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Doc. No.

: 26071-203-V21A-000-00065

Job No. : 26071 Rev.001

METHOD STATEMENT TIE-IN WORK FOR PIPING


TIE-IN OF EARLY TANK TRANSITION LINES WORK
PACKAGE

PROJECT : Engineering, Procurement and Construction (EPC) Inside


Battery Limits (ISBL) and Outside Battery Limits (OSBL) for
the Refinery Development Master Plan (RDMP) Project
RU V Balikpapan
LOCATION : Refinery Unit V Balikpapan, East Kalimantan,Indonesia
OWNER : PT PERTAMINA (Persero)
PO NO. : 26071-203-HCA-PP00-00021

RE-ISSUED FOR
002 03-Oct-2020 IHSAN MUJIB AHDAN B.
CONSTRUCTION
RE-ISSUED FOR
001 22-Sep-2020 IHSAN MUJIB AHDAN B.
CONSTRUCTION
ISSUED FOR
000 05-Aug-2020 IHSAN MUJIB AHDAN B.
CONSTRUCTION
00A 29-Dec-2019 ISSUED FOR REVIEW TONI R. MUJIB AHDAN B.

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

PT.YASA INDUSTRI NUSANTARA

Page 1 of 15
Doc. No. : 26071-203-V21A-000-00065

Job No. : 26071 Rev.001

REVISION LOG

REV.NO. DATE PAGE DESCRIPTION

00A 29-Jun-2020 - ISSUED FOR REVIEW


000 05-Aug-2020 - ISSUED FOR CONSTRUCTION
001 22-Sep-2020 - RE-ISSUED FOR CONSTRUCTION
002 03-Oct-2020 - RE-ISSUED FOR CONSTRUCTION

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Doc. No. : 26071-203-V21A-000-00065

Job No. : 26071 Rev.001

TABLE OF CONTENTS

1. PURPOSE .............................................................................................................................................................. 4
2. SCOPE ................................................................................................................................................................... 4
3. DEFINITION ........................................................................................................................................................... 4
4. REFERENCE ......................................................................................................................................................... 5
5. WORK PREPARATION ......................................................................................................................................... 5
5.1 Safety Consideration during Welding and Tappin Application ................................................................. 5
5.2 General Safety Plan ........................................................................................................................................ 6
5.3 Site Preparation .............................................................................................................................................. 6
5.3.1 Construction Work .................................................................................................................................. 6
5.3.2 Welding Work ........................................................................................................................................... 7
6. METHOD OF EXECUTION ................................................................................................................................... 7
6.1 Shop Fabrication............................................................................................................................................. 7
6.2 Tie-In Preparation ........................................................................................................................................... 7
6.3 Pre Tie-In Work ................................................................................................................................................ 8
6.4 Tie-In Work (Flange Connection) .................................................................................................................. 8
6.5 Tie-In Work (Weld Connection) ..................................................................................................................... 9
6.6 After Tie-In Work ........................................................................................................................................... 10
7. ROLES AND RESPONSIBILITIES ..................................................................................................................... 11
7.1 Shop Fabrication........................................................................................................................................... 11
7.2 Tie-In Preparation ......................................................................................................................................... 11
7.3 Pre Tie-In ........................................................................................................................................................ 11
7.4 Tie-In Execution ............................................................................................................................................ 12
7.5 After Tie-In Execution ................................................................................................................................... 13
8. EQUIPMENT, MATERIALS, AND MANPOWER ............................................................................................... 13
8.1 Equipment Requirement .............................................................................................................................. 13
8.2 Manpower Requirement ............................................................................................................................... 13
8.2.1 Manpower Distribution ............................................................................................................................... 13
8.2.2. Personnel Responsibilities ....................................................................................................................... 14
9. TIE –IN LIST ........................................................................................................................................................ 15
10. LIST OF APENDICES ......................................................................................................................................... 15
10.1 Plot Plan and Key Plan Tie-In Location ...................................................................................................... 15
10.2 P&ID ................................................................................................................................................................ 15
10.3 Test Block Diagram ...................................................................................................................................... 15
10.4 Isometric and Spool Drawing ...................................................................................................................... 15
10.5 Marking Drain, Slip Blind Installed for Positive Isolation ........................................................................ 15
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Doc. No. : 26071-203-V21A-000-00065

Job No. : 26071 Rev.001

1. PURPOSE
The purpose of this method statement is to describe and establish requirements from the piping tie in
procedure within the RDMP RU-V Balikpapan Project for Piping Tie-In of Early Tank Transition Lines
Work Package (Work Package No. 320-01).
Detail of each commodity, application procedure, management of reporting database and equipment,
tools to be used, shall be developed by Subcontractor and applied by all parties, subject to Contractor
approval.

