IDBE-WO-YPZZZ-En0001 Onshore Construction Execution Plan, Rev 0

______________________________
Banyu Urip Project

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Onshore Construction Execution Plan
IDBE-WO-YPZZZ-EN0001
19 Feb 08
ISSUED FOR USE
RP
BT
PF
31 Jan 08
ISSUED FOR APPROVAL
RP/FH
BT
PF
29 Nov 07
ISSUED FOR COMMENT
FH/RP
BT
PF
Rev
Rev Date
Description
Prepared By
Checked By
PM
Client
BANYU URIP PROJECT
Mobil Cepu Limited
Non-Technical Document Management

Procedure
IDBU-ED-BPDCC-000002
9th April 2007
Rev 0
MPI: COMPANY USE ONLY
Page 2 of 57
BANYU URIP PROJECT
ONSHORE CONSTRUCTION EXECUTION PLAN

19 Feb. 2008
Rev 0
Page 2 of 52
REVISION MODIFICATION LOG
Revision
Section
A
B
0
All
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Description
Issued for Comment

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Issued for Use
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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
Codes & Standards
1.6
Construction methods
10
2.0
FIELD LAYOUT
11
3.0
SAFETY, HEALTH, ENVIRONMENTAL, SECURITY QUALITY
12
3.1
Safety
12
3.2
Health
12
3.3
Environment
12
3.4
Security
12
3.5
Emergency Response Plan
12
3.6
Emergency Evacuation Plan
13
4.0
5.0
COMPANY SCOPE OF WORK
14
4.1
ROW
14
4.2
Procurement and supply of LLI
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
Worthiness Certification of the Work (SKKP)
16
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6.0
MOBILIZATION
17
7.0
WORKFORCE, ACCOMMODATION AND TRANSPORTATION
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
TRANSPORTATION AND STAGING OF PIPE & COMPANY SUPPLIED ITEMS
25
8.1
Transportation and staging of pipe
25
8.2
Transportation and storage of Company supplied items
25
RECOMMENDED CONSTRUCTION METHODS
26
9.1
Basis for recommended construction methods
26
9.2
Assumed construction methodologies
26
9.3
Construction challenges
28
9.4
ONSHORE PIPELINE BUOYANCY CONTROL
32
CONSTRUCTION EXECUTION STRATEGY OVERVIEW
33
10.1 Kp. 0.000 to Kp. 7.497
33
10.2 Kp. 7.497 to Kp. 8.072
33
10.3 Kp. 8.072 to Kp.24.153
33
10.4 Kp.24.153 to Kp.24.558
33
10.5 Kp. 24.558 to Kp.29.898
33
10.6 Kp.29.898 to Kp.30.325
33
10.7 Kp.30.325 to Kp.38.888
33
10.8 Kp.38.888 to Kp.49.000
33
10.9 Kp.49.000 to Kp.69.653
34
10.10Kp.69.653 to Kp.70.399
34
10.11 Kp.70.399 to Kp.71.472
34
KP.0.000 TO KP.7.947 CONSTRUCTION PLAN
35
11.1 Temporary workspace & access
35
36
36
37
37
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14.0
KP 24.153 TO KP 24.558 CONSTRUCTION PLAN
38
38
39
39
40
16.1 Temporary working space and access
40
41
41
42
42
43
44
20.0
QA / QC REQUIREMENT
45
21.0
PRE COMMISSIONING
46
21.1 Pipeline sections
46
21.2 Valves
46
21.3 Electrical systems
46
21.4 Pipeline completion
46
22.0
COMMISSIONING
47
23.0
ELECTRICAL & INSTRUMENTATION
48
24.0
PROGRESS REPORTING
49
24.1 Site management
50
25.0
RESTORATION AND RE-VEGETATION
51
26.0
LESSONS LEARNED
52
15.0
16.0
17.0
18.0
19.0
ATTACHMENTS
Attachment A
Crossing Matrix (7 pages)
Attachment B
March Chart (1 page)
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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
Environmental Impact Analysis
BU
Banyu Urip Project
CONTRACTOR
J P Kenny, Trading Division of PT Wood Group Indonesia
CSR
Company Site Representative
EPP
Early Project Plan
EEP
ERP
HDD
Horizontal Directional Drill
HSES
Health, Safety, Environment and Security
ITP
Inspection and Test Plan
LD
Lay Down area (used for staging of pipe)
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MCL
Mobil Cepu Limited
MIGAS
Indonesian Regulatory Authority for Oil and Gas
MLWS
Main Line Welding spread
MMLWS
Mini Main Line Welding Spread
PLN
Perusaan Listrik Negara (State Electricity Company)
PPE
Personal Protective Equipment
ROW
Right-of-Way
SKPP
Surat Kelayakan Pengunaan Peralatan (Worthiness

Certification)
VS
1.4
Valve Station
References
IDBE-WO-BPPPP-000002
FEEP Plan
IDBE-WO-YBDES-E00001
Design Basis
IDBE-WO-CCCAL-EF0012
Preliminary Pipeline Shore Approach Design
IDBE-WO-YRZZZ-EN0001
Initial Site Survey Report
No number provided
Early Project Plan
Laydown & Access Report
Pipe & Equipment Transport Report
IDBE-WO- YRZZZ-EN0011
Contractor Questionnaire Workshop Final Report
IDBE-WO-YSPDS-EN0005
Onshore Pipeline Installation Specification
Onshore Constructability Report
Estimate Basis Memorandum (EBM) for Scope B Pipelines

Onshore Pipeline
IDBE-WO-YCCAL-EN007
Onshore Pipeline Weight Coating Requirements
IDBU-ED-QSPDS-000006
Upstream
Project
Requirements
IDBU-IB-GBSIT-000001
Report on Geotechnical review of pipeline route, CPF and

