TPPI Olefin Complex Development Project

Title : Underground Piping System for Pressure

Lines

Doc. No. : 21071-S-0000-3600-0013 Rev.O

Basic Engineering Design Package (BEDP),

Front End Engineering Design (FEED) and
Engineering, Procurement and Construction (EPC)
Scope of Work for Olefin Complex PT. Trans
Pacific Petrochemical Indotama
Development Project

Contract No.: SP-21071

Underground Piping System

for Pressure Lines

First Issue
O 21 Sep 2022 S.H. Song H.G. Lee S.B. Kim
for Information
Rev. Date Issue Purpose Prepared by Checked by Approved by

Document Number

Job Number Document Prefix Unit Number WBS Sequence No.

21071 S 0000 3600 0013

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REVISION LOG

REV. NO. DATE PAGE DESCRIPTION

O 21 Sep 2022 - First Issue for Information

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CONTENTS

1 INSTRUCTION .................................................................................................5

1.1 PURPOSE .....................................................................................................5

1.2 TERMS AND ABBREVIATIONS ...................................................................5

2 GENERAL .....................................................................................................7

2.1 UNDERGROUND PIPING SYSTEM .............................................................7

2.2 TYPES OF UNDERGROUND PIPING SYSTEMS FOR

PRESSURE LINES ......................................................................................7

2.3 DESCRIPTION OF UNDERGROUND PIPING SYSTEMS FOR

PRESSURE LINES ......................................................................................7

3 DESIGN CONSIDERATIONS AND SIZING CRITERIA ...................................8

3.1 UNDERGROUND FIREWATER NETWORK ................................................8

3.2 UNDERGROUND COOLING WATER SUPPLY/RETURN NETWORK ......10

4 PIPE MATERIAL SELECTION .......................................................................11

4.1 FACTORS TO CONSIDER IN SELECTING PIPE MATERIALS.................11

4.2 MOST COMMONLY USED PIPING MATERIALS ......................................12

4.3 DESIGN CONSIDERATIONS......................................................................12

5 LAYOUT PROCEDURES UNDERGROUND PRESSURE PIPING SYSTEMS ..

- GENERAL ................................................................................................12

5.1 CONCEPTUAL LAYOUT/FRONT END ENGINEERING DESIGN (FEED) .12

5.2 UG PIPING PLANNING SKETCHES/STUDIES..........................................15

5.3 DETAILED DESIGN ....................................................................................17

6 CONSTRUCTION REQUIREMENTS FOR UNDERGROUND PIPING ..........22

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6.1 MATERIAL QUANTITIES ...........................................................................22

6.2 DELIVERABLES .........................................................................................22

7 ENVIRONMENTAL/SUSTAINABLE DEVELOPMENT CONSIDERATIONS .24

7.1 ENVIRONMENTAL CONSIDERATIONS ....................................................24

7.2 SUSTAINABLE DEVELOPMENT CONSIDERATIONS ..............................24

8. ATTACHMENT ...............................................................................................25

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1 INSTRUCTION
1.1 PURPOSE
The purpose of this Document is to describe the procedure to be followed when developing
pressure flow underground piping systems within a industrial facility related to the Project
which to be submitted by Contractor whom will perform the works under the Contract for
“Basic Engineering Design Package (BEDP), Front End Engineering Design (FEED) and
Engineering, Procurement & Construction (EPC) Scope Of Work for TPPI Olefin Complex
Development” Project (hereinafter called the “Project”) located in Tuban, East Java, Indonesia
approximately 580 kilometers east of Jakarta.
Used in conjunction with applicable codes and regulations, it adheres to all normal industry
practices. Deviations to meet Pertamina requirements will be addressed on a case by case
basis.

1.2 TERMS AND ABBREVIATIONS

ABBREVIATIONS DESCRIPTION

ANSI American National Standards Institute

ASTM American Society for Testing and Materials
AWWA American Water Works Association
BACKFILL Material placed from 300 mm above the pipe to
grade.
CATCH BASIN A receptacle designed to collect wastewater from the
floor surface of an open structure unit.
CATHODIC PROTECTION Preventing corrosion by use of sacrificial anodes or
direct current to circumvent corrosive damage by
electric current in soils.
CI/DI/MI Cast gray iron, cast ductile iron, and cast malleable
iron.
CLASS Designation given to flanges and fittings to replace lb
rating, e.g., class 150 instead of 150 lb.
CS Carbon Steel
CURB A 150mm to 300mm concrete wall placed around
paved units or equipment to contain liquid spills.
DENSITY The ratio of the weight of a substance to its volume.
DIKE An earth or concrete structure usually less than 1.8m
high to contain liquid spills or ruptures from storage
tanks.
DITCH A channel excavated to collect and move
stormwater.
DUCTILITY The property of elongation above the elastic limit but
under the tensile strength.
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EFFLUENT Outflow of water that has been treated in a septic

