be per this specification.
5.9.9 Equipment Inspection
The calibration of the weigh-batcher and the water gauge shall be checked at least
once per week.
5.10 Permissible Repairs
All removal and replacement of concrete not meeting the specification shall be at
CONTRACTOR's expense.

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5.10.1 Repairs to Uncured Coating

Repairs to uncured coating may be made by hand patching if the damaged area is
less than 1 sq.ft. Such patching shall be carried out by removing the affected
coating down to the reinforcing level, taking care not to damage the reinforcement
and making good the cavity using a similar mix to that used in the coating process
with addition of just sufficient water to allow hand application.
If the damaged area is in excess of 1 sq.ft., but not extending over more than 3 ft.
of the pipe length, repair shall be carried out by removal of all concrete within the
affected length down to the reinforcement and the repair carried out using the
gunite process or by hand.
If the damaged area is in excess of 1 sq.ft. and extends over more than 3 ft. of the
pipe length, the entire pipe shall be recoated.
5.10.2 Spalling
Spalling hardened concrete due to compression or shearing caused by impact
against other objects which causes a loss of not more than twenty-five (25) percent
of the total thickness of the coating in an area of less than 1 square foot, where the
remaining concrete is sound, will be accepted without repairs. Should the area
affected be more than 1 and less than 3 square feet, the concrete remaining in place
over that area shall be undercut, unless the position of reinforcement prevents this,
so as to provide a key lock for the same basic materials as the coating. Should the
damaged area be more than 3 square feet, the coating shall be removed around the
entire periphery of the pipe throughout the entire damaged area. Repairs shall be
made by satisfactorily restoring the reinforcing, if necessary, removing all cracked
or broken concrete at the point of coating damage, wetting the fresh surface of the
broken coating and trowelling a stiff mixture of cement, water and aggregate into
and through the reinforcing. This mixture shall be built up until the surface is level
with the coating around the repair. Repair by the gunite process is also acceptable.
The pipe will then be carefully laid in a position where it shall be allowed to cure
for a minimum of 36 hours.
The resulting coating shall be equal in weight, density, uniformity strength, and
characteristics to the original coating.
5.10.3 Cracking
Care shall be exercised to minimize cracks due to pipe deflection in handling.
Cracking of concrete may occur due excessive deflection of pipe in handling or
storage. Cracks that are in excess of 1/16 inch width and extend over 180°
circumferentially around the pipe or where cracks are over 12 inches in length
longitudinally along the pipe, irrespective of width, excluding hair line cracks, will
be repaired.
Repair shall be made by chiseling the crack out to a width of not less than 1 inch
throughout the length of the crack, taking care not to damage the reinforcement.
The crack shall be repaired with materials similar to that from which the coating is
made and in a manner similar to that outlined for spalling.
Coatings that appear defective at the time of coating shall be satisfactorily repaired
before the pipe is put into stockpile.
5.11 Reporting
The following information must be recorded against each pipe serial number and provided to
COMPANY :
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- Steel pipe serial number

- Steel pipe diameter
- Average of five girth measurements (DA) w/concrete coating
- Weight after impingement
- Length of pipe
- Weight of pipe and corrosion and insulation coating
- Date of impingement coating
- Calculated fully saturated negative buoyancy of empty pipe
- Insulation cutback length
- Concrete cutback length
- Tests or samples taken
- Repair records.
In addition to the ASTM code requirements, the following information must be recorded for
each compressive strength, density, and water absorption test :
- type of test (i.e. cylinder compressive, core compressive, dry density and water
absorption, or pipe water absorption)
- steel pipe serial number (from which sample was taken)
- date of taking sample dried weight, water volume displaced, and saturated weight (for
concrete piece water absorption test)
- saturated pipe weight; starting, finish and duration of immersion with date; and all coated
pipe data as above (for coated pipe water absorption test).

6.0 GUARANTEE
Material and/or equipment shall be guaranteed by CONTRACTOR to perform in accordance with
specification requirements and to be free of defects and poor workmanship including, but not
limited to, those caused by inadequate preparation for shipment, for a period of one (1) year after
material/equipment is placed in service, but not exceeding eighteen (18) months following delivery
to the contracted destination.
CONTRACTOR shall repair or replace all defective items during the guarantee period at no cost to
COMPANY.
CONTRATOR shall obtain a similar guarantee from Manufacturer to warrant the raw materials
provided.

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