MELIWIS DEVELOPMENT PROJECT –

CONSTRUCTION AND ENGINEERING

BLANKET STRUCTURE – PIPING
PROCEDURE
SUPPLY AND FABRICATION SERVICES
Consortium BOS - BMDA
DOCUMENT NO. 9706-120-PRO-1004 REV. 0
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CONSTRUCTION AND ENGINEERING PROCEDURE

Contract No. 904094

UNAUTHORIZED COPYING OF THIS DOCUMENT IS NOT PERMITTED

Project
Rev Date Purpose Originator Checker Contractor Company Date
Engr
0 09 Apr 19 Issued For Review WHY FR DC OY
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RECORD OF REVISIONS

THE REVISIONS LISTED BELOW HAVE BEEN INCORPORATED IN THIS COPY OF THE
DOCUMENT

Rev Implemented
Section Page Company Comment Explanation
No. (Y/N)
added section for
its totally confuse between explain in more
title and content? the detail about
E1 General 7 Y
content is most like construction and
engineering scope put in (and) word
in the title
Need to consider to
added:
For any utilization of
repaired/used/recondition added those
E1 Material 9 Y
material, it shall be statement
approved first by QA/QC
material inspector,
Discipline Engineering.
Need to consider to
added:
For Any modification,
substitution and alteration
from approval
added those
E1 Fabrication 10 construction, it shall be Y
statement
approved by Discipline
engineering, filed
engineering or other
authorized parties
.
Need to consider added We are added
new paragraph regarding: new section
E1 Fabrication 10 Y
Fit-up and Alignment & based on
please specify request
Please added:
All welding shall conform
added those
E1 Welding 10 to requirement of Y
statement
ANSI/ASME B31.3 and
this specification
All welding fabrication
activities shall be carried
out base on approved added those
E1 Welding 10 Y
construction drawing, statement
strictly follow the used
qualified WPS PQR and
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comply with codes,

standard and specification

Please added:
Weld Map & NDT plan added those
E1 Welding 11 Y
shall be prepared for each statement
of fabrication activity.
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Table of Contents
1.0 INTRODUCTION ......................................................................................................................................... 5
1.1 PROJECT OVERVIEW ..................................................................................................................... ....5
1.2 PROCEDURES OVERVIEW ................................................................................................................. 6
2.0 SCOPE ........................................................................................................................................................ 6
3.0 DEFINITION ................................................................................................................................................ 6
4.0 CODES, STANDARDS AND REFERENCES ...................................................................................................... 7
4.1 International Codes and Standards ................................................................................................... 7
5.0 UNITS......................................................................................................................................................... 7
6.0 LANGUAGE ................................................................................................................................................ 8
7.0 SPECIFICATION ........................................................................................................................................... 8
7.1 Quality Control................................................................................................................................. 8
7.2 Engineering Shop and As-Build Drawing ........................................................................................... 9
7.3 Engineering Calculation .................................................................................................................... 9
7.4 Materials........................................................................................................................................ 10
7.5 Fabrication ..................................................................................................................................... 11
7.6 Fit-up and Alignment...................................................................................................................... 12
7.7 Welding ......................................................................................................................................... 13
7.8 Erection/Handling .......................................................................................................................... 14
7.9 Flanging and Bolting ....................................................................................................................... 14
7.10 Coating .......................................................................................................................................... 15
7.11 System Completion ........................................................................................................................ 15
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1.0 INTRODUCTION

1.1 PROJECT OVERVIEW

The Meliwis field is located in the Madura Offshore PSC in the Madura Straits approximately
46 km south of Madura Island and 142 km east of Surabaya. The field is 11 km south of the
Maleo gas field, which is commenced gas production in September 2006.

Figure 1.1 – Meliwis Field Location (Maleo PSC)

The Madura Offshore Production Sharing Contract (PSC) is operated by Santos (Madura
Offshore) Pty Ltd on behalf of the Madura Offshore PSC Joint Venture with participant equity
interests as follows:

Santos (Madura Offshore) Pty Ltd 77.5%

PC Madura Ltd 22.5%
The Meliwis field was discovered by the Meliwis-1 well in April 2016, which encountered a
53 m gross column in the Upper Mundu, GlobigerinidLimestones. Two drill stem tests
(DST’s) were carried out, with a maximum test rate of 13.07 MMSCFD.