tank or treatment plant.
EGS Engineering Group Supervisor
ELASTOMER An elastic rubber-like substance that stretches at low
stress to at least twice its length at ambient
temperature. It retains its original shape upon
release.
EROSION The gradual destruction of material by abrasive
action of liquids and/or solids.
FRP Fiberglass Reinforced Plastic (Use RTRP for pipe).
GRADE The surface elevation of the ground.
GRE Glass Reinforced Epoxy
GROUT A fluid mixture of cement, sand, and water that can
be easily placed or pumped.
HDPE High Density Polyethylene
HOT TAP Installing a branch connection on an existing pipe
under pressure.
INSULATING A central gasket, bolt sleeves, and washers
FLANGE GASKET composed of materials that resist the passage of
electric current between buried metal piping and
above grade metal piping.
INVERT The lowest point on the inside bottom of the pipe.
NFPA National Fire Protective Association
NPS Nominal Pipe Size
PIV Post Indicator Valve
ppm Parts per million or milligrams per liter.
POTABLE WATER Water considered satisfactory for domestic
consumption.
PROCESS SEWER A piping system used for conveying contaminated
wastewater.
RCP Reinforced Concrete Culvert, sewer and drain pipe.
RTRP Reinforced Thermosetting Resin Pipe
SDR Standard Dimension Ratio. The outside diameter of
a plastic pipe divided by its average minimum wall
thickness.
SANITARY SEWER A piping system used for conveying sanitary
wastewater from toilet facilities.
SEWER A pipe or conduit, generally closed, but not normally
flowing full, for carrying sewage.
TURBULENCE Any deviation from parallel or laminar flow in a pipe
due to rough interior, obstructions, or directional
changes.
WATER HAMMER The destructive forces which develop in a piping
system when a non-compressible liquid flowing
through a pipe at a given pressure and velocity is
stopped abruptly.

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2 GENERAL
2.1 UNDERGROUND PIPING SYSTEM
All pressure piping which is normally installed below finished grade, whether buried or
located in an open trench. Engineering, design, and procurement responsibility should be
established early in the planning phase between Plant Design and CSA.

2.2 TYPES OF UNDERGROUND PIPING SYSTEMS FOR PRESSURE LINES

2.2.1 Underground Piping System
2.2.1.a Underground Firewater Network
2.2.1.b Underground Cooling Water Supply/Return Network
2.2.1.c Underground Water Services (Potable, Utility, etc.)
2.2.1.d Underground Utility Services (Air Services, nitrogen, etc.)
2.2.1.e Underground Sanitary Sewer Force Main

2.2.2 Underground Objects by Other Disciplines

2.2.1.a Foundations and Piles
2.2.1.b Culverts and Drainage Ditches
2.2.1.c Electrical concrete ducts (permanent or temporary)
2.2.1.d Instrumentation concrete ducts
2.2.1.e Direct bury electrical and cathodic protection cable
2.2.1.f Temporary piping (i.e., water, air, sanitary), telephone, electrical conduit, etc. for
construction

2.3 DESCRIPTION OF UNDERGROUND PIPING SYSTEMS FOR PRESSURE LINES

2.3.1 Underground Firewater Network
Fire Protection pipe network that distributes water to all fire protection appurtenances which
includes, but is not limited to hydrants, monitors, hydrant/monitor combinations, (See
Figures 1 thru Figure 5) hose reels, deluge systems and supplying fire water system in
buildings.

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2.3.2 Underground Cooling Water Supply/Return Network

Cooling water pipe network that distributes water to and from all pieces of equipment
requiring cooling water as established on the cooling water P&ID's developed by Project
Engineering. Work with the aboveground piping design team to establish when the
distribution system can be below grade or above grade on piperacks. In most cases large
diameter supply and return lines are below grade due to the weight and space
considerations when these lines are on piperacks.

2.3.3 Underground Water Services

In many cases routing of water services, which includes but is not limited to potable water,
utility water, service water, etc. will be below ground. This applies when there is no pipe
rack and/or sleepers to remote locations requiring these services.

2.3.4 Underground Utility Services

In many cases routing of misc. utilities, which includes but is not limited to plant air,
instrument air, nitrogen, etc. may be below ground. This applies when there is no pipe rack
and/or sleepers to remote locations requiring these utilities.

2.3.5 Underground Sanitary Sewer Force Main

In many cases routing of the sanitary sewer force main will be below ground. This applies
when there is no piperack and/or sleepers to the ultimate disposal source, whether that is
an onsite sewage treatment plant or an interface with the local municipal sanitary sewer
network.

3 DESIGN CONSIDERATIONS AND SIZING CRITERIA

3.1 UNDERGROUND FIREWATER NETWORK

Fire Protection pipe network that distributes water to all fire protection appurtenances which
includes, but is not limited to hydrants, monitors, hydrant/monitor combinations, hose reels,
deluge systems and supplying fire water system in buildings. The underground fire water
system shall be a dedicated service and shall not be used to supply other plant functions.
The distribution system shall be a looped configuration around the perimeter of the plant
with branch lines or grids into the units as required. All underground fire water system
equipment shall be listed and/or approved for the fire protection service intended.

3.1.1 Division of Responsibility

Project Engineering - Responsible for the development of the firewater system P&ID's. This
effort should be coordinated with Process Safety to ensure proper line sizing based on
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firewater coverage demands and with PD&P to ensure the P&ID matches the geometric
configuration of the firewater system layout.

