PROJECT PROCEDURE SHEET 1 OF 12

OPERATING INSTRUCTIONS COLD CUTTING

84512 – 4430 – 2R – 002

HANG TUAH MODIFICATION

PROJECT
CS70 – 12616

D 10 Sep 2006 IFR

REV DATE ISSUE PREP’D CHK’D APP’D COPI Approved

 MODIFICATION PROJECT

TABLE OF CONTENT

1.0 OBJECTIVE .................................................................................................................................................... 3

1.1 SAFETY STATEMENT ................................................................................................................... 3
2.0 GENERAL ....................................................................................................................................................... 3
2.1 DEFINITION OF PARTIES ............................................................................................................ 3
2.2 PROJECT TITLE ............................................................................................................................. 3
2.3 ABBREVIATIONS ........................................................................................................................... 3
3.0 OPERATING INSTRUCTIONS INTRODUCTION 10” – 16” PIPE CUTTING EQUIPMENT ........... 3
4.0 MACHINE MOUNTING AND OPERATION ............................................................................................. 4
4.1 PRIOR TO MOUNTING THE MACHINE, ENSURE THAT: .................................................... 4
4.2 THE MACHINE MAY BE MOUNTED TO THE PIPES AS FOLLOWS: ................................ 4
4.3 STRADDLE MOUNTING ............................................................................................................... 4
4.4 JUDUL 4 ............................................................................................................................................ 6
4.5 JUDUL 5 ............................................................................................................................................ 6
4.6 JUDUL 6 ............................................................................................................................................ 6
4.7 WHEN CUTTING IS COMPLETED ............................................................................................. 6
5.0 CUTTING PRECAUTIONS .......................................................................................................................... 6

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1.0 OBJECTIVE

This procedure outlines the detailed requirements for Operating Instructions Cold Cutting
for the execution of the CONOCOPHILLIPS INDONESIA INC. LTD., HANG TUAH
MODIFICATION PROJECT.

1.1 SAFETY STATEMENT

Sarku Enjinering Utama, PT, the contractor for the ConocoPhillips Indonesia Inc.
Ltd. will execute the project following the project execution plan outlined in this
document within the guidelines of ConocoPhillips Indonesia Inc. Ltd. and Sarku
Enjinering Utama, PT Safety Health and Environmental policies.

“Safety in the workplace is paramount and will take priority over financial or
material concerns.”

2.0 GENERAL

2.1 DEFINITION OF PARTIES

COMPANY : CONOCOPHILLIPS INDONESIA INC.

LTD.

CONTRACTOR :

2.2 PROJECT TITLE

Project Title : HANG TUAH MODIFICATION PROJECT

Contract Type : EPC CONTRACT

Company Contract No. : CS70 – 12616

2.3 ABBREVIATIONS

COPI = ConocoPhillips Indonesia Inc. Ltd.

3.0 OPERATING INSTRUCTIONS INTRODUCTION 10” – 16” PIPE CUTTING

EQUIPMENT

The 10” – 16” machine is a lightweight portable pipe cutting machine, designed for the
in-situ cutting and machining of tubes and pipes.

Its lightweight construction and split body design enables it to be used on continuous run
pipe and the simple clamping system makes it quick and easy to set up.

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All settings and adjustments are made with only a few tools and the use of form cutting
tools make weld preparations and difficult machining operations more readily achieved.

The machine consists of a clamping and bearing assembly to which is fitted a faceplate
with an integral drive gear. Toolboxes are fitted to the faceplate and a range of toolboxes
are available to cover any machining operation i.e. cutting and beveling, out of roundness
compensation, counter boring etc.

The machine has a four position clamping system, each clamp being independently
adjustable and range of clamp inserts are supplied to cover any size of pipe or tube.

Drive is provided via an air motor which transmits drive to the faceplate. As the faceplate
rotates, the striker wheels on the tool slide feed screws are indexed via contact with the
striker pin. This motion continues until the cutting tool contacts the pipe and
subsequently machines the required profile.

