EAST BENGKALAM FIELD

DEVELOPMENT PROJECT
PHASE 1&2
BKL-SMPL1&2/EPSCI
PT. CTR INDO
P T. CP Y INDONES IA

EAST BENGKALAM FIELD PROJECT

DEVELOPMENT

PILING PROCEDURE
 PT. CTR INDO
P T. CP Y INDONES IA

PILING PROCEDURE

COMMENT REVIEW SHEET

Section/ Contractor
No Contractor Energy Comments Remarks
Page ref. Response

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P T. CP Y INDONES IA

PILING PROCEDURE
REVISION DETAIL TABULATION

DATE PAGE REVISION REVISION DETAILS

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Table of Contents

1 GENERAL..................................................................................................................... 5
1.1 PROJECT DESCRIPTION.............................................................................................5
1.2 PURPOSE..................................................................................................................... 6
1.3 REFERENCE.................................................................................................................7
1.4 DOCUMENT ORDER OF PRECEDENCE.....................................................................7
1.5 DEFINITION................................................................................................................... 8
1.6 ABBREVIATION............................................................................................................8
2 GENERAL..................................................................................................................... 9
2.1 RISK ASSESSMENT.....................................................................................................9
2.2 ROLES AND RESPONSIBILITIES.................................................................................9
2.3 TOOLS AND EQUIPMENT..........................................................................................11
3 EXECUTION................................................................................................................ 11
3.1 PREPARATION........................................................................................................... 11
3.2 PILE HANDLING, TRANSPORTING AND STORAGING.............................................12
3.3 PILE RECORD............................................................................................................. 12
3.4 PILING TESTING.........................................................................................................13
3.5 PILING WORK............................................................................................................. 17

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1 GENERAL

1.1 PROJECT DESCRIPTION

PT. CTR Indo (Company) is operator of the Bengkalam Field, Indonesia. The field comprises two
Phase (1&2) and the Area Production Facility (APF). The produced fluids are oil, associated gas
and produced water. Production from Phase 1 and 2 began in the 4th quarter 2011. According to
the Bengkalam Optimized Development Plan, production from two new Phase (Phase 1&2) will
start up in the 3rd & 4th quarter 2013.
New pipelines are required to connect Phase 1 and 2 with the APF. New well testing facilities are
required since the number of production wells will increase. Production from Phase 2 will be routed
to Phase 1 and share a common pipeline to the APF. Phase 3 will have a new independent pipeline
connecting to the EPF, about 3 km away.
PT. Contractor Energy (henceforth referred as “CONTRACTOR”) has been awarded an EPCI
contract for Phase 1&2 Intra-field Flowline Project.

LOCATION

LOCATION MAP
East Bengkalam Field

(Location Map)

1.2 PURPOSE

The purpose of this document is to provide the detail method and sequence and requirements for
transporting, handling, storaging and piling operations during construction work of East Bengkalam
Field Project Development.

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1.3 REFERENCE

The following documents are referred in this document.

DOC NO. REV. DOCUMENT TITLE
A. Indonesian Acts and Regulations
- - - -
B. Project Documents (Specifications, Datasheets, Drawing, MR/MTO etc.)
[B1] AKT-CI-SP-00-010-0002 A Specification for Reinforced Concrete

C. COMPANY Specification
Wellpad C & D EPCI Technical
[C1] AKT-GE-SW-20-010-0001 1
Specification
[C2] AKT-GEN-BOD-23-000-001 8 Wellpad C & D EPCI Basis of Design

D. International Codes and Standards

Building Code Requirements for
[D1] ACI 318 – 08 - Structural Concrete with Design
Applications.
Standard Test Methods for Pile under
[D2] ASTM D1143 -
Static Axial Compressive Load
Standard Test Method for Individual Piles
[D3] ASTM D3689 -
Under Static Axial Tensile Load
Standard Methods of Testing Piles Under
[D4] ASTM D3966 -
Lateral Loads
Standard Specification for Deformed and
[D5] ASTM A615 - Plain billet Steel Bars for Concrete
Reinforcement.
Standard Specification for Concrete
[D6] ASTM C33-08 -
Aggregates
[D7] AWS D 1.1 - Structural Welding Code
Design, Manufacture and Installation of
[D8] ACI 543-00 -
Concrete Piles