2. SCOPE
This method statement covers piping tie in works within the RDMP RU-V Balikpapan Project for Piping
Tie-In of Early Tank Transition Lines Work Package (Work Package No. 320-01) and provides
problem statement or description of work.

3. DEFINITION
Project : Engineering, Procurement and Construction (EPC) Inside
Battery Limits (ISBL) and Outside Battery Limits (OSBL) for the
Refinery Development Master Plan (RDMP) Project RU V
Balikpapan
Location : Refinery Unit V Balikpapan, East Kalimantan, Indonesia.

Owner : PT. Pertamina, and includes its legal successor or permitted


assigns.
IPMT : Integrated Project Management Team consists of a
combination of OWNER Personnel and select third-party
personnel

Subcontractor : Yasa Industri Nusantara


Contractor : RDMP Balikpapan JO.

Vendor or Sub : The party selected by either Company or Contractor, which is


Contractor responsible for the purchase agreement or purchase order of
the goods/service specified in the Contract.

IPMT

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Job No. : 26071 Rev.00A

4. REFERENCE
The following codes, standards and specification form an integral part of this specification.

No. Document Number Document Title


1 ASME B31.3 Process Piping
2 26071-100-3PS-P30-00001-000 Piping Material Specification (Amandement)
3 26071-100-GQI-GCQ-00001-002 General Welding Inspection and NDE Procedure
4 26071-100-GQI-GCQ-00007-000 ITP for Shop and Field Painting Works at Site
5 26071-100-GQI-GCQ-00011-000 ITP for AG Piping Fabrication & Installation
6 26071-100-GPP-FB00-00001-001 Flange Management Procedure
7 26071-100-3DR-P30-00001-000 Design Basis for Piping
8 26071-100-GPP-P000-00001 Construction Work Package for Piping Tie-In of Early
Tank Transition Lines (Work Package No.320-01)
9 Document Number Not Status P & ID and Isometric Drawing

5. WORK PREPARATION

5.1 Safety Consideration during Welding and Tappin Application


a. Non spark tools shall be used in this tie-in work. The engines used shall be equiped with
muffler complete with spark arrestor and Vibration and noise of Engine to be check.
b. Prior to start of any activities, the Contractor’s Safety Officer shall check the work zone with
gas detector. The gas detector monitoring will be performed continuously during the work
period.
c. Adequate powder fire extinguisher will be placed at welding location.
d. Obtain the proper permits for welding.
e. Ensure flammable and/or combustible materials have been cleared from working area
according to safety procedure.
f. Existing equipment shall be protected with fire blanket during welding activities.
g. Ensure all rigging equipment is inspected and certified with valid certificate.
h. Ensure rigging work area clear of worker/person.
i. Ensure proper earthing is established during welding.
j. Ensure a safe evacuation route(s) is planned and properly brief to each personnel involved.
k. Ensure all work areas are kept clean.
l. Container for scrap metal shall be provided and utilized.

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5.2 General Safety Plan


a. For emergency purpose, the access to welding location from main road shall not be locked by
any vehicles and Install safety sign or warning notification.

b. Install safety / warming sign specific activity

c. All lifting, as provided by Subcontractor shall be properly certified in accordance to Conractor


