Contract High Technology Steam field Civil Construction and Infrastructure Works Stage 2 Date : 01 Nov 2018

Tittle Lifting Procedure Author Sutan Adlan Sakti

Location SAE Baturaden Area, Central Java Status High Priority

Client PT. Sejahtera Alam Energi

802-CBN-00-PR-CE-LIFTING PROCEDURE-049-A
OF CIVIL CONSTRUCTION AND INFRASTRUCTURE WORKS, STAGE 2

HISTORICAL DOCUMENT APPROVAL

REV DATE INITIATED REVIEWED VERIFIED APPROVED DESCRIPTION
BY BY BY BY
A 011118 SAS AMS AMS RP/TAL

TABLE OF CONTENTS

MAP OF SITE LAYOUT PLAN 3 of 11

1 INTRODUCTION………. ................................................................................................................. 4 of 11
2 DESCRIPTION ................................................................................................................................ 4 of 11
3 SCOPE............................................................................................................................................. 4 of 11
4 PURPOSE........................................................................................................................................ 4 of 11
5 ROLES AND RESPONSIBILITY………………..………………………………………………………… 5 of 11
6 LIMITATION OF PROCEDURE………………..…………………………………………………………. 6 of 11
7 TOOLS AND EQUIPMENT………………………………………………………………………………... 8 of 11
8 LIFTING RADIUS AND LOAD CALCULATION…………………………………………………………. 10 of 11
9 LIFTING PROCEDURE AND EXECUTION……………………………………………………………... 10 of 11
10 HOUSEKEEPING………………………………………………………………………………………...... 11 of 11
11 REFERENCES………………………………………………………………………………………………. 11 of 11

Prepared by:

PT. CIPTA BANGUN NUSANTARA

EPC, Consultants & Project Managers
Jl. M.T. Haryono, Kav. 15
Jakarta 12810, Indonesia
 Contract High Technology Steam field Civil Construction and Infrastructure Works Stage 2 Date : 01 Nov 2018

Tittle Lifting Procedure Author Sutan Adlan Sakti

Location SAE Baturaden Area, Central Java Status High Priority

Client PT. Sejahtera Alam Energi

802-CBN-00-PR-CE-LIFTING PROCEDURE-049-A
OF CIVIL CONSTRUCTION AND INFRASTRUCTURE WORKS, STAGE 2

PT. Cipta Bangun Nusantara EPC,

Consultants & Project Managers Graha
Pratama Building 18th Floor
Jl. MT. Haryono, Kav. 15
Jakarta 12810
Tel: +62 21 8379 3811
Fax: +61 21 8379 3627
Web: www.cbn-cepm.com

COPYRIGHT: The concepts and information contained in this document are the property of PT. Cipta Bangun
Nusantara. Use or copying of this document in whole or in part without the written permission of PT. Cipta Bangun
Nusantara constitutes an infringement of copyright.

LIMITATION: This report has been prepared on behalf of and for the exclusive use of PT. Cipta Bangun
Nusantara’s Client, and is subject to and issued in connection with the provisions of the agreement between
PT. Cipta Bangun Nusantara and its Client. PT. Cipta Bangun Nusantara accepts no liability or responsibility
whatsoever for or in respect of any use of or reliance upon this document by any third party.

Project Execution Plan – Baturraden Geothermal Project Page 2 of 11

Contract High Technology Steam field Civil Construction and Infrastructure Works Stage 2 Date : 01 Nov 2018

Tittle Lifting Procedure Author Sutan Adlan Sakti

Location SAE Baturaden Area, Central Java Status High Priority

Client PT. Sejahtera Alam Energi

MAP OF SITE LAYOUT PLAN

 Contract High Technology Steam field Civil Construction and Infrastructure Works Stage 2 Date : 01 Nov 2018

Tittle Lifting Procedure Author Sutan Adlan Sakti

Location SAE Baturaden Area, Central Java Status High Priority

Client PT. Sejahtera Alam Energi

1. INTRODUCTION
Landslides has been occurred at the Access Road to Well Pad F on October 27th, 2018 which is resulted in the Water
Distribution System (WDS) pipe is being displaced from its position. The contractor has the responsibility to repair the
WDS pipe by means of lifting the displaced pipe. The contractor will use and excavator to lift the pipes with calculation
and lifting procedures that will describe in this Standard Operational Procedure.

