TIE-IN EXECUTION PLAN
PROJECT : PENGADAAN EPC MUARA KARANG – MUARA
BEKASI PIPELINE PROJECT (CP-9)
CLIENT : PT PERUSAHAAN GAS NEGARA
LOCATION : MUARA KARANG – MUARA BEKASI
DOCUMENT NO. :
PROJECT NO. :
A Issued For Review 02 Aug 13
APVD BY
REV DESCRIPTION DATE PREPARED CHECKED APVD OWNER
KONSORSIUM REKIND - YIN
SHEET 2 OF 9
JOB NO. : REV
Tie-In Execution Plan DOC. NO. A
DATE BY CHKD APVD
02 Aug 13
REVISION HISTORICAL SHEET
Rev No Date Description
A 02 Aug 13 Issued for Review
DISTRIBUTION ORDER
KONSORSIUM YIN - REKIND PT. PERUSAHAAN GAS NEGARA (Persero), Tbk
Project Manager Project Manager
Wakil Peroject Manager Wakil Peroject Manager
KONSORSIUM REKIND – YIN EPC Muara Karang-Muara Bekasi Pipeline Project (CP-
9)
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TABLE OF CONTENT
1. Purpose
2. Reference Document, Code and Standard
3. System Description
4. Tie-In/Interconnection Scope of Work
5. Engineering & Procurement
6. Organization
7. Proposed Schedule
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1. PURPOSE
The purpose of this Tie-In Execution Plan (TEP) is a guidance to the following
activies : Engineering, Procurement and Site Construction including shop
fabrications for EPC Muara Karang – Muara Bekasi Pipeline Project (CP-9).
Considering most of the Interconnection Works to be executed during Exisiting Plant
turn around (before main project site activities), the Tie-in task team, schedule,
material and method are to be organized separately from main project. However
all tie-in activities will be in accordance with the project procedures, design,
specifications, construction, safety, quality term of works.
1. REFERENCE DOCUMENT, CODE AND STANDARD
Document No. Title
Field Inspection Procedures
General Requirements for Piping Welding in
Field Construction
Control Manual of Welder and Welding
Material Performances
Pressure Test Procedure for Piping
Bolting Procedure for High Pressure
Flanged Joint Pipe Supports
Thermal Insulation Design
Coating and Wrapping of Underground
Steel Pipes Cleaning procedure for Tie-In
Indonesian Regulation
No. 300.K/38/M.PE/1997 The Safety of Oil and Gas Pipeline Work
84.k/38/DJM/1998 Guidelines and Procedures of Working
Safety Inspection on Installation, Equipment
and Engineering used in Natural Gas Mining
and Geothermal Source Exploitation.
06P/0746/M.PE/1991 Safety Audit to Installation, Equipment and
Technique used in Oil and Gas Mining and
Geothermal.
KONSORSIUM REKIND – YIN EPC Muara Karang-Muara Bekasi Pipeline Project (CP-
9)
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American National Standards Institute
ANSI Z49.1 Safety in Welding and Cutting.
ANSI /AWS F4.1 Recommended Safe Practices for the
Preparation for Welding and Cutting of
Containers That Have Held Hazardous
Substances.
American Petroleum Institute
API Publ. 2009 Safe Welding and Cutting Practices in
Refineries, Gas Plants and Petrochemical
Plant.
API Publ. 2201 Procedures for Welding or Hot Tapping on
Equipment Containing Flammables.
API Publ. 941 Steels for Hydrogen Service at
Elevated Temperatures and Pressures in
Petroleum Refineries and Petrochemical
Plants.
API 570 Piping Inspection Code
API RP 579 Fitness-For-Service
API RP 2201 Safe Hot Tapping Practices in the Petroleum
& Petrochemical Industries
American Society for Mechanical Engineers
ASME B31.3 Process Piping
ASME B31.8 Gas Transmission and
Distribution Piping System
Williamson, T.D. Stopple Fitting
Roark, R.J. Formulas for Stress and Strain (4th Edition)
A. Keith Escoe Piping and Pipelines Assessment Guide
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2. SYSTEM DESCRIPTION
There are two basic conditions that exist when doing a "Tie-In." The first condition is
when a Tie-In must be made where the line can be shutdown and made safe for
welding or other work. This is called a "Cold" tie-in. The second condition is when a Tie-
In must be made when the line cannot be shutdown. This is called a "Hot-Tap" tie-in.
Making hot tap is often done by a specialist Contractor, although COMPANY personnel
also do this work in some operating locations.
During expansion projects, hot tapping into existing lines is necessary to avoid shutting
down the existing operating facilities. Hot taps are used only where it is impractical to
take the system out of service. Specifying hot taps requires inspection, design, and
testing to ensure that this operation is accomplished in a safe and reliable manner. Thus,
hot tapping should be considered only when other options are evaluated and not
possible.