A conceptual study was performed in 2017 by Santos which concluded that the optimum
development option is a minimum facility wellhead platform option tied
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1.2 PROCEDURES OVERVIEW

This Standard Specification is applicable to all new project within OPHIR-Energy Assets
under Construction of The consortium of BOS-BMDA and. Projects designed to upgrade or
expand an existing facility may choose to remain consistent with the design philosophies or
Specification already in place at that facility or use this Specification only in areas that do not
conflict with the facility’s existing Specification.

The document shall not be altered or revised without review and approval by the Technical
Authority assigned to this standard specification. Revisions and addendums to this standard
specification shall be approved by the OPHIR-Energy. Each deficiency of this standard
specification must follow other specifications in the related subject/section.

2.0 SCOPE

This specification defines the minimum technical requirement for fabrication and erection
both for shop and field fabricated and erection.

This document and the codes, specifications and referenced documents listed below are
not intended to be all-inclusive. The requirements set forth do not relieve Contractor of his
responsibility to perform all services in a safe manner, to meet applicable codes and
standards, to comply with government regulations or to supply a product capable of
performing its intended service.

This standard specification shall be used by Contractor to ensure uniformity of approach in

design within the engineering team.

3.0 DEFINITION

Term Definition
Company OPHIR-Energy
Consortium BOS-BMDA
Purchaser Persons responsible for procurement of equipment,
material and or services
Shall Shall is an absolute requirement which shall be
followed strictly when referenced
Should Strongly recommended suggestion
Standard Specification Business unit standard technical specification
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4.0 CODES, STANDARDS AND REFERENCES

The following section of this specification may define specific codes and standards which
must be followed. However, when there are conflics or when no design codes or standards
are specified, Contractor shall perform the design on the basis, standards and practice.
4.1 International Codes and Standards

International codes and standards to be referred to :

 American Society of Mechanical Engineers (ASME)

No. Standard Description
1 ASME B31.8 Gas transmission and Distribution Piping System
2 ASME Section II Part Material Specification
A-C
3 ASME Sect IX Welding and Brazing, Qualification

 American Petroleum Institute (API)

No. Standard Description
1 API RP 14E Welding Guidelines for the Chemical, Oil and Gas
Industries
2 API Specification 5L Specification for Line Pipe

 American Welding Society (AWS)

No. Standard Description
1 B1.10 Guide for the Non-Destructive Inspection of Welds
2 D1.1 Structural Welding Code-Steel

 International Standard of Organization (ISO)

No. Standard Description
1 ISO. 10721-2 Steel Structures
2 D1.1 Structural Welding Code-Steel

5.0 UNITS

There is a mix of imperial units, metric units, and various other systems of units on existing
OPHIR drawings and documents. As general rule, The consortium of BOS-BMDA shall use
consistent units to those on the original drawing or document, whenever revisions to these
existing documents are required.
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6.0 LANGUAGE

All documents, drawings, specifications, vendor data, reports and all other written
information prepared by Contractor or by Suppliers to Contractor for the work shall be in the
English Language. Any document submitted to Company by Contractor which does not
comply with this requirement will be rejected until such time that Contractor resubmits the
document in English Language.

The only exception to this requirements is that all maintenance and operating manuals shall
be furnished separately in English editions and in Indonesian language editions.

7.0 SPECIFICATION

7.1 Quality Control

 The consortium of BOS-BMDA shall have a quality control system and quality control
covering all fabrication activities. Controlled copies of the quality control manual shall be
available for OPHIR approval and for monitoring of all construction activities.
 The consortium of BOS-BMDA shall establish detailed procedures for control of welding
quality. The following procedures shall be submitted for review and approved by OPHIR-
Energy prior to starting fabrication :
a. Welding and weld repair
b. Storage, control, and identification of welding consumable
c. Welder qualification records
d. Inspection/NDT
e. Post-weld heat treatment, if required
f. Monitoring the progress and quality of welding

 The consortium of BOS-BMDA/Supplier shall ensure the “in progress” material

documentation is maintained on a daily basis. All materials, which require documentation
in use during fabrication or installation that cannot be identified with documentation shall
be immediately removed from area and replaced at the consortium of BOS-
BMDA/Supplier expense.
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 All Structure and piping materials shall be provide with Mill Test Report or Certified
Test Report. The reports shall be identify the type of steel, composition, heat number
and any special test that has been performed

7.2 Engineering Shop and As-Build Drawing

 The consortium of BOS-BMDA shall prepare piping isometric and spool drawing for all
piping. The isometric drawings should show spool numbers, welded attachments,
location and type of welds (shop or field).
 The consortium of BOS-BMDA shall prepare shop drawing for Topside and other
detailed drawing based on contract project with OPHIR-Energy.
 The consortium of BOS-BMDA shall prepare all shop drawing and spool drawing refer
to Plan drawing and detailed drawing for determine all elevations, sections, and
dimension of object related.
 The consortium of BOS-BMDA shall maintain an up to date, complete and accurate
record of all changes made to design drawing during the fabrication and erection of the
structure and piping.

