Muara Bekasi Rawa Maju Onshore Gas Distribution Pipeline

South Sumatera - West Java Gas Pipeline Project Phase II Design Basis Manual Pipeline Onshore

DESIGN BASIS MANUAL PIPELINE - ONSHORE

TABLE OF CONTENTS

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0

INTRODUCTION DEFINITIONS ENVIROMENTAL CONDITIONS CODES, STANDARDS AND SPECIFICATIONS PRECEDENCE PIPELINE ROUTING PIPELINE DESIGN LINE PIPE PIPELINE COATING HYDROSTATIC TESTING

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Muara Bekasi Rawa Maju Onshore Gas Distribution Pipeline

South Sumatera - West Java Gas Pipeline Project Phase II Design Basis Manual Pipeline Onshore

1.0

INTRODUCTION This document describes the design basis for Muara Bekasi to Rawa Maju section of Gas Distribution Pipeline.

2.0

DEFINITIONS The following words shall have the meaning indicated when used herein: PGN PROJECT II Contractor Sub-Contractor Pipeline Construction Contractor selected by PGN The party(s) that carry(s) out all or part of the design, procurement, installation and testing of the system(s) as specified by the Contractor The party which supply material materials, equipments, technical documents/drawings and services to perform the duties specified by PGN. Indicates a mandatory requirement Indicates a strong recommendation to comply with the requirements of this document. PT. Perusahaan Gas Negara (Persero) Tbk. South Sumatera - West Java Gas Pipeline Project Phase

SUPPLIER/VENDOR

SHALL SHOULD

The term PGN is also synonymous with EMPLOYER 3.0 ENVIRONMENTAL CONDITIONS The climate is tropical monsoon, which is characterized by hot and humid condition throughout the year. There are two distinct seasons the dry season and rainy season. The Rainy Seasons covers month period from November to May. The Dry Seasons typically occurs between June and October. Temperature and Pressure Ambient Temperature Maximum Minimum Average Relative Humidity Maximum Minimum Average Rainfall Average Annual Maximum (day) Wind Maximum wind speed Muara Bekasi Rawa Maju 89.60 deg F 76.82 deg F 83.30 deg F 90 % 75 % 78 % 1619 mm/year 365.2 mm/day 3 m/s

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Muara Bekasi Rawa Maju Onshore Gas Distribution Pipeline

South Sumatera - West Java Gas Pipeline Project Phase II Design Basis Manual Pipeline Onshore

4.0

CODES, STANDARDS AND SPECIFICATIONS This Design Basis Manual was prepared based on following codes and standards. Unless otherwise noted, references made herein to codes, standards and specifications are to be the latest edition. Codes, standards and specifications are listed in the parts of the Design Basis Manual to which they apply. AASHTO American Association of State Highway and Transportation Officials Standard Specification for Highway Bridges API American Petroleum Institute RP 14E RP 521 RP 1102 Spec. 5L Spec. 6D STD 1104 ASME Design and Installation of Offshore Production Platform Piping Systems Guide for Pressure Relieving and Depressurizing Systems Steel Pipelines Crossing Railroads and Highways Specification for Line Pipe Specifications for Pipeline Valves (Gate, Plug, Ball and Check Valves) Welding of Pipelines and Related Facilities

American Society of Mechanical Engineers B31.8 Gas Transmission and Distribution Piping Systems

ASME/ANSI

American Society of Mechanical Engineers / American National Standard Institute B16.5 B16.9 Pipe Flanges and Flanged Fittings FactoryMade Wrought Steel Butt Welding Fittings

NACE

NACE International RP 0169 Control of External Corrosion on Underground or Submerged Metallic Piping Systems

GOVERNMENT REGULATION Decree of Minister of Mining and Energy Concerning Oil and Gas Pipeline Occupational Safety SJ2-00-M-SP-010-A4 SJ2-82-L-SP-001-A4 SJ2-00-S-BD-001-A4 5.0 SJ2-00-S-BD-002-A4 PRECEDENCE Specification for Ball Valves Specification Linepipe Onshore Muara Bekasi Rawa Maju Design Basis Manual-Civil Design Basis Manual-Soil Erosion Control Measures
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Muara Bekasi Rawa Maju Onshore Gas Distribution Pipeline

South Sumatera - West Java Gas Pipeline Project Phase II Design Basis Manual Pipeline Onshore

