JANGKRIK COMPLEX PROJECT

EPC EAST KALIMANTAN SYSTEM (EKS) MODIFICATION FOR

BADAK MANIFOLD EXPORT (BEM) AND KM 53

EPCI-2

BLOWING & FLUSHING PROCEDURE

00 EX-CO 10/11/2018 Issued For Review ABS BS JS

Rev
Validity
Numbe Prepared Checked Approved
Status Date Description
r
Revision Index
Company logo and business name Project name Company Document ID
220802DJPCME710
Jangkrik Complex
EniMuaraBakau B.V. Project Job N.
Contractor logo and business name Contractor Document ID
PT. MEINDO ELANG INDAH 220802DJPCME710

Contract N.

Facility Sub Facility Name Scale Sheet of Sheets

EPC EAST KALIMANTAN SYSTEM (EKS) MODIFICATION
FOR BADAK MANIFOLD EXPORT (BEM) AND KM 53 n.a. 1 of 17

Document Title Supersedes N.

BLOWING AND FLUSHING PROCEDURE
Superseded by N.
Plant Area Plant Unit
ONSHORE PHSS

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 2 of 14
EniMuara Bakau B.V. 00 EX-CO

Jangkrik Complex Project / Document Title

Project / Initiative name Blowing and Flushing Procedure
ABSTRACT

The purpose of this document is to provide blowing and flushing procedure in Jangkrik new field
Abstract

development. This procedure define the requirements for preparation and execution of blowing and
flushing activities during construction work of Jangkrik new field developments.

Document Verification
Signature
Prepared by Date
Arief Bashori 10-Nov-2018
Vendor Prepared

Signature

Checked by Date
Basir Sinaga 10-Nov-2018

Signature
Approval by Date
Jakarias Haloho 10-Nov-2018

Checked by Unit Signature Date

Company
Checked

Checked by Unit Signature Date

Proj. Dev.

Approved by Unit Signature Date

Company
Approved

Proj. Dev.

Endorsed by Unit Signature Date

Proj. Dev.

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 3 of 14
EniMuara Bakau B.V. 00 EX-CO

REVISION LIST

REV NUMBER REVISION DESCRIPTION

00 ISSUED FOR REVIEW

RECORD OF AMENDMENT
No Section Para No Description of Changes

HOLD LIST
Section Description of Hold

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 4 of 14
EniMuara Bakau B.V. 00 EX-CO

TABLE OF CONTENTS

1.0 INTRODUCTION ............................................................................................................................... 5

1.1 Project Overview ................................................................................................................................ 5
1.2 Document Scope ............................................................................................................................... 5

2.0 ABBREVIATIONS ............................................................................................................................. 5

3.0 REFERENCES .................................................................................................................................. 6

3.1 Company Reference .......................................................................................................................... 6
3.2 Contractor Reference ........................................................................................................................ 6
3.3 International Standard ....................................................................................................................... 7

4.0 BLOWING AND FLUSHING ACCEPTANCE CRITERIA ................................................................. 7

5.0 EQUIPMENT & TOOL REQUIREMENT ........................................................................................... 7

6.0 EQUIPMENT & INSTRUMENT PROTECTION ................................................................................ 8

7.0 PERSONNEL REQUIREMENT ......................................................................................................... 8

8.0 ROLES AND RESPONBILITY .......................................................................................................... 9

8.1 Pre-commissioning Manager / Pre-commissioning Engineer ............................................................ 9
8.2 QA/QC Inspector ............................................................................................................................... 9
8.3 Safety officer ...................................................................................................................................... 9
8.4 Testing Supervisor ............................................................................................................................. 9
8.5 Mechanic ............................................................................................................................................ 9
8.6 Instrument Technician ....................................................................................................................... 9
8.7 Fitter and Helper ................................................................................................................................ 9

9.0 BLOWING & FLUSHING PREPARATION AND EXECUTION ....................................................... 9

9.1 Blowing and Flushing Preparation ..................................................................................................... 9
9.2 Blowing and Flushing Detail Procedure ........................................................................................... 11

10.0 HSE ENVIRONMENT ...................................................................................................................... 12