FPSO
IDBE-IT-YBSIT-EN0004
Geotech survey ITS July/ Aug.2007 - Appendix. Borehole

logs
IDBE-WO-YSPDS-EN0003
Cathodic Protection Requirements for Onshore Pipelines
Quality
Assurance
General
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IDBU-WO-WPZZZ-0004
Systemisation, Schedule
Commissioning
&
Precedence
IDBE-WO-BLLLE-000001
Long Lead Equipment List
IDBE-WO-YDPAL-EN0001
Pipeline Alignment Sheet (49 sheets)
IDBE-WO-YDPLX-EN0001
Onshore Pipeline Construction Typical Creek Crossing Open Cut
IDBE-WO-YDPLX -EN0002
Onshore Pipeline Construction Typical River Crossing Open Cut
IDBE-WO-YDPLX -EN0003
HDD Crossing
IDBE-WO-YDPLX-EN0004
Onshore Pipeline Flume Pipe Crossing Typical Through

Watercourses
IDBE-WO-YDPAL-EN0001-001
Onshore Pipeline Drawing Legend/Symbol/Notes
IDBE-WO-YDZZZ-EN0001
Onshore Pipeline Construction Typical Trench and ROW

Detail
IDBE-WO-YDZZZ -EN0002
Onshore Pipeline Construction Typical Rail Road Crossing
Onshore Pipeline Construction Typical Road Crossing

Thrust Bored
Warning Sign for Negotiable Waterway
Onshore Pipeline Construction Typical Overhead Powerline

Crossing
Onshore Pipeline Construction Typical Overhead Powerline

Parallel Encroachment
Onshore Pipeline Typical Construction Detail for Paddy Field

Crossing
Onshore Pipeline Construction Typical Irrigation Ditch

Crossing
Onshore Pipeline
Crossing
Onshore Pipeline Construction Typical 3 rd Party Pipeline

Crossing
Onshore Pipeline HDD Crossing KP 07+497 to KP

08+072.51
Construction
Typical
Network
Main
for
Road
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1.5
IDBE-WO-YDZZZ E10001
Onshore Pipeline VS-E1 Plot plan at KP 12+300
Onshore pipeline Ahmad Yani ST and rail crossing KP

24+153 to KP 24.558.20
DELETED
Onshore Pipeline District Road Crossing at KP 29+652
IDBE-WO-YDZZZ -E20001
Onshore Pipeline (KP -29+521) VS-E2 Plot Plan on

upstream of Solo River Crossing
Onshore Pipeline HDD Crossing 3 KP 29+898 to KP

30+325.61
VS-E3 (KP 30.334) Plot plan downstream of Solo River

Crossing
Onshore Pipeline District Road Crossing at KP 32+456
Onshore Pipeline Provincial Road Crossing Bojonegoro

to Tuban at KP 38+888
DELETED
Onshore Pipeline VS-E5 (KP 51+768) Plot plan
Onshore Pipeline Existing 8 Pipeline Crossing at KP

51+824 and Provincial Road Crossing KP 51+832
Onshore Pipeline Provincial Road Crossing at KP 55+663

and Existing 8 Pipeline Crossing at KP 55+668
DELETED
Onshore Pipeline Existing 8 Pipeline Crossing at KP

67+882 and District Road Crossing KP 67+886
DELETED

and Existing 6 Pipeline Crossing at KP 71+426
Codes & Standards

API RP
1102 Steel pipelines Crossing Railroads and Highways 1993
API STD
1104 Welding of pipelines and related facilities
ASME
B16.5 Pipe Flanges and Flanged Fittings, 2003
ASME
B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and other Liquids
National regulations:
SNI 429
Sistem Transportasi Pipa Penyalur Katup Pipa Penyalur
SNI 73
Pertambangan dan Penggalian
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UU 13/2003 Undang-undang Republik Indonesia tentang Ketenagakerjaan

PP 11/1979 Peraturan Pemerintang Republik Indonesia tentang Keselamatan Kerja pada
Pemurnian dan Pengolahan Minyak
1.6
Construction methods
For this document several construction methods have been assumed:
Conventional construction:
Construction on relatively dry land where normal pipe lay equipment

such as standard side booms can be used. Stringing of pipeline will
be performed ahead of the main line welding spread. The main line
welding spread will move ahead while trenching and burial is
progressing at the same pace as construction of pipeline. The trench
will not be open for more or longer than necessary. If water is present
in the trench it will be disposed of by using pumps prior to lowering
the pipe (dry trench method)
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:
Construction technique in relatively wet areas. Here the welding

station is stationary and pipeline is pushed out (floating) inside the
water filled pre-dug trench, hence no stringing is required. It is
guided at the end by an (swamp) excavator. Once a pre determined
length has been welded and pushed/ pulled into the trench, the
trench will be pumped dry allowing the pipe to settle on the bottom.
Then, the trench will be backfilled.
HDD:
Horizontal Directional Drilling will be used in those cases where

conventional construction is deemed impractical, too costly or
otherwise unfeasible.
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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.
Figure 2.1 Export Pipeline Route Based on 2006 Survey
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3.0
SAFETY, HEALTH, ENVIRONMENTAL, SECURITY QUALITY
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

The construction contractor shall develop an Emergency Response Plan (ERP) which will contain
precise procedures to be followed for medical and security emergencies, flow charts of action to be
taken and parties involved (with contact number) in case of emergency. The interface parties will
be Company, construction contractor, security authority (police, fire fighting, etc), local hospital,
transportation service (helicopter, ambulance, etc) depending on the type of emergency.
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3.6

As part of the ERP, the construction contractor shall develop his own Emergency Evacuation Plan
(EEP) which will contain precise procedures to be followed for medical and security evacuations,
usually in the form of flow charts of action to be taken and parties involved (with contact number) in
case of emergency. The interface parties will be Company, construction contractor, security
authority (police, fire fighting, etc), local hospital, transportation service (helicopter, ambulance, etc)
depend on the type of emergency. The EEP will then be coupled to Companys EEP by a bridging
document, also prepared by the construction contractor.
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4.0
COMPANY SCOPE OF WORK
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
Procurement and supply of LLI