Safety Regulation.
d. Suitable ladder/equipment for access to/from welding area shall be provided.
e. The total time spent by the required personnel in excavated area shall be minimized.
f. First aid facilities shall be provided at site. Only authorized person shall be allowed in the
working area. A list of authorized persons shall be available on site before commencement of
the operation.
g. In addition to above points, the following recommendation shall be taken into account:
 The atmosphere to height of 2 meters ground level or above the welding zone within
radius of 15 meters, shall always remain free from hazardous concentration of gas or
vapors or/and free from storage of flammable materials: in this case, consideration shall
be given to wind directions.
 When welding is to be done on a buried piping, an excavation of adequate dimensions
shall be provided with suitable access stairways and escape route and suitable means of
ventilation to prevent the accumulation of hazardous gas concentration, and shelter from
rain and direct sunlight.
 Scaffolding with safe access stairways and safe escape ways shall be provided in case of
welding in elevated location; proper safety gears shall also be provided against welding
spark
 Protective clothes inclusive of face masks and gloves shall be provided for all people
engaged in the welding operation
 Operable fire-fighting facilities example fire extinguisher to be made available and when
necessary, fire fighter from fire engine shall be on standby to control any unforeseen
circumstances.
 Critical activities shall be performed in the presence of safety Officer and dedicated
personnel.
5.3 Site Preparation

5.3.1 Construction Work


a. Prior to commencement of the excavation or any welding/hot tap application, dewatering of the
Trapped water in and around the proposed excavation area shall be removed by means of
pumping. Sand bags or soil will be placed around the pit to prevent flow of water towards
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excavated area pit, if required, as well as supplying of working pumps to keeps the pit
dry.
Barricading and installation of signs for selected excavation area are required
b. Scaffolding/shoring/excavating work shall be provided adequately and conform to establish
safety standard. Sheet pilling shall be installed not closer than 1 m to existing lines without
prior approval of Contractor.
c. When welding is done on hot pipeline (over 400 0C), cover should be taken that the metal is not
weakened to the point of failure
d. Lifting, handling equipment with operator is required to be provided by the Vendor or Sub
Contractor for moving the equipment from one tie-in point to another and also for loading and
unloading of equipment from the truck.
5.3.2 Welding Work
a. Prior to start any welding activities, verify with the Contractor the pressure and flow of product
and it shall be verified with the relevant/stated data sheet. Contractor will keep Subcontractor
fully informed as to the operating condition of the pipeline during the work. Subcontractor may
halt and suspend the work if the Contractor fail to provide the required operating conditions as
agreed for work.
b. Approved welders for the specific WPS shall be used for wlding.
c. Welded surfaces shall be clean and free from grease, oil, paint or other foreign material.
d. Welding activities shall be carried out in accordance to approved WPS/PQR. Visual inspection
shall be maintained throughout the welding.

6. METHOD OF EXECUTION
6.1 Shop Fabrication
a. Spool fabrication as per isometric drawing is done in piping shop first prior to installation on
site.
b. Spool shall undergo NDE Test after fabrication finished. Spool that passed NDE Test shall
then undergo Pressure Test.
c. Spool sand blasting and painting shall be done prior to spool loading to site.
d. Identification of heat numbers, marking to dimension in relevance with drawing shall be ensure
before cutting.

6.2 Tie-In Preparation


a. Contractor shall prepare Permit to Work (PTW), JSA, Method Statement LOTO, and Flange
Management Procedure prior to commencing tie-in work.
b. The following construction tools and equipment shall be prepared as minimum requirement to
tie- in work:
 Welding Machine
 Grinding Machine
 Cold Cutting Tools
 Welding Protection
 All consumable welding
 Crane (if necessary)
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 TMC Truck Mounted Crane (if necessary)
 Chain Block (if necessary)

 Tripod frame (if necessary)


 Scaffolding (if necessary)
c. The following safety tools and equipment shall be prepared as minimum requirement to tie-in
work:
 APAR & hose for water spray
 Fire Blanket
 Gas Detector
 First Aid Kit
 Safety Sign
 LOTO card (for block valve)
 Standby fire watcher
 Personal protective Equipment:
o Gloves
o Safety helmet + chin Strap
o Safety Glass
o Safety Shoes
o Ear plugs/muff
o Dust masker
o Face shield
o Coveralls
o Full body harness (for person who work at high)
d. Checking the thickness and condition of existing pipe at tie-in location.