Any case of apparent conflict between the requirements of this Specification and any other relevant documents shall be brought to the PGNs notice. Unless otherwise agreed the following descending order of precedence shall apply: 1. Equipment Data Sheet (where applicable) 2. This specification 3. Other Project Specification 4. PGNs Standard/Specification 5. Other international Code and Standards 6.0 PIPELINE ROUTING Based on the results of preliminary pre-construction survey data, the proposed route of Muara Bekasi to Rawa Maju is indicated on the route alignment drawing with the following exceptions and provisions; i) The Contractor is required to undertake additional mapping survey between KM 11 to KM 27 where there is a 30 m corridor within which the pipeline shall be constructed. Between KM 27 to KM 34 where construction space becomes restricted, the Contractor shall propose a route to PGN for approval which suites the Contractor preferred construction methods, always providing that the Contractors selected route generally follows hat shown on the PGN alignment sheets.

ii)

For other sections of the route the Contractor may propose re-alignments to the route to improve constructability, improve pipeline safely or to satisfy environmental or socioeconomic concerns. All proposed pipeline alignment changes shall be submitted for PGN approval. 7.0 PIPELINE DESIGN 7.1 General The pipeline shall be designed in accordance with ASME B31.8 for onshore portion. The design pressure and temperature of the pipeline and various piping systems shall be in accordance with the following: Location Muara Bekasi Rawa Maju 7.2 Onshore Requirements 2.1.1 Sectional Valve Sectional valve shall be installed in the new distribution pipelines at the time of construction. The spacing between valves on a new distribution line shall refer to ASME B31.8 and PGN requirements as shown in Location Sectional Valve Muara Bekasi Rawa Maju (Drawing No. SJ2-82-L-DG-000-A3) Blow-down valve shall be provided so that each section of pipeline between main line valves can be blow down. Sectional valve design shall meet the requirements of API Spec. 6D and shall be suitable for underground and above ground installation. Design Temperature Design Pressure

150o F

720 psig

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Muara Bekasi Rawa Maju Onshore Gas Distribution Pipeline

South Sumatera - West Java Gas Pipeline Project Phase II Design Basis Manual Pipeline Onshore

2.4.2

Temporary Pig Traps A pipeline should be designed to allow internal inspection using pigs. Consideration should be given to equipment for loading and unloading pigs and to the selection of bends, valves, tees and other components, so as to permit effective and safe pigging. Care should be taken in the operation of temporary pig launcher and receiver during the test and these should not be opened unless the pressure in launcher or receiver is zero. Test end manifolds shall incorporate end enclosure and bypass valves and piping to enable cleaning constructed pipeline and gauging pigs to be launched and received in continuous series. Test ends shall be fully welded to the pipeline. Temporary pig traps shall be removed following the completion of the pigging program.

7.2.3 Ditch Configuration The minimum depth of cover over the onshore pipeline through various types of soils and land usage shall be as indicated in the typical pipeline installation drawings, unless otherwise specified on the alignment sheets. Depth of cover is measured from the top of pipe (and coating, as applicable) to the normal ground or streambed elevation, excluding the ditch crown. Calculations shall be performed to ensure that adequate cover is provided at over bends, sag bends and side bends to resist the tendency of the pipeline to move. Bedding and padding shall be used in the pipeline ditch to protect the pipelines corrosion-resistant coating and provide continuous uniform support and lateral restraint to the pipe. Ditch spoil or materials obtained nearby may be used as bedding and padding, with screening being used where necessary to remove rocks and achieve a gradation that does not damage the pipe coating. Stones or rocks larger than 15 millimeters diameter in the bedding and padding shall be prohibited. A minimum 15 centimeters of bedding shall be placed under the pipe in rock ditch and padding to a level of at least 15 centimeters above the installed pipe. Ditch breakers shall be designed and installed in accordance with Design Basis Manual-Soil Erosion Control Measures (Doc.No SJ2-00-S-BD-002-A4) to control the water flow in the pipeline ditch on slopes where backfill washout is anticipated. 7.2.4 Crossings 7.2.4.1 Road and Rail Crossings Pipeline crossings of roads and rail shall be designed as uncased crossings in accordance with ASME B31.8 and API RP 1102. The Contractor shall recommend additional protection as his calculations may determine. Pipe wall thickness at road and rail crossings shall be determined on a case-by-case basis taking into consideration pipeline Location Class and appropriate Design Factor. In cases where heavier pipe wall is required compared to pipe wall thickness adjacent to crossings), the thicker pipe shall extend between the rail or road right-of-way limits (if they exist) or a minimum 12 meters from the outside lane on each side of the roads centerline. Crossings shall be installed to ensure a minimum 2.0 meters of cover from the top of the pipe (or pipe coating) to the traveled surface of the rail or road and a minimum of 1.2 meters to the bottom of the adjacent ditches. The angle of crossing shall be as
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Muara Bekasi Rawa Maju Onshore Gas Distribution Pipeline