 Each piece of major equipment shall be identified on the drawings. The identity shall
correspond to the title and tag number indicated.
 Each shop drawing that produced shall be identified with the drawing number in
accordance with the OPHIR-Energy details drawing related.

7.3 Engineering Calculation

All calculations prepared by consortium of BOS-BMDA shall comply with the minimum
requirements defined in the following :
a) Each calculation shall be identified by a subject description consisting of Company
number, discipline, and descriptive tittle.
b) Names of the persons preparing and checking the calculation shall be entered with the
first initial followed by the full last name. Names shall be printed rather than written.
Dates shall refer to the day each person started working on the calculation.
c) All assumptions shall be clearly stated after defining the problem, including references,
if any.
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d) Sources of formula, equations, data and other references used in the calculations shall
be clearly stated.
e) Numerical approximations and other "judgement" type assumptions made by the
preparer shall be identified with phrases similar.
f) All logical steps shall be numbered and identified with a brief phrase.
g) A summary of all significant results and/or conclusions shall be made at the end of the
calculation.
h) Calculations shall be made using the units defined in this Scope of Work.
i) Calculations shall not be considered valid until they have been checked by a second
qualified person. The checker will mark through incorrect item sand write the correct
item adjacent to them. Checkers shall not erase data from the computation. The
checker will return the calculation to the prepared when checking is complete
j) Calculations shall be prepared to support all significant design engineering decisions,
and, where applicable, shall be referenced to the appropriate drawings.
k) Copies of significant drawings, sketches, graphs, and other original work shall be
included as part of the calculation.
l) Computer calculations shall be supported by print outs which clearly defined all input
data, results and the method consortium of BOS-BMDA.

7.4 Materials

 Material used for structure and piping shall meet the requirement of OPHIR material
specifications or request by OPHIR.
 Special attention shall be paid to segregation of carbon steel and corrosion resistant
alloy materials during storage, fabrication, transport and handling. All necessary
measures shall be taken to prevent contamination of stainless steel, duplex or
superduplex materials. The area used for storage of fabrication of stainless steel
material shall be segregated from areas where carbon steel is stored or fabricated.
Tools for cutting, grinding and similar operations on carbon steel shall not be used for
stainless steel.
 If any utilization of repaired/reused/recondition material, the consortium of BOS-BMDA
shall be needed approved by QA/QC material inspection or discipline engineer from
OPHIR-Energy
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 The consortium of BOS-BMDA shall submit to Company for approval a written

procedure covering material receipt, inspection and storage. The procedure should
cover but not limited to:
a. Defective materials,
b. Storage and Segregation,
c. Materials allocation,
d. Transfer of Markings for trace ability

7.5 Fabrication

 Piping shall be fabricated in accordance with the requirements of this specification and
the latest edition of the piping codes and regulations specified under the individual
material specification classes
 Steel Structure shall be fabricated with the requirement of this specification and refer to
shop drawing that has been approved by OPHIR or based on request by OPHIR.
 Piping design drawings and piping line isometrics shall govern dimensions and
materials.
 Steel Structure design drawings and Shop drawing shall govern dimensions and
materials.
 Where field welds are designated, the prefabricated pipe and steel structure should be
cut off to suitable over lengths longer than the dimensions shown on the fabrication
drawings to allow for precise fit-up in place. The location of field welds where not
indicated on the drawings will be the responsibility of the general Contractor.
 The consortium of BOS-BMDA shall maintain "clean" fabrication areas for the
fabrication of stainless steel and nickel alloy piping to minimize the possibility of
contamination.
 The consortium of BOS-BMDA shall utilize shop tools and equipment compatible with
materials in fabrication, including but not limited to grinding discs, cutting tools, and
wire brushes designed for use with stainless steel and/or other high alloy materials.
 Where reinforcement pads (doublers) or saddles are required they shall be of the same
material as the run pipe or steel structure (unless specified otherwise) and shall be
formed and contoured to provide a good fit.
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 For any modification, substitution and alteration from approval construction drawing, it
shall be approved by discipline engineering, field engineering or other authorized
parties.

