PENGGANTIAN SUBSEA LOADING LINE TERMINAL BUNYU

DI PT. PERTAMINA EP ASSET 5 – BUNYU FIELD

Swamp Dredging Procedure

PT. PERTAMINA EP ASSET 5

Nama Jabatan Tanggal Tanda Tangan

Febri Iswanto Surface Engineer

Dohar J. Sihombing Engineering Asst. Manager

PT. ONASIS INDONESIA

A 13-Agustus-18 Issued for Review TH LR / MU AM

Rev Tanggal Deskripsi Disiapkan Diperiksa Disetujui

Dokumen No : PEP-AS5-BYU-SPL-PM-PEP-001 Kontrak No : 3900444263

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LEMBAR HISTORI REVISI

Rev. Tanggal Halaman Deskripsi

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DAFTAR ISI

1. INTRODUCTION 5
1.1. Background................................................................................................................... 5
1.2. Objectives..................................................................................................................... 6
1.3. Scope............................................................................................................................ 6
1.4. Associated Document...................................................................................................6
1.5. Pipeline Reference........................................................................................................6
1.6. Abbreviation.................................................................................................................. 7
1.7. Unit................................................................................................................................ 7
2. REFERENCES 8
2.1. Indonesian Regulations and Codes...............................................................................8
2.2. International Codes and Standards...............................................................................8
2.3. Project Documents and Others Reference....................................................................8
3. SUMMARY and CONCLUSIONS 9
3.1. Summary....................................................................................................................... 9
3.2. Conclusions................................................................................................................... 9
4. DESIGN DATA 10
4.1. Pipeline Design Life.....................................................................................................10
4.2. Geumetic Datum dan Coordinate System...................................................................10
4.3. Key Facilities Location.................................................................................................10
4.4. Pressure and Temperature..........................................................................................10
4.5. Pipeline Mechanical Properties...................................................................................11
4.6. Internal Corrosion Allowance.......................................................................................11
4.7. Manufacture Wall Thickness Tolerance.......................................................................12
4.8. Environment Data........................................................................................................12
4.8.1. Seabed Bathymetry (Water Depth)............................................................................12
4.8.2. Wave and Current Data.............................................................................................12
4.8.3. Seawater Parameters................................................................................................13
5. DESIGN CRITERIA and METHODOLOGY 14
5.1. Internal Pressure Containment....................................................................................14
5.2. Collapse Due to External Pressure..............................................................................15
5.3. Buckling due to Combined Bending and External Pressure........................................15
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5.4. Propagation Buckling..................................................................................................16

5.5. Load Case...................................................................................................................17
6. RESULTS 18
6.1. Pipeline Wall Thickness Verification Results...............................................................18
7. APPENDICES 19
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1. INTRODUCTION

1.1. Background

Bunyu Terminal is located on Bunyu Island, Bulungan Regency, North Kalimantan

province. Bunyu Island itself is located in the eastern of Sulawesi Sea, north-east coast of
North Kalimantan.

Bunyu terminal receives oil production from Bunyu Main Gathering Station and carry
100,000 barrels of oil to the tanker using a 1460 m loading lines twice a month. PT
Pertamina Asset 5 plans to replace the 16" export loading lines from the Bunyu Facility
Terminal to the Pipeline End Manifold (PLEM) because the existing facilities has been
operating since 1985. The existing 16" export loading lines at Bunyu Terminal are shown in
figure below.

Figure 1. – Existing 16” Export Loading Lines Pipeline

The purpose of this project is to replace the new Subsea Loading Line from the existing
Subsea Loading Line by installing 16" NPS new pipelines from the Bunyu Facility Terminal
to the End Manifold Pipeline (PLEM) with the length of ± 1460m, and also installing 1 set of
PLEM along with a new flexible hose as a replacement for existing PLEM and flexible hose.

The general scope of work in this work is as follows:

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1. Preparation and Permit

2. Engineering
3. Material Procurement
4. Material Fabrication
5. Pipeline Installation
6. PLEM Installation
7. Flexible Hose Installation
8. Comissioning & Testing
9. Flushing Loading Line Existing & Recovery Flexible Hose Existing
10. Maintenance

1.2. Objectives

verify the nominal wall thickness and material grade selected for subsea pipeline as part
of Bunyu Terminal Project. The minimum wall thickness required for pressure
containment, external collapse and propagation buckling is calculated in accordance with
ASME B31.4 and supplemented by API RP 1111

1.3. Scope

The purpose of this document is present the procedure for installing the 14” pipeline with
surface pull method from the PLB MITRASINDO 2 to the Tambak Lorok shore line using
single drum winch with 35MT capacity. The single drum winch shall be located
approximately 5m near at KP 198.245, whilst PLB MITRASINDO 2 shall be located at KP
197.145