Process Safety- Responsible for the physical location of all firewater appurtenances (i.e.
hydrants, monitors, hyd/mons, hose reels, block valves, etc.) which are shown on Firewater
Location Plans as issued by Process Safety. They are also responsible for line sizing based
on specific worst case firewater demand scenarios and to ensure there is sufficient pressure
so that all appurtenances function as required. In addition, Process Safety will develop data
sheets which will be the basis for procurement of hydrants, monitors, hyd/mon combinations,
hose reels, block valves, etc.

PD&P - Responsible for coordinating the design and layout of the fire protection system to
ensure all layout and procurement requirements are in alignment with the P&ID's as
developed by Project Engineering and the underground network as shown on Firewater
Location Plans and the procurement of firewater appurtenances in accordance with data
sheets developed by Process Safety.

3.1.2 Fire Protection Piping

All underground fire protection shall be listed and approved for fire water service. All ferrous
metal piping shall be externally coated and lined to conform with the requirements of ANSI
A21.4-80 (AWWA C104-85), Pipeline Coatings and Linings. In highly aggressive soils
consideration should be given to the use of polyethylene encasement materials.
Depth of bury shall consider freeze conditions and soil loadings. Minimum depth of bury
shall be 900mm.
The minimum line size for mains shall be 6 in (150mm). Check Pertamina requirements for
main line sizes larger than sizes identified by hydraulic analysis.

3.1.3 Hydrants
All non-critical, non-flammable equipment should have hydrant coverage from at least one
hydrant (See Figure 1) based on 45m spray coverage. This includes but is not limited to
sub-stations, water treatment facilities, administrative buildings, parking lots, guard houses,
etc. Coordinate this requirement with the Process Safety team based on the issued
Firewater Location Plans. Any deviation to this requirement should have approval and
verification from the Lead Process Safety Engineer.

3.1.4 Monitors
All pieces of equipment in a process unit should have coverage from at least two monitors
(See Figure 3 and 4) and/or hydrant/monitors (See Figure 2) based on 15m to 120m spray
pattern radius (See Figure 6). Coordinate this requirement with the Process Safety team
based on the issued Firewater Location Plans. Any deviation to this requirement should
have approval and verification from the Lead Process Safety Engineer.

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3.1.5 Hose Reels

Coordinate the requirement for hose reels with the Process Safety team based on the
issued Firewater Location Plans. Any deviation to this requirement should have approval
and verification from the Lead Process Safety Engineer.

3.1.6 Fixed Suppression System Risers

Coordinate the requirement with the Process Safety team based on the issued Firewater
Location Plans. Any deviation to this requirement should have approval and verification
from the Lead Process Safety Engineer.

3.1.7 Sectional Valves

Block Valves (See Figure 5) should be installed to sectionalize the fire water main grid so
that only part of the system will be out of service during failure or repair. Block Valves
should be spaced so that there is no more than 6 firefighting users shall be installed
between sectional valves, counting one firefighting user as each of the hydrants, the
monitors or the feeds to the spray or foam system. The sectional valve for fire water main
shall be gate valve with post indicator showing closed or open status of the valve.
Coordinate this requirement with the Process Safety team based on the issued Firewater
Location Plans. Any deviation to this requirement should have approval and verification
from the Lead Process Safety Engineer.

3.1.8 Design Considerations

PD&P to ensure that the design and layout of the underground fire protection system follows
the requirements as set forth in NFPA 24 (Standard for the Installation of Private Fire
Service Mains and Their Appurtenance)

Accessibility to Appurtenances 一 Unencumbered access to hydrants, monitors, block

valves, etc. should be of primary consideration when placing these items. Review grading
drawings to ensure there is ease of access to these items by the firefighting team. Steep
drop-offs, ditches, guard rails, etc. should be addressed and mitigating fixes should be
coordinated with the design team responsible to ensure ease of access to these critical
items.

3.2 UNDERGROUND COOLING WATER SUPPLY/RETURN NETWORK

3.2.1 Division of Responsibility
Project Engineering - Responsible for the P&ID's showing the distribution network for the
cooling water system. Ensure the P&ID's clearly reflect above ground to below ground
breaks, as well as pipe spec breaks and type of connection.

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3.2.2 Design Considerations

Establish Underground Piping Corridors - When large diameter supply and return lines are
below ground, corridors should be established and coordinated with above ground and CSA
to ensure adequate spacing and minimize conflict with other underground lines as well as
foundations, ditches, culverts, etc.
Coordination of Riser Locations - Work closely with the above ground piping team to
establish riser locations early in the project.

4 PIPE MATERIAL SELECTION

4.1 FACTORS TO CONSIDER IN SELECTING PIPE MATERIALS

4.1.1 Application and Service
Coordinate with Materials Engineering and Technology (MET) the preferred pipe material
based on fluid medium, design temperature, design pressure, and intended service. MET
has responsibility to develop and issue the Piping Material Selection Guide which
documents the piping material for all services.