4.0 MACHINE MOUNTING AND OPERATION

4.1 PRIOR TO MOUNTING THE MACHINE, ENSURE THAT:

• The faceplate item 1 and clamping item 12 split lines are aligned.
• The faceplate retaining screws are securely tightened. Release lock-nut at item
5 (four positions) and tighten the four locking screw item 5.
• The tool slides are fully retracted and the striker pin disengaged.

4.2 THE MACHINE MAY BE MOUNTED TO THE PIPES AS FOLLOWS:

• Select the clamp inserts to suit the pipe to be cut (set of four). The clamp
inserts are identified with the pipe range marked on the side.
• Assemble the required clamp insert set to the clamping jaws items 24, 25 &
26 and fasten in position by tightening the captive screws.
• Adjust the clamp screws item 11 such that the distance between opposing
clamps jaws is approximately equal to the pipe outside diameter. The distance
between the clamping jaws and the clamping must be equal on all four
positions.

Fully retract the lower two clamps.

The machine may be assembled to the pipe in a number of ways.

PS. Please refer to drawing no. LC0236M

4.3 STRADDLE MOUNTING

• Ensure that the locking screw item 5 is fully tightened and the swivel hinges
item 17 is well fitted to the base of the clamping item 20.
• (ii) Release both the faceplate and clam ping’s secure screws item 18 and 23
using the supplied allen key.
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• (iii) Assemble the machine over the pipe to be cut, re-engaging the location
pins and fastens both the faceplate and clam ping’s secure screws.

NOTE:

Care must be taken to avoid twisting the machine during the re-alignment as this
will tighten the hinge mechanism and make re-assembly difficult.

• Tighten the lower clamp screws until the clamp insert contacts the pipe.
• Using an engineers square, check that the machine faceplate is square
(perpendicular) to the pipe. This must be checked at four equidistant positions
around the pipe.
• Should the machine not be square to the pipe then it is simply pushed or
pulled until an acceptable degree of squareness is achieved.
• The machine is then centralized to the pipe by judiciously tightening and
releasing opposing clamp screws until suitably central.

For this purpose, measurements are taken adjacent to the clamp screws.

The clamp screw nearest to the highest measurement (widest gap) between the
machine and pipe is first released and the opposing clamp screws tightened until
an equal measurement between opposing clamp screws is attained.

• When the machine is centralized to the pipe, tighten the clamp screws to a
maximum of 35ft/lbs.

NOTE:

When subsequent cuts are to be taken on pipes of the same diameter, the top two
clamps may be left “pre-set” and the machine mounted and de-mounted using the
bottom two clamps only.

• Select the drive motor and assembly to the drive gear at the drive unit item 20.

PS. Please refer to drawing no. LC0236M.

Lubrication:

The bearing configuration within the machine requires lubrication to ensure the
long life of the bearings and the general smooth running of the machine.

The lubrication procedure is simple but it is important to ensure that it is carried

out on a daily basis prior to use.

• Locate the oilers on the machine faceplate.

• Rotate the machine until the joint faces of the faceplate are aligned with those
on the machine body.

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• Charge each of the oilers daily by applying a few drops of oil through the oil
nipples on the faceplate.

4.4 JUDUL 4

• Attach the air-line connection to the motor; the faceplate must rotate
clockwise when the on/off valve is opened.

NOTE:

The air supply must be properly filtered and lubricated using quality airline oil.
The airline used must deliver 90 P.S.I. at 90 C.F.M.

• Observe the faceplate when rotated to ensure that there are no obstructions to
motion. Stop the machine.

4.5 JUDUL 5

• Select the required cutting tools and assemble them to the tool sides, ensuring
that they are fitted to cut in a clockwise direction.
• Advance the tool slides by rotating the feed screws anti-clockwise until the
cutting tools are approximately 3mm from the pipe. Further advance the
leading tool (pointed) until it leads the parting tool (square) by 1-1.5mm.

4.6 JUDUL 6

• Rotate the machine slowly and again check for obstruction and fouling
conditions.
• Open the on/off valve to allow the machine to run at the cutting speed.
• Engage the striker pin. The cutting tools will automatically advance until the
pipes has been cut and/or beveled.

4.7 WHEN CUTTING IS COMPLETED

• Disengage the striker pin.

• Stop the machine.

Disassembly of the machine is the reverse procedure to that of assembly.

