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RP
BT
PF
31 Jan 08
RP/FH
BT
PF
29 Nov 07
FH/RP
BT
PF
Rev
Rev Date
Description
Prepared By
Checked By
PM
Client
IDBU-ED-BPDCC-000002
9th April 2007
Rev 0
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IDBE-WO-YPZZZ-EN0001
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Revision
Section
A
B
0
All
All
All
Description
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Table of Contents
1.0
INTRODUCTION
1.1
General
1.2
Scope of Document
1.3
Abbreviations
1.4
References
1.5
1.6
Construction methods
10
2.0
FIELD LAYOUT
11
3.0
12
3.1
Safety
12
3.2
Health
12
3.3
Environment
12
3.4
Security
12
3.5
12
3.6
13
4.0
5.0
14
4.1
ROW
14
4.2
14
INTERFACES
15
5.1
Pipe coating
15
5.2
Pipe delivery
15
5.3
Valves
15
5.4
Offshore contractor
15
5.5
CPF contractor
15
5.6
Shore Approach
15
5.7
Local authorities
16
5.8
Local population
16
5.9
16
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6.0
MOBILIZATION
17
7.0
18
7.1
Workforce
18
7.2
Accommodation
23
7.3
Training
23
7.4
Transportation
24
8.0
9.0
10.0
11.0
12.0
13.0
25
8.1
25
8.2
25
26
9.1
26
9.2
26
9.3
Construction challenges
28
9.4
32
33
33
33
33
33
33
33
33
33
34
10.10Kp.69.653 to Kp.70.399
34
34
35
35
36
36
37
37
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14.0
38
38
39
39
40
40
41
41
42
42
43
44
20.0
QA / QC REQUIREMENT
45
21.0
PRE COMMISSIONING
46
46
21.2 Valves
46
46
46
22.0
COMMISSIONING
47
23.0
48
24.0
PROGRESS REPORTING
49
50
25.0
51
26.0
LESSONS LEARNED
52
15.0
16.0
17.0
18.0
19.0
ATTACHMENTS
Attachment A
Attachment B
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1.0
INTRODUCTION
1.1
General
Banyu Urip is an oil and gas field located in the Cepu Block in Central Java, Indonesia. The
expected peak production is 185 kbpd (165 kbpd annual averages) of sour crude and associated
gas from four well pads. The field development will involve conventional onshore oil and gas
facilities (including well pads, Central Processing Facility (CPF), flow line, water disposal and gas
injection) and an export pipeline to transport processed crude oil to a Floating, Storage and Offloading (FSO) facility. The crude oil will be sweetened in CPF and sent via onshore and offshore
pipelines to a FSO vessel located 23 km off of the north coast of Java near the city of Tuban.
JP Kenny has been appointed to update the original 2001 Front End Engineering Design (FEED)
for onshore and offshore export pipelines and develop Front End Execution Plan (FEEP).
1.2
Scope of Document
The scope of this document is to present a conceptual construction execution strategy for
installation of the proposed 71 Km of 20-inch onshore thermally insulated pipeline from kilometer
post Kp. 0.00 to Kp. 71.483.
This Onshore Construction Execution Plan should be read in close cooperation with the attached
crossing list (Appendix A), which, amongst other details, specifies chainage versus construction
method. It also species how each road, river, ditch, etc. will be crossed and refers to a typical
construction drawing for each type of crossing. Hence specific construction methods are not
discussed in this document.