7.6 Fit-up and Alignment

 For fit-up activities shall be conform to requirement of this specification

 Before fit-up activities, fitter must obtain approval from QC and Engineer of the
consortium of BOS-BMDA to ensure the material cutting profile matches the approval
construction drawings.
 After fit-up material, from QC and Engineer of the consortium of BOS-BMDA need to
check the orientation, shape and dimension to ensure compatibility with approval
construction drawings.
 Gap maximum and minimum fit-up of steel structure must be following figure 7.1
Shape connection of profile must be following figure 7.2.

Figure 7.1. Butt weld connection and fillet connection

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Figure 7.2. Shape of connection main beam to branch

 Cleaning and internal surface shall be free of rust, grease and paint for at least 13mm
from the root face

Figure 7.3. Shape of connection main beam to branch

7.7 Welding

 Welding process, welding procedure and welder performance qualification shall comply
with requirement of code and standard ANSI/ASME B31.3, AWS D1.1 and this
specification.
 All welding fabrication activities shall be carried out base on approved construction
drawing, strictly follow the used qualified WPS PQR and comply with codes, standard
and specification
 Welding Spacing
a. Circumferential butt welds shall be separated by the maximum possible distance
and not less than 1 x D without written approval from OPHIR. However, between
piping fittings, etc., short pipe lengths may be required. In this situation, butt welds
shall not be within 3 inches (75 mm) of adjacent butt welds. For pipe sizes less than
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3 inches nominal bore, butt welds may be within the greater of 4 times the wall
thickness or one pipe diameter of adjacent butt welds, whichever is greater.
Circumferential butt-welds closer than the above limits shall be brought to the
attention of the OPHIR representative for approval
b. Longitudinal but weld shall be separated by maximum possible distance and not
less than 2in without written approval from OPHIR.
c. Welding gap for piping and steel structure is ± 3mm or based on request by OPHIR-
Energy.
 Welder and Welding Operator shall be qualified in accordance with essential variable
of ASME section IX.
 Welding Map & NDT plan shall be prepared for each fabrication activity.

7.8 Erection/Handling

 Piping and Steel Structure shall be erected in accordance with detailed drawing
 All component shall be installed true based on related drawing
 Erection of piping and steel structure shall be scheduled so that no undue strain will be
inflicted on equipment due to lack of support, dead weight or misalignment. It shall be
design, fitted and assembled / erected strain free without any misalignment.
 Piping which has been painted prior to erection shall be handled with care to avoid
damage to coatings.
 The consortium of BOS-BMDA shall provide padded slings or straps for handling coated
pipe or steel structure and nonferrous padded slings for stainless steel and alloy steel.
The consortium of BOS-BMDA shall exercise care in lowering, assembling and installing
all coated piping.
 Internal grinding or machining may be conducted to improve root alignment of
misalignment equal to or less than 1/16” (1.6 mm). However, the taper shall not exceed
1 in 4 and the minimum wall thickness shall be maintained.

7.9 Flanging and Bolting

 Flange bolt holes shall straddle horizontal and vertical centre lines unless noted
otherwise on the construction drawings.
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7.10 Coating

 All process piping and component shall be coated in accordance with applicable
consortium of BOS-BMDA Coating Standard Specification.
 In general, piping shall be blasted and painted up to the final coat of paint prior to
installation on skid packages or platform interconnections.

7.11 System Completion

 Piping
In order to demonstrate system completion ready for pre-commissioning consortium of
BOS-BMDA shall carry out a ‘line by line’ walk to check the system and its components
have been installed in accordance with the latest revision of the P&ID’s. The installed
system shall also be checked against the isometric and pipe support design for
compliance and a punch list produced of outstanding items for rectification
 Steel Structure
In order to demonstrate system completion ready for pre-commissioning consortium of
BOS-BMDA shall carry out a ‘Structure by structure’ walk to check the system and its
components have been installed in accordance with the latest revision of the Detail
Drawing. The installed structure shall also be checked against the shop drawing design
for compliance and a punch list produced of outstanding items for rectification