1.4 DOCUMENT ORDER OF PRECEDENCE

All WORKS shall be performed in accordance with the following order of precedence of the
following codes and standards:
 Indonesian Act and Regulations.
 Project Specification and Datasheet.
 COMPANY Specification
 Internationally recognized Codes and Standards.
 Good engineering practice.
In case of conflict between the requirements of this specification with its attachments and the
referenced specifications or codes and standards, CONTRACTOR/VENDOR shall bring the matter
to the COMPANY’s attention for resolution and Approval.
It is CONTRACTOR’s/VENDOR’s responsibility to present the issues and/or differences among the
codes and standards above to the COMPANY for resolution. The more stringent requirement shall
prevail unless otherwise advised by COMPANY.

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Any latest amendments / new additions to the standard and regulation shall be incorporated.

1.5 DEFINITION

In and throughout this document, unless the context otherwise requires, the following definitions
apply:
COMPANY : PT. CTR INDO EAST BENGKALAM FIELD
CONTRACTOR : PT. CONTRACTOR ENERGY
SUB CONTRACTOR/
VENDOR/SUPPLIER : Party which supplies equipment/materials or services specified and
ordered by CONTRACTOR (or COMPANY). Vendor Covers
“Manufacturer”
Shall : Means absolute requirement to be followed strictly in order to
conform the philosophy
Should : Means recommendation, alternative solutions having the same
functionality and quality are acceptable
May : Means course of action that is permissible within the limits of the
philosophy

1.6 ABBREVIATION

Abbreviation Description

ANSI American National Standards Institute

AOTS Akatara Oil Transportation System

API American Petroleum Institute

CS Carbon Steel

EPCI Engineering, Procurement, Construction and Installation

EPF Early Production Facility

FEED Front End Engineering Design

FJC Field Joint Coating

HC Hydrocarbon

HDD Horizontal Directional Drilling

ID Inside Diameter

ISO International Organization for Standardization

MEI Meindo Elang Indah

MEL Mandala Energy Lemang

NPS Nominal Pipe Size

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OD Outer Diameter

PCI PetroChina International Ltd.

ROW Rights of Way

SP Standard Practice

TBC To Be Confirmed

WT Wall Thickness

2 GENERAL

2.1 RISK ASSESSMENT

Before site project execution, it is require to perform an assessment to identify the risk level that will
appear during site project execution, every step of job have its own risk, therefore early
identification of risk shall be done in order to support the overall project execution.
Below step shall be done in order to identify the risk level:
 Gathering information and identify the issues
 Assessment to all facts
 Action plan based on assessment
 Communication of action plan
 Implementation
 Monitoring

2.2 ROLES AND RESPONSIBILITIES

2.2.1 Construction Manager

He responsible to manage site facilities and utilities as required during construction works or as per
project condition, communicate with COMPANY site representative about related issue of the work.
Prepare, support and maintain requirement of all construction activities. Coordinate with client and
in-house related field counter parts.

2.2.2 Field Engineer

He is responsible to ensure that the piling works are done as per COMPANY requirement and
specification.

2.2.3 Piling Supervisor

Perform piling activities according to the latest drawing, specification and procedure. Perform the
piling activities as are pre construction schedule. Manage the piling equipment utilized properly and
effectively. Ensure that the work follow the proper safety work methods, regulation and
requirements.

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2.2.4 Lifting Supervisor
Lifting Supervisor is responsible to check the validity, condition and availability of all lifting tools and
equipment’s, which will be used for unloading pile and piling work. Coordinate with Pilling
Supervisor during pilling activities work as per approved procedure, COMPANY Specification and
HSSE Requirements.

2.2.5 HSSE Officer

The HSSE officer shall be responsible for the implementation of the HSSE plan, Security Plan and
compliance with all statutory regulation.

