JOB PERTAMINA – MEDCO E&P SIMENGGARIS

PROJECT TITLE: SOUTH SEMBAKUNG GAS PLANT

DOCUMENT TITLE: SPECIFICATION FOR MATERIAL HANDLING EQUIPMENT

DOCUMENT NO. SMN-M-ES-36-006

Attachment No.
Attachment No. of Pages
PT. RAGA PERKASA EKAGUNA JOB P - MEPS

DESCRIPTION PREPARED CHECKED APPROVED APPROVED

REV DATE NAME NAME NAME NAME DATE

A 02-SEP-10 ISSUED FOR REVIEW RMP HA WHY/TRK

B 07-OCT-10 ISSUED FOR APPROVAL RMP HA WHY/TRK

C 30-NOV-10 RE-ISSUED FOR APPROVAL RMP HA WHY/TRK

0 08-DEC-10 ISSUED FOR CONSTRUCTION RMP HA WHY/TRK

JOB P-MEPS Doc No: REV.

SMN-M-ES-36-006 0

SIMENGGARIS BLOCK MECH. STATUS IFC

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Table of Contents

1 INTRODUCTION ...................................................................................................................... 4
2 SCOPE...................................................................................................................................... 4
3 DEFINITION OF TERMS .......................................................................................................... 4
4 CODES, STANDARDS AND OTHER REFERENCES ............................................................ 5
5 TOOL AND EQUIPMENT TYPE .............................................................................................. 6
5.1 Rigging Equipment and Hook handling .................................................................................... 7
5.2 Powered Equipment and Vehicles for Handling and Transportation ........................................ 7
6 MATERIAL HANDLING PHILOSOPHY................................................................................... 7
7 LAYDOWN AREAS .................................................................................................................. 8
8 SPECIFIC MATERIALS HANDLING ....................................................................................... 9
8.1 Desiccant / Solvent / Liquid Chemicals & Consumables .......................................................... 9
8.2 Compressed Gases .................................................................................................................. 9
8.3 Pipeline Pigs ............................................................................................................................. 9
8.4 Electrical Equipment ................................................................................................................. 9
8.5 Structural Steels ...................................................................................................................... 10
9 MAINTENANCE HANDLING REQUIREMENTS ................................................................... 10
9.1 General ................................................................................................................................... 10
9.2 Rotating Machinery ................................................................................................................. 10
9.3 Valves, Actuators, Spool Pieces and Blind Flanges ............................................................... 11
10 MATERIAL HANDLING EQUIPMENT DESIGN .................................................................... 11
11 MATERIALS HANDLING REPORT ....................................................................................... 13

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1 INTRODUCTION

JOB Pertamina- Medco E&P Simenggaris is planning to develop its Simenggaris Block
located in South Sembakung, East Kalimantan. South Sembakung Gas Plant is expected to
produce max. 25 MMscfd of gas from 4 (four) Production Wells. South Sembakung Gas is
sweet with low CO2 and no H2S content. Gas Plant is to built at South Sembakung for
processing the gas to meet requirement for sales gas water content and delivery pressure to
buyer. South Sembakung Gas Plant will be run initially on HP (high Pressure) condition and
decrease to LP (low Pressure) condition after several years.

2 SCOPE

This specification outlines the overall for material handling facilities and lifting requirements to
be provided on the South Sembakung Field Development Project. The detail engineering
CONTRACTOR shall prepare detailed material handling report and provide necessary
facilities for handling. COMPANY may include additional equipment specific requirement
during document review.

3 DEFINITION OF TERMS

Terms used in this specification are defined as follows:

COMPANY/ PURCHASER is defined as JOB PERTAMINA – MEDCO E&P

SIMENGGARIS

CONTRACTOR is defined as CONTRACTOR or representative

appointed by JOB Pertamina-Medco E&P Simenggaris.

SUPPLIER/VENDOR is defined as the party selected to supply the equipment

and service detailed in this specification. This is the
entity having unit responsibility as defined in the industry
codes and standards.

OTHERS are defined as parties which have been contracted by

JOB PERTAMINA – MEDCO E&P SIMENGGARIS to
supply equipment, services or material.

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4 CODES, STANDARDS AND OTHER REFERENCES

SUPPLIER’s Proposal shall clearly state and list exceptions to this specification and all
referenced codes and standards. In the event of any conflict arising between this specification
and other documents listed herein, refer comments to COMPANY/ CONTRACTOR for
clarification before design or fabrication commences for resolution.