1.3
Abbreviations
AOC
Area of concern
ACS
Access Road
AMDAL
BU
CONTRACTOR
CSR
EPP
EEP
ERP
HDD
HSES
ITP
LD
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MCL
MIGAS
MLWS
MMLWS
PLN
PPE
ROW
Right-of-Way
SKPP
VS
1.4
Valve Station
References
IDBE-WO-BPPPP-000002
FEEP Plan
IDBE-WO-YBDES-E00001
Design Basis
IDBE-WO-CCCAL-EF0012
IDBE-WO-YRZZZ-EN0001
No number provided
IDBE-WO-YRZZZ-EN0007
IDBE-WO-YRZZZ-EN0008
IDBE-WO- YRZZZ-EN0011
IDBE-WO-YSPDS-EN0005
IDBE-WO-YRZZZ-EN0013
IDBE-WO-YRZZZ-EN0004
IDBE-WO-YCCAL-EN007
IDBU-ED-QSPDS-000006
Upstream
Project
Requirements
IDBU-IB-GBSIT-000001
IDBE-IT-YBSIT-EN0004
IDBE-WO-YSPDS-EN0003
Quality
Assurance
General
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IDBU-WO-WPZZZ-0004
Systemisation, Schedule
Commissioning
&
Precedence
IDBE-WO-BLLLE-000001
IDBE-WO-YDPAL-EN0001
IDBE-WO-YDPLX-EN0001
IDBE-WO-YDPLX -EN0002
IDBE-WO-YDPLX -EN0003
HDD Crossing
IDBE-WO-YDPLX-EN0004
IDBE-WO-YDPAL-EN0001-001
IDBE-WO-YDZZZ-EN0001
IDBE-WO-YDZZZ -EN0002
IDBE-WO-YDZZZ -EN0003
IDBE-WO-YDZZZ -EN0004
IDBE-WO-YDZZZ -EN0005
IDBE-WO-YDZZZ -EN0006
IDBE-WO-YDZZZ -EN0008
IDBE-WO-YDZZZ -EN0009
IDBE-WO-YDZZZ -EN0010
Onshore Pipeline
Crossing
IDBE-WO-YDZZZ -EN0013
IDBE-WO-YDZZZ -EN0014
Construction
Typical
Network
Main
for
Road
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1.5
IDBE-WO-YDZZZ E10001
IDBE-WO-YDZZZ -EN0016
IDBE-WO-YDZZZ -EN0017
DELETED
IDBE-WO-YDZZZ -EN0018
IDBE-WO-YDZZZ -E20001
IDBE-WO-YDZZZ -EN0020
IDBE-WO-YDZZZ -E30001
IDBE-WO-YDZZZ -EN0022
IDBE-WO-YDZZZ -EN0023
IDBE-WO-YDZZZ -EN0024
DELETED
IDBE-WO-YDZZZ -E50001
IDBE-WO-YDZZZ -EN0026
IDBE-WO-YDZZZ -EN0027
IDBE-WO-YDZZZ -EN0028
DELETED
IDBE-WO-YDZZZ -EN0029
IDBE-WO-YDZZZ -EN0030
IDBE-WO-YDZZZ -EN0031
DELETED
IDBE-WO-YDZZZ -EN0032
API STD
ASME
ASME
B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids
National regulations:
SNI 429
SNI 73
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1.6
Construction methods
For this document several construction methods have been assumed:
Conventional construction:
Wetland construction:
This is the area where it is too wet to use normal pipe lay equipment
but not wet enough to do push pull. In this area special wetland
equipment may be used, such as swamp backhoes, in combination
with a roller system to push the pipe along the terrain.
Push-pull construction:
HDD:
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2.0
FIELD LAYOUT
The Banyu Urip export pipeline consists of one 20 onshore thermally insulated pipeline of
approximately 71 km long from CPF to the Palang shore crossing. The onshore survey is being
finalized and the preliminary export pipeline layout is presented in Figure 2.1.
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3.0
3.1
Safety
The concept Safety is the concern of everybody involved will be widely promoted. The safety on
the sites will be championed by front line supervisors and will be strictly monitored by construction
contractor HSES officers. It is recommended that the usual safety incentive programs are
implemented and that Safety supervision on site will be in the order of 1 HSES officer against 20-25
workers. From Company side there will be HSES supervisors too, working close together with the
construction contractors HSES officers. Additionally, it will be essential to have EPC contractor
management committed to safety.
3.2
Health
Health on the sites will also be monitored by the HSES officer in cooperation with the construction
contractor doctor. All personnel involved in the project will be submitted to a medical check-up prior
to employment. The temporary camps (if any) and/ or local accommodation will be inspected by
construction contractor doctor, HSES officer and Company HSES representative before
authorization for usage is given. Subsequently weekly HSES checks will be performed by
construction contractor HSES officers. A monthly check and/ or random checks will be carried out
by Company HSES representative on site.
3.3
Environment
All environmental issues will be monitored by a construction contractor Environmental Specialist, it
is anticipated that one such specialist will be employed to cover multiple sites. This function is a
stand alone function and the Environmental Specialist shall not spend part of his/ her time fulfilling
other functions. The Environmental Specialist will be responsible that the recommendations made
in the AMDAL and any other project documents related to the environment are followed and
executed to the full satisfaction of Company. A key document used to achieve this will be the
Contractors Environmental Management Plan.
An aerial photographic survey will be performed before and after completion of project activities,
this will be required to monitor and access the impact of project activities during construction. It will
also serve to show that construction contractor has restored the ROW to its original condition.
3.4
Security
Security on the sites and camps will be provided by dedicated and trained Security officers, locally
referred to as Satpam. These officers will be in charge of the security around the worksites, pipe
lay down areas, warehouse(s) and/ or temporary camps. It is envisaged that personnel for security
will be locally recruited. However, it should be noted that the use of locally recruited personnel for
security tasks may lead to problems, please see section 26.
