Construction Method For Installation of Pig Trap

 

HSS-005-XXX-XXXX-XXX

 

CONSTRUCTION METHOD

INSTALLATION OF PIG TRAP OPEN ACCESS REFINERY UNIT VII KASIM PERTAMINA

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June 28, 2019

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CONSTRUCTION METHOD

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: HSS-005-XXX-XXXX-XXX 

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Dept. : Project 

INSTALLATION OF PIG TRAP

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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

OPEN ACCESS REFINERY UNIT VII KASIM

CHANGES

 

CONSTRUCTION METHOD

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TABLE TAB LE OF CONTENT 1.  PURPOSE

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2.  SCOPE OF WORK   3.  REFERENCE

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3.1. CODE AND STANDARD 3.2. PROJECT SPECIFICATION 3.3. PROJECT DRAWINGS 4.  RESPONSIBILITIES

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4.1. CONSTRUCTION SUPERINTENDENT 4.2. CONSTRUCTION SUPERVISOR 4.3. HSE OFFICER 4.4. QC / WELDING INSPECTOR 4.5. PROJECT ENGINEER 5.

DEFIN DEFINITIONS ITIONS / AB ABBREVIATIONS BREVIATIONS

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6.

PERSONNEL

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7.

EQUIPMENT

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8.

HSE REQUIREMENTS

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8.1. SAFETY REQUIREMENTS 8.2. ACCIDENT PREVENTION SAFETY PROCEDURES 9.

QUALITY CONTR CONTROL OL

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10.  WORK EXECUTION

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10.1. PREPARATION 10.1.1. 10.1. 1. MATERIAL D DELIVERY ELIVERY AND RECE RECEIPT IPT 10.1.2. INSPECTION AND SITE STORAGE 10.2. SITE SITE INSTALL ATION 10.2.1. CONSTRUCTION (PIG TRAPS INSTAL INSTALLA LA TION 10.2.2. 10.2. 2. MECH MECHANICAL ANICAL COMPLETIO COMPLETION N 10.2.3. PRE-COMMISSIONING 10.2.4. COMMISSIONING AND START-UP 10.2.5. 10.2. 5. FINAL ACCEPTANCE

OPEN ACCESS REFINERY UNIT VII KASIM

 

CONSTRUCTION METHOD

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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 of the Pig in Pertamina Open Access Refinery Unit VII Kasim project, safe Segetremoval 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 3.1                    

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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 Cod Codes es a and nd Stand Standards ards relate related d to Pig La Launcher uncher a and nd Pig Receiver from Company

3. 3.2. 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

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3. 3.3. 3. Project Drawings   General Arrangement Drawing

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

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OPEN ACCESS REFINERY UNIT VII KASIM

 

CONSTRUCTION METHOD

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: HSS-005-XXX-XXXX-XXX 

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4. RESPONSIBILITIES 4.1. Construction Superintendent   He overall on responsibility forsite the preparation, installation works of all Pig Launchers and Pig has Receivers site including 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 t he 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. 4.5. 5. Project Engineer He shall monitoring progress of the work (related construction, precommissioning activities, testing, commissioning and start-up) as per project schedule and as per project procedures and Company regulation.

5. DEFIN DEFINITION ITIONS S / AB BREVIATIONS

Company Main Contractor Contractor HSE ITP QA QC  AFC PPE PIG TRAPS

OPEN ACCESS REFINERY UNIT VII KASIM

Pertamina Open Access Refinery Unit-VII Kasim Project PT. Adhi Karya (Persero) Tbk. PT. HSS Health Safety Environment Inspection Test Plan Quality Assurance Quality Control Approved For Construction Personal Protective Equipment 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 E Engineer ngineer / Commissio Commissioning ning Engineer 3. QC / Welding Inspector 4. HSE Inspector 5. Construction Supervisor 6. Material Control / St Store ore 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 equipment and tools for this project is as per list below: 1. 2. 3. 4. 5.