During the FEED for the BU project, The FEED Contractor has identified the list of Long Lead
Items. This list of items will be procured by Company and supplied to construction contractor. The
main items on this list are the line pipe and valves. Delivery and collection points will be specified in
a later stage.
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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
Worthiness Certification of the Work (SKKP)

At the end of construction, during the pre commissioning stages of the work, the construction
contractor shall be responsible for obtaining the worthiness certificate (SKKP), issued by MIGAS,
for government approval of the export pipeline system. The inspection for certification is usually
conducted by a MIGAS approved 3 rd party, whereby MIGAS acts as a witness. If MIGAS indeed
elects to use 3rd party for the inspection, construction contractor shall make contractual provision
for obtaining the inspection service from the 3 rd party approved by MIGAS as stipulated in Appendix
H of the Contract (refer to document number IDBU-ED-QSPDS-000006, Upstream Project Quality
Assurance General Requirements, Rev. C)
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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
WORKFORCE, ACCOMMODATION AND TRANSPORTATION
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
Infrastructure preparation and renovation spread

This team will perform early preparation work such as the upgrading and/ or widening of roads,
preparation of Lay Down areas, construction of temporary camp, preparation of push pull platforms,
etc. After completion of preparation work it might be restructured as a ROW and clearing spread.
Later it will be used to the renovation work on any roads, if required.
Preparation work for access and lay down areas are identified in the Pipe and Equipment Transport
report referred to in section 1.4.
The make of this team is such that it can easily be split up in 2 separate teams working
independently on different locations.
Equipment
Manpower
2 Cranes (20T)
2 excavators
2 trucks
2 Piling hammers
2 Compactors
Asphalt
Concrete
2 + 2 Banks man/ helper

Supervisor
HSES officer
Medic
Manual workers
Total
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
ROW clearing and grading spread

This is a medium sized spread that will move ahead of the main line welding spread and clear the
way. It is mainly made up of local workers who will have had safety induction and have been
provided with the appropriate PPE. An excavator has been added to this spread for grading and to
make access bunds for workers as and where necessary.
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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
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
1 Crane (20T) at lay down

area
1 Side boom
2 Pipe carriers

Supervisor
HSES officer
Medic
2
4
1
1
1
Rigging team
5 (incl. supervisor)
Survey team
Total
3
19
7.1.4
Mainline pipeline welding spread (MLWS)

This is the main pipeline welding spread that moves along the pipeline route. It is the largest
spread in the set up and will do the bulk of the pipeline welding. It is preceded by the ROW clearing
and grading spread and followed by the backfilling and restoration spread.
Equipment
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
7.1.5
Mini pipeline welding spread (MMLWS)

A smaller version of the mainline welding spread, this mini spread is used to prepare the HDD
strings and other small stretches of pipeline, where it would be impractical to deploy the main line
welding spread.
Equipment
Manpower
1 Side boom
1 Excavator
1 Crane (20T)
9 Welding machines
1 Welding support truck

1 + 1 banks man/ helper
Mechanic
1 + 1 helper
Supervisor
Welding Foreman
HSES officer
Medic
Welders
Grinders
Helpers
Riggers
NDT team
Coating team
Survey team
Total
NDT equipment
Coating equipment
Survey equipment
Total
2
2
2
1
2
1
1
1
1
8
6
6
2
4
3
3
45
7.1.6
Bored crossings spread (Specialist team 1)

The bored crossing spread will only be deployed 3 times during this project and will construct the
crossings under pre determined roads (RDX10, 11 & 13). It is a stand alone team that will prepare
the crossings prior to the arrival of the main line welding spread.
Equipment
Manpower
1 Machine
1 Excavator
1 Crane (20T)
Operators
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
7.1.7
HDD spread (Specialist team 2)

The HDD team will be deployed 3 times during the project and is supported by the Infrastructure
preparation & renovation spread, the mini main line welding spread and the tie-in spread.
Equipment
Manpower
Total
1 HDD rig
1 Hydraulic power pack
Superintendent
Driller
1
1
1 High pressure mud pump

1 Mud mixing unit
1 Mud recycling shaker unit
1 Mud tank (placed under
shaker unit)
1 Office / canteen
Steering engineer
HSES officer
Medic
Rig hands
1
1
1
2
Pipe side Foreman
1 Workshop
1 Store
Pipe side hand

Store man
Mud engineer
Mud man
Mechanic
Labour
Plant operators
Total
1
2
1
1
1
2
2
18
7.1.8
Tie-in spread (Specialist team 3)

The tie-in spread will support HDD activities such as preparation of sites and will move in at those
locations where the main line welding spread has completed and a tie-in needed to complete a
crossing. It is a relatively small team with a wide variety of equipment suitable for multi tasking.
Equipment
Manpower
2 Side booms
1 Excavator
1 Crane 20T (optional)
3 Welding machines
Various water pumps
2 + 2 Banks man / helper

Mechanic
Supervisor
HSES officer
Medic
Welder
Grinder
Fitter
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
7.1.9
Pre commissioning team (Specialist team 4)

The pre commissioning team is a small specialist team that will be deployed to perform cleaning,
brushing, flushing and gauging for the different sections of pipe (including the HDD strings pre and
post pulling). During times of idling, its team members and equipment can easily be absorbed by
any other spread where ever necessary.
Equipment
Manpower
1 Excavator
1 Hydro test spread

Supervisor
HSES officer
Medic
Hydrotest engineer
Helpers
Mechanic
Total
1 Generator
Total
2
1
1
1
2
4
1
12
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
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
TRANSPORTATION AND STAGING OF PIPE & COMPANY SUPPLIED ITEMS
8.1
Transportation and staging of pipe