3.5
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3.6
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4.0
4.1
ROW
From the start of the project, Company has been surveying the proposed ROW and compiled a
long list of land owners. Upon finalization of the pipeline route, negotiations with those land owners
that are affected by the ROW will begin and shall be completed before the ROW is handed over to
the construction contractor.
4.2
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5.0
INTERFACES
5.1
Pipe coating
The pipeline has been designed with a thermally insulated cover. Pipe coating is a very specialized
process and coating will most likely be done by a coating company in Batam or Bintan, Indonesia.
5.2
Pipe delivery
The present strategy by Company is that the onshore construction contractor will collect the pipe at
the coating yard. The construction contractor will take receipt of the coated pipe at the coating yard
and will organize transport to site.
5.3
Valves
Valves may be purchased by Company if considered Long Lead Items. If so, only purchasing will
be done by Company, shipping of the valves to the nearest practical port, importation into
Indonesia and transport to the site will be the responsibility of the construction contractor.
For the valve stations, the construction contractor will have to pull the cable from instrument and
electrical equipment to the communication building and to PLN power lines, after obtaining PLN
permission. The connection of the cables inside the communication building and the installation of
the telecommunication equipment will be performed by the EPC1 contractor.
5.4
Offshore contractor
It is of utmost importance that good coordination between onshore and offshore contractors is
established and maintained throughout the project. Regular interface meetings will be scheduled,
with their frequency increasing as activities increase. Both construction contractors shall coordinate
in such a way that the tie-in between onshore and offshore pipeline shall not result in any delay to
either party. Company will attend the interface meetings but coordination of activities shall be
construction contractors responsibility.
5.5
CPF contractor
Similar to the above, good coordination will be required between the onshore pipeline construction
contractor and the CPF contractor. Regular interface meetings will be scheduled, with their
frequency increasing as activities increase. Both contractors shall coordinate in such a way that the
tie-in between the onshore pipeline and CPF shall not delay either party. Company will attend the
interface meetings but coordination of activities is construction contractors responsibility.
5.6
Shore Approach
The shore approach design and construction up to offshore/onshore tie-in point (landfall point) is
included in offshore scope of work and will be performed by either Pre-Trenching and/or Horizontal
Directional Drilling (HDD).
Therefore, the onshore construction contractor should leave his part of the work scope in such a
way that the offshore construction contractor will be able to perform the shore approach section
and tie-in between the two sections without delays to his operation. For this purpose regular
interface meetings shall be organized between the onshore and offshore construction contractors,
(see section 5.4).
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5.7
Local authorities
It will be unavoidable that construction contractors come in contact with local authorities, especially
for the application of permits. All permits required for the (preparation of) construction work will be
organized and applied for by the construction contractor.
5.8
Local population
The construction contractor shall pay great attention to maintain the harmony with the local
population. For this purpose construction activities around densely populated areas should be
restricted as much as possible. Wherever possible, construction contractor shall do his best effort
to employ locally available personnel.
After completion of the work and after the restoration of temporary access roads, pipe lay down
areas, camp facilities etc. has been completed the construction contractor shall obtain Land Owner
Sign-off certificates to avoid potential future claims. These certificates will be handed over to
Company for filing and future reference.
5.9
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6.0
MOBILIZATION
Due to the intricate route of the pipeline (dry area, wet area, HDD, road/ river crossings, tie in, etc.),
limited amount of roads available and the fact that the route traverses through densely populated
areas careful mobilization of personnel and equipment is of vital importance. The construction
contractor shall prepare his mobilization schedule taking in account all the previously mentioned
issues and ensure that enough time is planned so that personnel, equipment and material will
arrive in time at the correct work location for each specific activity as described in section 7.0
Workforce, Accommodation, and Transportation.
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7.0
7.1
Workforce
Where ever possible the contractor shall use locally recruited personnel which, shall be trained in
safety issues in order to fulfil their tasks (see section 7.3). It is anticipated that unskilled labour will
make up a large part of the work force.
The skilled part of the labour, such as Supervisors, welders, NDT specialists and the like will most
likely brought in by the construction contractor and accommodated in the temporary camp.
The direct versus indirect costs are extensively discussed in the EBM (Estimate Basis
Memorandum).
The work will be executed with one mainline spread, one mini mainline spread and several smaller
specialist spreads as per tabulations below:
7.1.1
Manpower
2 Cranes (20T)
2 excavators
2 trucks
2 Piling hammers
2 Compactors
Asphalt
Concrete
Total
4
4
4
2
2
2
24
42
Note: This is due to the fact that the equipment and manpower columns were not meant to be aligned.
7.1.2
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Equipment
Manpower
Total
1 excavator
1 + 1 Banks man
1 Bulldozer
1 Truck
1 + 1 Banks man
1 + 1 helper
Supervisor
HSES officer
Medic
Manual workers
Total
2
2
1
1
1
20
29
Note: This is due to the fact that the equipment and manpower columns were not meant to be aligned.
