ID-N-CG-YY4-PRT-PL-25-0002 - Constructability Review Report

Document Title: EPC Grissik – Pertagas Ultrasonic Custody metering And
Pipeline Tie-In
Constructability Review Report
COPI Doc No.: ID-N-CG-YY4-PRT-PL-25-0001
Originator: PT. PratiwiPutriSulung

CPGL Group Owner: UO - Project
Area: CG | Grissik
Location: PL | Central Gas Plant
System: 25 |Gas Export and Metering
Document Type: PRT | Project Reports
Discipline / Subdiscipline: Y | Project / Y4 | Construction
Old CPGL Document No.: -
Issued for Agus Tutur Saidi

0A IFI 3-Sept-18 Alif Danang Andri Siagian
Information Kartika Widodo Oemar
Lead
Sr. Project Facilities
Prepared Checked Approved Unit Owner
Engineer Modification
Reason for
Rev Status Issue Date Projects
Issue
Contractor Approvals CPGL Approvals
Printed initials in the approval boxes confirm that the document has been signed.
The originals are held within Document Management.
Constructability Review Report ID-N-CG-YY4-PRT-PL-25-0001_Rev.1
EPC Grissik – Pertagas Ultrasonic Custody metering And
Pipeline Tie-In
ConocoPhillips (Grissik) Ltd. Page 2 of 16
Revision Sheet
ConocoPhillips (Grissik) Ltd.
REVISION DATE DESCRIPTION OF CHANGE

1 03-Sept-18 Issued for Information
Additional Approvers (If Applicable)
Name Designation Signature Date

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Table of Content
1. INTRODUCTION............................................................................................................................ 4
2. PROJECT DESCRIPTION............................................................................................................. 4
2.1 Summary Scope of Works....................................................................................................... 4
2.2 Shutdown Scope of Works...................................................................................................... 7
3. HIGH LEVEL STRATEGY.............................................................................................................. 7
3.1 Provision of Shutdown Tie-in................................................................................................... 7
3.2 Pre-fabrication and Pre-cast Works......................................................................................... 8
4. WORKING SEQUENCE................................................................................................................. 8
4.1 Site Works Activity Before Shutdown......................................................................................8
4.2 Site Works Activity During Shutdown......................................Error! Bookmark not defined.
4.3 Site Works Activity After Shutdown......................................................................................... 9
4.4 Pre-Commissioning................................................................................................................. 9
4.5 Commissioning and Start-up................................................................................................. 99
5. CRITICAL ACTIVITY...................................................................................................................... 9
5.1 Critical Lifting of Shutdown Manual Ball Valve.........................................................................9
5.2 Critical Lifting of Fabricated Spool Header (for PERTAGAS).Error! Bookmark not defined.3
6. CONSTRUCTIBILITY REVIEW SUMMARY..............................................................................155
6.1 Input Register and Path Forward......................................................................................... 155
6.2 Operation Supports Required.............................................................................................. 155
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1. INTRODUCTION
The existing Grissik-Duri USM(s) Metering QSonic Series Ill are used to measure loading
gas for PT. Chevron Gas Indonesia (CPI) and gas sales to PT PGN ARGSPA and PT
ENERGASINDO has been in service since 2002.
Elster-lnstromet as an existing ultrasonic meter Supplier has announced the obsolescence
of the existing Q-Sonic Series Ill in 2008. The spare part and its support were no longer
provided. The latest series of Elster-lnstromet QSonic has been release. The migration to
the latest series of QSonic will allow maintaining the unit in the field for the next minimum 10
years.
ConocoPhillips (Grissik) Ltd. conducted the obsolescence study of the Grissik DURI USM(s)
meter and the results shows that the potential risk of USM reliability will reach high risk level
in 2018¬2019.
According to Regulation of Republic Indonesia's Minister of Trade, No. 70/M-
DAG/PER/10/2014 that governs the period of "Wet Calibration" for Ultrasonic Gas Flow
meter every 5 years. The existing USM has been wet calibrated during project phase
installation/construction in 2002.
* This Documents is refer to “Construction Execution Plan” Rev.B
2. PROJECT DESCRIPTION
2.1 Summary Scope of Works
Grissik DURI USM(s) Upgrade Project consist of procurement and installation of metering
isolation valves and USM metering package with detail as follows:
A. 5 Units Isolation valves replacement (Total Shutdown Corridor Block)
• Site personal mobilization, site transportation, PTW, etc.
• Preparation work before shutdown date.
• Dismantle and reinstall existing shelter/ roof, bridge, etc.
• Dismantle existing limit switch and existing valves
• Replacement existing isolation valves with new isolation valves
• Tightening, QA/QC inspection, flange management, etc.
• Function testing, SAT, and start up.
B. Engineering. procurement. fabrication and assembly of 2 unit new USM(s)metering
• Engineering, procurement, fabrication and assembly of 2 unit new USM(s) metering.
• Dry calibration at the USM manufacturer and transportation to the international
recognized calibration facilities for Wet Calibration
• Procurement and fabrication of 2 unit flow conditioners.
• Procurement all the piping material (pipe, flanges, fittings, gaskets, stud and bolts,
washer, etc.)
• Engineering, Fabrication and honing of the upstream / downstream spool in
Indonesia fabricator including hydrotest witnessed by MIGAS.
• Temporary Export, custom clearance of the calibration spool to the International
recognized calibration facilities for Wet Calibration Meter.
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• Conducted dry and wet calibration of 2 (two) unit new ultrasonic meter package at
internationally recognized calibration facilities.
• Proper packaging and preservation during transportation
• Deliver the 2 unit USM(s) metering completed with spools from the recognize
calibration facilities country origin to Indonesia (Grissik warehouse)
• As-built project documentation.
• Re-instatement of the shelter, structural, piping, civil, de-mobilization and closing
• Dry calibration at the USM manufacturer and transportation to the international
recognized calibration facilities for Wet Calibration
 Preservation of the USM(s) Metering in Grissik warehouse after Wet Calibration.
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The schematic drawing for USM Duri Upgrade Project is as below, as for early PFD and PID
drawing can be seen in Attachment 2 – Early PFD and PID Drawing Layout.
Figure 2-1 PFD Drawing of USM Duri Upgrade Project
Figure 2-2 PID Drawing of USM Duri Upgrade Project