1.4. Associated Document

Following table listed all documents that referred by and related to this report.
Table 1.4-1. Related Document

No. Document No. Description

MGS-R-262-16-SS01- Pre-lay Survey of Loading Subsea Pipeline For Crude
1.
FINAL-24-10-2016_R1 Oil Transport

1.5. Pipeline Reference

The Submarine pipeline and Riser that is required to be installed as part Bunyu Terminal
Project is described in table below.
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Table 1.5-2. Pipeline Reference

Pipeline OD
Description Origin Termination Service
(mm)
16” NPS
Bunyu Facility
Export Loading 406.4 PLEM Crude Oil
Terminal
Lines Pipeline

1.6. Abbreviation

The following abbreviations are applied throughout this document.

ASME American Society of Mechanical Engineers
API American Petroleum Institute
ASTM American Society of Mechanical Engineerings
ID Inner Diameter
OD Outer Diameter
PHE ONWJ Pertamina Hulu Energi Offshore North West Java
SMYS Specified Minimum Yield Strength
UC Unity Check

1.7. Unit

International Unit System (SI) shall be applied in this document, unless otherwise
noticed. Any conversion in parenthesis may be provided where appropriate
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2. REFERENCES

Unless the edition of any code, standard or document is specifically referenced, the
latest edition will apply. The following Government Regulation, Standard and Code,
shall be followed, but not limited to

2.1. Indonesian Regulations and Codes

1. 300.K/38/M.PE/1997 Occupational safety of oil and natural gas
pipelines
2. 84K/38/DJM/1998 Inspection guidelines and procedures for safety of
the plant, equipment and engineering of oil and
gas and exploitation of geothermal resources.
3. SNI 3473 Sistem Transportasi Cairan Untuk Hidrokarbon

2.2. International Codes and Standards

1. ASME B 31.4 Pipeline transportation systems for liquid
hydrocarbons and other liquids
2. API RP 1111 Design, Construction, Operation, and Maintenance
of Offshore Hydrocarbon Pipelines (Limit State
Design)
3. API 5L 45th Edition Specification for Line Pipe
2.3. Project Documents and Others Reference
1. MGS-R-262-16-SS01- Pre-lay Survey of Loading Subsea Pipeline For
FINAL-24-10-2016_R1 Crude Oil Transport
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3. SUMMARY OF SHOR PULL PROCEDURE

In general the Construction Superintendent has overall responsibilities for all push pull
operation while the onshore construction supervisor, barge master, and surveyor will
liaise with him to ensure the push pull operation is maintained as per planning and
requirement.

The push pull activity will start after the pre-trench activity and the onshore preparation
at Tambak Lorok site completed, and pipe haul barge ready at site. The pulling shall be
conducted by 35 Ton single drum winch at onshore site which will be located
approximately at KP 198.245.

The pipe will be welded on board MITRASINDO 2 start from KP 197.145, 1100 m in
front of land fall point (KP 197.145). Along 1100 m pulling, the pipes and the pulling
cable will be floated using 208 liters floatation drums as the buoyancy agent (16 drums
per joint pipe).

There will be a bamboo/wooden stake every 25m that will be staggered at both side of
shore approach portion trench area from KP 198.245 until KP 197.145. These bamboos
installed before pre-trench activity commenced as a border marking of trench area.
After the trenching operation completed, these bamboos will be kept in position to keep
the pipe align with the trench line when the pipe pulled from the onshore

4. PIPELINE DATA AND INFORMATION

4.1. Pipeline Characteristic

Table 4.1 – Pipeline Characteristic

Description Unit Subsea Pipeline

Pipeline Services - Gas

Design Life Year 20
Outside diameter mm 355.6
Pipeline wall thickness
mm 23.82
(Nominal)
Pipeline length - Approx. 1.745 km
Operating Pressure Mpag (psig) 13 (1885.491)
(1)
Hydrotest Pressure Mpag (psig) 20.41 (2960.22)
Design Temperature °C 0(min) - 60(max)
API 5L X65
Line pipe material -
(as per DNV OS F101)
Manufacturing Process - ERW
SMYS/SMTS MPa 450/535
Steel density kg/m3 7850
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Description Unit Subsea Pipeline

Young’s modulus MPa 207000

Poisson’s ratio - 0.3
Coefficient of thermal expansion /oC 1.17 x 10-5
Maximum Density kg/m3 77
3
Minimum Density kg/m 19
Note:
1. Hydrotesting pressure is 1.4 of Design Pressure

Table 3.2 – Pipeline Burial Status

Kilometer Post Burial Depth Trench Method

Description (From TOP)

Pre Trench + Post

KP 188.814 to KP 198.245 2m
Trench

4.2. Facilities Coordinates

The reference co-ordinate of the sectional pipeline relocation is listed as following

table:

Table 4.3 – Facilities Coordinate

Location Coordinate
Facility
Northin Eastin
g (m) g (m)
Start Point : KP 197.145 9 233 439
657.268 066.47
End Point : KP 198.245 9 232 438
630.072 668.06
4.3. Marine Spreads

Contractor will provides marine spreadsheet to support all activities during shore
pull work phase. Contractor will classify the marine spreadsheet according to
work phase as describe in the following table.