4.1.2 Cover and Loading Requirements

Consideration should be given to minimum amount of earthen cover above a buried pipe to
address frost penetration depth. The BEDD document should have maximum frost
penetration depth for the plants intended location. In addition, consideration should be
given to the loads imposed on buried pipes from vehicular, truck, and crane loads.
Calculations should be performed to ensure no damage will be imposed on the buried pipe
based on depth of cover and wheel loading data.

4.1.3 Physical and Chemical Soil Properties

Coordinate with Materials Engineering and Technology (MET) the optimum method to
protect the buried pipe from attack from the physical and chemical properties of the soil.
Consideration should be given to methodologies to extend the life of metallic pipe, fittings,
and appurtenances which include but are not limited to MET recommended paint, coating
and wrapping, and cathodic protection via sacrificial anodes, and/or impressed current.

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4.2 MOST COMMONLY USED PIPING MATERIALS

4.2.1 Carbon Steel - CS change to CS Galvanize
4.2.2 High Density Polyethylene - HDPE
4.2.3 Polyvinyl Chloride - PVC/CPVC/UPVC
4.2.4 Fiberglass Reinforced Pipe – FRP/GRE

4.3 DESIGN CONSIDERATIONS

4.3.1 Manning’s Roughness Coefficient

Roughness coefficient refers to the interior lining of the piping material and the impact to
the hydraulic performance. Smooth wall interior piping such as HDPE and PVC have low
roughness coefficients’ while piping systems like cement lined ductile iron and concrete
pipe have higher values. Refer to Table 1 for typical values.

4.3.2 Relative Economics of Construction and Installation

Consideration should be given to the construction total installed cost as a factor when
determining which piping material to be used for the various underground piping systems.
Coordinate with construction and estimating for historical data, lessons learned, and
recommended practices when finalizing piping material requirements.

5 LAYOUT PROCEDURES UNDERGROUND PRESSURE PIPING SYSTEMS

- GENERAL

5.1 CONCEPTUAL LAYOUT/FRONT END ENGINEERING DESIGN (FEED)

5.1.1 Responsibilities
It is the responsibility of the PD&P EGS to coordinate the development of conceptual
layouts and material quantities for required underground piping systems and associated
commodities for all Proposals, LSTK estimates, FEED’s, and base case/template layouts.
A Division of Responsibility (DOR) shall be developed by the PD&P delineating the
following:
 Design, layout and material quantification of process and utility pressure piping
systems
o UG process lines
o UG utility lines
o Pipe sleeves
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o Firewater lines, including hydrant and monitor locations

o UG force mains

When design for UG commodities is split between PD&P and CSA the DOR should clearly
delineate who has design, layout, drawing and MTO responsibilities. Transmittal of material
quantities to estimating should be all inclusive with no regard to which discipline has design
responsibility.

5.1.2 Design and Layout

5.1.2.a UG Pressure Piping Design Specification

The Design Specification will be used as a guide for the development of the UG piping
systems and all associated commodities.

 Pertamina Specifications - Review Pertamina specifications, design guides, standard,

practices, etc. to determine required underground piping systems. Pertinent data to
establish underground scope of work can be found in the Pertamina piping, civil, fire
prevention, electrical, and environmental specifications, design guides, etc. Determine
the preferred piping materials, as well as, plant specific design, material and
construction requirements.

 Deviations to Pertamina Specifications - Changes or deviations to Pertamina

requirements shall be approved by the PD&P EGS and documented in a manner
consistent with proposal policy.

5.1.2.b Underground Pressure Piping Systems

All required underground pressure piping systems and associated commodities shall be
designed in accordance with the UG Piping Design Specification and standard industry
practice. Underground systems include, but are not limited to, Process and Non-Process
Area Underground Fire Protection network, Underground Cooling Water Suction and
Return lines, Underground Utility lines, and other misc. systems. In addition, all existing
UG commodities should be documented and recorded, this includes existing UG pipe,
existing ditches/culverts, existing electrical commodities and existing foundations.

5.1.2.c Inter-Discipline Coordination

In order to properly design underground piping systems, it is important to understand the

underground requirements and deliverables from other disciplines. Refer to Section 5.1.1
for preliminary division of responsibility requirements. The UG Lead to ensure all UG
pressure piping systems are accounted for and properly documented in accordance with
Section 5.1.3 below.

 AG Piping – Items to coordinate with AG Piping include cooling water(CWR,

CWS)/firewater(FW) riser requirements, sump and/or buried tank requirements,
and location of UG specialties (i.e. hydrants, monitors, manholes, catch basins,
etc.).

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 Civil/Structural/Architectural – Items to coordinate with CSA include, but are not

limited to, finished grade model, foundation types(i.e. piles, spread footings),
foundation depths, preliminary foundation sizes, building drain and utility
requirements, sumps/vaults, trenches, and structural requirements for UG
specialties(i.e. manholes, catch basins, valve vaults, etc.).

 Electrical – Items to coordinate with Electrical include, but are not limited to, UG
duct bank and direct bury cable requirements (i.e. size, depth, and layout),
documentation of existing underground entities, and cathodic protection
requirements.

 Project Engineering – Items to coordinate with Project Engineering include, but

are not limited to, documentation of UG systems (i.e. P & I D’s, block diagrams,
etc.), review and sign-off of UG fire protection philosophy/layout, UG pressurized
utility line philosophy/layouts, hydraulic calculations, and documentation of tie-ins
and tie-in conditions.