6.3 Pre Tie-In Work


a. Contractor shall ensure all valves on upstream are closed.
b. Prior to handing over to Subcontractor, Contractor installs slip blind and LOTO card on block
valves (upstream & downstream).
c. After handing over to Subcontractor, Subcontractor shall ensure that all valves have already
closed by Contractor. Subcontractor then installs LOTO card on block valves.
d. Subcontractor fills Acceptance Form Isolation Line tie-in to ensure whether the tie-in line clear
from hazardous material and ready for tie-in prior to filling.
6.4 Tie-In Work (Flange Connection)
a. Subcontractor shall ensure that JSA Job Safety Analysis and Permit to Work (PTW) is ready
The duration for tie-in work shall follow permit to work.
harness
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b. Prior to tie-in work, tool box meeting or safety meeting should always be held.
c. Socialization of tie-in procedure, LOTO System, and JSA shall be addressed to all tie-in team.
d. Barricade around the work area for tie-in shall be installed to ensure safety around the work
area.
e. Subcontractor shall ensure that shop fabrication activities, tie-in preparation activities, and pre
tie-in works have already been completed before commencing tie-in work.
f. Contractor’s and Subcontractor’s Safety Officer shall be ready on work area before tie-in work
begins.
g. Contractor’s Safety Officer shall check the work zone with gas detector. The gas detector
monitoring will be performed continuously during the work period.
h. New pipe shall be cleaned first prior to being connected to existing line.
i. The cleanliness of existing pipe shall be checked first prior to being connected by new pipe.
The cleanliness checking of existing pipe shall be witnessed by Contractor and Owner.
j. Blind flange shall be separated from existing valve first by loosening off bolt and nut of blind
flange prior to connecting pipe spool to the existing valve. After connecting pipe spool and
existing valve, gasket shall be installed as per drawing and witnessed by Contractor and
Owner. Bolt and nut between the flange of new spool and the existing valve shall then be
tightened, this work referred to the Flange Management Procedure.
k. Bolt and nut tension shall be checked with proper tools after completing the connection.
l. Subcontractor shall clean tools and safety sign from work area after tie-in work.
m. Contractor’s and Subcontractor’s LOTO card shall be released.
n. Subcontractor shall handover finished tie-in area to Contractor. Contractor shall sign off
acceptance on tie in certificate that states tie in work has been finished.
6.5 Tie-In Work (Weld Connection)
a. Subcontractor shall ensure that JSA and Permit to Work (PTW) is ready for the duration of the
tie-in work and shall follow permit to work.
b. Prior to tie-in work, tool box meeting or safety meeting Shall always be held.
c. Socialization of tie-in procedure, LOTO System, and JSA shall be addressed to all tie-in team.
d. Barricade around the work area for tie-in shall be installed to ensure safety around the work
area.
e. Subcontractor shall ensure that shop fabrication activities, tie-in preparation activities, and pre
tie-in works have already been completed before commencing tie-in work.
f. Contractor’s and Subcontractor Safety Officer shall be ready on work area before tie-in work
begins.
g. Contractor’s and Subcontractor Safety Officer shall check the work zone with gas detector.
The gas detector monitoring will be performed continuously during the work period.
h. New pipe, flange, and fitting shall be cleaned first prior to being connected to existing line.
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i. Existing pipe shall be cut with cold cut method and then cleaned using proper tools.
j. The cleanliness of existing pipe shall be checked first prior to being connected by new pipe.
The cleanliness checking of existing pipe shall be witnessed by Subcontractor, contractor, and
owner.
k. New pipe spool and existing line shall be fitted and then inspected by QC inspector. Each tie-
in point will have 2 (two) fit up points in on existing line.
l. For cement line pipe, cement line surface shall be sealed with compound (x-pando) and then
inspected by QC inspector.
m. Metal surface of fit up point then shall be welded with tools and consumables as per Welding
Procedure Specification (WPS). The welding joint then shall be inspected using NDE test
and/or Visual Test.
n. Hydrotest (if necessary).
o. New valve shall then be installed. After that, the continuity of the new spool completed with its
accessories such as bolt, nut, and gasket shall be installed. Bolt and nut between the flange of
new spool and new valve shall then be tightened, this work refers to Flange Management
Procedure.
p. Bolt and nut tension shall be checked with proper tools after completing the connection.
q. Subcontractor shall clear tools and safety sign from work area after tie-in work.
r. Contractor’s and Subcontractor’s LOTO card shall be released.
s. Subcontractor shall handover finished tie-in area to Contractor. Subcontractor shall sign off
acceptance tie in certificate that states tie in work has been finished.
6.6 After Tie-In Work
a. Contractor shall release all blinds at downstream and upstream valves the reconnect all the
line with the valve.
b. All isolation block valve shall be re-opened Subcontractor.
c. Contractor LOTO card shall be released.
d. Show the item for repair welding :
 After repair excavation need to visual examination and magnetic / penetrant test on the
groove.
 If repair are done after hydro test, the same will be repeated after repair.
 Welding repair shall be done only twice.