2. DESCRIPTION
Stability is one of the most important measures of good design machine and lift capacity is its consequence. Stability
is the final outcome of how total weight of machine is distributed over an excavator. Since undercarriage of an excavator
is never a square and tilt lines distances from slew center differ between front and side, lift capacity rating over side is
often lower and so is a considered a measure of functional stability. Lift capacity chart guides an operator and engineer
on safe lifting loads at various distances from the slew center (reference standard ISO 10567 and SAE J1097). When
loads are lifted close to the machine, the maximum lift capacity is no longer limited by machine tipping limit but by the
cylinder pressures generated by the load. When the cylinder pressure exceeds the hydraulic cylinder, relief setting the
load is not sustainable and constitutes the hydraulic limit. Both tipping and hydraulic limits are measured simultaneously
and lower of these values are considered for rating purposes. For reporting, rated lift capacity values, test values are
reduced by 25% if machine hit the tipping limit first and by 13% if hydraulic limit is lower than tipping limit. The above
figure uses SAEJ1097 which was superseded by ISO 10567 in 2008.

3. SCOPE
The procedure described below checks pair-wise accuracy of “stability limited” rating values published in Lift Capacity
Rating Charts of manufacturers per ISO 10567 for hydraulic excavators.

4. PURPOSE
The purpose of this Procedure is to describe and determine the processes and techniques to be implemented and to
ensure that lifting activities comply with standard and safety. This procedure also details the techniques and practices
for the subsequent of lifting activities to comply with the requirements of the Project's Quality, Health & Safety and
Environmental Plans, and the statutory legislation and regulations applicable to the contract. Job Safety Analysis (JSA)
will be carried out to identify any specific hazards that may not be addressed in this Procedure, and control measures
will be established to mitigate any risks identified. This document shall be issued to Company (PT. Sejahtera Alam
Energi or PT. SAE) for review and approval.

Project Execution Plan – Baturraden Geothermal Project Page 4 of 11

 Contract High Technology Steam field Civil Construction and Infrastructure Works Stage 2 Date : 01 Nov 2018

Tittle Lifting Procedure Author Sutan Adlan Sakti

Location SAE Baturaden Area, Central Java Status High Priority

Client PT. Sejahtera Alam Energi

5. ROLE AND RESPONSIBILITIES

Roles and responsibilities shall be in accordance with the PT. SAE and PT. CBN, Health, Safety and Environmental
(HSE) Procedures and those defined in the Project-Specific Quality, Health, Safety and Environmental Management
Plans. Lifting activities will be good result if there is a responsible person in accordance with the position and job title.
The responsibility personnel are:
1. Project Manager
Overall responsibility for all activities, insofar as projects are concerned, Project Management represents Contractor’s
Senior Management and hence, assumes overall responsibility for concrete repair result and safety during filed
activities. Project Manager is accountable to the Project Director for all survey activities under the scope of this contract.
2. Site Manager and Site Coordinator
SM and SC is ensuring Engineer planners, Implementers and the workers who do the right work, according to the initial
plan, the technical specifications, on schedule, budget, and quality.
3. Heavy Equipment (HE) Coordinator
HE coordinator prepare work lifting procedure, material type and specification, cost estimates for the above-mentioned
work, work schedules and coordinate with the executive team on the field,
4. Construction Supervisor
Construction supervisor supervises all the work and make sure that the work following to the Procedure, material type
and specifications, quality, schedule and budget. Construction supervisor also conduct to coordination or tool box
meeting and ensure that all the workforce use PPE and comply with safety requirement.
5. Safety Officer/Safety Man
Safety officer can make JSA and MSDS (Material Safety Data Sheet) for concrete material repair before start the work.
It aims to anticipate and mitigate the risk and hazardous in the field. He also helps supervisor to ensure that all the
workforce use PPE and all the work in the safe condition. He can explain HSE regulation in the coordination or tool
box meeting.
6. Operator Heavy Equipment
Operator is the person, who works in the safe condition and comply with the HSE requirement. He also dutiful to HE
Coordinator.
7. Workforce or labor
Workforce or labor will perform the work in the field and dutiful to foreman, HE Coordinator and supervisor in order to
good result. Workforces also are complying with regulation and HSE requirement.

