HSS-005-XXX-XXXX-XXX

CONSTRUCTION METHOD

INSTALLATION OF PIG TRAP

OPEN ACCESS REFINERY UNIT VII KASIM

PERTAMINA

REV. DATE PREPARED REVIEWED APPROVED NO. OF PAGES

0 June 28, 2019 MI AHY 11

 CONSTRUCTION METHOD No. : HSS-005-XXX-XXXX-XXX
Rev. : 0
Dept. : Project
INSTALLATION OF PIG TRAP Date : Jun 28th, 2019
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REVISION HISTORY SHEET

Doc. No. SEU-005-XXX-XXXX-XXX

Doc. Title Construction Method for Installation of Pig Trap
Rev. No. 0
Issue Date July 04th, 2019

REV. SECTION CHANGES

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 CONSTRUCTION METHOD No. : HSS-005-XXX-XXXX-XXX
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TABLE OF CONTENT

1. PURPOSE 4

2. SCOPE OF WORK 4

3. REFERENCE 4

3.1. CODE AND STANDARD

3.2. PROJECT SPECIFICATION
3.3. PROJECT DRAWINGS

4. RESPONSIBILITIES 5

4.1. CONSTRUCTION SUPERINTENDENT

4.2. CONSTRUCTION SUPERVISOR
4.3. HSE OFFICER
4.4. QC / WELDING INSPECTOR
4.5. PROJECT ENGINEER

5. DEFINITIONS / ABBREVIATIONS 5

6. PERSONNEL 6

7. EQUIPMENT 6

8. HSE REQUIREMENTS 7

8.1. SAFETY REQUIREMENTS

8.2. ACCIDENT PREVENTION SAFETY PROCEDURES

9. QUALITY CONTROL 7

10. WORK EXECUTION 8

10.1. PREPARATION
10.1.1. MATERIAL DELIVERY AND RECEIPT
10.1.2. INSPECTION AND SITE STORAGE

10.2. SITE INSTALLATION

10.2.1. CONSTRUCTION (PIG TRAPS INSTALLATION
10.2.2. MECHANICAL COMPLETION
10.2.3. PRE-COMMISSIONING
10.2.4. COMMISSIONING AND START-UP
10.2.5. FINAL ACCEPTANCE

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1. PURPOSE

The purpose of this document is to describe the construction and installation of Pig
Trap as equipment which shall be used for inserting the Pig into the pipeline and to
ensure safe removal of the Pig in Pertamina Open Access Refinery Unit VII Kasim
project, Seget West Papua.
Contractor will implement and to ensure the work is completed on time based on project
schedule, consistency with Company requirements, and comply within project budget.
All will be based with a target of ZERO Incidents by adopting Company’s HSE
Standards.

2. SCOPE OF WORK

The Scope of Work is to install two (2) Pig Launchers and two (2) Pig Receivers for
Crude and Heavy Oil. The installation will including remedy of the foundations,
grouting, ground assembly, site fabrication, erection, piping and welding works,
instrument tubing work, cabling and cable connection works, insulation and cladding
work, commissioning and testing works, site painting and touch up painting.

3. REFERENCE

3.1. Code and Standard

• AWS D1.1
• ASME Section IIA, IIC
• ASME Section V
• ASME Section VIII Division 1
• ASME Section IX
• ASME B16.5
• ASME B31.1
• ASME B31.3
• API 1104
• Any Codes and Standards related to Pig Launcher and Pig Receiver from
Company

3.2. Project Documents

• S-00-1351-001 Rev-2: General Specification Pig Launcher And Receiver

• S-00-31A0-001 Rrev-2: Specification For Painting
• OAR-RFQ-MEC-002 Rev-0: Requisition For Pig Launcher & Receiver

3.3. Project Drawings

• General Arrangement Drawing

• AFC Drawing for Structurers
• Any Others Related Company’s Drawings (if any)

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4. RESPONSIBILITIES

4.1. Construction Superintendent

He has overall responsibility for the installation works of all Pig Launchers and
Pig Receivers on site including site preparation, site fabrication and assembly,
erection, commissioning and testing works.
He shall also coordinate with Main Contractor Representative to ensure the
work completion within scheduled time and the observance of HSE and quality
procedures and practices in accordance with the relevant regulation of
authorities.
4.2. Construction Supervisor
He has responsibility for all construction and installation work scopes. He shall
control the execution works and supervise his subordinates.