7.1.3
Stringing spread
This spread may either move ahead or in tandem with the main line welding spread (see 6.1.4). Its
purpose is to distribute the pipe from the Lay Down areas along the pipeline route and/ or supply
pipe to the main line welding spread as it moves along the pipeline route.
Equipment
Manpower
Total
2
4
1
1
1
Rigging team
5 (incl. supervisor)
Survey team
Total
3
19
Note: This is due to the fact that the equipment and manpower columns were not meant to be aligned.
7.1.4
Manpower
4 Side booms
2 Excavators
1 Crane (20T)
3 Pipe carriers
12 Welding machines
1 Generator
2 Trolleys
Rock breaking equipment*
Various water pumps
4 + 4 helpers
2 + 2 helpers
1 + 1 helper
3 + 3 helpers
Mechanic
Operators
Supervisor
Welding Foreman
HSES officer
Medic
Total
8
4
2
6
2
2
1
2
3
1
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Equipment
NDT equipment
Coating equipment
Survey equipment
Pipe bending machine and
associated equipment
Manpower
Welders
Grinders
Helpers
Riggers
NDT team
Coating team
Survey team
Pipe bending team
Total
* This equipment is optional and will only be used occasionally
Total
10
10
8
4
5
4
3
5
80
Note: This is due to the fact that the equipment and manpower columns were not meant to be aligned.
7.1.5
Manpower
1 Side boom
1 Excavator
1 Crane (20T)
9 Welding machines
1 Welding support truck
NDT equipment
Coating equipment
Survey equipment
Total
2
2
2
1
2
1
1
1
1
8
6
6
2
4
3
3
45
Note: This is due to the fact that the equipment and manpower columns were not meant to be aligned.
7.1.6
Manpower
1 Machine
1 Excavator
1 Crane (20T)
Operators
1 + 1 Banks man/ helper
1 + 1 Banks man / helper
Supervisor
HSES officer
Total
2
2
2
1
1
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Equipment
Manpower
Total
Medic
Rigging team
Helpers
Total
1
4
6
19
Note: This is due to the fact that the equipment and manpower columns were not meant to be aligned.
7.1.7
Manpower
Total
1 HDD rig
1 Hydraulic power pack
Superintendent
Driller
1
1
Steering engineer
HSES officer
Medic
Rig hands
1
1
1
2
1 Workshop
1 Store
1
2
1
1
1
2
2
18
Note: This is due to the fact that the equipment and manpower columns were not meant to be aligned.
7.1.8
Equipment
Manpower
2 Side booms
1 Excavator
1 Crane 20T (optional)
3 Welding machines
Various water pumps
Total
4
2
2
1
1
1
1
2
2
1
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Equipment
Manpower
1 compactor
Selection of water pumps
Rigging team
Driver + banks man
Helpers
Total
Total
2
2
4
25
Note: This is due to the fact that the equipment and manpower columns were not meant to be aligned.
7.1.9
Manpower
1 Excavator
1 Hydro test spread
1 Generator
Total
2
1
1
1
2
4
1
12
Note: This is due to the fact that the equipment and manpower columns were not meant to be aligned.
7.1.10
Restoration spread
The restoration spread will be deployed behind the main line welding spread and backfill the
trench. Its manual workers will clean up the ROW, restore paddy fields and perform re plantation
where required.
Equipment
Manpower
1 excavator
1 + 1 Banks man
Supervisor
HSES officer
Medic
Manual workers
Total
Total
2
1
1
1
20
25
Note: This is due to the fact that the equipment and manpower columns were not meant to be aligned.
7.2
Accommodation
The contractor questionnaire workshop did not give a clear indication about this issue but in this
study it will be assumed that at least one temporary camp will be erected along the pipeline route.
The assumption will be that the camp will be erected in the area near LD 08 (Kp.29.575), located at
the HDD entry point of the Solo River HDD.
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This location is centralized yet slightly outside a major city (Bojonegoro) to which it has easy
access. The Kp. location in relation to the pipeline is approximately Kp.29.500. There appears to be
ample space alongside the road for temporary camp erection.
The size of the camp should be sufficient to accommodate approximately 175-200 personnel.
Adjacent to the camp there will be a temporary fabrication yard and secure storage facility for
selected Company supplied items (such as valves and E&I equipment).
7.3
Training
As an ongoing part of HSE, construction contractor shall develop and maintain a training program
to ensure that all construction contractor personnel are trained in accordance with the construction
contractors HSE manual.
Locally recruited unskilled personnel may be trained in simple tasks such as cleaning, banks man,
office boy, laundry, basic security etc.
The training program will be executed in such a way that it will not have any effect on the progress
of the work.