 Construction – Items to coordinate with the Construction team include, but are
not limited to, constructions sequence, priority areas, tie-in requirements, crane
access areas, etc.

5.1.3 Deliverables

5.1.3.a Underground Pressure Piping Drawings

Underground pressure piping drawings should be developed showing all required UG

pressure piping systems. When UG piping design and layout work is split into pressure
piping and non-pressurized piping between PD and CSA, the UG Lead will coordinate the
development of one set of underground piping drawings. The UG Lead will ensure all UG
piping systems are properly documented and designed to minimize depth, maximize
installation and align with project requirements.

Underground piping drawings shall be of sufficient scale and contain sufficient information
to define all UG piping systems, materials, sizes, depths, tie-in points, as well as, potential
problem areas and “HOLDS”.

5.1.3.b Back-Up Data

All information that dictates design requirements for the underground piping systems shall
be kept on file for future reference. This includes but is not limited to, hydraulic
calculations, flow diagrams, P & I D’s, Conference Notes, e-mails, design specifications, tie-
in conditions, assumptions, and clarifications.

5.1.3.c Material Quantities

Coordinate with the PD&P EGS and CSA EGS how material quantities will be developed
and transmitted to Estimating. Material and commodity requirements include pipe, fittings,
valves, manholes, catch basins, hydrants, monitors, guard posts, and other underground
specialty items. Take-offs will be by UG system, with sufficient information for the estimating
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team to establish total installed cost, which includes but is not limited to pipe and commodity
layouts, quantities, depths, and details.

 3-D Model – UG pressure piping systems will be input into the 3-D model from
preliminary layouts and/or studies. Downloading of pipe and associated
commodities will follow the work process used by AG piping. This data is then
transmitted to Estimating for pricing.

 Manual Take-off – Quantities for pipe and associated commodities will be taken
from issued layouts for each UG system. This data is then transmitted to
Estimating for pricing.

5.2 UG PIPING PLANNING SKETCHES/STUDIES

5.2.1 Scope
UG pressure piping planning sketches/studies shall be developed as a tool to document the
UG pressure piping requirements as an engineering support document that will be issued
for inter-discipline coordination, construction strategy and Pertamina review prior to detailed
design.

5.2.2 Responsibilities
The UG Lead Designer will be responsible for coordinating the design, development and
checking of the deliverables as defined in Section 5.1.3, as well as managing the division of
responsibility between PD&P and CSA established during the conceptual/FEED phase. In
addition the UG Lead Designer will be responsible for coordinating construction sequence
and material requisition requirements.

The UG Lead shall coordinate staffing, budget, and design review requirements with the
PD&P EGS. In addition any major changes to layouts, material quantities, etc. from the
Conceptual/FEED phase should be addressed with the PD&P EGS and UG EGS.

5.2.3 UG Pressure Piping Planning Layout

Use the Conceptual Layout/FEED as the basis for the UG Pressure Piping Planning Studies.
Maintain the division of responsibility between PD&P and CSA established during the
Conceptual/FEED phase for development of the UG pressure piping planning studies.

Layout of the UG systems should be adjusted to reflect changes to the plot from the
conceptual/FEED plot plan to the currently issued plot plan. UG Piping Planning Studies will
be issued for inter-discipline/construction review and Pertamina approval, followed by an
“Issued For Design” release that will be the basis for detailed design and 3-D model
development.
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The Planning Studies shall be of sufficient scale and contain sufficient information to define
all UG pressure piping systems, materials, sizes, depths, tie-in points, as well as, potential
problem areas and “Holds”.

5.2.4 UG Pressure Piping Design Specifications

Using the UG pressure piping design specification from the conceptual phase as a base,
there should be documentation of guides, standards, and specifications used for the design
and layout of the UG pressure piping systems.

5.2.5 UG Pressure Piping Construction Specification

The UG Pressure Piping Construction Specification should contain specifications for
excavation, bedding, pipe laying, backfill, tamping, hydrotesting, etc. for the installation of
the UG Pressure piping systems.

5.2.6 Back-Up Data

All pertinent data used to develop the UG planning study should be kept for historical
purposes. This data includes, but is not limited to hydraulic calculations, tie-in requirements,
existing conditions, as well as all correspondence relating to UG design.

5.2.7 Inter-Discipline Coordination

UG requirements for the various disciplines should be expanded from the Conceptual
Layout during the planning phase.

 AG Piping – Review locations of UG specialties (i.e. hydrants, monitors, block

valves, etc.) to verify accessibility and that it does not restrict access to equipment,
laydown areas, etc. Coordinate firewater, cooling water riser interfaces with AG
piping. In addition, misc. UG lines should be identified (i.e. UG force mains, pump
suction/discharge, etc.). Establish a division of responsibility for buried tanks,
addressing tie-ins, tank depth, pump suction and discharge piping and sump
enclosure requirements.