4.3. HSE Inspector

He has overall responsibility for the implementation of HSE plan according to
the Project HSE Plan.

4.4. QC Inspector
He has overall responsibility for the control and inspection of quality according to
the QA/QC plan and ITP. He shall review the Contract specifications and
drawings, identify project criteria and prepare required checklist for QA/QC
inspection.
4.5. Project Engineer
He shall monitoring progress of the work (related construction, pre-
commissioning activities, testing, commissioning and start-up) as per project
schedule and as per project procedures and Company regulation.

5. DEFINITIONS / ABBREVIATIONS

Company Pertamina Open Access Refinery Unit-VII Kasim Project

Main Contractor PT. Adhi Karya (Persero) Tbk.
Contractor PT. HSS
HSE Health Safety Environment
ITP Inspection Test Plan
QA Quality Assurance
QC Quality Control
AFC Approved For Construction
PPE Personal Protective Equipment
PIG TRAPS Pig Launcher and Pig Receiver

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6. PERSONNEL

Planned Construction personnel for this project is as per list below:

1. Construction Superintendent
2. Project Engineer / Commissioning Engineer
3. QC / Welding Inspector
4. HSE Inspector
5. Construction Supervisor
6. Material Control / Store Keeper
7. E/I Technician
8. Welder
9. Fitter
10. Rigger / Scaffolder
11. Insulator
12. Civil Worker
13. Painter
14. General Helper

7. EQUIPMENT

Planned Construction equipment and tools for this project is as per list below:

1. TMC / Boom Truck 12 ton

2. Air Compressor 390 cfm c/w Air Manifold and Hoses
3. Welding Machine set c/w Tig Welding and Accessories
4. Hydrotest / Pressure Test Equipment Set c/w Consumables
5. 20 ft Sea Container
6. Conventional Painting Spray Set
7. Flame Cutting Torch Set c/w Flashback Arrestor, Regulator and Hoses
8. Grinding Machine
9. Abrasive Cutting Machine
10. Hand Drill
11. Lifting Gear and Rigging Tools
12. Hydraulic Torque Wrench set
13. Inspector Tools
14. Welder Hand Tools
15. Fitter Hand Tools
16. Civil Hand Tools
17. Painter Hand Tools
18. Fire Extinguisher
19. Gas Detector
20. Radio Communication Portable (Handy Talkie)

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8. HSE REQUIREMENTS

8.1. Safety Requirements

• All personnel must follow the rules and regulations applicable in Pertamina
Refinery Unit VII Kasim Project.
• Before job starts check if protective & safety requirements are provided.
• Appropriate PPE must be used by personal doing the task.
• Pre job talk must be done and all personal assigned to do the task must
understand the hazards associated with the job and the control measures in
place.
• All personnel will be issued with and instructed to always maintain safe
working practices especially for the Hot Work Activities. Any flame cutting
works, grinding works, welding works shall be use additional PPE such as:
Welding / Face shield, masker, ear plug, welding apron.
• Any working at Hight shall be wear the safety full body harness.
• All of Construction personnel included the team leader shall passed with the
Medical Check Up and have safety training as required by Client.
• Emergency Response Plan must be developed and implemented to all
personnel acquainted with the relevant provisions and know what to do in
case of any emergency.