2.2.6 Maintenance Supervisor

Maintenance supervisor shall be responsible to maintenance lifting gears such as “webbing sling,
shackle, wire sling, steel plate and crane/excavator accessories”. He shall also to make sure that all
lifting gears shall followed color code as approved by COMPANY.

2.2.7 Crane Operator

The Crane Operator is responsible for:
 Correctly operating the equipment in accordance with the manufacturer’s instruction and the
safe work practice,
 At any time responding to the Signalman,
 Performing the daily pre-use inspection and recorded.
 Filling up the equipment log book and recording any mechanical, or structural defect and any
incident or accident, or unusual occurrence, reported to the relevant superintendent,
 Ensuring communication with signalman use radio and hand signal
 If in doubt, crane operator must stop and repeat the Tool Box Talk (TBT) with all lifting teams
 Follow the signal from the signalman until the job is finish
 Ensure all safety devices installed and function properly
 Ensure load chart table available
 Operate crane max 80 % of capacity crane in accordance with valid crane load chart / table.

2.2.8 Signalman
He shall ensure that clear and precise commands are given to the operator of the lifting equipment,
either in carrying out the lifting operations or when the equipment is being move.
Signalman is responsible for:
 Ensure the work permits are available prior to lifting operation
 Relaying signals to the crane operator and for initiation and direction of safe movement of the
lifting equipment.
 Agree method of signaling with the crane operator
 Ensure Communication with crane operator use radio and hand signal
 Ensuring a tool capable of lifting used to more objects
 Implemented the lifting check list before lifting and sign it

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 Standing in the right position so it can see the rigger and the load well and also seen by the
crane operator properly
 Using jacket or a sing to be easily identify as signalman
 Directing the safe movement of the equipment and its load to maintain the safety of all
personnel,
 Being thoroughly trained in a hand-signaling system,
 Check the attaching, detaching of slings to and from the load,
 Ensure that nobody is within crane radius during lifting operation

2.2.9 Riggers
Riggers are appointed where it is necessary to ensure those loads are correctly attached to the
lifting equipment. He will gate assessment by COMPANY
Rigger is responsible for:
 Ensuring the safe movement of the equipment and its load to maintain the safety by using tag
line.
 Being thoroughly trained in a handling system,
 Attaching, detaching slings to and from the load
 Follow the signal from the signalman until the job is finish

2.2.10 Quality Control Inspector

The QC Inspector shall be responsible for daily inspection for piling activity, conduct joint inspection
with COMPANY representatives and prepare all required inspection documents.

2.3 TOOLS AND EQUIPMENT

DESCRIPTION QUANTITY
Survey Tools 2 sets
Generator 1 unit
Welding Trafo & Welding Machine As required
Trailer Truck As required
Crawler Crane 1 unit
Pilling Crane As required
Rigger Tools As required
PDA Test Tools 1 set
Hand Tools As required

3 EXECUTION

The methods of handling, transporting, storaging and piling are made to avoid any damage to pile
by impact or by undue bending.

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3.1 PREPARATION

 Studying at site condition as below:

- Piling installation area will be crossed by swamp area, CTR to provide Crane mat for stability
equipment during installation.
- Piling installation, CTR will make sure existing pipe save from impact during installation.
- Method statement for both case state on Attachment “J” and “K”
 Studying drawing work and equipment as bellow:
- Piling Layout. (will use layout drawing approved, considering existing FRP location, refer to
appendix J and Appendix K)
- Setting axis out (coordinate), elevation, bench mark (BM) and preference.
- Penetration depth and or final set.
- Prepare form to be used.
 Prepare man power, crew piling, supervisor, officer safety, etc.
 The crane piling at the swampy area location will used crane mate to support the crawler crane
in good position. Crane mate will be developed using combination of coconut trunk, steel pipe
and steel plate, (refer to Appendix J crane mate sketch)
 The method at the existing FRP area which is some area is swampy will be use the same
method as above. During the piling activity there is no protection required on the existing
pipeline since the new pile will be 2-meter radius from the existing position. (refer to Appendix K
piling layout on the existing FRP area).
 Manual digging to be performed on random area to identify the actual position for existing
underground FRP pipeline.
 Any heavy equipment required to move above the existing FRP line, the mate protection will be
installed refer to appendix K mate protection above Existing FRP pipeline.
 Checked the readiness of working equipment/tools, piling rig and hammer which according of
the size and penetration deepness of pile (according engineer’s recommendation)
 Performing measurement and marking center line of pile base on approved engineering drawing

 Prepare access way, work position, material and equipment layout.