7.4
Transportation
The workforce that is accommodated in the camp will be shuttled to the work locations by bus and/
or light vehicles. The same transportation may be used to collect the local workforce that will stay
accommodated in their private houses and that will gather on pre determined collection points.
Transportation along the ROW may be done by 4WD vehicles, or buses.
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8.0
8.1
LD01
LD02
LD03
LD04
LD05
LD06
LD07
LD08
Kp.71.421
Kp.67.886
Kp.59.293
Kp.55.663
Kp.51.833
Kp.38.888
Kp.32.456
Kp.29.652
167 joints
500 joints
500 joints
333 joints
833 joints
750 joints
417 joints
125 joints
600m2
1800 m2
1800m2
1200m2
3000m2
2700m2
1500m2
50m2
LD09
LD10
LD11
LD12
LD13
LD14
LD15
Kp.26.883
Kp.24.287
Kp.20.430
Kp.12.301
Kp.7.565
Kp.1.472
Kp.0.843
292 joints
333 joints
417 joints
625 joints
0
458 joints
167 joints
1050m2
1200m2
1500m2
2250m2
0
1650m2
600m2
Note: LD13 will only be used as a set up area for the HDD equipment. Transport of pipe and
equipment should be limited as much as possible as to reduce impact on residents.
8.2
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9.0
9.1
9.2
Alignments sheets
Satellite imaginary
Site visits
Independent consultants
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construction has been named push pull or wetland construction. In these areas temporary stationary
welding platforms will be erected and pipe pushed-pulled into a pre excavated and flooded trench.
Limestone:
It has been noted that limestone outcrops exist along the pipeline route, the table below is extracted
from the 2007 Geotechnical report and indicates the boring location versus the chainage in the
crossing list:
Bore hole
number
Limestone
encountered under
surface at:
Kp.
Location
BHPL 25
- 2.25 meter
55.663
BHPL 30
- 3.00 meter
67.886
BHPL 32
- 1.25 meter
71.421
The Report on Geotechnical Review of Pipeline Route, CPF and FPSO (IDBU-IB-GBSIT-000001)
states that the limestone encountered along the route is of a fresh limestone consistency with a site
classification of SD (stiff soil).
For estimation purposes rock breaking equipment has been incorporated in the equipment list for the
Main Line Welding Spread but it is strongly recommended that construction contractor should make
his own assessment of the impact limestone will have on his construction schedule. For this
particular Plan it has been assumed that the limestone deposits will not have a significant effect on
the schedule.
Pre commissioning:
For purposes of this Plan it has been assumed that each pipeline section (including the HDD strings)
will be separately cleaned, brushed, flushed, gauged and hydro tested by the hydro test team.
Normally, once two adjacent sections have been completed the valve will be installed and welded in
place with 2 Golden Welds. In such cases where the valve position is to be installed below the local
ground water level, the temporary pit will be kept dry by the use of pumps until such a time that the
tie-in has been completed. Then upon completion of the installation of the last valve, the pipeline will
be de-watered, dried, capped and inerted by Nitrogen.
Cathodic protection
Anode beds will be installed along the pipeline route by the spreads that are deployed at that
particular time to avoid having to go back along the complete pipeline route. It is of vital importance
that anode beds will be available prior to start of pipeline installation activities.
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9.3
Construction challenges
Approximately 64 kilometer of the pipeline route traverses through paddy fields and/or cultivated
land. In addition there are 13 main road crossings, 53 village road crossings, 6 track/ footpath
crossings, 1 operational railway crossing, 20 river crossings, 15 watercourse crossings (creek or
stream), 84 irrigation ditch crossings, 8 pipeline crossings, 1 buried cable crossing, 1 buried fiber
optic cable crossing and 2 main river crossings (Kalitidu River and Bengawan Solo River). Five
major construction challenges have been identified:
1.
To have all pre construction activities (such as preparation of lay down areas, temporary
access roads, reinforcement of bridges, widening of roads, temporary camp, recruitment of
personnel, permit application, etc.) completed in the 6 months after contract award and
before start of pipeline construction activities.
2.
To obtain access to and transfer equipment, material and personnel along the ROW under
difficult conditions
3.
To perform road crossings with the least disruption to local traffic as possible
4. To complete the pipeline route in the timeframe set by Company and partially during wet
season.
5.
To keep all working areas (especially trenches) safe for and from the local population
The major pipeline sections and construction methods for the pipeline are presented in the table
below. Specific construction execution methods are detailed in the Project Crossing Matrix,
included as Attachment A of this document.