Project Execution Plan – Baturraden Geothermal Project Page 5 of 11

 Contract High Technology Steam field Civil Construction and Infrastructure Works Stage 2 Date : 01 Nov 2018

Tittle Lifting Procedure Author Sutan Adlan Sakti

Location SAE Baturaden Area, Central Java Status High Priority

Client PT. Sejahtera Alam Energi

6. LIMITATION OF THE PROCEDURE

• Pair-wise values mean = a pair of (Rating over front, Rating over side) values for same Load Point Radius (LPR).
This procedure does not calculate individual lift capacity values.
• For hydraulic limited lift capacity rating, formula below defines only an upper limit for pair-wise consistency.
• The procedure is limited to hydraulic excavators without dozer blade. In machines equipped with dozer blade most
of the ratings are hydraulic limited and this procedure cannot be applied directly.
• Key Assumptions:
o Center Gravity (CG) of Undercarriage is assumed to be collinear with the Axis of rotation (AR). This
procedure is still valid if the distance between Undercarriage CG and AR is very small compared to the
total distance between Rear and Front Tipping lines.
o Symmetric undercarriage is a reasonable assumption. Since ISO requires that if the undercarriage is
unsymmetrical, the machine should be positioned in the least stable position for tipping limit calculations;
our assumption of symmetry should give a conservative value.
Variable names (Refer fig below)

Figure 1. Excavator for Lifting Procedure

Project Execution Plan – Baturraden Geothermal Project Page 6 of 11

 Contract High Technology Steam field Civil Construction and Infrastructure Works Stage 2 Date : 01 Nov 2018

Tittle Lifting Procedure Author Sutan Adlan Sakti

Location SAE Baturaden Area, Central Java Status High Priority

Client PT. Sejahtera Alam Energi

Front and Side tipping conditions for same LPR are super-imposed. The hatched areas are tracks in side tipping
condition.
1. Wf = (Front Lift capacity Rating / 0.75) (known)
2. Ws = (Side Lift capacity rating / 0.75) (known)
3. LPR = Load Point Radius (front) = Load Point radius (side) (known)
4. a = Distance between FTL and RTL
5. b = Distance between STL
• Calculating ‘a’:
o a is the distance between FTL (front tipping line) and RTL (rear tipping line). For track type
undercarriage, per ISO 10567, the line joining the centers of support idlers is FTL and
o centerline of sprockets is RTL. Since we are assuming the undercarriage to be symmetrical,
o FTL and RTL are equidistant from the slew center and a = Distance between tumblers (distance
between sprocket and idler centers)
• Calculating ‘b’:
o ISO 10567 for track type undercarriages gives the side tipping lines (TL) for balance point calculations
as below:
o For right-extreme track scheme, assuming ‘b’ to be equal to Track Gauge (distance between left and
right track center lines) wouldn’t give very wrong results. For other two track chain configurations, use
the table below for calculating ‘b’.
o b=Track Gauge + (A or B)
• Now with a and b calculated Wf, Ws and LPR from published lift capacity data; one can calculate the
following values:
o m = Wf. (LPR - a/2) where Wf = (Front published rating / 0.75)
o n = Ws. (LPR - b/2) where Ws = (Side published rating / 0.75)
o k = [(a– b)/2]
o Wc = [(m– n)/k]

Now check if Wc≤ Wp where Wc is calculated Operating weight and Wp is Published Operating Weight of machine
(see below sample lift chart). If Wc and Wp are within±5% of each other as set out by ISO standard, then we have
a valid pair-wise accurate stability rating. Let’s look at a sample of excavator manufacturer’s stability data and see
how they fare with our accuracy check. While data is from real machines, all the model names have been changed.