11.0 ATTACHMENT ................................................................................................................................ 12

ATTACHMENT A ............................................................................................................................................ 13

List of Equipment .......................................................................................................................................... 13

ATTACHMENT B ............................................................................................................................................ 14

Blowing schematic ........................................................................................................................................ 14

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 5 of 14
EniMuara Bakau B.V. 00 EX-CO

1.0 INTRODUCTION
1.1 Project Overview
Jangkrik field is located about 70 km from the coast, in the Muara Bakau permit area,
Makassar Strait, offshore Kalimantan, at water depth ranging from 250 to 500 m. ENI through
its Indonesian subsidiary, operates the Muara Bakau PSC.
The treated gas and condensate from FPU are exported via 24 inch treated gas export
pipeline and 4 inch condensate export pipeline to shore at Sapi landfall. An onshore receiving
facility (ORF) fiscal metering system for gas and condensate is located approximately 4 km
downstream of Sapi Landfall. Gas and condensate pipelines are the tie-in to existing East
Kalimantan pipeline network. Another tie-in at KM 21.65 is required for the gas line to allow
the full capacity of jangkrik gas. For this purpose, a 15 km of new pipelines is to be installed
parallel to existing line with TEPI’s ROW from ORF to KM 21.65, and will be tie-in to existing
20 inch Handil-Nilam pipeline and modification to be done at Nilam, BEM, and KM 53 inside
POMA area. Final destination of Jangkrik treated gas is to the Bontang LNG Plant and
domestic Bontang market; and the final destination of Jangkrik condensate is to Senipah
Plant.

1.2 Document Scope

The scope of work of this procedure is to establish the general requirements of the flushing &
blowing piping system for BADAK MANIFOLD EXPORT (BEM), KM 53 and PK52,
CONTRACTOR prefers to use Flushing and Blowing with quick decompression method by
using quick opening valve and rupture disk. This blowing & flushing activities aim to clean the
inner part of equipment and piping, to remove loose foreign matter from the inside of piping
lines such as welding rods, sand, dirty, pebbles, nuts and bolts, tools, rags, wild insect etc., in
order to avoid line blockages before Hydro test activities. Mark up P&ID.
This procedure describe the methodology and organization put in place by CONTRACTOR
under coordination of Pre-commissioning Team and Engineering Department, inspection by
Quality Control (QC) Department, witness and approval by COMPANY.

2.0 ABBREVIATIONS

AA : Area Authority
QC : Quality Control
CONTRACTOR : PT Meindo Elang Indah
COMPANY : Eni Muara Bakau B.V
HSSE : Health Safety, Security and Environment

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 6 of 14
EniMuara Bakau B.V. 00 EX-CO

NDE : Non Destructive Examination

PA : Performing Authority
PPE : Personal Protective Equipment
PROJECT : Jangkrik Complex
SDV : Shutdown Valve
TRA : Task Risk Assessment

3.0 REFERENCES
The following documents are referred to in this document.
3.1 Company Reference

No. Description Eni Doc Number Rev

[A1] Scope of Work –EKS Modification at BEM and KM 53 Area 220802DLSCE0354 02

[A2] Pipe and Piping component for Plants 05892.PIP.MEC.SDS 03

[A3] Piping Weld Examination-General Requirements 20377.PIP.MEC.FUN 01

[A4] Manual Valves 15801.PIP.MEC.SDS 05

[A5] Carbon Steel Piping Welding 20368.PIP.MEC.FUN 01

[A6] Piping Classes 20367.PIP.MEC.SDS 02

3.2 Contractor Reference

No. Description Doc Number Rev

Pedoman Pelaksanaan Pengendalian Alat Angkat

[B1] PP-HSE-B06-005 -
(Operation Procedure for Lifting Operation)

[B2] Work Permit Procedure - -

[B3] Emergency Response Plan 220802DFPAME001

[B4] Inspection Test Plan For Work 220802DBQBME001

[B5] NDT Procedure for Pipeline Work 220802DBQRME002

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 7 of 14
EniMuara Bakau B.V. 00 EX-CO

