Salak Brine Heat

Recovery Binary Power

Plant Project

PO Number 9773-CISS-3240002338 Rev.0

Equipment / Matrerial
STEEL STRUCTURE, MECHANICAL AND PIPING
/ Service

DISCONTINUITY (HOLIDAY) TESTING PROCEDURE

2023.01.11
13:41:48
+07'00'
0 Issued for Construction 08-Jan-23 MDH WLF KEO
A Issued for Review 07-Jan-23 MDH WLF WLF
Rev Reason for Issue Date Author Checked Approver

Contract Number COMPANY Doc Number EPC CONTRACTOR Doc Number

3200000922 SEGS-BHR-CI-AA70-PCD-1042-0 9773-CISS-3240002338-SDR-0001

 Salak Brine Heat Recovery Binary Power Plant Project
Discontinuity (Holiday) Testing Procedure

Revision History
Amendment Revision Amender
Amendment
Date Number Name
07-Jan-23 A M. Danny H Issue for Review
08-Jan-23 0 M. Danny H Issue for Construction

Holds
Hold Section
Short description of hold
No Number

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 Salak Brine Heat Recovery Binary Power Plant Project
Discontinuity (Holiday) Testing Procedure

COMMENT SHEET
Date Rev. Page/Section Company Comment Contractor Response

7-Jan-23 A Page 1 Approval Signature Revise 0, IFC

7-Jan-23 A Attachment Attachment Report Revise 0, IFC

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 Salak Brine Heat Recovery Binary Power Plant Project
Discontinuity (Holiday) Testing Procedure

Table of Contents
1 INTRODUCTION ................................................................................................................... 5
1.1 Project Background ............................................................................................... 5
1.2 Project Location .................................................................................................... 5
1.3 Purpose ................................................................................................................ 5
1.4 Scope.................................................................................................................... 6
2 INFORMATION PRIOR TESTING ............................................................................................ 6
2.1 Extent of Testing ................................................................................................... 6
2.2 Safety Precoution .................................................................................................. 6
3 PROCEDURE QUALIFICATION ............................................................................................... 6
3.1 High Voltage Spark ............................................................................................... 7
3.1.1 Equipment ......................................................................................................................... 7
3.1.2 Procedures for Use ........................................................................................................... 8
3.1.3 Verifying Sensitivity of Equipment .................................................................................... 9
3.1.4 Verifying Tester Calibration or Sensitivity ......................................................................... 9
4 ACCEPTANCE CRITERIA ........................................................................................................ 9
5 RECORDING INDICATION AND INTERPRETAION .................................................................... 9
5.1 Reporting .............................................................................................................. 9
6 TESTING OF REPAIRED AREA .............................................................................................. 10

List of Tables
Table 1 Minimum Testing Voltage for Various Coating Thickness ....................................7

List of Figures
Figure 1 Project Location ...........................................................................................5

Abreviation and Definition ............................................................................................... 11

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 Salak Brine Heat Recovery Binary Power Plant Project
Discontinuity (Holiday) Testing Procedure

1 INTRODUCTION

1.1 Project Background

Star Energy Geothermal Salak, Ltd (SEGS) intends to develop a Brine Heat Recovery (BHR)
project at the Salak Geothermal field, in West Java, Indonesia.
This project aims to generate and export additional electrical power by utilizing the heat from
separated brine before the brine is injected to the geothermal reservoir. The objective of the
BHR project is to install an efficient power plant operating on binary ORC (Organic Rankine
Cycle) technology.
The basic outline of the project is as follows:
 The BHR plant shall be designed to maximize net generation capacity with the brine
flow rate and conditions given in Basis of Design.
 The brine shall be supplied to site via an existing 24” brine line running from the WPS
to reinjection well AWI-18. The BHR is located on the route between the WPS and AWI-
18.
 The method of heat rejection shall be by air-cooled condensers.
 A section of this existing brine line (plus the two adjacent condensate lines, Fiber Optic
and electrical supplies) and existing road currently running through the power plant site
shall be realigned to accommodate the BHR.
 The HV cable and fiber optic cable from the BHR plant to GIS PLN Unit 1/2/3 shall be
installed underground.

1.2 Project Location

Figure 1 Project Location

1.3 Purpose
This procedure of Discontinuity (Holiday) Test provides requirements guideline to conduct
discontinuity (holiday) examination in a coating film systems that are applied to conductive
substrates by electrical detection for salak brine heat recovery binary power plan project. This
procedure covers all work activities associated with piping Installation, fabrication, and Testing
to be performed by Baharu Penta Kencana (BPK).

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Discontinuity (Holiday) Testing Procedure

1.4 Scope
This written procedure divided into 2 (two) main groups of test method and equipment; low voltage
wet sponge testing and high voltage spark testing Reference Document. Scope of this written
procedure is High Voltage Spark Test which will be used for Geothermal Salak Brine Heat
Recovery Binary Power Plan Project (SEGS-BHRBPP). The following documents shall be
referred and followed.