Project Execution Plan – Baturraden Geothermal Project Page 7 of 11

 Contract High Technology Steam field Civil Construction and Infrastructure Works Stage 2 Date : 01 Nov 2018

Tittle Lifting Procedure Author Sutan Adlan Sakti

Location SAE Baturaden Area, Central Java Status High Priority

Client PT. Sejahtera Alam Energi

For other pairs of data that are hydraulic limit rating values, including those that have one of the pair stability
limited, Wc should be definitely less than Wp. If it is not then, one or both the published lift capacity values are
wrong. Engineers measuring lift capacity can use this equation to estimate side tipping limit if front is already
tested accurately.
Table 1. Load Data for lifting Pipe
Material Weight Contingency Design load Unit

Carbon Steel Pipe 1,750 10.00% 1,925.00 kg

Shackle 50.00 20.00% 60.00 kg
Sling 30.00 20.00% 36.00 kg
Snatch blok 150.00 20.00% 180.00 kg
Bucket 635.00 10.00% 698.50 kg

Sub total 2,615.00 2,899.50 kg

a. Load contingency value is determined as follow:

b. Load data from estimation: 20%
c. Load data from calculation with estimated data: 20%
d. Load data from calculation with exact data: 10%
e. Load data from weighed: 3%

7. TOOLS AND EQUIPMENT

From the load and estimated working radius, hydraulic excavator PC-200 or equivalent is selected.
a. One unit, PC-200 or equivalent
b. One unit, snatch block (10 ton)
c. 2 each, nylon webbing sling (4 inch and 6 inch- 4 ton and 6 ton)
d. 4 each, forged shackles ¾ (4 ¾ ton)
e. 2 each, hand chain hoist (6 ton)
f. 1 each, tifor - camlong (10 ton)
g. 2 each tag line

Project Execution Plan – Baturraden Geothermal Project Page 8 of 11

 Contract High Technology Steam field Civil Construction and Infrastructure Works Stage 2 Date : 01 Nov 2018

Tittle Lifting Procedure Author Sutan Adlan Sakti

Location SAE Baturaden Area, Central Java Status High Priority

Client PT. Sejahtera Alam Energi

Figure 2. Sample of the lifting

8. LIFTING RADIUS AND LOAD CALCULATION

From the planned lay out, the boom length and working radius are as follow:
1. Excavator : PC-200
2. Bucket hook height : 6 meter
3. Maximum Working Radius : 6 meter

Based on Excavator lifting chart, the SWL for this plan is 5950 kg/5.95ton (see load chart on the last page of this
document) Check
Lifted load = 2,899.5 kg
SWL = 5,950 kg
Safety factor = 2,053→OK

9. LIFTING PROCEDURE/EXCECUTION
1. Pre-Execution
a. Conduct safety meeting involving supervisor, operator and riggers.
b. Ensure work permit is approved
c. Define clearly which persons shall be in charge
d. Construction Supervisor and Safety Officer shall check and ensure the lifting equipment to be used for
lifting process, in a good working condition. Also, lifting tool, such as shackles, wire sling, should be
checked by Heavy Equipment inspector and Safety Officer to ensure all tools in a good condition.