Table 4.4 – Marine Spread

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N
Vessel Name Vessel Purpose
o

1. MITRASINDO 2 Pipelaying Barge

2. MRP 11 Anchor Handling Tug

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5. TECHNICAL REQUIREMENT

5.1. General
During the mobilisation of the MITRASINDO 2, the following work status shall be ready:

 All works and procedures under this specification shall be subjected to inspection by
COMPANY/Representative. All the defective works not conforming to this
specification shall be repaired at cost of CONTRACTOR/SUB CONTRACTOR.

 COMPANY approval of CONTRACTOR/SUB CONTRACTOR procedures and

manufacturing process does not relieve the CONTRACTOR/SUB CONTRACTOR
from the obligation to provide products in accordance with this specification and other
application codes and specifications.

 The CONTRACTOR/SUB CONTRACTOR shall be responsible for all inspection and

testing as required by this specification.

 CONTRACTOR/SUB CONTRACTOR shall be fully responsible for Quality Assurance

and associated Quality Control process in accordance with requirements of purchase
order.

COMPANY has the right to inspect CONTRACTOR/SUB CONTRACTOR’s facilities to

determine the current condition of facilities and to confirm the facilities are capable
according to this specification.

5.2. Equipment and Tools

Make sure the major preparation below have been ready before initiation conducted:
 All equipment and specification shall be subjected to inspection by
COMPANY/Representative. All the defective works not conforming to this
specification shall be repaired at cost of CONTRACTOR/SUB CONTRACTOR.
 Personnel for push pull activity are as follow:
Position Quantity Remark
Onshore Personnel
Onshore 2 For two shift
Coordinator persons operation
Operation HSE 2
Coordinator persons
QA/QC Engineer 2
persons
Safety Officer 2
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Position Quantity Remark

persons
Surveyor 2
persons
Civil Work 2
Supervisor persons
Foreman 2
persons
Winch Operator 2
persons
Helper 8
persons
Offshore Personnel (on board MITRASINDO 2)
Offshore 1 person
Superintendent
Offshore 1 person
Supervisor
Field Engineer 2
persons
Operation HSE 4 Safety and Medic
Coordinator persons persons
QA/QC Persons 4 Inspector and
persons traceability
Safety Man 4
persons
Surveyor 7 1 Chip party and 6
persons Surveyors
NDT Man 10 Supervisor and
persons Interpreter
Construction 64 Welder, Rigger,
Crew persons Fitter, Helper,
Storeman, Crane
Operator,
Electrician, Radio
Operator
Diving Team 14 2 Supervisor, 2
persons Medic, 8 diver, 2
Technician
Marine Crews 20 2 Barge master, 4
persons winch operator, 2
mechanic, 2
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Position Quantity Remark

electrician, 2 oiler,
2 chief engineer, 2
HSE, 2 barge
owner reps, 2
tensioner operator
Catering Crews 20 Camp boss, cook
persons and utility

 Major equipment and tools used in push pull activity are :

Manpower Equipments
No Activity Classification Name of
s Equipment
1 Survey Field cord Measurement
and surveyor Probe
stacking Surveyor Echo sounder
Labour
2 Clearing &  Foreman Backhoe
Trenching  Oprtr
heavy
equipment
s
 Labour
3 Push pull :  Push pull - Winch
1. Pulling supervisor (single
the pipe  Surveyor drum 35
onshore  Safety officer Ton)
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2 .Floater  Civil work - Pulling

Installat supervisor Wire (1 ½”
ions  Welder IWRC 1100
3. Lower  Opt. heavy m),
& Lay equipments including

 Winch Operator wire lock /

 Welding Inspector shackle

between
 Labour
sectional
pulling wire
- Floater (16
ea every
joint for
pipe, 1ea
every 30m
for pulling
wire)
- Rubber
boat
- MITRASIN
DO 2 PLB
- Spudcan
Pontoon
- Messenger
Rope, 1 ¼”
polypropyle
ne.
4 Backfilling Foreman Backhoe,
Opt. heavy Pontoon
equipments
Labour
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6. DETAIL PROCEDURE