5.0 CUTTING PRECAUTIONS

• READ THE OPERATION MANUAL CAREFULLY. Learn the operation,

application, and limitations as well as the specific potential hazards peculiar to this
machine.
• Do not touch the machine while it is working. Keep clothing and other loose objects
away from moving parts of the machine.
• Do not attempt to adjust the cutting tools while the machine is in motion.

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• Ensure that the air supply is adequate to run the machine i.e. 90 p.s.i. at 90 c.f.m.
• Ensure that the air or hydraulic supply is properly filtered and clean and that the air
supply is lubricated.
• Ensure that all hose connections are to the correct safety specifications.
• Ensure that the machine is properly secured to the pipe before commencing
operations.
• If the cutting tools should jam in the pipe while cutting is taking place, stop the
machine immediately.

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PARTS LIST OF DRIVE UNIT FOR LC MODELS

ITEM QTY PARTNO. DESCRIPTION

1 LCD1000 Drive Unit
1 1 LCD0001 Gear
2 2 LCD0002 Bearing
3 3 LCD0003 Clip
4 1 LCD0004 Bush
5 1 LCD0005 Clip
6 5 LCD0006 Screw
7 1 LCD0236 Body
8 4 LCD0008 Screw
9 1 LCD0009 Handle Knob
10 1 LCD0010 Screw
1 1 LCD00 1 Striker
1 1 LCD001 Striker Pin
1 1 LCD001 Holder
1 2 LCD001 Screw
1 4 LCD001 Screw
1 1 LCD001 Cover

PS. Please refer to drawing no. LC0236D.

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PARTS LIST OF CARRIAGE FOR LC MODELS

(STANDARD LENGTH OF 100MM)
ITEM QTY PART NO. DESCRIPTION

ITEM QTY PARTNO. DESCRIPTION

1 LCC1000 Carriage
1 6 LCC1001 Screw
2 6 LCC1002 Screw
3 3 LCC1003 Set Screw
4 3 LCC1004 Screw
5 1 LCC1005 Tool Slide
6 1 LCC1006 Feed Screw
7 1 LCC1007 Clamp Plate
8 1 LCC1008 Bearing
9 1 LCC1009 Bearing
10 1 LCC1010 Bearing
11 1 LCC1011 Slide Way(StdLgth:100mm)
12 1 LCC1012 Steel Ball
13 1 LCC1013 Set Screw
14 1 LCC1014 Spring
15 1 LCC1015 Lock Nut
16 1 LCC1016 Lock Washer
17 1 LCC1017 Star Feeder
18 1 LCC1018 Key
19 1 LCC1019 Clamp Plate

PS. Please refer to drawing no. LC0236C.

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PARTS LIST OF MAIN BODY FOR LC 10-16

ITEM QTY PART NO. DESCRIPTION

ITEM QTY PARTNO. DESCRIPTION

1 2 LC1016G2001 Faceplate
2 2 LCG0002 Centering Pin
3 2 LCG0003 Screw
4 2 LCG0004 Key
5 1 LCG0005 Locking Screw
6 8 LCB0006 Needle Bearing
7 8 LCB0007 Needle Bearing
8 8 LCB0008 Needle Bearing
9 8 LCB0009 Needle Bearing
10 8 LCB0010 Needle Bearing
11 4 LCB0011 Clamp Screw
12 2 LC1016B2001 Clamping
13 2 LCB0013 Key
14 2 LCB0014 Screw
15 2 LCB0015 Centering Pin
16 2 LCB0016 Screw
17 1 LCH0001 Swivel Hinges
18 4 LCB0018 Secure Screw
19 8 LCB0019 Screw
20 8 LCB0020 Washer
21 1 LCD1001 Drive Unit
22 1 LCD2000 Carriage
23 2 LCC1000 Carriage
LCC1200 Carriage
LCC0700 Carriage
24 2 LC1016G0024 Secure Screw
25 4 LCSJ00 Clamping Jaws
LCSSJ00 Clamping Jaws
26 4 LCSJ05 Clamping Jaws
LCSSJ05 Clamping Jaws
27 4 LCSJ10 Clamping Jaws
LCSSJ10 Clamping Jaws

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