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2.2 Shutdown Scope of Works

Amongst the works described on previous section, there are 2 works that will required total
shutdown of Corridor Block to perform, which are:
2.2.1 20”-600# (5 Unit) Ball Valves Replacement (Mark with Red Arrow)
2.2.2 Pertagas Header Replacement (Mark with Blue Color)
3. HIGH LEVEL STRATEGY

3.1 Provision of Shutdown
Provision of shutdown is required to perform the replacement of existing manual ball valve
20”-600# on USM Duri skid with new Ball Valves 20”-600# with same location and position.
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Also to replace the Pertagas Header 30” with new fabricated spool header to accomodate
future tie-in for Pertagas line.
The shutdown tie-in provision itself need to be performed in total shutdown window since it
is tied-in to existing facility. The shutdown is confirmed will be executed on 10 December
2017.
3.2 Pre-fabrication and Pre-cast Works

This window is going to be utilized for pre-fabrication of piping and pre-cast of foundation for
time optimization. The pre-fabricated spool and pre-casted foundation item will then installed
at site when the field construction works is performed.
4. WORKING SEQUENCE
4.1 Site Work Activity Before Shutdown
USM DURI
• Roof dismantling including lighting for Duri USM shelter
• Grating Removal for Duri USM skid
• Laying and test new cable for limit switch positioner from valves to JB
• Equipment and Tools Mobilization (crane, compressor, etc.)
• Install temporary facility (Shelter, warehouse, Portable toilets)
• Repair access way for heavy equipment
• Material (valves, gasket, stud bolt & nut) setting for shutdown position
• Access bridge removal from metering skid and modification
PERTAGAS HEADER
• Roof dismantling including lighting for SSWJ USM shelter
• Grating Removal for SSWJ USM skid
• Ground Scanning Area Pertagas Header Foundation
• Demolish conblock, excavation and backfill for installing Pertagas
• Header new foundation and pipe support (pre-cast at PPS Workshop)
• Material (valves, gasket, stud bolt & nut) setting for shutdown position
• Assembling pertagas header (spool & valves)
• Assembling internal panel wiring (mapping) c/w wire tagging
• Download, programming, function and integration test DCS/SIS and HMI
• Marking hole for gland plate (E/I) at raised floor, CCR and PCR 1
4.2 Site Works Activity During Shutdown
USM DURI
• Dismantling and replace 5 Unit of Ball Valves 20”- 600#
• Dismantling and install 2”-600# venting spools
• Re-configure 1”-600# equalizing spools
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• Dismantling, replace and termination cable connection for valve limit switch
positioner
• Assessment USM Duri power junction box (Exd junction box)
PERTAGAS HEADER
• Dismantling and replace 30” header for SSWJ metering
• Dismantling and replace 2” flare line
• Dismantling and replace 2”-150# end flange for instrument air header
• Modification & Upload DCS SIS and HMI at CCR building
• E/I panel holing at PCR and CCR (on gland plate)
4.3 Site Works Activity After Shutdown