6.1. Preparation

Push pull activity will be commenced upon confirmation of readiness the below items:
Onshore Site Preparation
1. Standard arm excavator will be used to clear and level the general area of winch
and excavate the hold back anchor behind the winch location. This excavator will
be moved on the site via road.
2. Bench mark and bamboo stake at both side of the trench ROW to be built
staggered every 25 meters distance from KP 198.245 to KP 197.145 prior to
commencement of pre-trenching work and push pull.
3. Mobil lighting will be installed on site to support work in night at required area and
will be adjusted based on site condition. Mobil generator set will be used as power
source.
4. Safety zones will be marked. Safety zones as required for winch operator and
access space. These areas will be protected by using barricades. For safety
reason, trenched soil area will be protected using temporary fences.
Pre-trenching Work
Push pull activity will be commenced after the completion of pre-trenching work and
the pipe barge haul at site. Cofferdam is installed properly surrounding the facilities to
avoid flooded by sea current and sea wall is opened as necessary for access of the
pipe entering the ORF area. The detail and procedures of this pre-trenching works
including cofferdam, protection and reinforcement of cable tray and existing pipes
provided in Doc. KJG4-TLE-3300-02-OF-PR-003, Pre-trenching Procedure

6.2. Readiness of Equipment and Personnel

 Pipe lay barge has been arrived at site and make sure all required certificates are
available onboard such as under water work permit, Principle permit, any
calibration and certification of equipments that endorse by Migas, entrance permit
to Jakarta water territory, etc.
 Supporting vessel i.e. AHT, material barge & Tugs, crew boat and accommodation
barge are available on site.
 Supporting equipments i.e. diving, NDT, Crane, Welding machine, internal clamp,
Field Joint Coating, Catering have been on board
 Personnel including PMT and labors have been ready on board with two shifts
separation to support the push pull operation throughout completion until
commissioning of the project. All personnel should be ensured to hold sea survival
certificate and medical checked up, and sufficient certificate required as common
prevailing in any operation of offshore industry particularly for labors
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6.3. Pulling Winch and Hold Back Anchor Installation

The winches location shall be prepared to ensure that the dead load of the winch is
evenly supported and correctly aligned with the trench for pulling the pipe. The exact
position of the hold back anchor and linear winch positions will be staked out prior to
installation.
 Winch and power pack will be installed above pontoon.
 The pontoon then towed to landfall location at KP 198.245. The spudcan pile (4 ea) then
installed in every corner of pontoon.
 Install Anchor Hold Back behind the pontoon and connect to Winch using wire.
 Pre-tension will be done for each wire anchor, prior to commencement of push pull. The
final tension will be taken when first push pull conducted.
 Sequence of Operation
 Spud can pile installation
 Anchor Hold Back system installation
 Anchor pre-tensioning to the expected maximum tension required during push pull,
lowering and normal lay.
 Pulling winch installation and tie with the hold back anchor pile.
 Cut the anchor wire if required to suit the length

6.3.1. Function Test of the Winch

 If required, function test will be conducted in order to make sure winch to work
properly.
 1 ½” wire sling will be attached on the winch. On the other end, wire will be connected
to the pile/anchor/appropriate structure as the dead man anchor.
 After all arrangement ready, heave up the winch tension.

6.3.2. Guide Pile Installation

Using echo sounder, the pre-trenching can be monitored width and depth using the
following procedure:
 After all of trip pre-trenching performed by TSHD from 188.814 to 195.100 KP
surveyor will survey the result of pre-trenching, so we know actual the depth that
has been reached.
 During a survey conducted by the surveyor bathymetric, TSHD will stand by until
the surveyor finish survey (actual dredging produced).
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 On the plan by using TSHD, pre-trenching pas will be done approximately in four
passes, and each completed pass pre-trenching surveyor will return to the actual
measurement of the depth and volume produced.
 If the target has been reached, the pre-trenching work has been completed for
this area, but if the target is not reached then TSHD will be back next pass again
until the target is reached.
 Work pass shall start at KP 188.814 and TSHD shall continue pass until it
reached KP 195.100. The subsequent pass shall then return to KP 188.814. This
process will be repeated until the required trench depth is achieved.
 If required, shorter passes shall be undertaken to complete pre-trenching in a
piecemeal fashion.
 For the acceptance criteria can be completed if reaches dredging depth of 3
meter. The target of pipe burial is minimum 2 meters burial from Top of Pipe, refer
to drawing KJGI-PGS-3300-OS-DG-006 Rev 0).

Picture 13 : Sketch example design pass pre-trenching.

6.3.3. Post Trenching Survey

Final survey will be performing with echo sounder. Trenching depth shall have minimum
Company regulation (Refer to Drawing KJG1-PGS-3300-OS-DG-006 Rev 0). It will also
with the MIGAS depth of cover regulation. The recorded data shall be documented and
converted into bathymetric/topography maps and longitudinal profile

7. APPENDICES

• Appendix 1 : 16” Pipeline Wall Thickness Verification Calculation

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LAMPIRAN A

16” Pipeline Wall Thickness Verification Calculation