 Civil/Structural/Architectural – Review foundation requirements, confirming piles

versus spread footings, depth or top of concrete elevations, and approximate sizes.
Coordinate trench and sump/vault requirements, establishing division of
responsibility for sizing, depth, design and procurement of specialties. In addition,
coordinate drain and utility requirements for buildings designed by CSA,
establishing division of responsibility for tie-ins and procurement of specialties.
Based on soil reports determine settlement control of UG specialties (i.e. manholes,
catch basins, valve vaults, etc.), this may be in the form of piles, thickness
requirements, special backfill, etc

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 Electrical – Review duct bank and direct bury requirements, confirming size, routing,
and depth. Coordinate underground utility needs. and confirm the requirements for
cathodic protection have been addressed and requirements have been established
and documented.

 Project Engineering – Work with the project team to develop P & I D’s for the
various underground piping systems. Development and maintenance of P & I D’s
will require a concerted effort between Project and UG Piping. This coordination
shall address line number requirements, layout changes, and shall continue till both
the UG layout and P & I D are “IFC”. In most cases the P & I D is derived from
layouts developed by UG piping and is therefore subject to changes as design
information becomes available. As is the case with AG piping, a master set of P & I
D’s should be kept and updated regularly to reflect the latest layout as well as
tracking the progress of the 3-D model. In addition, definition of fire protection
requirements and philosophy should be established and approved by the Process
Safety Group leader, tie-ins and tie-in conditions should be documented and a
division of responsibility should be in place to address cathodic protection
requirements.

5.3 DETAILED DESIGN

5.3.1 Responsibilities
5.3.1.a UG Lead
Assist in the development of the UG work plan, which includes, but is not limited to,
manpower requirements, schedule of deliverables, material requisition’s, Design reviews,
and technical issues.

5.3.1.b UG Lead Designer

Coordinate the timely flow of information from the Project team to the UG design team.
Confirm all model volumes are established and in accordance with the UG work process.
Responsible for insuring all deliverables (i.e. orthos, iso’s, MR’s, spec’s, etc.) are checked
and issued in accordance with the project schedule.

5.3.1.c UG Designer
Responsible for input of pipe, fitting and UG commodities into the 3-D model from the UG
Planning Studies. In addition, responsible for the extraction of isometrics, orthographics,
details and schedules.

5.3.2 Design and Layout

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5.3.2.a UG Piping Layout

Use the previously issued UG piping planning study as the basis for development of
detailed design.

5.3.2.b Specifications
 Design Specifications – Using Pertamina design specification take the previously
issued “IFD” specification, modify as required, and “Issue For Construction”.
 Construction Specifications – Using Pertamina construction specification take the
previously issued “IFD” specification, modify as required, and “Issue For Construction”.

5.3.2.c Professional Engineers Stamping Requirements/Certification

For most domestic jobs all underground piping drawings will require a P.E. stamp. Confirm
with the Project Engineering Team what the contractual requirements are regarding this
issue.

5.3.2.d Construction Requirements

The construction sequence established during the planning phase, will dictate which areas
or systems will be prioritized. The release of material, isometrics, and orthographics shall
coincide with the construction sequence so that all required material and/or pipe spools, as
well as all required drawings are available to construction for installation of the UG pipe.
The release of material requisitions, fabrication drawings, isometrics, and orthographics
should take into account fabrication cycles, delivery requirements, etc.

The release of design documents should be coordinated with Project Controls to ensure the
delivery of material to construction when needed. It is recommended the release of UG
piping deliverables be managed by above ground design area. The release and installation
of UG piping commodities should coincide with the release and installation of foundations
for each above ground design area.

5.3.3 3D CAD Underground Piping Model

5.3.3.a Volumes
It is the responsibility of the PD CAD coordinator to establish design volumes (also referred
to as design models) for both the aboveground as well as the underground requirements.
Underground volumes should be established by system (i.e. firewater, cooling water etc.).
Each system will have a piping model (PDS) or a design area/module folder (SP3D) for the
input of pipe, as well as an equipment model which will be used for misc. items including
but not limited to manholes, catch basins, fire protection items, etc. In some cases,
depending on the complexity, some piping system models should be broken into two or
more volumes to allow more than one person to input into the models.

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5.3.3.b Underground Piping Specifications

It is the responsibility of the UG design team that all pipe, fittings, and UG commodities are
available in the database for placement into the model. It is recommended that early in the
model development, each item in the pipe spec is tested by placing it in the model.

5.3.3.c Model Reviews

30% and 90% model reviews are established by the PD&P EGS for each above ground
design area. Participation by underground piping is required for the 30% as well as the
90% review.

 30% Model Review – The main objective of the 30% model review is to review the
location of major underground pressure piping entities, which includes but is not limited
to all hydrants, monitors, block valves and envelopes for deluge piping. During the
review confirm UG pressure piping related entities are not blocking major access way
for truck and crane. In addition a preliminary review of underground cooling water
regarding equipment shall be done.
 90% Model Review – Final review of underground major pressure piping will be done
during the 90% model review. In addition, review all major underground firefighting,
cooling water and etc. piping regarding equipment.