USM Metering Duri Area:
• Demolish existing USM and its spool stream B
• Install new USM and its spool stream B
• Pre-Comm and Comm stream B
• Demolish existing USM and its spool stream A
• Install new USM and its spool stream A
• Pre-comm and comm stream A
• Re-assembly existing shelter roof/structure
• Re-assembly existing access bridge
CPR Area:
• Flow Computer Upgrade and Modification
• HMI Modification
• Metering Panel Wiring Modification
4.4 Pre-Commissioning
 Closing punch list A
 Loop test for instrument
 Communication test between USM, Flowcom and DCS
 Energize for electrical
 N2 leak test and purging for piping
 Flange management works
4.5 Commissioning and Start-up

 Support commissioning and start-up (manpower and tools/equipment)

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5. CRITICAL ACTIVITY
5.1 Critical Lifting of Shutdown of Manual Ball Valves
Shutdown Tie-in provision is considered as critical activity because of its lifting configuration.
From preliminary lifting plan lifting study, it was discovered that the lifting will need lifting
radius approximately 30 meter with lifting load of 3.4 ton. It is also classified as complex
lifting due to its location in existing facility.
Weight of 4.4 ton is rounded calculated value of the manual valves, and lifting accessories .
Combined with safety factor of SWL crane, it is early defined that the crane require to be
minimum at 160 ton capacity.
As per above data the lifting plan calculation is :
On Crane load chart page 4 to 5 we have data :

Boom radius = 30.44 meter
Boom length = 39.3 meter
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Boom angle = 33°

Crane SWL = 12.6 ton
Estimate for used crane capacity 80% = 80% x 12.6 ton
= 10.08 ton (maximum load)
Equipment weight +lifting gears = 4.4 ton
For onshore lifting safety factor is = 1.3
Max Equipment weight + lifting gears = 1.3 x 4.4 ton
= 5.72 ton
Max crane swl at 80% > max equipment weight, it’s safe to lift.
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5.2 Critical Lifting of Fabricated Spool Header (for Pertagas)

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As per above data the lifting plan calculation is :

On Crane load chart page 4 to 5 we have data :
Boom radius = 11.7 meter
Boom length = 21.9 meter
Boom angle = 53°
Crane swl = 46.5 ton
Estimate for used crane capacity 80% = 80% x 46.5 ton
= 37.2 ton (max load)
Equipment weight +lifting gears = 11.9 ton
For onshore lifting safety factor is = 1.3
Max Equipment weight + lifting gears = 1.3 x 11.9 ton
= 15.4 ton
Max crane swl at 80% > max equipment weight, it’s safe to lift
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6. CONSTRUCTIBILITY REVIEW SUMMARY

6.1 Input Register and Path Forward
Constructability review discussion to be settled by ConocoPhillips (Grissik) Ltd and PT. PPS
to find out the result of input register and path forward.
6.2 Operation Supports Required
USM Duri Upgrade project is a critical project in nature since it required total shutdown
during construction phase and will obstruct to ConocoPhillips (Grissik) Ltd sales gas.
To do so, there are several collaboration requested from ConocoPhillips (Grissik) Ltd and
Contractor for construction activities, as below examples.
 Opportunity and permission to provide new entry gate and access route for personnel
and/or HDE
 Support for ground disturbance works utilizing Operation personnel and tools
 N2 purging for shutdown scope
 Permission to provide temporary storage and shelter area in working location
Pipeline Tie-In
Layout of Equipment and Manpower Route

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Document Title: EPC Grissik – Pertagas Ultrasonic Custody metering And

COPI Doc No.: ID-N-CG-YY4-PRT-PL-25-0001

Originator: PT. PratiwiPutriSulung

Issued for Agus Tutur Saidi

Contractor Approvals CPGL Approvals

REVISION DATE DESCRIPTION OF CHANGE

Additional Approvers (If Applicable)

Name Designation Signature Date

Figure 2-1 PFD Drawing of USM Duri Upgrade Project

Figure 2-2 PID Drawing of USM Duri Upgrade Project

2.2 Shutdown Scope of Works

2.2.2 Pertagas Header Replacement (Mark with Blue Color)

3. HIGH LEVEL STRATEGY

3.2 Pre-fabrication and Pre-cast Works

4.3 Site Works Activity After Shutdown

4.5 Commissioning and Start-up

As per above data the lifting plan calculation is :

On Crane load chart page 4 to 5 we have data :

Boom angle = 33°

5.2 Critical Lifting of Fabricated Spool Header (for Pertagas)

As per above data the lifting plan calculation is :

6. CONSTRUCTIBILITY REVIEW SUMMARY

Layout of Equipment and Manpower Route

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