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7. ROLES AND RESPONSIBILITIES
7.1 Shop Fabrication

No SCOPE OF WORK RESPONSIBILITY REMARKS


YIN JO
1 Shop Fabrication
1.1 Spool Fabrication as of spool drawing V
1.2 NDE Test for the respective spool at V
workshop.
1.3 Blasting and Painting the respective V
spool
1.4 Fabrication Slip Blind V

7.2 Tie-In Preparation

No SCOPE OF WORK RESPONSIBILITY REMARKS


YIN JO
2 Tie in Preparation
2.1 Hot/Cold Work Permit Application V
2.2 LOTO method statement preparation V
2.3 Tool and Equipment Preparation V
(including scaffolding installation if
required)
2.4 Safety Equipment Preparation V
2.5 Checking thickness tie in point and V
actual condition existing

7.3 Pre Tie-In

No SCOPE OF WORK RESPONSIBILITY REMARKS


YIN JO
3 Pre-Tie In
3.1 To ensure the surrounding area of tie V V
in location is safely clean from oil spill
3.2 To ensure safety condition working
area of tie in location (if any) e.g V V
Permanent Platform
3.3 To ensure upstream block valve of tie V V
in location has been closed
3.4 To ensure downstream block valve of V V
tie in location has been closed
3.5 To install blind at the upstream block V V
valve of tie in location
3.6 To install blind at the downstream
block valve of tie in location V V
3.7 To perform draining, venting, flushing
and/or purging in order to ensure there
is no remains flammable fluid inside V V
the line
3.8 Material Hose Y Conection V
To install YIN's LOTO card after JO
has firstly installed their LOTO card.
3.9 Kindly remind that JO can remove their V V
LOTO card only after YIN has
previously released its card
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To fill the acceptance form for releasing
flammable gas and line isolation. Kindly
remind this form shall be completed with the
relevant P&ID to indicate which valves has
been closed and installed LOTO card. This
3.10
form will be prepared by YIN to be filled by V V
JO and to be returned to YIN, The hand over
this form will be along the approval Cold/Hot
permit which has been proposed
previously.
3.11 To prepare and review checklist on V
item 3.1- 3.8

7.4 Tie-In Execution

No SCOPE OF WORK RESPONSIBILITY REMARKS


YIN JO
4 Tie In Execution
4.1 To ensure JSA and Work Permit has V
been prepared
To do tool box meeting before
4.2 execution including socialization for the V
Tie In Procedure, LOTO system and
JSA to all the team who involve in the
activity.
4.3 To barricade the tie in area V

To ensure the acceptance form for


4.4 releasing flammable gas and line V
isolation has been received from the
JO
4.5 To ensure the area free from the V V
adverse gases by performing a gas
testing
4.6 To ensure the safety person of both V V
parties has been presented at the tie in
location
To cut the existing line as of drawing
4.7 using cold work method or to do hot V
tapping as per approved method
statement
4.8 To bevel the existing line V
4.9 To check the cleanness the existing V
line which witnessed by JO
4.10 To set and install tie in spool and V
continue to be welded
4.11 To do NDE Test as per specification V
4.12 To do hydrotest (if necessary) V
4.13 To do painting on the surface of tie in V
point
4.14 To install the valve V
4.15 To clean the working area V
4.16 To release the YIN's LOTO card V
4.17 To hand over the tie in facility to the JO V