Once the pipe has arrived in the nearest practical port it will be offloaded and loaded onto the
transportation trucks (subcontractor of construction contractor). These trucks will distribute the pipe
along the pipeline route to pre determined and prepared lay down areas (LD). Transport
management process and procedures for safe transport of pipe need to be developed as the pipe
will be transported through congested and populated area.
Once the trucks arrive at the lay down area they will be offloaded and pipe stored in a correct
manner. A QA/QC system shall be in place to assure that no damage to the pipe has occurred
during transport and subsequent offloading, and if it has, to document and follow-up accordingly.
The basis for the calculations concerning the space requirements for the lay down areas (LD) , has
been that stacking of the pipe will not exceed 3 layers.
The temporary lay down areas are located at the approximately Kp. positions mentioned below.
Exact location and access routes can be found in the Pipe & Equipment Transportation Report
referred to in the beginning of this document.
Approximate amount of joints and storage area per laydown area:
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
Transportation and storage of Company supplied items

Similar to the pipe, once these items have arrived in Surabaya or Jakarta they will be offloaded and
loaded onto the transportation trucks (subcontractor of construction contractor). These trucks will
transport the items (such as valves) over the public roads towards the temporary camp for
temporary storage. Once the trucks arrive at the storage area they will be offloaded and items
stored in a correct manner. A QA/QC system shall be in place to assure that no damage to the
items has occurred during transport and subsequent offloading.
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9.0
RECOMMENDED CONSTRUCTION METHODS
9.1
Basis for recommended construction methods

The proposed construction methods for the installation of the proposed 71 Km of 20-inch onshore
thermally insulated pipeline are based on the following:
9.2
Route illustrated on Topographic map.
Alignments sheets
Survey & geotechnical reports provided by Company
Satellite imaginary
Site visits
Feedback obtained from Onshore Contractor Questionnaire & workshops
Local experienced construction personnel
Independent consultants
Pipe and equipment transportation Report
Assumed construction methodologies

For this Plan Contractor has assumed that conventional onshore pipeline construction (I.e. the use
of one mainline spread using several side booms, welding, trenching and burying as the spread
moves along the pipeline route) will be the preferred option of the construction contractor. Several
smaller specialist spreads such as a mini mainline spread, tie-in spread, bored crossings spread,
HDD spread & hydro test spread will support the activities and work ahead and/ or in parallel with
the main pipeline spread.
The Plan also assumes that the construction contractor will start near the CPF area and work his
way towards Palang. However, should the construction contractor decide on a different approach
(i.e. due to weather conditions) the segmentation built into the plan will allow for easy adjustment
either way.
Preparation of ROW, grading, clearing & stringing will have preceded the start of the mainline
welding activities. The MLWS will move along the ROW and weld the pre-strung pipe. Initially, a
trench will be excavated and the first 100 meter of pipe lowered into it after welding, NDT and
coating. The spread will then move ahead as a train: excavators in front to excavate the trench,
welders/ NDT team and coaters to fabricate the pipe, side booms in the middle to lower the pipe and
excavators at the end to backfill after pipe has been lowered into the trench.
Part of the pipeline route will traverse through relatively wet areas and in such areas it is expected
that the construction contractors will either switch to a push pull method and/or start using equipment
that is more suitable for this kind of environments. For estimation purposes, the expected daily
productivity rate of 500 meter per day will drop by 40% to 300 meter per day. In this Plan, this type of
BANYU URIP PROJECT
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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
Bojonegoro- Tuban road crossing (RDX 10)
BHPL 30
- 3.00 meter
67.886
Pakah village road crossing (RDX 12)
BHPL 32
- 1.25 meter
71.421
Tuban to Gresik road crossing (RDX 13)
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.
Tabulated Construction Methods

Legend
Light green Conventional construction using tracked side booms
Light yellow Horizontal Directional drilling
Light blue
Construction in relatively wet areas, possibly need swamp like equipment or push
pull option
Continued on next page.
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Pipeline
Kilometer Post
20-inch Pipeline Section

Description
0.00 - 7.497
Pig Launcher to HDD-1 Entry
7.497 - 8.072

(HDD-No.1) 575 meter
8.072 - 12.332
HDD-1 exit to VS-E1 location
12.332
VS-E1 location
12.332 20.430
VS-E1 to LD11
20.430 24.153
LD11 to HDD No.2 entry point
24.153-24.558

(HDD no.2) 405 meter
24.558-29.521
Exit HDD No.2 to VS-E2
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

Description

(HDD no.3) 427 meter
HDD construction. Entry site at Kp.29.898, exit

site at 30.325. This HDD will cross under the
Bengawan Solo river. The area around the HDD
entry point will also be used as a pipe lay down
area LD 08. Access via district road.
Exit point HDD No.3 to VS-E3
Normal construction, access via village road
VS-E3
30.334-38.888
VS-E3 to Provincial road
38.888
Provincial road crossing
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
Provincial road to Petrochina

pipeline crossing
Pipeline crossing (PL02)
Pipeline crossing (PL03)
Petrochina line to dyke
crossing
Flood protection dyke and
gravel road crossing
Flood protection dyke to Kp.49
Kp.49 to VS-E5, via VS-E4
VS-E4
10 Petrochina pipeline
crossing (PL04)
VS-E5
VS-E5 to district road
District road
8 Pipeline crossing (PL05)
District road to Provincial road

valve will be by constructing a new road from
the existing village road.
Conventional construction. The pipeline route
passes through paddy fields and crosses some
village and district roads; access is therefore by
ROW. The route passes pipe lay down area LD
07
Open cut, bypass to be constructed
Pipe lay down area LD 06 is also located at the
side of this Provincial road.
Conventional construction but possible wetland
construction during wet season, access via
ROW
Typical pipeline crossing, access via ROW and
village road
Typical pipeline crossing, access via ROW and
village road
Wetland construction, predominantly through
paddy fields, access via ROW
Wetland construction. This area is located in
relatively wettest part of pipeline route. Access
via ROW.
Wetland construction through paddy fields,
access via ROW
Conventional construction through paddy fields,
access via ROW.
Valve No.4 (check valve) will be buried.
Typical pipeline crossing
valve will be by constructing a new road from
the existing village road. This area will also be
used as a pipe lay down area LD 05
Wetland construction, passing trough paddy
fields.
Bored
Bored
Conventional construction through paddy fields;
access through ROW. The area at Kp.59.293
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Pipeline
Kilometer Post