3.3 International Standard

No. Description Doc Number Rev

Pipeline Transportation Systems for Liquid Hydrocarbon

[C1] ASME B31.4
and other Liquids

[C2] Gas Transmission abd Distribution Piping System ASME B31.8

[C3] Specification for Line Pipe API SPEC 5L

[C4] Specification for Pipeline Valve API SPEC 6D

[C5] Standard Specification for Carbon Structural Steel ASTM A.36

[C6] Structural Welding-Steel AWS D1.1

4.0 BLOWING AND FLUSHING ACCEPTANCE CRITERIA

The acceptance criteria of blowing and flushing as followed:
Description of
Acceptance Criteria Remark
activities
Blowing & No foreign material found or debris on
Flushing target plate (prior to hydro test)

5.0 EQUIPMENT & TOOL REQUIREMENT

The following equipment as a minimum should be available to conduct all the testing:
No. Description Quantity Unit Remark
Air compressor capable to
1 produce dry air with air 1 Set
pressure capacity 110 Psig
Pressure Gauge for Pressure Gauge shall have
2 indicate air pressure up to 1 Ea valid calibration certificate to
10 Bar, Locally mounted on be attached
discharge pipe
3 Hoses and connector 1 Lot
4 Blind Flange 1 Lot
5 Ball Valve 1 Ea

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 8 of 14
EniMuara Bakau B.V. 00 EX-CO

Rupture disk (aluminum

6 sheet 0,4 mm thk) 3 Sheet
7 Hand tools 1 Lot See attached for detail
8 Radio Communication 1 Pair
9 Seal tape 4 Ea
10 Target Plate 1 Ea

6.0 EQUIPMENT & INSTRUMENT PROTECTION

During blowing and flushing, all fragile internal equipment should be dismantled or opened.
The following instrument and equipment is considered as being fragile:
 Pressure Safety Valve
 Control Valve
 Check Valve
 Process Instrument
 Pressure Gauge
 Orifice Plate
 Level Glass and Level Switch

Process impulse or injection to the lines should be disconnected. Control valve, Globe Valve &
Safety Valve will be dismantled and replaced by a dummy spool piece if required. Gate valve and
ball valve shall be removed and replace by dummy spool /spool piece if required. All vessel or
equipment should be blinded.
All mechanical equipment such as process pumps shall be blinded from the flushing and drying
network. Check and ensure spring support hangers (if any) are still blocked according to
manufacture standard prior to flushing. The lock shall be released only prior to commissioning.

7.0 PERSONNEL REQUIREMENT

The flushing team should consist of at least the following and shall has experiences of handling
previous flushing works:

No. Description Quantity Unit Remark

Pre-commissioning
1 1 Person
Manager
Pre-commissioning
2 1 Person
Engineer
3 Testing Supervisor 1 Person
4 Mechanic Compressor 1 Person
5 QA/QC Inspector 1 Person
6 Safety officer 1 Person
7 Fitter 2 Persons

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 9 of 14
EniMuara Bakau B.V. 00 EX-CO

8 Helper 2 Persons
9 Company Rep 1 Person

8.0 ROLES AND RESPONBILITY

8.1 Pre-commissioning Manager / Pre-commissioning Engineer

He is responsible to manage yard facilities and utilities as required during pre-
commissioning work or as per project condition. He has to communicate with COMPANY
site representative.

8.2 QA/QC Inspector

He is responsible for control and monitoring the activities are comply with specification,
standard and follow approved documents and drawings. The QC Inspector will counter
sign the pre-commissioning test sheet and validating the test.

8.3 Safety officer

The safety officer shall be responsible for the HSSE plan implementation and comply
with all statutory regulation.

8.4 Testing Supervisor

Supervisor shall be responsible for all testing activities on yard or site. He shall be
responsible for the work and will oversee blowing and flushing activities as peer
approved method statement, COMPANY specification, and HSSE requirement. He shall
also be responsible for assessing the work permit at site prior to start the blowing and
flushing work.

8.5 Mechanic
Prepare testing requirement tools & standby during testing activities and responsibilities
for any emergency / damage on the tools/ testing equipment.

8.6 Instrument Technician

Technician shall be responsible for the protection, connection or disconnection for all
instrument required for testing.