Construction in relatively wet areas, possibly need swamp like equipment or push
pull option
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Pipeline
Kilometer Post
0.00 - 7.497
7.497 - 8.072
8.072 - 12.332
12.332
VS-E1 location
12.332 20.430
VS-E1 to LD11
20.430 24.153
24.153-24.558
24.558-29.521
29.521
29.521-29.898
VS-E2
VS-E2 to entry point HDD
No.3
Construction Method
Conventional construction. This area consists
mainly of elevated paddy fields and occasional
village road & creek crossing; access will be via
the main MCL road continued by excursion into
ROW. This route will have access to pipe lay
down areas LD 15, LD 14 & LD 13.
HDD Construction, Entry Site at Kp.7.4.97 Exit
Site at Kp.8.072. This HDD will cross under a
village road, a district road, a creek and the
Kalitidu river.
Conventional construction. This area consists of
paddy fields, few creek crossings and village
road crossings. This area will be accessed via
the ROW through incursion point at Kp.12.300,
also pipe lay down area LD 12
VS-E1 is located next to a village road; access
will be via this road and ROW. Power to the
valve station will be supplied by the locally
available power line next to the road.
Conventional construction, the area consists
mainly of paddy fields with a few river and track
crossings; access will be via ROW from
incursion points LD 12 and LD 11
Conventional construction. The pipeline
traverses mainly through paddy fields with 2
district road crossings. Bypasses are to be
constructed here. Main access will be via ROW.
HDD construction. Entry site at Kp.24.153, exit
site at 24.558. This HDD will cross under an
operational railway, fibre optic cable, water pipe
(pipe line crossing PL01), power line and
Provincial road. The area around the HDD entry
point will also be used as a pipe lay down area
LD 10. Access to the HDD entry and LD10 will
have to be constructed over the railway.
Conventional construction but possible push-pull
or wetland construction during wet season. This
route traverses paddy fields and also goes past
the Petrochina facility, limited access mainly via
the ROW. The route passes pipe lay down area
LD 09
Valve station no.2 will be buried. Access to this
valve will be constructing a new road from the
existing road.
Conventional construction but possible push-pull
or wetland construction during wet season. This
route traverses paddy fields.
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Pipeline
Kilometer Post
29.898-30.325
30-325 30.334
30.334
VS-E3
30.334-38.888
38.888
38.888-38.894
38.894
39.950
38.894-42.757
43.087
43.087-49.000
49.000 51.768
49.051
51.824
51.768
51.768-55.663
55.663
55.668
56.498-59.293
Construction Method
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Pipeline
Kilometer Post
Construction Method
will also be used as pipe lay down area LD 03
56.083
59.293
59.293-62.365
62.365-67.886
67.882
67.886
District road
67.886-69.653
69.653
69.653-70.399
70.399-71.323
71.426
71.323-71.445 &
71.472
9.4
Conventional construction
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River crossings that utilise the HDD construction technique do not require concrete coating
because the HDD construction technique is a trench less type construction method that contains
the pipeline within a drilled hole that has a cover depth greater than the minimum required 1.2 m.
The buoyancy control locations are located at the approximately KP position in the table on the
next page:
Crossing No.
Sta. KP
Buoyancy Control
RVX01
6828
CC = 36 m
RVX03
11430
CC = 24 m
RVX04
14007
CC = 24 m
RVX05
16758
CC = 24 m
RVX06
17740
CC = 167 m
WX08
19571
CC = 19.571 m
RVX07
26943
CC = 24 m
RVX08
28024
CC = 36 m
RVX09
28879
CC = 24 m
RVX10
29167
CC = 24 m
RVX12
33541
CC = 24 m
RVX13
34512
CC = 24 m
RVX14
40839
CC = 24 m
RVX15
53650
CC = 36 m
RVX16
60661
CC = 36 m
RVX17
62365
CC = 24 m
RVX18
63764
CC = 24 m
RVX19
67058
CC = 24 m
RVX20
68545
CC = 24 m
For more details please refer to the alignment sheets.
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10.0
10.1
10.2
10.3
10.4
Kp.24.153 to Kp.24.558
The 4th segment is a HDD under an operational railway and Provincial road.
10.5
10.6
Kp.29.898 to Kp.30.325
The 6th segment is a HDD under the Bengawan Solo River
10.7
Kp.30.325 to Kp.38.888
The 7th segment is from the exit point of HDD No.3 to a Provincial road crossing. This area is
relatively high and conventional onshore pipeline installation through paddy fields, ditches, village
roads and a river.
10.8
Kp.38.888 to Kp.49.000
The 8th segment is from the Provincial road through the low lying area at the flood protection dyke
and up again to higher ground around Kp.49.000. This is the wettest area along the pipeline route
and push pull technique and/ or wet land construction methods are likely to be used here. The
area consists mainly of paddy fields and irrigation ditches.