South Sumatera - West Java Gas Pipeline Project Phase II Design Basis Manual Pipeline Onshore

close to perpendicular as practical. Pipe stress calculations shall be performed to assure that sufficient pipe strength is provided at the rail or road crossing due to anticipated design loads. The AASHTO HS20-44 truck shall be used as a design load with a safety factor of 1.25. The Design Factors for allowable stress to be used in conjunction with API 1102 shall be as follows: Circumferential (Hoop) Stress shall be in accordance with API 1102. Design factor, temperature derating factor and longitudinal joint factor according to ASME B31.8 latest edition. Total Effective Stress shall be less than or equal to Specified Minimum Yield Strength (SMYS) x Design Factor (F) as prescribed in ASME B 31.8 latest edition. Circumferential and Longitudinal Cyclic (fatigue) Stress shall be in accordance with API 1102.

Pipe stress calculation shall be performed for both pressurized conditions at internal operating pressure equals to maximum allowable operating pressure (MAOP) and for un-pressurized condition at internal operating pressure equals to zero. The pipe horizontal deflections (ovality) due to combined effect of the external loads shall not exceed 3% of pipe outside diameter. Installation of road crossings may be achieved by boring or open cutting, depending on local regulations, traffic, and construction equipment availability. All paved roads and rail shall be installed by thrust boring or Horizontal Directional Drilling. Where boring or directional drilling are used, a mechanical protective coating shall be applied over the corrosion-resistant coating. The mechanical protective coating may consist of a thin concrete coating, an extra-thick corrosion-resistant coating, or another material subject to PGN approval. For the location of road and rail crossing refer to Topography and Alignment Drawing. 7.2.4.2 River, Stream and Canal Crossings Pipeline crossings of rivers and streams shall be buried. Crossing installation may be achieved by open cutting. The Contractor may propose appropriate alternative methods for these crossing. With PGN approval construction technique shall be selected based on, but not limited to, the following: 1. Specific site conditions, 2. Special environmental requirements, and 3. Stream velocity. For open cut crossings, continuous concrete coating or concrete weights shall be designed to provide a minimum of 10 percent negative buoyancy relative to the specific gravity of buoyant media. For HDD crossings the pipe shall be sited in firm stable subsoil to a degree where the overburden provides an adequate anchor which counters pipeline buoyancy. The use of external forces in pipe lowering operations, water filling of pipe will not be allowed.
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Muara Bekasi Rawa Maju Onshore Gas Distribution Pipeline

South Sumatera - West Java Gas Pipeline Project Phase II Design Basis Manual Pipeline Onshore