For the next detail engineering phase, It shall have further studies related to the tie-ins
such as:
· Conduct an inspection for existing piping to determine exact tie-in location
· Comprehensive tie-in risk assessment study (SIMOPS workshop)
· Review the latest integrity report for existing piping especially on tie-in
location .
Table 3.1 below shows the comparison between cold tap and hot tap in general.
Table 3.1 Cold Tap and Hot Tap comparison .
No Description Cold Tap Hot Tap
1 . More costly because of It can be done by Specialist Contractor.
plant shut down and turn Price is cheaper than down time loss.
around. It implies to a lost
production time.
1 Safety
. Relatively safe for welding Hot tap has a very safety risk that
aspect and material requires thorough safety and
degradation. engineering assessment including
approval from Facility Owner and
As the work is below higher level of management.
ground, the area must be
checked for flammable gas Consequently, hot tap shall be
to ensure safe to work minimized and as a last option.
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2 Procurement
. Need purchase of regular Need purchase special material such
material such pipe, saddle, as mention at Item 5.
consumable, etc.
3 Procedure
. It can be done for all It can be routine made on lines
services line containing water, nitrogen, steam,
natural gas, crude oil and petroleum
product. Prohibited for oxygen,
chlorine, compressed air, acids, or
nitrates lines.
Many pre-cautions such as: internal
lining, wrong buried pipe, encased line,
for liquids above flash point, etc
4 Equipment
. Use regular equipment Need special equipment: split fitting,
hot tap machine, stopple-plug.
5 . Schedule Planned schedule — longer Anytime — tight working time
working time
For detailing of the tie-ins, it shall be part of detail engineering on EPCI contract .
3. TIE-IN/INTERCONNECTION SCOPE OF WORK
a) Piping
Supply and install 142 items service line
- Including necessary rerouting exisiting spool (See
Attachment-1)
- Execution tapping point work (*)
b) Electrical
- Tie-In for 20 KV Switchgear at Exisiting
Subsstation-1
- Tie-In for 3.3 KV Switchgear at Exisiting Substation-
23
- Rerouting cable at pipe rack around Boiler F.
c) Instrument
- Tie-In for Gas leak Detector & Fire Alarm Tie-In for New Tank Gauging
System
- Rerouting cable at pipe rack around Boiler F
d) Civil
- Civil Work related to the designated piping
e) Panting & Insulation
Note: *) Execution to be confirmed for 2003 Existing Plant TA
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4. ENGINEERING & PROCUREMENT
a. To provide Hydraulic Analysis in order to ensure the line sizing base-on
ITB data and incorporate the latest information
b. To check and updating the exisiting data (drawing & material
specification), and site survey
c. To check the actual existing installation space and constructability
d. To provide all Tie-in Drawings
e. To finalize all design and bidder list (for client approval)
f. Issuing MTO, Requisition and Placing Purchase Order
g. Updating Schedule and Status Report
h. To provide Welder Qulification, Safety Procedure, Field Inspection
Procedure, Working Permit Procedure, Installation Procedure, Field
Communication Procedure
i. To select Subcontractor
To prepare Construction Method
j. To prepare Site Mobilization Procedure
5. TIE-IN WORK PROCEDURE
A. Document
The following sheets are to be prepared as of the completion of work
acceptance.
1. Application for Inspection
2. Welding Record
3. Welding Inspection Report
4. Line check
5. Punch List for Mechanical Completion
6. Isometric Drawing
B. Site Preparation
1. Safety Talk Meeting (weekly)
2. Tool box Meeting (daily) s.
3. Material Completion Check
4. Safety Tools Check
5. Working Area Protection
6. Work Application
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7. Safety Permit
C. Spool Preparation
1. Fabrication of spool for Tie-in shall be done previously, the spools
shall be thoroughly cleaned and provided with cap to avoid entering of
foreign matter
2. To hand all the materials including nuts, bolts & gaskets to the Tie-In
location
D. Inspection & Testing Prior to Tie-in work
1. Existing pipe shall be inspected by Pertamina / Rekayasa joined team and
should determine the quality of existing pipe, if it is corroded due to long
time corrosion abrasion or whatever, those piping section shall be changed
by PGN and suitable condition for Tie-in work shall be established.
2. Hydrotesting of spool for Tie-in may be done beford Tie-in work or
full Radiographic Test in lieu of hydrostatic test in conditions where
hydrotest is impractical.
E. Work Location
1. The work location must be gas free and precautions should be taken
to prevent ignition of fiamable or combustible materials. Safety of
Pertamina shall be required to witness the work on flamable & explosion
area
2. To make sure the existing line has been completely out of service
and all valves shall be in closed position. Draining out the fluid inside
3. Before welding/cutting is performed the surrounding work location
must be protected (other closed pipes & equipments) with fire
blanket, especially above or near oily surface, the areas should be
flushed with water, steam cleaned or covered with clean dirt or sand.
F. Work Execution
1. To prepare detail procedure for each tapping point (shall be prepared at site)
2. To protect the working area from rainy water or other splashing
water by cover sheet.
G. To cut properly each tapping positions as per ISO Drawing
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