Description
Construction Method
will also be used as pipe lay down area LD 03
56.083
59.293
59.293-62.365

Provincial road crossing,
Tuban-Surabaya
Provincial road to edge of
forest
62.365-67.886
Edge of forest to district road

crossing
67.882
67.886
District road
67.886-69.653
69.653
69.653-70.399
70.399-71.323
71.426
District road to village road

Village road & start of
congested area
Congested area
Village road and end of
congested area.
Provincial road crossing &
6 pipeline crossing (PL08)
71.323-71.445 &
71.472
9.4
Conventional construction

Irregular contour, bored crossing.
Conventional construction, lightly forested area;
access via ROW
Wetland construction, this area consists mainly
of paddy fields with creek and village road
crossings.
Open cut, bypass to be constructed. This area
will also be used for pipe lay down area LD 02
Wetland construction, mainly through paddy
fields. Access via ROW
Specialist construction, access via ROW
Specialist construction, access via ROW
Paddy fields and unused shrimp ponds.
Conventional construction mixed with wetland;
access via ROW.
Bored. There will also be a pipe lay down area
here LD 01; access from the Provincial road.
The Manual Valve and Motor Operated valve
will both be buried.
ONSHORE PIPELINE BUOYANCY CONTROL

In order to keep the pipeline in place during installation, buoyancy control is required when the
pipeline route crosses free standing or flowing water (such as a river crossing).
For this Plan, the method selected to control this buoyancy is continuous concrete coating but the
construction contractor might opt for another stabilization technique such as concrete saddles. The
areas that potentially need concrete coating along the export pipeline route are rice paddy fields
(that cannot be dewatered) and waterway crossings. Concrete coating is not required in paddy field
areas where the trench can be pumped during installation. Waterway crossings and all areas
where a wet installation is anticipated require concrete coated pipe (refer to alignment sheets).
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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
CONSTRUCTION EXECUTION STRATEGY OVERVIEW

The construction strategy for the installation of 71 Km of 20-inch thermally insulated pipe is based
on the route illustrated on the Pipeline Alignment Sheets (49 Sheets) and references mentioned in
section 9.1. The majority of the pipeline will be installed using conventional onshore pipeline
construction; however, some sections are installed by HDD and others maybe installed using push
pull technique and/ or equipment suited for wet areas.
10.1
Kp. 0.000 to Kp. 7.497

The 1st segment is from the Pig Launcher site at CPF to the entry point of HDD No.1. The pipe will
be installed using conventional onshore pipeline installation through paddy fields, a few creeks,
power cable, a river, and two gravel MCL roads.
10.2
Kp. 7.497 to Kp. 8.072

The 2nd segment is a Horizontal Directional Drill under a village road and the Kalitidu river
10.3
Kp. 8.072 to Kp.24.153

The 3rd segment is from the exit point of HDD No.1 to entry point of HDD No.2. The pipe will be
installed using conventional onshore pipeline installation through paddy fields, gravel roads,
ditches, district roads and a river.
10.4
Kp.24.153 to Kp.24.558
The 4th segment is a HDD under an operational railway and Provincial road.
10.5
Kp. 24.558 to Kp.29.898

The 5th segment is from the exit point of HDD No.2 towards the entry point of HDD No.3. It
includes the VS-E2. This area is relatively low and passes by the Petrochina facility, the
construction contractor might choose to use push pull construction technique here.
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

The mainline welding spread (MLWS) will be mobilized via ACS 22B and incursion will start from LD
15 towards CPF. Then the spread will turn around and proceed towards the East (Note: the tie-in
between the onshore pipeline and CPF will be performed by the CPF construction contractor). As
this is relatively high ground the pipeline construction will be done by conventional method. Any
roads, rivers, ditches, etc. will be crossed as indicated on the alignment sheets and crossing matrix.
Temporary bypasses will be constructed during the preparation phase at ACS 22A & 22B, ACS 21.
Meanwhile the HDD spread will be mobilized to HDD entry point No.1 via ACS 21. LD 13 will be
used to stage and prepare the HDD drilling pad.
4 weeks before the mobilization of the HDD spread the mini mainline welding spread (MMWS) will
be mobilized to the area after the exit point of HDD No.1 (Kp.8.072). The mini mainline welding
spread will be mobilized via ACS 22A. It will proceed to the exit point by incursion into the ROW at
LD 12 and start fabricating the HDD string. Once the HDD string is completed it will be pre-tested.
Once the pre test on the HDD string has been completed, the mini mainline welding spread will
move to the next HDD exit point location (Kp.24.558)
Upon completion of reaming, the prepared HDD string will be pulled in the hole. Once the pull has
been completed the pipe will again be tested. Upon successful hydro testing, the HDD spread will
be demobilized to the next HDD entry point at Kp.24.153.
By this time the mainline welding spread will have reached the HDD entry No.1 and will perform the
tie-in between mainline pipe and HDD.
Once that is completed the MLWS will be transported out by ACS 21 and back into the ROW by
ACS 20A.
11.1
Temporary workspace & access

Access Roads: ACS 21, 22, ACS 22A & ACS 22B (MCL Roads) to transport pipe.
Temporary workspace is located at:
KP 0.843 (LD15) : On the ROW next to MCL gravel road
KP 1.472 (LD 14) : On the ROW next to MCL gravel road
KP 7.565 (LD 13) : On the ROW (No stacking here as to minimize disturbance to residential area
Kalitidu).
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12.0