 Arrange pile close with piling point but do not obstruct piling rig access.
 Prepare working procedure attention stake column, starting point and final point to get fluently
sequence or according to job priority.
 Prepare pilling layout
- Piling layout as according engineering drawing.
- Marking deepness every 0.5 meter at pile with permanent clear paints (before piling).

3.2 PILE HANDLING, TRANSPORTING AND STORAGING

Piles handling, transporting, and storaging shall following manual as shown in APPENDIX A of this
document.

3.3 PILE RECORD

The following information shall be recorded for each pile during installation:
 Pile identification & Pile location
 Serial number and type of Equipment used to install the piles.
 Indicated the pile location, size, length, ground elevation, top elevation and penetration
 The log record blows for every 1,000 mm of pile penetration.
 Any unusual behavior or circumstances during driving such as re-driving, heaving, obstacles,
and interruptions that may occur.

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 Beginning and ending time for piling in for each pile section. This shall include time spent to
check position and verticality of pile, also other interruption during pile driving.
 Beginning and ending time to cut pile.
 Time lost due to bad weather, equipment failure, incidents, etc.
 Pile cut off elevation.
 As built coordinate of pile position and final depth penetration of each pile.
 Add final set for last 10 Blows

3.4 PILING TESTING

Pile testing will be performed at areas (Please see Appendix I for piling test location plan).
At each location, the pile test including PDA Test and Static Lateral Test shall be done for 8 nos PC
Spun Pile D300 consist of 4 pile 12 m length with penetration depth 11 m and 4 pile 18 m length
with penetration depth 17 m.
Pile test result shall be compared to single pile capacity for each penetration depth.
Single pile capacities as the result of calculation refer to Drawing/Document Piling Calculation and
summarized as below:

Area Pile Pile Axial Tension Lateral

Diameter Penetration Compression Capacity Capacity
(mm) Depth Capacity (ton) (ton)
(m) (ton)
SPT CPT SPT CPT
Data Data Data Data
Phase 1 300 11 1.73 1.34 1.63 0.64 1.76
17 52.67 2.91 14.50 1.53 1.76
Phase 2 300 11 1.96 1.21 1.47 0.64 1.76
17 8.20 4.98 7.10 2.34 1.76

3.4.1 PDA Test

Pile testing performed by using dynamic pile testing which is Pile Drive Analysis (PDA) Test.
Performing authorities for this job will be a 3rd party which has been approved by COMPANY.
The target of examination of pile with Pile Driving Analyzer (PDA) is to get data concerning:
1) Axial bearing capacity of pile
Determination of axial bearing capacity based on characteristic of wave bound given by soil
reaction (friction and cones).
2) Perfection / pile integrity
Damage pile foundation earn happened because some matters for example at the time of lifting
of spun pile or during pilling activities. This damage can be detected by PDA test. Based on F
(Force) and V (speed) which was recorded from wave during propagation as long as pile,
location of damage can detect from remain of wide area of pile can be estimated. If only