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7.5 After Tie-In Execution

No SCOPE OF WORK RESPONSIBILITY REMARKS


YIN JO
5 After Tie In Execution
5.1 To release blind at the downstream V V
and upstream valve
5.2 To re-connect all the line with the valve V V
5.3 To re-open the block valve V V
5.4 To release the JO's LOTO card V V

8. EQUIPMENT, MATERIALS, AND MANPOWER


8.1 Equipment Requirement
Hydrotest!!
Tools
Item Material Description Size Qty Unit Remark
1 Combination Wrench 3 set
2 Metal square 3 ea
3 Water pass 3 ea
4 Web sling 3 ea
5 Measuring Tape 10 ea
6 Grinding machine 3 ea
Consumable
Item Material Description Size Qty Unit Remark
7 Fire Extinguisher 1 ea
8 WD 40 2 can
9 Cotton Glove 2 pairs
10 Grinding cutting disc 15 ea
11 Electrode 35 kg
Equipment
Item Material Description Size Qty Unit Remark
12 Barricade line White/red 1 roll
13 Dust masker 1 Box
14 Majun cloth 1 kg
15 Welding Machine 4 set
16 Lighting & Genset 1 set (if night shift)
8.2 Manpower Requirement
8.2.1 Manpower Distribution
Manpower / Shift
Item Description Qty Unit Remark
1 Qualified Construction Manager 1 peson
2 Qualified Piping Supervisor 1 peson
3 Qualified Piping Foreman / Work Leader 1 peson
4 Qualified Piping Fitter 2 peson
5 Qualified Welder 2 peson
6 Qualified HSE Stand By 1 peson
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7 Qualified Bolting / Flange Management 1 Crew
8 Qualified PTW Coordinator (Common 1 person
For All Tie-In Point)
9 Qualified QC Inspector (Common For All 1 person
Tie-In Point)
10 Qualified Helper 2 person
11 Qualified Mechanical & Electrical 1 person
12 Fire Watcher 1 person

Note: All personnel shall be equipped by completed minimum PPE standard

8.2.2. Personnel Responsibilities

8.2.2.1 Subcontractor’s Piping Construction Manager


 Monitoring & controlling during Tie-In work activity.
 To ensure Tie-In work will follow predefined schedule.
8.2.2.2 Subcontractor’s Piping Tie-In Coordinator
 To issue work planning for all tie-in points (schedule, manpower, and equipment).
 To coordinate with Contractor regarding the tie in work.
8.2.2.3 Subcontractor’s Piping Superintendent
 To coordinate with operation personnel (Contractor) regarding the tie in work.
 To prepare Permit to Work and Job Safety Analysis (JSA) for tie-in work.
8.2.2.4 Subcontractor’s Piping Supervisor
 To ensure all manpower and equipment are ready to use for tie-in work.
 To ensure all isolation valve are closed with LOTO prior tie-in works.
 Supervise all activity during tie-in work.
 Housekeeping around work location after tie-in work with team personnel.
8.2.2.5 Subcontractor’s HSE Personnel
 To ensure all equipment are inspected by authorized person.
 To ensure all Permit to Work and Job Safety Analysis (JSA) regarding tie-in work are
completed.
 To check all LOTO prior to tie-in work.
 To ensure the tie-in location is clear from hazardous material.
 To release all LOTO for all isolation valve with Owner after tie-in work complete.
8.2.2.6 Subcontractor’s QC Personnel
 To inspect the material, material set-up, welding joint, bolt tension and other works
related with tie-in work, with Contractor.
8.2.2.7 Subcontractor’s Construction Manager
 Planning and assist due date of tie-in work.
 Monitoring activities of tie-in work.

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9. TIE –IN LIST

No. TIE-IN No. P&ID No.


1 TP-050 A/B 26071-203-M6-333-00001
2 TP-051 A/B 26071-203-M6-333-00001
3 TP-052 A/B 26071-203-M6-333-00001
4 TP-053 A/B 26071-203-M6-333-00001
5 TP-054 A/B 26071-203-M6-333-00001

10. LIST OF APENDICES


10.1 Plot Plan and Key Plan Tie-In Location
10.2 P&ID
10.3 Test Block Diagram
10.4 Isometric and Spool Drawing
10.5 Marking Drain, Slip Blind Installed for Positive Isolation

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