8.2. Accident Prevention Safety Procedures

• All machinery and equipment shall be kept in well-maintained conditions to

reduce emissions.
• Precautions will be taken to minimize the risk of fuel spillages. If there is any
spillage, the material will be removed as specified in the spill contingency plan.
• Application, maintenance, storage of electric, and oxygen cutting welding
units shall conform to applicable standards.
• No Permit To Work - No Work shall be kept in mind of each personnel.
• Any Hot Work activities should be covered by partition to prevent the welding
or cutting sparks spread to anywhere.
• Gas Detector and Safetyman shall be standby at the location during hot work
activities conducted.
• Portable Fire Extinguisher always be nearby the hot work location.
• Information of Lifting activity to all personnel at the area, will be informed
immediately before lifting operation was performing.
• Any person dealing with assembly, installation and commissioning of the Pig
Traps and the accessories (valves, pig signals, testing equipment, etc.) must
be able to prove they possess professional qualifications for implementing the
work.

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9. QUALITY CONTROL

• The required inspection for each work activity will be monitored by QC /

Welding Inspector during construction and installation.
• All inspection report shall be submitted to Company according to above
mentioned.
• All precaution and note listed in Client Specification shall be followed before
any hot works.
• Inspection, Testing and Recording shall be in accordance with the approved
Inspection & Test Plan (ITP).

10. WORK EXECUTION

10.1. PREPARATION

• Preparation shall be started after contract award with Engineering and Design,
Procurement and Fabrication works.
• Equipment-Tools-Consumable included supporting material on site will prepared
in Contractor workshop and delivered to site including the pig traps c/w the
accessories.
• Assembly of the Pig Traps (Launchers and Receivers) with its accessories shall
be completed in Contractor workshop.
• Contractor shall prepare site warehouse and site workshop for supporting the
construction activity.
• All heavy equipment, equipment, tools, consumables including material (Pig
Traps and the accessories) will be kept in site warehouse / site workshop.

10.1.1. Material Delivery and Receipt

• The pig traps are packed on wooden pallets or boxes prior to delivered.
• Valve ends are sealed with PE protective caps or wooden caps to prevent the
penetration of dirt and moisture.
• Valves of the additional connections are in “OPEN” position.
• Weld-on ends and mounted flange sides are coated with an anti-corrosive
product.
• Only use the original packaging for transporting the pig traps to its place of
installation.
• Only use lifting devices that are appropriate to the weight being moved.

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10.1.2. Inspection and Site Storage

• Check the delivery notes to make sure that the delivery is complete. The Client
shall be attended when the inspection performed.
• Check the delivery immediately on receipt for damage incurred during transport.
In the event of damage, observe the stipulations of the insurance company which,
among other things, prescribe that evidence of damage is confirmed immediately
by the forwarding agent.
• If applicable, photograph damage to proof evidence.
• Store the pig launcher in its original packaging.
• Take suitable measures to protect the pig traps against external influences, dirt
and moisture.

10.2. SITE INSTALLATION

10.2.1. Construction (Pig Traps Installation)

• Installation of the Pig Traps will conducted by using TMC 12 ton.

• The existing foundation shall be remedy and embedded of the anchor bolts for
the pig trap supports.
• Lifting work performed by the lifting lugs attached at the pig trap body and
executed by certified riggers and as per lifting plan.
• The packaging of the pig traps and the protective caps will not remove until
installing the pig traps to its foundation.
• For delivery, the flange sealing surfaces have been provided with anti-corrosion
protection. The flange sealing surfaces must be carefully cleaned before being
installed in the pipeline.
• The pipeline counter flanges must be aligned plane-parallel and concentrically.
• Install all ball valves into the pipeline with the ball position “OPEN”.
• Install the pig traps into the pipeline as stress-free as possible.
• Retighten the screw connections crosswise and evenly with the appropriate
tightening torque. Recommended tightening sequence.
• External tractive, compressive or bending forces must be avoided or reduced to
a minimum using suitable measures (such as erecting a foundation).
• Earthing cable for each pig traps shall be installed after installation of pig traps to
its foundation have completed. Cabling work from earthing lugs to earthing rods
will pulled when the rods had planted to the ground.
• All equipment and accessories will be supplied with surface preparation and at
least with primer coating. Where necessary, touch up painting shall be done after
erection in full compliance with the applicable paint specification.
• Inspections and, if required, touch up of the painted surfaces of the equipment will
be carried out prior to the final erection and completion. At touch up painting
completion, an inspection will be undertaken of all activities and witnessed by
parties as per ITP.