For directionally drilled river and stream crossings, special pipe stress and constructability considerations shall be given to selection of the pipe wall thickness to prevent pipe buckling and collapsing during pipeline installation and operation. Depth of cover shall be adequate to ensure the pipeline is not adversely affected by anticipated scour. Entrance and exit locations shall be located to account for anticipated bank migration. In all cases the Contractor shall present calculations to PGN proving the choice of anti buoyancy methods. There may be sections of route in the area of canals where the pipeline will be routed beneath and parallel to the canal and the Contractor shall adequately design for this condition. For the location of river and stream crossing refer to Topography and Alignment Drawing. 7.2.4.3 Crossings of Marshland, Flooding and Swamp Areas Pipeline installed in marshland, swamp areas, rice paddy fields, and other areas subject to routine flooding shall be buried. Special consideration shall be given to control pipeline buoyancy by applying continuous concrete coating, concrete weights or screw anchors to provide a minimum of 10 percent negative buoyancy relative to the specific gravity of buoyant media. In all cases the Contractor shall present calculations to PGN proving the choice of anti buoyancy methods. 7.2.5 SCADA System Pipeline features that shall be connected to the SCADA system include the Branchline block and shutdown valves located at stations. Information collected shall be reported to the Master Control Station located in Cilegon Station. The pipeline system shall be designed to operate as simply and maintenance-free as possible, with the flexibility to add remote control capabilities to remote valves in the future if necessary. To ensure worker safety, the facilities used in the pigging operations shall not be controlled remotely. 7.2.6 Signs and Markers Warning signs shall be installed at major road and river crossings and at each shoreline to identify the pipeline location and provide emergency contact information. Warning signs shall also identify roads, rivers and change of direction and be in dual languages (Indonesian and English). Aerial markers shall be installed at approximately 10-kilometer interval along the pipeline alignment to permit clear identification of the distance from the start of the pipeline by aerial reconnaissance. Kilometer markers shall be installed at approximately 1-kilometer interval along the pipeline for more precise identification of distance. 7.2.7 Right-of-Way 7.2.7.1 Acquisition Effort will be made to route the pipeline to minimize disruption of land used by the right of way. The Contractor shall reference ownerships and obtain permission to install the pipeline and to undertake a route survey
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Muara Bekasi Rawa Maju Onshore Gas Distribution Pipeline

South Sumatera - West Java Gas Pipeline Project Phase II Design Basis Manual Pipeline Onshore

to identify and negotiate an adequate Right of Way for the works including the demolition of property, the permanent or temporary removal of inhabitants and their property wherever so affected by the works and to pay all compensation arising from the process 7.2.7.2 Requirements The minimum proximity distance from normally occupied building of pipeline route is according to MIGAS regulation. Within the construction right-of-way, disturbance shall be kept to a minimum. Certain areas may have a reduced right-of-way width, such as on side slopes, in rock, and where constricted by man-made or natural structures. In such cases, special construction techniques may be required to install the pipeline. Maintenance of drainage patterns and erosion control on the right-of-way are of primary concern. Designs to mitigate the effects of the pipeline installation shall be incorporated. 8.0 LINE PIPE 8.1 General Line pipe mechanical properties required for the onshore will be as the followings (also refer to Linepipe Specification Muara Bekasi to Rawa Maju): Location Linepipe SMYS (Min/Max) Tensile Strength YS/TS Ratio Max Elongation % Min W.T Class 4 Approx.Horizontal length : : : : : : : : Muara Bekasi to Rawa Maju API 5L X-65 65,000/87,000 psi 77,000 psi 0.90 As per API Spec 5L Table 3 0.688 inch 34680 meters

Approximate horizontal length is taken from alignment sheet drawing. 8.2 Line pipe onshore Line pipe onshore will be manufactured, tested, and inspected in accordance with API 5L. Linepipe will be 32 inch API Grade X-65 with wall thickness to comply with the requirements of ASME B31.8. 9.0 PIPELINE COATING 9.1 Internal Coating The line pipe will be supplied with external corrosion-resistant coating and internal coating suitable for continuous service at 150 F. The coating will be shop-applied to all, but the pipe joint ends to allow welding in the field. 9.2 Corrosion Coating Three-Layer Polyethylene shall be utilized for external corrosion protection of the onshore pipeline. Physical properties of Three-Layer Polyethylene shall be accordance with National Standards of Canada CAN/CSA-Z245.21-M92. Weld joints shall be protected compatible material with the primary coating shrink
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Muara Bekasi Rawa Maju Onshore Gas Distribution Pipeline

South Sumatera - West Java Gas Pipeline Project Phase II Design Basis Manual Pipeline Onshore

sleeves, joint coating is designed to be field applied to the joints. 10.0 HYDROSTATIC TESTING The pipeline shall be hydrostatically tested in accordance with ASME B31.8 shall not exceed to 95 percent of the specified minimum yield strength (SMYS). The test pressure shall be minimum 1.4 times the MAOP (maximum allowable operating pressure). Water sources that can provide an adequate supply of clean fresh water shall be selected. Streams or rivers cannot be sources where more than 10 percent of the normal flow of the waterway would be required to satisfy the test section fill rate. Seawater may be used as a test medium if corrosion inhibitor chemicals are added. The Contractor may propose and submit chemical alternatives for PGN approval. Test section lengths shall be determined taking into consideration the source and quantity of the available test water, disposal sites for the test water, and the elevation difference between the high and low point in the test section.

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