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perfection of just pile which required, a sub-system of PDA so-called Pile Integrity Tester more
economical to be used from PDA.
3) Efficiency of energy transferred
PDA measuring actual piling energy transferred during examination. Since piling hammer weight
and high fall stroke hammer known, hence efficiency of energy transferred can be calculated.
The pile dynamic test result shall be completed until interpretation and final report of the pile
capacity, including the assessment of the pile integrity.
Preliminary report of the PDA test shall be submitted to COMPANY as soon as possible for
guidance of piling activity.
Steps of PDA Test execution:
 Determine location and quantity of pile test.
 Piles to be tested shall have been driven for at least 7 days ago; to allow pile set condition and
has developed its friction capacity.
 Make sure that the pile head is straight, edge and have a flat surface. Pile to be cut if
necessary.
 Dig a hole around test pile with max depth 1 meter from top of pile, as safety protection for the
PDA Test tools and to reduce any vibration caused by load dropped during PDA Test.
 Marks location for 3 nos of 6 mm diameter holes on two opposite sides of the pile for the
attachment of strain transducer and accelerometer of the Pile Driving Analyzer. To avoid
irregular stress concentrations at the end of the pile, location of transducer is at least 1.5 times
of pile diameter from top of the pile. Make sure that both location of the transducer is
approximately 180o and located in a straight surface perpendicular to pile body.
 Drill 3 nos of 6 mm diameter hole on two opposite sides of the pile for the attachment of strain
transducer and accelerometer of the PDA Test tools.
 Attach strain transducer and accelerometer to the sided section of pile with bolt using wall
plugs.
 Connect strain transducer and accelerometer cable to PDA and its associated storage
computer equipment via a main 19-wire cable (up to 50 meter length).
 Check strain transducer and accelerometer cable connectivity of all instruments using PDA
equipment.
 Install wooden cushion to the pile head. This protection is considered necessary to protect the
pile top from being damaged.
 Lift and drop the load following PDA performing authority guidance.
 Input all data to PDA PAX.
 After test completed, the PDA Test data will be transferred and analyzed using CAPWAP
program to stimulate the load transfer in pile and soil behavior; such as friction, en-bearing
capacity, elastic and net settlement.
 Dismantle the transducer and accelerometer after test is done.
Tools and Equipment to be used as bellow:
 Pile Driving Analyzer ( PDA )
 Strain Transducer ( qty = 2 ea _valid calibrate )
 Accelerometer ( qty = 2 ea_valid calibrate )
 Cable connector
 Electric motor drill
 Wrench
 Drop Hammer

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Equipment can be packed into box (except Drop Hammer will be provided at site). Each set PDA
test requiring one or two box that is size about 600 x mm 500 x mm 400 mm, each weight about
30 kg. All equipment and tools used for proposed dynamic load pile test shall be inspected and
certified as applicable. Relevant inspection certificates shall be witnessed by CTR and CPY prior to
commencement of test.

3.4.2 Lateral Test

This test method covers procedures for testing vertical and batter piles either individually to
determine the load‐deflection relationship when subjected to lateral loading. It is applicable to all
deep foundation units regardless of their size or method.
The actual lateral load capacity of the pile‐soil system can best be determined by lateral testing.
METHOD
Lateral load test shall be performed when the spun pile has reached its requirement strength.
 The pile head to be chipped off up to 300mm above cut-off level
 The test to be conducted at cut-off level.
 The test area a radius of 6 m from the test pile shall be excavated or filled to the final grade
elevation before testing the pile.
 Lateral test load shall be applied at approximately pile cut-off elevation
 Bearing plate shall be of adequate thickness to prevent bending under the applied load but
shall not be less than 50mm thk.
 Lateral load shall be applied using one hydraulic cylinder equipped with spherical bearing,
connected to a common manifold and pressure gage, and operated by hydraulic pump.

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PROCEDURE OF LATERAL STATIC LOADING TEST
Static lateral loading test carried out in accordance with American Society for Testing Materials
(ASTM) Designation D 3966-07.
200% OF THE DESIGNED LOAD – LATERAL TEST
MINIMUM TIME OF
DESIGNED LOAD ( % )
HOLDING LOAD ( MIN )
0 -
25 10
50 10
75 15
100 20
125 20
150 20
170 20
180 20
190 20
200 60
150 10
100 10
50 10
0 10

Lateral test load: 2.0 Ton x 2 = 4.0 Ton (200% x maximum single pile lateral load plan).
Following each application of an increment of load the load shall be held for not less than period
shown in the above table. For any period when the load is constant, time and settlements shall be
recorded immediately on reaching the load and prior to the next step of load.
Tools and Equipment to be used as bellow:
 Hydraulic Jack
 Water pass/Theodolite
 Concrete block
 Dial Gauge
All equipment and tools used for proposed static load pile test shall be inspected and certified as
applicable. Relevant inspection certificates shall be witnessed by CTR and CPY prior to
commencement of test. Dial gauge valid calibration shall be produced for verification.