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• Insulation and Cladding works will executed when all installation and testing works
have been completed and accepted by Main Contractor and Company.

10.2.2. Mechanical Completion

Contractor will responsible for Mechanical Completion (“MC”) Work and each
discipline should provide the requirements during the work. Mechanical completion
scope could include, but not be limited to:

- Ensure all equipment and any accessories are installed in accordance with
applicable drawings, specifications and manufacturers’ instructions;
- Check nameplates against data sheets and requirements;
- Check equipment against specifications, codes and standards;
- Visual inspections to check for complete and correct installation;
- Grounding check; and
- Bolts tightness check.

10.2.3. Pre-Commissioning

Contractor will complete all Pre-commissioning activities necessary to achieve

Mechanical Completion and ensure that all equipment complies with specifications,
data sheets, and purchase orders.

Contractor will provide all necessary labour to complete construction, installation, and
Pre-commissioning of the Work. Pre-commissioning includes all actions required to
bring the Work to Mechanical Completion.

• Function Test
o Before applying pressure to the pig traps for the first time, a function test must
be carried out when it is de-pressurized.
o Properly clean the interior of the ball valve and the closure.
o Fully close the ball valves and the closure and open again. The ball valves
must run through the entire stroke trouble-free.

• Leak Test
o Only use mechanically clean water with an admixture of anti-corrosive agent
as a test medium.
o If no anti-corrosive agent is used, the pig traps must be drained and dried as
quickly as possible after the pressure test in order to avoid corrosion.
o Close all installed ball valves before running the pressure/leak tightness test.
o Provide the pressure gauge connections with a manometer.
o Close all drainage and venting connections.
o Close the main connection ball valve for pressure relief.
o Use an expansion tube to fill the pig traps with water and vent it via the venting
connection.
o Drain the pig traps subsequently.

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 CONSTRUCTION METHOD No. : HSS-005-XXX-XXXX-XXX
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Dept. : Project
INSTALLATION OF PIG TRAP Date : Jun 28th, 2019
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10.2.4. Commissioning and Start-Up

Company will be responsible for commissioning and start-up the facilities and
Contractor shall provide labor and tools to support Company in the commissioning
activities.

Commissioning activities are those associated with final testing, start-up, and
operating of the new facilities, or a part thereof, by the Company following mechanical
completion, Pre-commissioning, and Handover of the Contract Objects.

Following Handover, Company will perform all maintenance, operating adjustments,

settings, etc., that may be required for satisfactory operation, except any such repair,
adjustment, and change required to meet the Company requirements which will be
performed by Contractor.

Contractor shall provide supervised skilled and unskilled labor, tools and construction
equipment, as requested by Company or Main Contractor to support commissioning
and start-up.

If required, Contractor will provide nitrogen (N2) for purging during commissioning
which includes N2 racks, certified purging manifold and adequate medium pressure
purging hoses. Purging activities during commissioning shall be performed by and at
responsibility of Contractor, including nitrogen supply as part of assisting Company
during commissioning. Purging activities during commissioning shall be under direct
supervision of Company.

10.2.5. Final Acceptance

Contractor shall be fully responsible for the project documents as per scope of work,
drawings and data and for the as-built and updating as necessary all existing facilities
documents, drawings and data.

Contractor’s obligations shall not be considered fulfilled until as-built is completed to

the satisfaction of Company. Contractor shall provide all final documentation
including, but not limited to:

• Engineering
• Procurement
• Construction and Pre-Commissioning
• All certification
• HSE
• Quality Control
• Project Report

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