Indonesian Regulations / Laws

The facilities development of South Sembakung Gas Plant shall be in accordance with the
latest Indonesian Regulations / Laws including:

 Government Regulation of the Republic of Indonesia No. 11, 1979 (LN of 1979 No. 18
TLN No. 3135) - Work Safety in Oil and Gas Refining and Processing

 Regulation of Minister of Mines and Energy No. 06/P/0746/M.PE/1991 - Inspection of

Work Safety on Installation, Equipment and Technique Utilized in Oil and Gas Mining and
Geothermal Resource Exploitation

 Dirjen Migas Regulation No. 84.K/38/DJM/1998 – Inspection Guidelines for Safety on

Facilities, Equipment and Technology used in Oil & Gas and Geothermal activities

 Government Regulation of the Republic of Indonesia No. 32, 2009. Environmental

Management and Prevention

Codes and Standards

The latest editions of the following codes and standards are considered a part of this
specification.

ASME B 30.16 Overhead Hoist

ASME Section V NDE Techniques

API RP 505 Classification of Location for Electrical Installation at

Petroleum Facilities Classified as Class 1, Zone 0,
Zone 1 & Zone 2.

API RP 540 Electrical Installation in Petroleum Processing Plant

API 9A Specification for Wire Rope

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AWS D 1.1 American Welding Society – Structural Welding Code

BS 466 Specification for Power Driven Overhead Traveling

Cranes, Semi-Goliath and Goliath Cranes for General
Use.

BS EN 13414 Steel Wire Rope Slings and Sling - Safety.

BS 2573 Specification for Permissible Stresses in Cranes.

(Part 1 - Structures and Part 2- Mechanisms)

BS 2903 High Tensile Steel Hooks for Chains, Slings, Blocks

and General Engineering Purposes.

BS 3243 Hand operated chain pulley blocks

HMI Hoist Manufacturer’s Institute Standard

Project Specification

SMN-M-SY-36-001 Material Handling Study

SMN-M-SY-36-002 Material Handling List

SMN-E-ES-36-001 Specification for General Electrical Construction

and Installation

Conflicting Requirements

In the case of conflict between documents, the order of priority shall be:

 Indonesian Statutory Requirements/Other relevant National or International Legislation in

the absence of Indonesian Legislation

 This Specification

 Referenced Project specifications

 Referenced Codes and Standards

5 TOOL AND EQUIPMENT TYPE

The detail engineering CONTRACTOR shall prepare detailed material handling report and
provide necessary facilities for handling refer to Project Specification No. SMN-M-SY-36-001,

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Material Handling Study and SMN-M-SY-36-002, Material Handling List. COMPANY may
include additional equipment specific requirement during document review. The tool and
equipment for handling consist of:

5.1 Rigging Equipment and Hook handling

Rigging equipment, including hooks, clamps, chains, ropes, shackles, eyebolts or other lifting
accessories, shall not loaded in excess of the recommended safe working load and should be
clearly marked to indicate the safe working load.

5.2 Powered Equipment and Vehicles for Handling and Transportation

All powered equipment and vehicles such as Fork Lift/ mobile floor crane/ truck and other
shall be operated only by qualified personnel who can inspect them prior to each use and
during use to make sure they are in safe operating condition. Any deficiencies shall be
repaired, or defective parts replaced before continued use.

Any mobile equipment and motor vehicles shall have seat belts as required for the operators
to use when the vehicles are in motion.

The motor shall be shut off when refueling or lubrication motorized equipment.

Crane shall be checked and lubricated in accordance with their operating manuals each time
before use.

When outriggers for mobile cranes are uses, they shall be positioned on pads or other solid
surfaces.

The crane operator should operate the crane only on signals from one authorized person
(signaler), but a stop signal should be obeyed regardless of who gives it.

The signaler shall always stand in clear view of the crane operator while maintaining a safe
distance from the hook or boom, and give discernible signals at all times.

6 MATERIAL HANDLING PHILOSOPHY

The material handling philosophy for the South Sembakung Field Development Project shall
follow the provision made below:

All material required for operation and maintenance of facilities shall be received in trucks via
road in the plant and stored in warehouse. Unloading of these shall be done by battery
operated Fork Lift or mobile floor crane.

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Handling of bags weighing less than 1MT but more than 30 kg for chemicals/ solvents/
desiccant/ consumables for transferring from storage area to working area and to charging
elevation, shall be by battery operated Fork Lift.

All solid materials from the facilities meant for shipment to outside shall be dispatched in
trucks and loaded by battery operated Fork Lift or mobile floor crane.

Equipment and components weighing less than 30 kg can be handled by hand.

Stand alone equipment/ valves, control valves and their actuators, shutdown valves, structural
steel, piping blinds, relief valves, drives of compressors, stand alone pumps etc. weighing up
to 3.5 MT shall be handled by mobile floor crane within the Onshore Terminal.