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10.9
Kp.49.000 to Kp.69.653
The 9th segment is from the higher ground towards the village (congested area near the coast). It
also includes the check valve station VS-E4 and valve station VS-E5. The pipe will be installed
using conventional onshore pipeline installation through paddy fields, gravel roads, ditches, district
roads and forested areas.
10.10
Kp.69.653 to Kp.70.399
The 10th segment is a congested area around Banjaranyar village. A small spread will be used
here as the pipeline route snakes through a village. Productivity in this area might drop by 50%.
10.11
Kp.70.399 to Kp.71.472
The 11th and last segment is from the edge of the village and ends at the shore approach. It
traverses through paddy fields, village roads, irrigation ditches, unused shrimp ponds and the main
Provincial road from Tuban to Gresik.
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11.0
11.1
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12.0
12.1
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13.0
13.1
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14.0
14.1
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15.0
15.1
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16.0
16.1
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17.0
17.1
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18.0
18.1
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19.0
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completing the work at VS-E4). The tie in will be done by the tie-in spread, which by this time, will
have completed work at the bored road crossing (RDX11). Note that limestone was encountered in
this area, see section 9.2)
The MLWS is demobilized at this point and shipped out to the North via the district road in front of
LD02. (ACS 01A). The tie in spread will now join the MMLWS and work together through the
congested area towards the Palang shore line.
The congested area starts at Kp.69.653 where the construction contractor will have to go very
carefully and slowly to weave the pipeline in between the local houses. Certain areas might have to
be dug by hand and productivity will slow down significantly. Once out of the congestion at
Kp.70.399 conventional construction may resume and will pass through paddy fields and unused
shrimp ponds up to Kp.71.323. Here a Provincial (coastal) road is encountered from Tuban to
Gresik. This road is heavily trafficked and a bored crossing will have been performed prior to arrival
of the MMLWS (RDX 13). (Note that limestone was encountered in this area, see section 9.2). The
MMLWS will then be demobilized.
Now, the section between VS-E5 and VS-EP can be cleaned and hydro tested. After hydro test VSE5 can be installed.
The work for the valve station VS-EP at the Palang shore line will be completed by the remaining
units of the tie-in spread. This work consists of the installation of 2 valves and civil works such as a
control building.
Once VS-EP and related pipe have been installed it will be cleaned and hydro tested by using the
water from the Bengawan solo River pumped via the pipe towards the shore.
The final tie-in between onshore and offshore pipeline will be done by the offshore construction
contractor.
19.1
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20.0
QA / QC REQUIREMENT
Quality assurance is an essential part for the execution of the project. The construction contractor
shall refer to document number IDBU-ED-QSPDS-000006 Upstream Project Quality Assurance
General Requirements, for the quality aspect of the work.
Throughout the project the construction contractor shall ensure that contractor QA/QC personnel
will be employed to follow the contractual requirements.
As a minimum, the construction contractor shall prepare and submit the following list of documents
for Company review and approval (it must be noted that this is a shortened list, the exact
requirements are stipulated in the document mentioned in the first paragraph):
Control Procedures
These documents are the implementation of Project Quality Plan for all phases of the work.
Each control procedure shall includes (as minimum) the detailed description of how the work
is performed, timing of the required check / inspections in the work sequence,
acceptance/rejection criteria, material tracking, welding records, NDT records, pipe heat
records, approval requirements, etc..
As built documentation.
Contractor shall perform the following activities (including document preparation) as per the
specific requirements for QA / QC:
Quality Audits
Design Control
Quality Documentation
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21.0
PRE COMMISSIONING
Pre commissioning of the pipeline sections will take place throughout the construction phase (see
section 9.2), the final and/ or other pre commissioning activities will continue for approximately 2
months after mechanical completion.
21.1
Pipeline sections
See section 9.2
21.2
Valves
The valves will have been tested in the factory.
Prior to and after the installation of the valves into the mainline, construction contractors pre
commissioning team will test the valves for functionality. In case any problems are encountered the
construction contractor will inform Company, who (as owner) will request vendor assistance. The
expenses for such assistance (travel, accommodation, etc) are usually under responsibility of the
construction contractor.
21.3
Electrical systems
Once the electrical systems have been put in place and connected, construction contractors E&I
team (Electricity and Instrumentation) will perform the testing of this system in accordance with
approved ITPs.
The connection of the E&I and communication equipment to CPF facilities will be done by the
EPC1 contractor when both systems are integrated.
The cathodic protection system functionality will be tested in accordance with document number
IDBE-WO-YSPDS-EN0003 Cathodic Protection Requirements for Onshore Pipelines (design
requirements, site studies, cathodic protection method, monitoring, commissioning requirements
and documentation).