TMC / Boom Truck 12 ton Air Compressor 390 cfm c/w Air Manifold and Hoses Welding Machi Machine ne set c/w Tig Welding an and d Access Accessories ories Hydrotest / Pressure T Test est Equipmen Equipmentt Set c/w Consumables 20 ft Sea Container

6. Spray 7. Conventional Flame CuttingPainting T Torch orch Set c c/w /w Set Flashback Arrestor, Regulator and Hoses 8. Grinding Machine 9. Abrasive Cutting Machine 10. Hand Drill 11. Lifting Gear and R Rigging igging 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 Porta Portable ble (Handy Talkie)

OPEN ACCESS REFINERY UNIT VII KASIM

 

CONSTRUCTION METHOD

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8. HSE REQUIREMENTS

8.1. Safety Requirements   All personn personnel el mus mustt follow the rules and re regulations gulations applicable in Pertamina Refinery Unit VII Kasim Project.   Before job starts check if protec protective tive & safety requirements are provided.   Appropriate PPE must be us used ed b by yp personal ersonal 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 is issued sued 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 w working orking at Hig Hight ht s shall hall be wear the safety full bo body dy harness. harness.

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  Medical All of Construction personnel included the team leader by s shall hall pas passed sed w with ith the Check Up and have safety training as required Client.   Emergency Res Response ponse Plan must be developed a and nd implemented to all personnel acquainted with the relevant provisions and know what to do in case of any emergency.

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8. 8.2. 2. Acci dent Pre Preventio ventio n S Safety afety P Procedur rocedur es   All machinery and e equipment quipment s shall hall be kept in well-maintained conditions to reduce emissions.   Precautions will be taken to minimize th the e 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 oxy oxygen gen cut cutting ting welding units shall conform to applicable standards.   No Permit To Work - No Work sha shallll be kept in mind of each personnel.   Any Hot Work activitie activities s sho should uld be covered by partition to prev prevent ent the welding or cutting sparks spread to anywhere.   Gas Detecto Detectorr and Safetyman shall be standby at the location during h hot ot work activities conducted.   Portable Fire Ex Extinguisher tinguisher always be nearby the h hot ot work location.   Information of Lifting activity activity to all personn personnel el at the area, will be informed immediately before lifting operation was performing.   Any pe person rson dea dealing ling wit with h asse assembly, mbly, installa installation tion an and d commissioning 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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OPEN ACCESS REFINERY UNIT VII KASIM

 

CONSTRUCTION METHOD

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: HSS-005-XXX-XXXX-XXX 

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9. QUALITY CONTR CONTROL OL

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

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Welding Inspector during construction and installation.   All inspection report shall be submitted to Company according to above mentioned.   All precautio precaution n and note listed in Client Speci Specification fication sh shall all be followed before any hot works.   Inspection, T Testing esting an and d Recor Recording ding shall be in accordance with the approved Inspection & Test Plan (ITP).

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10. WORK EXECUTION

10.1. PREPARATION

  Preparation s shall hall be started after contract award with Engineering and De Design, sign, Procurement and Fabrication works.   Equipment-Tools-Consuma Equipment-Tools-Consumable ble 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 Re Receivers) ceivers) with its acce accessories ssories s shall hall be completed in Contractor workshop.   Contractor s shall hall prepare site wareh warehouse ouse a and nd site workshop for supp supporting orting the construction activity.   All heavy equipment, equipment, to tools, ols, cons consumables umables including material (Pig Traps and the accessories) will be kept in site warehouse / site workshop.

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10.1.1. Ma Material terial De Deliv liv ery and Receipt

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  The pig traps are packed on wooden pallets or boxes prior to delivered. 

  Valve ends are seale sealed d with PE protective caps or w wooden ooden c caps aps to prevent the penetration of dirt and moisture.   Valves of the additional connections are in “OPEN” “ OPEN” position position..   Weld-on ends and mounted flange sides are coated w with ith an an anti-corrosive ti-corrosive product.   Only use the original packaging for transporting the pi pig g traps to its place of installation.   Only use lifting dev devices ices that are appropriate to the we weight ight bein being g moved.