 ASTM G 62 Standard Test Methods for Holiday Detection in Pipeline Coatings

 NACE SP0188 Standard Practice Discontinuity (Holiday) Testing of New
Protective Coatings on Conductive Substrates
 NACE SP0274 Standard Practice High Voltage Electrical Inspection of Pipeline
Coatings
 Product Data Sheet Wrapping Manufacturer Instruction

2 INFORMATION PRIOR TESTING

The following information shall be obtained prior to testing: Film thickness, Design and Service
conditions.

2.1 Extent of Testing

The shape and size of the testing object, and extent of the testing shall be based on appropriate
drawing or contract document. All testing object shall be 100% visually inspected prior to holiday
testing.

2.2 Safety Precaution

Precautions shall be taken to prevent electrical shock. This is particularly important if the tester is
powered by line voltage. The manufacturer’s safety instructions shall be followed to prevent
electrical shock. Prior to conducting high-voltage tests in an enclosure, an inspection shall be
conducted to indicate whether the enclosure is safe for entry, including testing for flammable or
explosive gas. Solvents retained in the coating can produce an explosive environment. If testing
is being conducted with a high-voltage spark tester, complete, proper electrical grounding (to
earth) of the substrate shall be ensured.

3 PROCEDURE QUALIFICATION
High voltage spark test equipment is generally used for determining the existences of
discontinuities in coating films having a total thickness of greater than 20 mils (0.5 mm). Unspecified
variables in this written procedure, will refer to coating, equipment and instrument manufacturer’s
design.

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 Salak Brine Heat Recovery Binary Power Plant Project
Discontinuity (Holiday) Testing Procedure

3.1 High Voltage Spark

High-voltage spark testers are suitable for determining the existence of discontinuities in coatings
of all thicknesses. The coating manufacturer should be consulted for proper test equipment and
inspection voltage. Suggested starting voltages are provided in Table 1 or calculation manually
by manufacture reference refer to NACE SP0274.

CAUTION: Coatings that are applied at a thickness of less than 20 mils (0.5 mm) may be
susceptible to damage if tested with high voltage spark testing equipment.

A high-voltage spark tester may be used to determine discontinuities in coatings on conductive

concrete substrates. The conductivity of concrete varies depending on moisture content, type,
density, and location of rebars. Conductivity shall be tested by attaching a ground wire to the
rebar or another metallic ground permanently installed in the concrete and touching the
electrode to the bare concrete. If the metallic ground is not visible, the ground wire shall be
placed directly against the bare concrete surface and weighted with a damp cloth or wet-sand-
filled paper bag. If the test indicates that the concrete is not conductive, determining
discontinuities with a high-voltage spark tester will be ineffective.

Table 1

Table 1. Minimum Testing Voltage for

Various Coating Thickness (NACE SP0271-2011)

3.1.1 Equipment
A high-voltage (in excess of 800V) spark tester is an electronic device used to locate
discontinuities in a nonconductive protective coating. It consists of an electrical energy source,
an exploring electrode, and a ground connection from the indicator signaling current flow
through a coating discontinuity to the substrate.

The exploring electrode shall be of the type capable of maintaining continuous contact with the
surface being inspected, including bolts, raised areas, etc. It shall be kept clean and free of
coating material.

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 Salak Brine Heat Recovery Binary Power Plant Project
Discontinuity (Holiday) Testing Procedure

A high-voltage spark tester can be identified as either a pulse type tester or a direct current
tester. A pulse type tester discharges a cycling, high-voltage pulse. A direct current tester
discharges continuous voltage.

3.1.2 Procedures for Use

Sufficient drying or curing of the coating shall be allowed prior to conducting a holiday test. The
length of time required for drying or curing shall be obtained from the coating manufacturer.
Solvents retained in the coating could produce erroneous results, as well as an explosive
environment.

The thickness of the coating shall be measured with a nondestructive dry film thickness gauge.
If the coating is less than 500 µm (20 mil), procedures for low-voltage testing should be
considered. Although the high-voltage spark tester is suitable for determining discontinuities in
coatings less than 500 µm (20 mil), the coating manufacturer should be consulted before using
this test. Certain coatings can be damaged if tested with this equipment.

The high-voltage spark tester shall be calibrated in accordance with Paragraph 2.1.4.

The high-voltage spark tester shall be adjusted to the proper voltage for the coating thickness
being tested. In selecting the inspection voltage, sufficient voltage shall be provided to break
the air gap that exists at the holiday. This air gap varies depending on the total applied film
thickness. Excessive voltage may produce a holiday in the coating. The maximum voltage for
the applied coating shall be obtained from the coating manufacturer. Table 1 contains
suggested voltages that may be used as guides.

The ground wire from the high-voltage spark tester ground output terminal shall be attached
to the conductive substrate, and positive electrical contact shall be ensured. When testing
concrete surfaces, the ground wire shall be attached to the rebars. If the rebars are not visible,
the ground wire shall be placed directly against the bare concrete surface and weighted with
a damp cloth or wet-sand-filled paper bag.