5.3.3.d Inter-discipline Coordination

 A/G Piping – Review the locations of underground commodities so that they do not
block access ways, create tripping hazards, and are not located directly below items
requiring access. In addition coordinate the location of hydrants, monitors, block valves,
hose reels, deluge stations, and etc.
 Civil/Structural/Architectural – Utilize the model to detect interferences with CSA U/G
structures. Prior to releasing isometrics for an area, coordinate running clash detection
against U/G structures. Check for system coverage against the CSA finished grade
model.
 Electrical – Utilize the electrical model to detect interferences with underground duct
banks, and mast lighting foundations, etc. Prior to releasing isometrics for an area,
coordinate running clash detection against the electrical model.

5.3.3.e 3-D Model Input

 Equipment model - The equipment model is used to develop underground pressure
piping entities that are not pipe and fittings. It can used to build hydrants, monitors,
block valves, hose reels, deluge stations, and etc. The recommended work process is
to build a base item (i.e. hydrant, hose reel, etc.) then populate the model by copying
and modifying it in accordance with the UG planning study.

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 Piping Model - The input of pipe, fittings, and associated commodities should be in
accordance with the “Issued for Design” Underground Piping Planning Study and
relevant P & IDs.

5.3.4 Deliverables
5.3.4.a Orthographics
 UG Plan drawings - For detailed design the orthographic plans are considered a
support document for the isometrics. Therefore the amount of annotation should be
sufficient enough to establish which isometrics apply for a particular pipe run.
 UG Detail drawings – Provide drawings showing dimensions, arrangements and
fabrication details of pressure piping related items such as hydrants, monitors, hose
reels etc.

5.3.4.b Isometrics
Unless directed otherwise, isometrics extracted from the 3-D model will become the primary
fabrication document for all underground pressure pipe and associated commodities.

5.3.4.c 3-D Model

Pertamina will require turnover of all 3-D models, including the underground model. This
should be done after the model is updated to reflect as-built condition.

5.3.4.d Material Requisitions

Quantities for material requisitions should be downloaded from the piping model. These
quantities will be released for purchase. In some cases, several releases will be required to
insure that all required material is at the job site when needed.

5.3.4.e Status Reports / Maps /Construction Scheduling

In order to effectively manage construction requirements, it is recommended that the UG
lead establish an “UNDERGROUND/ABOVEGROUND/CONSTRUCTION SCHEDULING
AID” that monitors and ensures upstream data for design completion is in place in a timely
manner.

Items to monitor include the following:

 IFC Site Plan/Plot Plan
 IFC Equipment Location Plans for each AG design area
 IFC Foundations for each AG design area
 IFC P & ID’s
 Projected UG piping construction start dates for each AG design area
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 Fabrication and delivery cycle time for UG piping spools

 Fabrication and delivery cycle time for manholes, catch basins, etc.
 Ortho release

5.3.4.f Critical Data

Following the detailed scheduling of the underground, aboveground and construction areas,
the UG Lead shall originate and manage a critical data checklist with the required dates for
data submission from the design disciplines. This should be used to plan the flow of design
data to the underground group, and identify potential remedial measures and re-scheduling
should data not be available.
Items to monitor include the following:

 Pertamina
 Design Specifications
 Tie-in Locations and Design Conditions
 Existing Underground Entities
 Civil/Structrual/Architectural
 Piles/Spread Footings Design
 Foundation Depths & Sizes
 Trenches
 Manhole/Catch Basin/Vault structural requirements
 Non-Process Drainage including culverts
 Rough and Final Grading plans and finished grade model
 Project and Process Safety
 UG System P & ID’s
 Utility Flow Diagrams
 Fire Protection Layout
 Hydrant/Monitor Configurations
 Electrical
 Duct Bank Location & Sizes
 MCC Drainage
 Cathodic Protection Requirements
 HVAC
 Building Drains & Utility Connections
 Construction
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 Construction Sequence
 Crane Access Areas
 Heavy Haul Roads
 Priority Areas
 PD&P
 Egress volumes
 Maintenance volumes
 AG Piping Design

5.3.4.g As-Built Underground Services Drawings

The construction team will maintain an as-built set of drawings showing actual coordinates
and elevations of the underground piping systems, ditch/culvert systems, foundations, and
underground electrical entities. This information will be used to update the piping, CSA,
and electrical models as well as generating an underground services drawings that will
serve as an as-built set of drawings. These underground services drawings will be
transmitted Pertamina for permanent records.

6 CONSTRUCTION REQUIREMENTS FOR UNDERGROUND PIPING

6.1 MATERIAL QUANTITIES

The “IFD” UG piping planning study and details shall be used to develop preliminary quantities of
pipe and associated commodities for each UG piping system. These quantities should be
compared to the material take-off done during the conceptual phase. Coordinate with the PD&P
EGS a method to address significant changes to material quantities.

6.2 DELIVERABLES
The intent of the deliverables as defined below are used to convey design, layout and material
requirements to the various disciplines, Pertamina, and the construction team. These documents
are then used to establish construction sequence, material delivery requirements, and to highlight
potential problem areas.