8.7 Fitter and Helper

They responsible for supporting the activity, and also maintain housekeeping in the work
area.

9.0 BLOWING & FLUSHING PREPARATION AND EXECUTION

9.1 Blowing and Flushing Preparation
Blowing and Flushing activities to be prepared are as listed below:

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 10 of 14
EniMuara Bakau B.V. 00 EX-CO

a) Prior blowing and flushing, the CONTRACTOR to prepare and submit a flushing notice
to all parties concerned by the witnessing of the test, with the following document
attached:
 Test pack data sheet
 Marked-up P&ID showing test limits or boundaries
 Isometric drawings
 Detail pipe support drawings
 Flushing/blowing and test layout showing:
 test limits or boundaries
 pressure utilized
 location of fluid inlet from pump or compressor
 location of gauges
 medium
 vents, drain or other fluid outlet
 Check lists form for line check
 Test sheets
 Punch List Form
 Blowing and Flushing Form
 Make sure the Blowing & Flushing Procedure must be in place prior blowing and
flushing activities.
 Make sure all line will be blowing and flushing have been NDT clearance.
 Make sure line to be flushing has been hydrotest

b) All check and test forms shall be prepared and ready for fill up and sign off by
CONTRACTOR Inspector and COMPANY inspector who witnesses the test.
c) Whenever possible, the cleaning shall flow from top to bottom.
d) The diameter of the outlet pipe shall be at least two third of the diameter of the line to be
flushed, and at least as large as the inlet pipe.
e) Main header shall be cleaned first.
f) Large diameter pipes shall be cleaned before small diameter ones.
g) Fragile devices included in the network shall be removed.
h) Each flushing shall have a test number which same as test package number.
i) During flushing, large quantities of dirty is spread out in the outlet point and around test
pack network. This air generally contains sand, particles of rust, etc and might damage
other equipment (ex: breaking the glass of a pressure gauge). Additionally, compressed
air itself may damage the insulation materials, the electric motors, etc. Accordingly, the
following actions shall be taken where necessary:
 To put a tarpaulin on motors, insulation, instruments near the flow outlet.
 To direct outlet flow toward a place where there is no (fragile) equipment.
 To change the direction of the flow by rotating an elbow.
 To add a dummy spool to extend the outlet further.
j) Determination of the network maximum allowable pressure:
 If the quick decompression method is used, the air pressure in the network shall
never exceed 6 Bar and use the calibrated pressure gauge.
 If should also be checked that all pipes and vessels of the network are designed to
with stand a pressure of 6 Bar.
 If a rupture disk is to be installed on a large diameter pipe, the set pressure of the
disk shall be carefully calculated in order to limit the energy released when bursting
occurs to an acceptable level.

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 11 of 14
EniMuara Bakau B.V. 00 EX-CO