Equipment weighing more than 3.5 MT but less than 20 MT requiring frequent
maintenance/operational handling, will be provided with runway beams for the attachment of
manual trolley hoist ( up to 10 MT ) and/ or electric hoist ( above 10 MT ) suitable for
hazardous area classification of equipment installation.

For movement of equipment/goods inside warehouse, mobile floor crane/ battery operated
Fork Lift shall be used. However movement from/to workshop shall be by the above
mentioned handling equipment or trucks.

Handling and loading/unloading of the transformers is a specialized scope of work and shall
be done by heavy lifting CONTRACTOR as and when required.

All access covers on pressure vessels and filters etc., will be provided with davits or hinges.

Columns shall be provided with column davit for replacement of internals and maintenance of
valves on the top of the columns.

Suitable lifting eyes at strategic locations shall be provided for tubular heat exchangers,
electric heaters bundle removal and support of bundle during pulling operation.

Runway beams with manual hoist and scissor trolley/ cradle can be provided for handling
electrical panels in equipment handling area in electrical sub-station.

Movement of circuit breakers within the switch room and racking in/ racking out of the
breakers shall be by circuit breaker lifting trucks, if required. Any such equipment shall be as
per VENDOR standard arrangement.

7 LAYDOWN AREAS

Maintenance lay down areas shall be provided adjacent to all major equipment items. The lay
down areas shall be sized to lay down spare parts and sections of dismantled equipment

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while maintaining. It shall be ensured that the maintenance laydown areas for
equipment/package, requiring very frequent top-up of consumables (supplied in
drums/containers) are adequate for unloading of these drums/containers.

Suitable areas for vehicular/ battery operated Fork Lift/ mobile floor crane access inside the
shed/ enclosure for equipment/ package shall be provided under cover and besides
equipment/ packages away from the normal access paths. Adequate access to these areas
shall also be ensured. Approach roads for vehicular/ battery operated Fork Lift/ mobile floor
crane access shall also be identified and provided during detailed engineering.

8 SPECIFIC MATERIALS HANDLING

The handling of specific materials and equipment shall comply with the following requirements
where applicable.

8.1 Desiccant / Solvent / Liquid Chemicals & Consumables

Liquid Chemicals/ Desiccant/ Solvent and other consumables will normally be brought in
drums/ bags and transferred to the respective storage tanks or respective equipment.
Handling of this inside the onshore terminal from warehouse/ vehicle to the working/ storage
area will be by battery operated Fork Lift. Methodology for Charging/ replenishment/ removal
of these shall be prepared in consultation with supplier.

8.2 Compressed Gases

Gas cylinders including cylinders for welding etc. are shipped in purpose-designed certified
racks and stored in a dedicated gas bottle storage area and a proper shelter shall be
provided. Transfer within the plant will be by mobile floor crane.

8.3 Pipeline Pigs

Mobile floor crane shall be used for handling the pigs if applicable within the facility.

8.4 Electrical Equipment

Maintenance, removal and installation of switchboards, transformers, PLC Control System,

etc. shall be as per equipment supplier’s recommendations.

For circuit breaker movement, racking in and racking out within the switch room/ substation
circuit breaker lifting trucks shall be used, where required by the switchgear design.

For movement of batteries within the switch room hand pallet truck/ trolleys shall be used.

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For handling of all the above electrical equipment and the panels outside the switch room
battery operated Fork Lift/ mobile floor crane/ truck shall be used.

8.5 Structural Steels

For handling of all the above Structural Steels, Fork Lift/ mobile floor crane/ truck shall be
used.

All material handling equipments for structural steel material handling activities shall be:

- Conform to total weight of steel structure material

- Conform to structural material cross section and weight classification

- No affecting defect to the body of structural material

9 MAINTENANCE HANDLING REQUIREMENTS

9.1 General

The maintenance requirements for the South Sembakung Field Development Project shall be
defined in the respective VENDOR operation and maintenance manual.

In all cases attention shall be paid to provide adequate overhead clearance for full
deployment of lifting aids or equipment, such that individual parts or sections of equipment
can be lifted well clear without risk or damage. This applies in particular to vertical equipment
such as towers and vessel internals and filter packs.

It shall be ensured that proper platform and access to manholes is provided for equipment like
columns to enable replacement of internals.

Also for tubular exchangers adequate guides shall be provided in the shell to enable smooth
withdrawal.

9.2 Rotating Machinery

Machines such as Diesel Engines, Gas Turbines, Compressors and Pumps, etc. have
specific methodology and specialized tools for stripping/assembling; removal and
maintenance which will be provided by equipment supplier. The detailed engineering
CONTRACTOR shall develop required methodology & provide necessary facilities and
equipment based on the philosophy given above.