Project Execution Plan – Baturraden Geothermal Project Page 9 of 11

 Contract High Technology Steam field Civil Construction and Infrastructure Works Stage 2 Date : 01 Nov 2018

Tittle Lifting Procedure Author Sutan Adlan Sakti

Location SAE Baturaden Area, Central Java Status High Priority

Client PT. Sejahtera Alam Energi

2. Preparation and Set Up

a. Revise this procedure on-site if the weight will be > 4 ton.
b. Check actual working radius with measure tape or other tools.
c. Prepare the area to provide secure bearing for undercarriage of excavator.
d. Ensure no power cable around the lifting and swinging area

3. Execution Lifting Pipe 36-inch STD 8" Std Carbon Steel Pipe
a. Locate the excavator rating over front position.
b. Position of the excavator shall be arranged so that maximum working radius is 6 m from CG of excavator
to center of pipe to be install.
c. Hitch arrangement of pipe by webbing sling and shackle.
d. Set the snatch block below the lifting point of bucket excavator.
e. Set the excavator on standby position and turn on knob of low gear (turtle picture knob, no rabbit picture
knob).
f. Set the tifor-camlong at pipe support existing.
g. Install shackle and sling min at 2 lifting points at pipe, Install tag line, minimum 2 ea at opposite corners
of the pipe.
h. Pulling the tifor for lift up the pipe slowly.
i. Excavator operator shall be position on cabin.
j. Rigger to check the radius on-site with measure tape then check the compliance with excavator load
chart.
k. Ensure rigger double check rigging sequence and center of gravity and marking.
l. Ensure no worker under working radius.
m. Start to lift to elevation of approximately 20 cm
n. Hold the load for 2 minutes
o. Observe the undercarriage of excavator and stabilization of machine.
p. If the soil cannot hold undercarriage, cancel the lifting, compact the soil, and repeat above procedure.
q. If the soil is good, continue lift up slowly and pay more attention when the pipe starts to rise.
r. Watch the pipe movement and anticipate the reaction
s. Use tagline to control unexpected movement of pipe during the lifting
t. Lower pipe smoothly once it is right base of existing pipe support.

Project Execution Plan – Baturraden Geothermal Project Page 10 of 11

 Contract High Technology Steam field Civil Construction and Infrastructure Works Stage 2 Date : 01 Nov 2018

Tittle Lifting Procedure Author Sutan Adlan Sakti

Location SAE Baturaden Area, Central Java Status High Priority

Client PT. Sejahtera Alam Energi

u. Disconnect all shackles and job completed.

v. Heavy equipment inspector will be on site during works.

10. HOUSEKEEPING

1. Clean for all work area;

2. Provide trash bin;
3. Separate all the type of waste;
4. Cleaned and laid all the equipment after be used.

11. REFERENCES

a. ISO 10567 – 2008 standard.

b. SAE J 1097 standard.
c. Construction Equipment Guide, second edition: David A. Day, Neal B.H. Benjamin
d. Lifting and Rigging Chevron Standard.
e. Komatsu Lifting capacity.

This work method does not properly describe the lift sequence. The pipe in question is 200
meters long. Your sketch only shows a short 12 meter section of pipe.
..
Since you do not mention cutting and welding, I assume the WDS line will not be cut into
sections as we do not want to disrupt the water supply to the drilling rig. If this is so, then the
work method needs to reflect the fact that you will lift one section of pipe onto the supports.
Then you will secure that pipe onto the supports so it does not move, while you reposition
the excavator and tifor to lift the next section of pipe. I estimate you will have to reposition
and lift about 12-15 times.
..
There should be stress calculations produced to show what is the maximum allowable bend
from lifting the pipe while each end will still be in contact with ground or a support.
I also do not recommend using tag lines on the pipe while attempting to reposition it onto
supports. If the pipe was cut and both ends were free, I agree with tag lines. If only one end
is cut or no cutting at all is performed, then putting a tag line on the pipe will only endanger
the workers. There is also no way they can physically control the pipe with a tag line with
pipe in the uncut condition.
..
There is no mention of how you will rectify the bench and sleepers in those spots where the
bench is damaged.

Project Execution Plan – Baturraden Geothermal Project Page 11 of 11