This is a HDD under a village road and Kalitidu river. The HDD spread will be mobilized via ACS
21. The drill pad will have been prepared during the preparation period before the actual start of
project.
As mentioned in section 11.0, the mini mainline welding spread will have prepared the HDD string,
ready to be pulled into the hole.
On completion of the hydro testing activities, the HDD spread will be demobilized via ACS 21 and
move to the next drilling location (see section 13)
12.1

Access Road: ACS 21
Temporary workspace is located at LD 13.
Note that the bridge encountered on ACS 21, nearest to the HDD entry point, will have to be
reinforced. This work will be done during the pre construction phase by the Infrastructure
preparation and renovation team.
KP 7.565 (LD 13) : On the ROW (No stacking here as to minimize disturbance to residential area
Kalitidu) next to the village road
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13.0

After completion of the tie-in between mainline pipe and HDD entry point at HDD No.1, the MLWS
will be mobilized via ACS 20A. Where ACS 20A crosses the ROW the MLWS will proceed into the
ROW going West towards the exit point of HDD No.1. Once it has arrived there (and to avoid the
mobilization of the tie-in spread to this point) it will tie in with the HDD string and resume
conventional laying operation back towards LD 12.
As this is relatively high ground the pipeline construction will be done by conventional method. Any
roads, rivers, ditches, etc. will be crossed as indicated on the alignment sheets and crossing matrix.
Temporary bypass will be constructed during the preparation phase at ACS 20A, ACS 19 & ACS18.
Prior to the arrival of the MLWS, the tie-in spread will have prepared the area for VS-E1. Now, the
MLWS continues its way Eastwards. Meanwhile the hydro test spread will clean and test the
complete section between HDD exit #1 towards Kp.0.000 and later HDD exit #1 towards VS-E1.
After preparation for installation of the valve (VS-E1) and related civil activities, the tie in spread will
move to its next location, namely the tie in between mainline pipe and HDD at HDD entry #2.
VS-E1 will be installed later, once the section between VS-E1 and VS-E2 has been cleaned and
hydro tested.
The 2 major road crossings will be encountered at Kp.20.430 (RDX 02) and Kp.21.778 (RDX03)
bypasses will have been constructed here during the preparation period.
The MLWS will continue following the ROW up to the HDD entry point of HDD No.2, once arrived
there, it will be loaded onto trucks and transported to LD 07 (Kp.32.456) via ACS14, see section 16.
13.1

Access Road: Via District Road (Bojonegoro Tuban), then ACS 20A
Kp. 12.301 (LD 12): On the ROW next to a village road
Kp. 20.430 (LD 11): On the ROW along district road
Kp. 24.287 (LD 10): On the ROW along Provincial road
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14.0

This is a HDD under an operational railway and busy Provincial road. During the preparation
phase extensive preparations will have been conducted to allow access for the HDD spread over
the railway. Phone and power cables will have been re-routed and temporary access road
constructed leading from the Provincial road (over the railway) and to the HDD entry point. The
HDD spread will be mobilized via ACS 17 during night time hours. The drill pad will have been
prepared during the preparation period before the actual start of project.
After the mini welding spread completed the work for HDD string #1, it moved away and prepared
the string for HDD #2. Mobilization of this spread was done via ACS 16 and incursion into ROW
towards the HDD exit point at Kp.24.558. The same spread would have installed the section from
LD 09 to the HDD exit.
After the drill and successful post pull hydro testing, the tie-in spread will standby to make the tie-in
between the HDD entry #2 and the main line. Once the tie-in is completed, the spread will move to
the tie in between main line and HDD entry #3 (see section 15).
Meanwhile, hydro test team will clean and test from HDD entry #2 towards VS-E1, Valve E1 can
then be installed. Later, the hydro test team will clean and test from HDD entry #2 towards HDD
entry #3.
14.1

Access will be obtained via the Provincial road. Extensive preparatory work would have been done
here prior to start of project (see paragraph 13.0)
KP 24.287 (LD 10):
Across the railway, reachable by new constructed temporary access road.
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15.0

This section is located in a relatively low area and the construction contractor might choose to use
push pull technique or wet land construction here. Whatever happens, it is likely that daily
productivity here will drop by 30%.
The mini mainline welding spread will have moved here after completion around HDD exit #1 and
will fabricate both the paddy string and the HDD string for HDD No.2.
It will first do an incursion from LD 09 towards the HDD exit point and then turn around. Once back
at LD 09, it will cross the road and continue towards the North, pass the Petrochina well pad and
up to the road (RDX 05) which will be crossed by open cut. A temporary bypass will have to have
been constructed during the preparation phase.
After that, the mini mainline welding spread will continue towards valve station VS-E2 (Kp.29.686).
The valve location will be prepared and civil work completed. Then the spread will move on to Kp.
29.898, where the HDD entry for HDD #3 is located.
Once reaching this point, the cleaning and hydro testing of HDD entry #2 towards VS-E2 can be
performed. After completion the tie-in between HDD entry #2 and main line can be made. The
hydro team spread then moves towards the HDD entry #3.
15.1

Access will be obtained via the ACS 16 (also used by Petrochina).
KP 26.883 (LD 09):
On the ROW next to the road
KP 29.652 (LD 08):
On the ROW next to the road and near to VS-E2 station.
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16.0

This is a HDD under the Bengawan Solo River. The HDD spread will be mobilized here after the
completion of the Railway and Provincial road crossing. During the preparation phase,
preparations will have been conducted to prepare the drilling pad. The HDD spread will be
mobilized from the district road over the ROW, a temporary access road will have been
constructed here
After the mini welding spread completed the work for HDD string #2, it moved away and prepared
the string for HDD #3. Mobilization of this spread was done via ACS 14 and incursion into ROW
towards the HDD exit point at Kp.30.325. The string will be prepared and pre-tested.
The tie-in between HDD entry #3 and main line will be performed last, so that water from the
Bengawan Solo River can be used to clean and hydro test all sections north of the Bengawan Solo
River.
Once the drill has been completed the pipe will again be hydro tested, after which a manifold will
be installed to pump the water into the next section (VS-E3 to VS-E4)
16.1
Temporary working space and access