21.4
Pipeline completion
Once the final weld has been completed and accepted, the pipeline or parts thereof, will be filled
with water, hydrotested, then de-watered, dried and inerted by Nitrogen as per Company
specifications. This sequence is part of a separate procedure but is estimated to take place within a
period of 4 weeks after mechanical completion of the line.
The tie-in between onshore and offshore will be performed by using a Golden Weld.
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22.0
COMMISSIONING
After successful completion of pre-commissioning activities, Company will start commissioning
activities with the assistance of construction contractor. The assistance that the construction
contractor is expected to provide consists of, but is not limited to:
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23.0
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24.0
PROGRESS REPORTING
In order to keep Company well informed about progress made the construction contractor shall
issue a Daily report for each site. It shall as a minimum contain:
Date
Weather conditions
Name of spread (i.e. Main Line Welding Spread, tie-in spread, etc)
Location
Name of construction contractor supervisor
Amount and designation of personnel
Progress booked
Problems encountered
Anticipated problems
48 hours look ahead
Breakdown times
Safety issues and statistics
Areas of concern
Space for Construction contractor and Company comments
As well as a complete running log of all activities for that particular work site
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24.1
Site management
On the construction contractor side it is assumed that the work will be supervised by either
expatriate or Third Country Nationals, except for those activities that require a relatively large
amount of manual labour, such as clearing and grading & restoration & infra structure preparations.
For Company it is recommended to have 1 CSR, Company Site Representative, (directly
responsible to Project Manager), expatriate Superintendents for each working area (the pipeline
route can be divided into 2 or 3 segments) and national supervisors, one for each working spread.
In addition, the Superintendent will be assisted by a national safety supervisor. The national safety
supervisor reports in tandem to his Superintendent and the Safety Superintendent.
The overall QA/QC is to be supervised by an expatriate welding superintendent with a national
welding supervisor attached to each spread where welding is performed. The welding
superintendent reports to the Superintendent in charge of that particular area.
Weekly site meetings will be held between the construction contractor and Company site
personnel. Daily reports for each spread will be submitted by construction contractor and signed by
the Company Superintendent.
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25.0
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26.0
LESSONS LEARNED
From previous projects the following lessons are to be taken into consideration:
Long Lead Items are to be available before start of project (especially anode beds are not to
be forgotten, this will avoid a lengthy and costly anode installation campaign after the
main pipeline has been completed).
Good and experienced Company supervision is a must and should be mobilized in the early
stages of the project.
Daily reports are crucial to counter any claims construction contractor might file.
Quality of the work will depend on the experience of the construction contractor and is
directly related to the amount and quality of supervision by Company.
The Contract should be applied in the most stringent way; only then will the best possible
result be obtained. However, certain leeway must be available to the judgement of the
Superintendents.
Contractor installation procedures should be ready and APPROVED by Company before
start of work on site.
A certain amount of days will certainly be lost due to the IDUL FITRI holiday
The backfilled trench needs to be crowned to allow for future settlement. If this is not done
correctly a channel will be the result and water will start flowing over the pipeline. The
creation of borrow pits should be strictly forbidden and the importation of additional soil to
make up for any shortcoming clearly dictated in the contract. This is an item that is very
often grossly underestimated by construction contractors resulting in endless discussions
between construction contractor and Company at the end of the project.
The selection of security personnel must be done very carefully. Experience obtained during
previous projects has shown that if security personnel are recruited from the same area
where the work is performed they are ineffective in fulfilling their task in case of conflicts,
as their residential status severely restricts their effectiveness. Likewise, bringing in a
security (contractor) from outside the area will spark unrest as they will be seen to be
stealing the work from the local people. A careful balancing act is usually the result.
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ATTACHMENT A
Crossing matrix
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ATTACHMENT B
March Chart
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Document Checklist
Project:
Job No:
140099.01
Document Title:
Document Number:
IDBE-WO-YPZZZ-EN0001
Date:
19 Feb. 2008
Issue / Revision:
Rev. 0
Checklist
(Write N/A if not applicable)
Numerical Accuracy
Title Sheets
Contents Format
Introduction/Document Scope
Summary, Conclusions, Recommendations
Assumptions
Legibility
Diagrams Clear
Units
Tables Clear And Complete
Sheet Headings (Inc. Signatures)
Referenced Documents Checked
Drawings Referenced
Drawing Consistent With Document
Sheet Numbering
Design Premise Compliance
Client Specification Compliance
Attachments/Appendices
Scope Of Work/Ctr Compliance
Contractual Requirements
Originator Qualified And Experienced
Checker Qualified And Experienced
Consideration Of Construction
Consideration Of Operations/ Inspection/Maintenance
Consideration Of Health Safety And Environmental Issues
Design Review Function (Small Projects, If Required)
Check Copy Correct
Originator
Self Check
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QA Checker
QA
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