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9.3 Valves, Actuators, Spool Pieces and Blind Flanges

Maintenance, removal and re-installation of manual valves, control valves, ON/OFF valves,
pressure relief valves, shutdown valves, actuators, spool pieces and blind flanges shall be
considered for access and removal for testing or repair by mobile floor crane and via battery
operated Fork Lift pallet to workshop. Valves at a higher elevation should be provided with
maintenance platform access and a monorail for lowering.

10 MATERIAL HANDLING EQUIPMENT DESIGN

- All the equipment components, items, devices of the package shall be designed suitable
for the environmental conditions.

- Hoists shall be intended for use in the day to day and periodic routine maintenance of
process equipment installed.

- Overhead traveling hoists shall be rated for a minimum of 150% of the largest specified
maintenance weight.

- It is intended that overhead traveling hoists shall be designed and supplied generally in
accordance with BS 466 / ASME B 30.16.

- Chain operated hoists shall be designed and supplied generally in accordance with BS
3243 / HMI.

- Hoist rail support beams shall form part of the building structure and will be part of the
building scope of work.

- All materials of construction shall be suitable for the environment and operating
temperature range.

- Special attention shall be given to electrical equipment on cranes installed under shelters
and above equipment generating heat.

- Chain Pulley Blocks, Manual Trolley hoists and Electric Trolley Hoist.

1. All hook on type chain pulley blocks and manual trolley hoists shall have manual
hoist.

2. Manual trolley hoists shall be provided with geared trolleys and operated by hand
chain. The monorail mounted manual trolley hoists shall be provided with a brake for
traversing motion.

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3. Hook-on type chain pulley blocks shall be provided with chain trough for load chain.
The trough shall be detachable type.

4. All chains shall be close link coil type, electrically welded, accurately calibrated,
pitched and polished. It shall be heat treated for wear resistance and ability to
withstand impact.

5. All load chains shall be Corrosion Protected.

6. All hand chains shall be suitably coated for the environmental conditions.

7. The length of the chains shall be such that the lowest point of loop shall be 0.4 m
above operating level.

8. Chain guides shall be provided for both the hand and load chains to ensure effective
guidance of chains into the chain wheel pockets.

9. All moving parts on hoist shall be provided with lubrication facility.

10. Hand chain wheels shall be preferably of pressed sheet steel and load wheels of
malleable cast iron or other equivalent materials. Idler wheels shall be provided to
avoid twisting of chain when passing around.

11. Multiple threaded screw and friction disc type self-actuating load pressure brake shall
be provided for mechanism safety.

12. The ratchet and crawl type arrangement suitable to hold rated load at any position
along the height of hoisting shall be provided. The crawl & ratchet shall be of steel,
hardened and tempered.

- For Manual trolley hoist, each trolley shall have at least 4 wheels. Wheels shall be forged
type & shall have double flanges. The wheels should have rolling bearings lubricated for
life. The running wheels shall be fitted with removable covers.

- Wheel tread shall be hardened to minimum 300 BHN. The wheel tread shall be machined
true to the beam profile. Wheels shall be forged steel.

- Trolley frame shall be of steel frame bolted, welded into stable assembly of suitable
strength to provide proper wheel and bearing alignment.

- All hooks shall be of non-sparking material and shall be fitted with spring safety latches.

- Top and bottom hooks shall be provided with safety latches. Hooks shall be swiveled on
ball bearings.

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- All moving parts of the hoist such as the coupling, gears and exposed rotating parts shall
be of spark and corrosion resistant type and provided with adequate guards.

- The safety factor shall be as per the specified codes and standards.

- The moving parts of all material handling equipment shall be provided with lubrication
facilities.

- Each item shall have a permanently affixed nameplate, showing tag number, equipment
description, SWL capacity, manufacturers name, date of manufacture, date of testing, etc.

- Hand Pallet Truck, Fork Lift and Battery operated Mobile Crane shall be manufacturer’s
standard. VENDOR shall furnish full details along with the bid.

11 MATERIALS HANDLING REPORT

During detailed design stage of the project, material handling report shall be generated based
on the VENDOR information & maintenance requirements as describe in this document.

The Materials Handling Report will comprise the following sections:

- Removal of Parts for Maintenance Schedule and Handling Studies

This Schedule and the Handling Studies will identify all components that require facilities
for removal prior to identifying the removal facilities that are to be provided. It will also
include handling methods, and will identify lifting equipment, access routes and lay down
areas to be used and expected frequency of removal. At minimum no sharing lifting
equipment shall be acceptable on the same area of the facilities.

- Materials Handling General Arrangement Drawings

These Drawings will show load movement access ways; lay down areas, runway beams
and other permanent handling equipment.

They are designed to be read in conjunction with the maintenance schedule.

- Consumable Handling Report

This Report will identify the consumables to be used on the platform and the methods of
handling the transfer of consumables onto and around the platform.

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