3.5 PILE TEST

All test piles 8 point shall be driven prior to installation of foundation piles in location designated by
COMPANY representative.
CONTRACTOR shall supply and installation the pile test, complete with reaction piles and
everything required for the performance of load test under ASTM D1143 codes.

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CONTRACTOR shall furnish a drawing of proposed test setup connection, and equipment, for
approval by COMPANY. Pile load test shall be performed in the presence of soil expert and
COMPANY representative.
A report presenting the test results shall be provided to the COMPANY.

3.6 PILING WORK

Methodology of Pilling Works is described below:

 Coordinate with COMPANY about sequence of work include the priority to be done first with
considering of schedule and work accessibility as per Work Procedure, Safety Requirement
and Effective Productivity.
 Synchronizing signal marking to be used during works for surveying and boundary marking to
differ for any pilling points with building points or any other points.
 Piling coordinate point will be set out according to drawing (IFC status).
 To prevent any displacement of all points, Reference Points must be prepared using
permanent sign.
 Check the center point of pilling against reference points with surveying tools (theodolite), if
there is any displacement, pilling points must be moved or relocate to the exact coordinate.
 Check verticality in X and Y axis plan every pile before, during and after pilling every 50 cm up
to 2 meter depth.
 Positioning Piling Crane in to its coordinate, check flatness of Crane using Water-pass
available inside Operator Cabin and Water-pass placed in the Crane.
 Marking all pile every 500 mm for Pile Driving Report & to meet target penetration.
 Transfer pile from stock pile to pile point using excavator / Crane.
 Pile which still lies above ground, will be erect by Service Crane using one lifting point (as per
drawing in section 3.2 Pile Handling).
 Lift up the 1st section of pile with main hooks.
 Insert 1st section of pile into piling position, check for position of pile.
 Perform survey check on position and verticality of pile. Checking shall be performed using
theodolite for X-Y axis plan.
 Continue lowering down the pile slowly & carefully until the pile stop and stable on its position.
During lowering process, survey team shall monitor and report deviation in X-Y axis plan of the
pile. Take corrective action if any tendency shows no good.
 The initial pile shall be self-penetrate due to its own weight and hammer.
 Perform survey check on position and verticality of pile. Adjust pile position and verticality if
needed.
 Record pile penetration due to self-weight of the pile and drop hammer.
 After position and verticality of pile is in tolerance, start drives the 1st section of pile.
 Stop the pile driving when the pile depth reaches the design penetration.
 Lift up the pile hammer and move to the next pile location.
 Welding PC pile Splice
 Welding inspection and coating (after welding joint shall be clean)
 Visually inspected and NDT tested with Dye Penetrant.
Tolerance of piling work shall be as follow:
 For a pile cut-off or above ground level the maximum permitted deviation of the pile center from
the point shown on setting out drawing shall be 100mm in any direction
 Angle of Rake shall be less than 2/100 of length.

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- APPENDIX A - Handling Manual of Spun Pile
- APPENDIX B - Piling Record Form
- APPENDIX C - Piling Equipment Drop Hammer 3 ton
- APPENDIX F - Lifting Operation Plan (LOP)
- APPENDIX G - Sketch Arrangement PDA Test Equipment
- APPENDIX H - Schematic Lateral Static Load Test Pile
- APPENDIX J - Piling Method on Swampy Area
-

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Handling Manual of Spun Pile
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APPENDIX B
Piling Record Form

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APPENDIX C
Drop Hammer 3 Ton

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APPENDIX D
Piling Rig using Crawler Crane CX-50

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APPENDIX E
Service Crane using Telescopic Crane SWL 45 ton

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APPENDIX F
Lifting Operation Plan (LOP)

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APPENDIX G
Sketch Arrangement PDA Test Equipment

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APPENDIX H
Schematic Lateral Static Load Test Pile

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APPENDIX I
Piling Test Location

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APPENDIX J
Piling Method Layout on Swampy Area

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APPENDIX K
Piling Method Around Existing FRP Pipeline

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