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OPEN ACCESS REFINERY UNIT VII KASIM

 

CONSTRUCTION METHOD

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: HSS-005-XXX-XXXX-XXX 

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10.1.2. Inspecti on and Site S Storage torage

  Check the delivery no notes tes to make sure that the delivery is complete. The Clie Client nt shall be attended when the inspection performed.

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  Check the d delivery elivery immediately on rec receipt eipt fo forr dam damage age 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 s suitable uitable me measures asures tto o protec protectt the pig traps against external in influences, fluences, dirt and moisture.

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10.2. SITE INSTALL INSTALLATION ATION 10.2.1. Construction (P (Pig ig Tra Traps ps Installa Installation) tion)

  Installation o off the Pig T Traps raps will conducted by us using ing TMC 12 ton ton..     The exis existing ting foundatio foundation n shall be remedy a and nd embed embedded ded of the anc anchor hor bolts for the pig trap supports.  supports.    Lifting work performed by the lifting lugs attached at the pig tr trap ap body and executed by certified riggers and as per lifting plan.  plan.    The pack packaging aging of the pig traps and the protective c caps aps will not remove until installing the pig traps to its foundation.   For de delivery, livery, 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 a aligned ligned plane-parallel and concentrically.   Install all ball valves into the pipeline with the ball position “OPEN”. “OPEN”.     Install th the e pig traps into th the e pip pipeline eline as s stress-free tress-free as possible.   Retighten the screw c connections onnections c crosswise rosswise and evenly with the appropria appropriate te tightening torque. Recommended tightening sequence.   External tractive tractive,, compre compressive ssive or bending forces mu must st be avoided or reduced to a minimum using suitable measures (such as erecting a foundation).   Earthing c cable able for each pig traps s shall hall be installed a after fter 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 acc accessories essories wi willll be su supplied pplied 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, to touch uch u up p of the pa painted inted surfac surfaces es of the eq equipment uipment will be carried out prior to the final erection and completion. At touch up painting

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completion, anITP. inspection will be undertaken of all activities and witnessed by parties as per

OPEN ACCESS REFINERY UNIT VII KASIM

 

CONSTRUCTION METHOD

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: HSS-005-XXX-XXXX-XXX 

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INSTALLATION OF PIG TRAP

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  Insulation and Cl Cladding adding works will exec executed uted when all installation and ttesting esting works have been completed and accepted by Main Contractor and Company.

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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 equipme equipment nt and any a accessories ccessories are installe installed d in accordance with applicable drawings, specifications and manufacturers’ instructions;  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.

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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.  

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Function Test

  Before applyin applying g pressure to the pig traps for the first time, a function test must be carried out when it is de-pressurized. o  Properly clea clean n the interior of the ba ballll valve and the clos closure. ure. o

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  Fully close the ball v valves alves and the closure and open again. The ball valves must run through the entire stroke trouble-free.

 

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Leak Test

  Only use mechanically clean water with an admixture of anti-corrosive age agent nt as a test medium. anti-corrosive ive agent is used used,, the pi pig g traps must be drained and dried as o  If no anti-corros quickly as possible after the pressure test in order to avoid corrosion. ball all valv valves es before running the press pressure/leak ure/leak tightness test. o  Close all installed b o  Provide the pressure gauge connections with a manometer. manometer. o  Close all drainage and venting connections. o  Close the main c connection onnection ball valve ffor or pres pressure sure relief. o  Use an expansion tube to fill the pig tra traps ps with water and vent it via the venting connection. o  Drain the pig traps subsequently.

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OPEN ACCESS REFINERY UNIT VII KASIM

 

CONSTRUCTION METHOD

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10.2.4. Commissioning and Sta Start-U rt-Up p

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 constr construction uction 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 as -built and updating as necessary all existing facilities documents, drawings and data. -built is completed to Contractor’s obligations shall not be considered fulfilled until as as-built 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

OPEN ACCESS REFINERY UNIT VII KASIM