Access to HDD entry point will be obtained via district road south of the HDD entry point and
temporary road.
KP 29.652 (LD 08): On the ROW next to the road.
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17.0

This section will start off with the HDD exit of HDD #3 and leads to valve location VS-E4. The
pipeline follows relatively high ground mostly paddy fields, 2 district roads, some ditches, a river
and a few village roads. The valve station location will be prepared by the tie-in spread. The main
construction here will be conventional and performed by the MMWLS starting at the HDD exit and
up to LD 07, after having completed the HDD string No.3. At LD 07 the MMWLS will be extracted
and the section from LD 07 to Kp.38.888 will be performed by the MLWS, which will do an incursion
into the ROW from LD 07 proceeding North. Once Kp.38.888 is reached the pipe need to cross a
provincial road. A bypass will need to be constructed here, prior to arrival of MLWS.
The cleaning of this section will be done pumping water from the HDD entry point #3 all the way up
to VS-E4.
17.1

Access to HDD exit point #3 will be obtained via ACS 14 and following the ROW. Access to the
North will also be via ACS 14 (towards Kp.38.888) and then by the ROW. (ACS 15 is not suitable
for heavy equipment)
KP 32.456 (LD 07): On the ROW next to ACS 14
KP 38.888 (LD 06): On the ROW next to Provincial road from Bojonegoro to Tuban.
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18.0

Once the MLWS crosses the Provincial road from Bojonegoro to Tuban it will enter the start of the
wettest section of the route, it will be entering the floodplain of the Bengawan Solo River.
Construction for this area can start with conventional construction and later progress to possibly
push pull or wetland construction. The route crosses the 8 Mudi pipeline at 39.950, a flood
protection dyke at Kp.43.087 and then reaches higher ground again at around Kp.49.000.
Cleaning of this section will again be done from HDD entry point #3.
18.1

Access to will be obtained by crossing the Provincial road from Bojonegoro to Tuban and following
the ROW.
KP 38.888 (LD 06): On the ROW next to Provincial road from Bojonegoro to Tuban.
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19.0

Once the MLWS spread reaches Kp.49.000 it will be coming onto higher ground again and
encounter check valve station VS-E4. This valve station will have been prepared by the MMLWS
after having completed the line from HDD exit #3 to ACS 14. Cleaning and hydro testing of this
section will be done from HDD entry #3 towards VS-E4. After hydro test, a manifold will then be
installed at the VS-E4 end, so in the future the water (which is in the pipe) can be pumped into the
section from VS-E4 to the shoreline. Valve VS-E3 can now be installed. VS-E4 will be installed
after cleaning and testing of the next section (VS-E4 to VS-E5).
The MWLS will continue north where it will come across the next valve station, VS-E5 (Kp.51.768),
located at the south side of the district road Regel to Tuban. This area also functions as LD 05. The
valve station will be supplied with an access road to a small village road that is a branch of the
Provincial road. This valve station will also have been prepared by the MMLWS spread before
moving to VS-E4.
Cleaning and hydro testing of the section VS-E4 to VS-E 5 will now be performed, by using water
from the Bengawan Solo River. The valve VS-E4 can then be installed; this will ensure the water
supply to the North of this valve. At the VS-E5 location a manifold will provide water from VS-E4
towards the shoreline.
Upon reaching the district road, the road will crossed by open cut (RDX 09). A bypass will have
been constructed here in preparation of this crossing. After having crossed the road, the MLWS will
continue north. The tie in spread will move in and perform preparations for the tie-in work at VS-E5
and the road crossing. MMLWS will have completed work around VS-E4 and will have moved to
Kp.67.792 where it will start conventional laying to the east of the district road and towards the
congested (village area)
The MLWS is now moving north towards Kp.55.587 where it will encounter the same district road
again. Here however, the pipe will be tied in to the pre installed bored crossing (RDX 10) by the tiein team that has by now completed the tie-in at RDX 09. This bore will have been done in
preparation and prior to arrival of the main MLWS. The bore crosses under the district road and 10
Petrochina pipeline. It must be noted here that the 2007 geotechnical survey indicated limestone
deposits at -2.25 meter (CPT 25).
Once the spread has moved to the opposite side of the road, it will continue conventional
construction towards the north. The area constitutes mainly of paddy fields but limestone deposit
has been encountered (see section 9.2). The tie-in spread will perform the tie-ins at the bored
crossing at Kp.55.663 (RDX 10).
Now the spread moves towards the Provincial road between Tuban and Surabaya (RDX11). This is
a main road and therefore heavily trafficked. For this reason, the road will be crossed by a bore,
which will have been completed prior to arrival of the MLWS.
The MLWS will move across the road and is now entering a forestry area. It starts off with scattered
trees and moves trough young forest towards the north. The construction will be done in the
conventional way. The edge of the forest is at approximately Kp.62.365 where construction will
encounter the start of a wet area again as the area starts coming nearer to the coast. The ground
conditions change back again to paddy fields. The MLWS continues constructing to the north then
at Kp.67.200 takes a turn to the right, passes LD 02 (67.886) and stops at the road. There the tie in
will be made to that part of the line already installed by the MMLWS that started here earlier (after
BANYU URIP PROJECT
19 Feb. 2008
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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

Access to this part of the pipeline route will mainly be by following the ROW. On those places
where the ROW crosses main roads lay down areas are staged and access possible via the main
road. The ROW is criss-crossed by smaller village roads, which can be used for small vehicles.
KP 51.833 (LD 05): On the ROW next to District road from Bojonegoro to Tuban.
KP 55.663 (LD 04): On the ROW next to District road from Bojonegoro to Tuban.
KP 59.293 (LD 03): On the ROW next to Provincial road Tuban barat to Surabaya
KP 67.886 (LD 02): On the ROW next to District road (ACS 01A)
KP 71.421 (LD 01): On the ROW next to Provincial road Tuban to Gresik & Surabaya
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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):
Project Quality Plan