 For pipes above 10” especially the first blowing will take place with the network
pressurized at only 2-3 Bar.
 Detail method of flushing will be indicated on each test pack which TP use air
flushing Blowing, which the TP use quick opening valve, and which TP use
mechanical cleaning prior.
9.2 Blowing and Flushing Detail Procedure
Once all preparation work is completed, Testing Supervisor / Engineer shall inspect the
preparation work and check specially that all protections (safety devices) are installed i.e.:
pipe restraints, clamps, supports, protection of equipment and obtain the clearance of HSE
coordinator/Testing Supervisor. Air inlets and outlets shall be made during site review to
determine the possible of location, and any necessary temporary pipes. Isometric drawings
shall be marked up, and the required equipment to be supplied and installed i.e.: pipes,
valves, gaskets and shall be determined.
Once the site check is satisfied and ensure no person / material in the area, the testing
Supervisor / Engineer shall give authorization to start the air blowing operation. Testing
area will be barricaded and only authorized person on the work location.
Main methods use for air blowing is Quick Decompression Method.
Where the quick decompression method has been selected, the network can be isolated.
The pressure release can be obtained by:
 A quick opening valve (required a quarter turn valve).
 A rupture disk.
In the first case, the flow rate may be roughly adjusted, if necessary, and the quick opening
valve may be closed in case of emergency. Due to the high velocity involved, the quick
opening valve might be eroded if it is used in an intermediate state (i.e. not completely
opened). Therefore, whenever possible, the valve shall be completely open.
a. If a quick opening valve is used, allow the air to enter the network and carefully check
that pressure in the system never exceeds the maximum allowable pressure (2-3 Bar).
When the required pressure is reached, check that all safety measures have been
adhered to, and open the valve. This operation shall be repeated several times.
b. If a rupture disk is used, after having checked that safety measures have been taken,
allow the air to enter the network, check continuously the pressure rise, and when the
rupture disk blows out, stop the air inlet in the network. The operation shall be repeated
several times.
Note: Nominal pipe size more than 4” decompression with rapture disk. Nominal pipe size
smaller than 3” decompression with method quick decompression with valve (quick
decompression method).
Cleanliness check:
 Mark Up P&ID and showing test limits or boundaries.
 Color of the air at the exit point. This will roughly indicate whether or not rust and dirt
remain in the piping. This is usually sufficient for the majority of process and utilities
piping.
 Use of a target plate. A polished aluminum or soft metal target is attached to the target
plate carrier on the tailpipe end.
 After air blow of the system, examine the plate at the end of the air blowing. If the plate
has become eroded and pitted, easily seen by a matt grey appearance and surface
pitting, continue air blowing. Ensure blowing and flushing area is closed to avoid any
flying object hit the people.
This document is property of Eni Muara Bakau B.V.
It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 12 of 14
EniMuara Bakau B.V. 00 EX-CO

 Mark each plate and store in a safe place for comparison.

 The target plate surface will become brighter after each subsequent blowing.
 When the plate surface remains bright it will be possible to count the number of impact
pits per blow caused by large dirt or rust particles.
 When the plate remains unmarked it may be assumed that the piping is clean.
 Ensure no dirt is re-introduced into piping during re-assembly following air blowing.
 Commissioning team witness during the flushing activities and authorized to stop
flushing when desired clean lines has been reached. The report shall be fully complete
by both QC Inspector and Client Authorized
 QC Inspector to make document SF-1 form for MC-1 for attachment before do blowing
and Flushing activities.

10.0 HSE ENVIRONMENT

Due to the high forces generated at the air outlet, the following particular precautions shall be
taken for this operations
 A work permit shall be issued prior to each flushing operation according to CONTRACTOR
safety procedure.
 Testing area to be barricaded with clear barricade and only authorized person on the work
location. Sufficient safety precaution or warning sign respectively In English and Indonesia
language shall be posted around the area detailing.

DANGER: “FLUSHING IN PROGRESS”

AND

BAHAYA: “FLUSHING SEDANG BERLANGSUNG”

 All un-authorized personnel are evacuated from that area, before the test is commenced.
 The discharge areas shall be free from people working and passing. They shall be at
minimum distance of 30 meters from horizontal discharge.
 The large quantities of dirty air released during the blowing and flushing carries particles of
sand, rust, welding rods, etc which could damage the equipment nearby and dangerous for
the personal. Therefore, adequate barricade must installed, such as hard barricade,
additional PPE, etc
 Protection for personnel carrying out the operation must be ensured by suitable protective
equipment (PPE shall be appropriate with a rule be valid). Such us ear protection, gloves,
coverall, goggles as a minimum.
Note: equipment checked by competent person including specification of hoses and
connectors. Check/inspection result should be tag on equipment

11.0 ATTACHMENT
 Attachment A - List of Equipment
 Attachment B – Blowing schematic

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 13 of 14
EniMuara Bakau B.V. 00 EX-CO

ATTACHMENT A

List of Equipment

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 220802DJPCME710 Revision Index

Rev Validity
Number Status
JANGKRIK COMPLEX PROJECT
Blowing and Flushing Procedure Page 14 of 14
EniMuara Bakau B.V. 00 EX-CO

ATTACHMENT B
Blowing schematic

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.
 FLUSHING/BLOWING SCHEMATIC
Schematic Draying

Air Compressor

Pipe Hose Pipe Spool

PG

AIR
KO COMPRESSOR
Drayer
POT /Water Saparator

Basket