Contact shall be made with the exploring electrode on the conductive substrate to verify that
the tester is properly grounded. This test shall be conducted periodically during the testing of
the coating.

The exploring electrode shall be moved over the surface of the dry coating at a rate of
approximately 0.3 m/s (1 ft/s) using a single pass. Moisture on the coating surface can cause
erroneous indications. If moisture exists, it shall be removed or allowed to dry before the test
is conducted.

Discontinuities that require repair shall be identified with a marker that is compatible with the
repair coating or one that is easily removable.

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Discontinuity (Holiday) Testing Procedure

3.1.3 Verifying Sensitivity of Equipment

The following procedures shall be used to verify operation of high-voltage spark testers:

 Test the energy source (battery) for proper voltage output according to the
manufacturer’s instructions.

 Connect the exploring electrode and grounding cable to the terminals of the tester.

 Switch the tester to the “on” position.

 Touch the exploring electrode to the ground cable alligator clip. The tester signal should
actuate in accordance with the manufacturer’s operating instructions.

 If the tester fails to signal, it shall be considered inoperative.

3.1.4 Verifying Tester Calibration or Sensitivity

Before the initial tests, the tester shall be calibrated to the specified voltage to be used for
holiday detection. The tester shall be recalibrated periodically thereafter. The following
procedure shall be used:

 Connect a high-voltage voltmeter between the probe and the ground lead.
 Switch the tester to the “on” position.
 Compare the voltage of the voltmeter with the output voltage of the tester. Depending
on the type of tester, adjust to the specified voltage (±5%) using either the variable
regulator or predetermined selector switch.
 Switch the tester to the “off” position.
 Disconnect the voltmeter.

4 ACCEPTANCE CRITERIA
Discontinuity is normally not permitted on any coating. If found retest on those areas that have
been repaired following the procedure as previously outlined. All discontinuity (holiday) testing
results shall be recorded in the applicable forms.

5 RECORDING INDICATION AND INTERPRETAION

The area surrounding and including the holiday should be cleaned of all contaminates and holidays
should be marked that will not contaminate the coating surface (do not use wax or oil type marking
devices). Generally a Sharpie maker is suitable.

5.1 Reporting
Discontinuity (Holiday) Testing Report (Attachment)

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Discontinuity (Holiday) Testing Procedure

6 TESTING OF REPAIRED AREA

Sufficient drying or curing of the repair coating shall be allowed prior to retesting. The length of time
required shall be obtained from the coating manufacturer. Conduct the test following the
procedures as previously outlined in this practice for the test instrument selected. Retest only those
areas that have been repaired, unless otherwise specified.

NOTE : All repairs should be made within the recoat window of the coating—generally 18 hours.
Repairs made outside of the recoat window require abrading and cleaning the coating surface per
manufacturers recommendations. All debris, amine blush or other contaminates need to be
removed from the coating surface before any repairs are made.

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Discontinuity (Holiday) Testing Procedure

ABREVIATION AND DEFINITION

Coating : A liquid, liquefiable, or mastic composition that, after application to a

surface, is converted into a solid protective, decorative, or functional
adherent film.
Discontinuity : (1) An interruption in the normal physical structure or configuration of
a coating such as cracks, laps, seams, inclusions, or porosity. A
discontinuity may or may not affect the usefulness of the coating. (2)
A condition in which the electrical path of a structure is interrupted by
a device that acts as a dielectric or insulated fitting. May also be
identified as a holiday or pinhole.
Holiday : A discontinuity in a protective coating that exposes unprotected
surface to the environment; in this procedure, a term used
interchangeably with discontinuity.
Holiday Detector : A device that locates discontinuities in a coating applied to a
conductive substrate.
Pinhole : A minute hole through a coat or coats that exposes an underlying
coat or the substrate.
Telegraphing : Current that travels through a moisture patch to a discontinuity,
causing an erroneous discontinuity test result.

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 DISCONTINUITY (HOLIDAY) TESTING REPORT

Project Title : Salak Brine Heat Recovery Binary Power Plant Project Report No. : 9773-BPK-A2B (HDR)-001
Job No. : 9773 Line No. :
Company : Star Energy Geothermal Salak.Ltd Report Date : 01-Aug-23
Contractor : PT. Tripatra-ORMAT Consortium Page : of
SubContractor : PT. Baharu Penta Kencana
Visual Inspection Holiday Test
Rev. Wide/
No. Item Name / Drawing Coating Test Remark
Sheet Length/Joint Status Date Result
Condition Voltage

Testing Specific :
1. Testing Object : Piping Underground DFT : 1.224 mm
2. Holiday Test Equipment : - Brand : PCWI Digital Series : DC30
- Serial Number : 13109-3 Volt Range : 1-30KV
- Cal. Date : 04 Jan 2023

Prepared By, Witness / Review By Review / Released By

PT. Baharu Penta Kencana PT. Tripatra - ORMAT Consortium Star Energy Geothermal Salak.Ltd

Wahyu L. Fais
NAME DATE NAME DATE NAME DATE