This document is the basis of the quality aspect for the project execution. This document
may be developed on an existing Contractor quality plan. However, the contents shall
comply with the requirements as stipulated in Appendix A of the Upstream Project Quality
Assurance General Requirements document.
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..
Inspection and Test Plans (ITPs)

Contractor shall perform inspection and testing in accordance with the ITPs approved by
Company. ITPs shall be developed in compliance with Appendix B of the Upstream Project
Quality Assurance General Requirements document.
As built documentation.
Pre commissioning documentation
Contractor shall perform the following activities (including document preparation) as per the
specific requirements for QA / QC:
Quality Audits
Design Control
Inspection & Testing
Quality Documentation
Worthiness of Installation and Equipment Operation Certification
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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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19 Feb. 2008
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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:
Construction Completion Procedure (Transfer from Construction to Static-Commissioning)
Motors Run-in Test
Commissioning Procedure for Lines Drying Out
Electrical Checking & Power-Up and Tests
Contractor shall refer to document number IDBU-WO-WPZZZ-0004 Systemisation, Schedule &

Precedence Network for Commissioning for more information.
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19 Feb. 2008
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23.0
ELECTRICAL & INSTRUMENTATION

One component of construction contractors work scope will be the installation of the E&I for
control of the valves and other monitoring equipment. It is assumed that a specialized
subcontractor will perform this work under the umbrella of the main construction contractor.
Civil works, such as the installation of the concrete foundations for the pig launcher, pipe supports,
installation of fencing, buildings, access roads and the like will be performed by the main
construction contractor using the Infrastructure preparation and renovation spread in combination
with the tie-in spread
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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
RESTORATION AND RE-VEGETATION

Prior to construction a survey will be done to identify environmental conditions along the ROW. It is
highly recommended that aerial photography is used as to establish an environmental base line.
During construction, the backfill and restoration spread will follow the main line welding spread
return the surface of the land to its original condition. Care will be taken that the backfilled trench
will be crowned as to avoid the creation of water channels.
Final Survey will be done to check the restoration and vegetation.
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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.
From this project the lessons learned consist of:

There should have been one large sized map covering the complete pipeline route indicating
terrain conditions.
A geotechnical engineer/ surveyor should have been part of the FEED team to analyze
geotechnical reports and assist/ advise the FEEP personnel.
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ATTACHMENT A
Crossing matrix
BANYU URIP PROJECT

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ATTACHMENT B
March Chart
BANYU URIP PROJECT

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32
BANYU URIP PROJECT
19 Feb. 2008
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Document Checklist
Project:
Banyu Urip Project
Job No:
140099.01
Document Title:
Onshore Construction Execution Plan
Document Number:
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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Checker
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Approver
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Signed:
Originator
Checker
Proj. Eng. / Approver
QA Checker
QA
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ISSUED FOR USE

ISSUED FOR APPROVAL

ISSUED FOR COMMENT

BANYU URIP PROJECT

Mobil Cepu Limited

Non-Technical Document Management

MPI: COMPANY USE ONLY

BANYU URIP PROJECT

ONSHORE CONSTRUCTION EXECUTION PLAN

REVISION MODIFICATION LOG

Issued for Comment

BANYU URIP PROJECT

ONSHORE CONSTRUCTION EXECUTION PLAN

Codes & Standards

SAFETY, HEALTH, ENVIRONMENTAL, SECURITY QUALITY

Emergency Response Plan

Emergency Evacuation Plan

COMPANY SCOPE OF WORK

Procurement and supply of LLI

Worthiness Certification of the Work (SKKP)

BANYU URIP PROJECT

ONSHORE CONSTRUCTION EXECUTION PLAN

WORKFORCE, ACCOMMODATION AND TRANSPORTATION

TRANSPORTATION AND STAGING OF PIPE & COMPANY SUPPLIED ITEMS

Transportation and staging of pipe

Transportation and storage of Company supplied items

RECOMMENDED CONSTRUCTION METHODS

Basis for recommended construction methods

Assumed construction methodologies

ONSHORE PIPELINE BUOYANCY CONTROL

CONSTRUCTION EXECUTION STRATEGY OVERVIEW

10.1 Kp. 0.000 to Kp. 7.497

10.2 Kp. 7.497 to Kp. 8.072

10.3 Kp. 8.072 to Kp.24.153

10.4 Kp.24.153 to Kp.24.558

10.5 Kp. 24.558 to Kp.29.898

10.6 Kp.29.898 to Kp.30.325

10.7 Kp.30.325 to Kp.38.888

10.8 Kp.38.888 to Kp.49.000

10.9 Kp.49.000 to Kp.69.653

10.11 Kp.70.399 to Kp.71.472

KP.0.000 TO KP.7.947 CONSTRUCTION PLAN

11.1 Temporary workspace & access

KP.7.497 TO KP.8.072 CONSTRUCTION PLAN

12.1 Temporary workspace & access

KP.8.072 TO KP.24.153 CONSTRUCTION PLAN

13.1 Temporary workspace & access

BANYU URIP PROJECT

ONSHORE CONSTRUCTION EXECUTION PLAN

KP 24.153 TO KP 24.558 CONSTRUCTION PLAN

14.1 Temporary workspace & access

KP 24.558 TO KP 29.898 CONSTRUCTION PLAN

15.1 Temporary workspace & access

KP 29.898 TO KP 30.325 CONSTRUCTION PLAN

16.1 Temporary working space and access

KP 30.325 TO KP 38.888 CONSTRUCTION PLAN

17.1 Temporary working space and access

KP 38.888 TO KP 49.000 CONSTRUCTION PLAN

18.1 Temporary working space and access

KP 49.000 TO KP 71.472 CONSTRUCTION PLAN

19.1 Temporary working space and access

21.1 Pipeline sections