6.2.1 UG Piping Planning Drawings

The UG piping planning studies are to be of sufficient scale to clearly indicate all UG piping
systems, diameters, depths, and tie-in requirements. Due to the preliminary nature of the
planning study, coordinates are not shown. In most cases drawings at a scale of 1:100 is
recommended. Using the IFR/IFD plot plan as the equipment background, add the UG
systems with sufficient detail to convey design and installation requirements. Checked
Planning Studies will be issued to the Project Team, Construction and Pertamina for

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Review/Approval. Comments/Changes to the Planning Study will be reviewed and

incorporated as needed, the Planning study will then be “Issued for Design”.

6.2.2 UG Piping Design Specifications

Using the design specification from the conceptual phase as the base, this document will
be used to develop the UG piping systems. The project specific specification/guide will
then be issued to the Project Team and Pertamina for review/approval. Comments to the
specifications will be reviewed and incorporated on an as needed basis, the Design
Specification will then be “Issued for Design”.

6.2.3 UG Piping Construction Specification

In most cases the Pertamina Construction specifications will be used to direct construction
on installation requirements. If there is Pertamina specification, one will be generated and
formally issued to the Project. The project specific specification/guide will then be issued to
the Project Team, Construction and the Pertamina for review/approval. Comments to the
specifications will be reviewed and incorporated on an as needed basis, the Construction
Specification will then be “Issued for Design”.

6.2.4 Requisitions
Working with the Material Lead, develop requisitions so that all UG pipe and commodities
are addressed. Confirm that all UG piping material managed by CSA is addressed and a
DOR is established for requisition of those material. During the planning phase, the
quantities developed from the “IFD” planning study shall be used to obtain quotes from the
various vendors. The UG piping team is responsible for developing Sections 1 and 2 of the
Material Requisition.

6.2.5 Details
Similar to the planning study and the design specifications, details will be issued to the
project for review/approval. Comments to the details will be reviewed and incorporated on
an as needed basis, the details will then be “Issued for Design”. Details include, but are not
limited to the following:

 Firewater Piping – Make and model for hydrants, hydrant monitors, stand alone
monitors, and block valves should be established. In addition bedding details, riser
details, thrust block details, metering requirements, and guard post details should be
addressed.
 Misc. Piping – Details for misc. requirements, include but are not limited to, cooling
water details, tie-in requirements and trench piping details.

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7 ENVIRONMENTAL/SUSTAINABLE DEVELOPMENT CONSIDERATIONS

7.1 ENVIRONMENTAL CONSIDERATIONS

7.1.1 Air Emissions
Coordinate design and installation requirements that may be required to address potential
sources of hydrocarbon/chemical emissions from underground piping systems. Sources
include but are not limited to equipment drain hubs, catch basins, manholes, sumps, and
vent pipes from systems that convey liquids with contaminants. Methods to mitigate
emissions include liquid-traps, carbon canisters, and sealed manhole covers (non-vented).
Coordinate with environmental which underground piping systems require mitigation of air
emissions and the method to be implemented.

7.1.2 Water Quality

The capture and treatment of rainwater that falls on an industrial facility requires
coordination with civil, environmental and GH & S to isolate sources that could become
contaminated from areas that have little or no potential for contamination. These groups
are responsible for defining the various systems and the methods to be implemented to
separate, treat, and discharge the various sources of rainwater into public waterways.
These requirements are then implemented in the design and installation of these
underground piping systems.

7.1.3 Public Health Requirements

Consideration should be given to those underground piping systems that directly affect the
safety, comfort and well-being of the population working at these facilities. Potable water
and sanitary sewer systems should be designed and installed in accordance with standard
practices, local codes, and health protocols’ that ensure these systems are safe.

7.2 SUSTAINABLE DEVELOPMENT CONSIDERATIONS

7.2.1 Underground Piping Performance

Ensure that the piping material chosen for the various underground piping systems is in
alignment with the design pressures, design temperatures, and the commodity being
conveyed.

7.2.2 Long Term Performance

Consideration should be given to mitigating factors to ensure underground pipe and

commodities are protected from corrosion due to attack from the inherent nature of the soil
conditions. Metallic pipe and commodities are especially susceptible to corrosion and
decay over time. Coordinate with the MET group design requirements to ensure the best
available technology is implemented and incorporated in the design. Methods to mitigate
corrosion and decay include but are not limited to protective paint, coating and wrapping,
and cathodic protection via sacrificial anodes, and/or impressed current.
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8. ATTACHMENT

ATTACHMENT DESCRIPTION

Figure 1 Hydrant Detail

Figure 2 Hydrant / Monitor Detail

Figure 3 Monitor Detail

Figure 4 Elevated Monitor Detail

Figure 5 Block Valve Detail (Post Indicator Type)

Figure 6 Effective Firewater Monitor Range

Table 1 Recommended Values of Manning’s “N”

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Figure 1 Hydrant Detail

buried depth
Flexible Expansion
Joint

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Figure 2 Hydrant / Monitor Detail

Flexible Expansion Joint

buried depth

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Figure 3 Monitor Detail

Flexible Expansion buried

Joint depth

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Figure 4 Elevated Monitor Detail

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Figure 5 Block Valve Detail (Post Indicator Type)

Flexible Expansion
Joint

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Figure 6 Effective Firewater Monitor Range

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Table 1 Recommended Values of Manning’s “N”

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