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PT. TEGMA ENGINEERING


TE-PEP-PR-JTB-001

PROJECT EXECUTION PLAN

LUMUT BALAI GEOTHERMAL FCRS AND POWER PLANT 1 X


55 MW PROJECT

A 25/05/2016
Prepared Checked Approved Approved
by by by by
Rev. Date Description
KONTRAKTOR KLIEN
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REVISION HISTORICAL SHEET

REVISION REVISION REVISION


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REVISION

Implementation
Rev Part Page Comment Remark
(Yes/No)
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TABLE OF CONTENTS

1. GENERAL ............................................................................................................................ 5
2. PURPOSE ............................................................................................................................ 5
3. DEFINITIONS ....................................................................................................................... 5
4. PROJECT SCOPE OF WORK ............................................................................................. 6
5. PROJECT SCHEDULE ........................................................................................................ 6
6. PROJECT ORGANIZATION ................................................................................................ 7
5.1 PROJECT ORGANIZATION CHART ........................................................................................................................................ 7
5.2 CONTRACTOR KEY-PERSONNEL ROLE AND RESPONSIBILITIES .......................................................................................... 7

6. HEALTH, SAFETY, ENVIRONMENT AND SECURITY ..................................................... 11


6.1 SAFETY PLAN ...................................................................................................................................................................11
6.2 HEALTH PLAN ...................................................................................................................................................................13
6.3 ENVIRONMENTAL MANAGEMENT ........................................................................................................................................13
6.4 SECURITY PLAN ................................................................................................................................................................13

7. QUALITY MANAGEMENT SYSTEM ................................................................................. 14


7.1 CONSTRUCTION APPROACH ..............................................................................................................................................15

8. PRE-CONSTRUCTION ACTIVITIES .................................................................................. 15


8.1 SITE OFFICE, HOUSES, EQUIPMENT YARD AND STOCK YARD ...............................................................................................15
8.2 MOBILIZATION ..................................................................................................................................................................16
8.3 PERMIT 16

9. PIPELINE CONSTRUCTION.............................................................................................. 16
9.1 RECEIVING, TRANSPORT, HAULING & HANDLING OF MAIN COATED PIPE ...............................................................................16
9.2 PRE-CONSTRUCTION SURVEY ...........................................................................................................................................17
9.3 MAINLINE SPREAD ............................................................................................................................................................17
9.3.1 Clearing.......................................................................................................................................................17
9.3.2 Hauling and Stringing ................................................................................................................................17
9.3.3 Pipe Support Installation ...........................................................................................................................18
9.3.4 Line-up Welding .........................................................................................................................................18
9.3.5 NDE .............................................................................................................................................................19
9.3.6 Mainline Section Tie-in...............................................................................................................................19
9.4 PAINTING AND SANDBLASTING ............................................................................................................................................19
9.5 REINSTATEMENT ...............................................................................................................................................................20

6. PRE-COMMISSIONING AND COMMISSIONING .............................................................. 20


6.1 PRE-COMMISSIONING .......................................................................................................................................................20
6.1.1 Cleaning, Gauging and Water Filling ........................................................................................................20
6.1.2 Pressurization and Holding Time ..............................................................................................................21
6.1.3 Testing ........................................................................................................................................................21
6.2 COMMISSIONING ...............................................................................................................................................................21
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7. APPENDIX ......................................................................................................................... 22
APPENDIX-A: PROJECT ORGANIZATION CHART .................................................................................................................23
APPENDIX-B: PROJECT SCHEDULE ......................................................................................................................................24
APPENDIX-C: MANPOWER AND EQUIPMENT LOADING ......................................................................................................25
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1. GENERAL
The purpose of this document is to describe the CONTRACTOR plan for the execution of Lumut
Balai Geothermal FCRS and Power Plant 1 x 55 MW PROJECT. This project installation 40 1.1km,
24 2 km, 20 3.1 km and 16 0.6 km pipeline re-injection from B.L GPP to LMB A and 40 3.4 km, 24
1.8 km and 16 1.6 km pipeline re-injection from GPP to CL6 & 9. This document covers the
CONTRACTOR plan including project management plan and construction execution plan as the
scope of work for above.

2. PURPOSE
The purpose of this document is to describe the CONTRACTORs plan, methodologies, strategies and timing
for the project execution. This plan establishes the project organization, discusses administrative processes,
identifies pre construction activities, and summarizes the key activities during project execution.

3. DEFINITIONS
CLIENT : TOSHIBA (TSB)
PROJECT : Lumut Balai Geothermal FCRS and Power Plant 1 x 55 MW PROJECT

CONTRACTOR : IKPT .
Days : A project calendar day which refers to calendar applied in project planning.
Materials : Material intended to form or forming part of the Permanent Works, including
the supply-only materials (if any) to be supplied by the CONTRACTOR
under the Contract.
NCR : A Report issued a product or process doesn't meet with the CLIENT
Standard.
Works : A Report issued a product or process doesn't meet with the CLIENT
Standard.
Site : The place where the Permanent Works are to be executed and to which
Plant and Materials are to be delivered, and any other places as may
specified in the Contract as forming part of the Site.
Right of Way : The land identified by the CLIENT within which the Permanent Works are to
(ROW) built, the CLIENT warranting by means of the issuance of a single
authorization to the CONTRACTOR to commence the Works that he has
secured full rights for such purpose.
Permanent : All material/facilities and its associated work under the Contract Package
material which to be designed, executed, and completed by CONTRACTOR.
Temporary : All temporary material/facilities of every kind required on Site for the
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material execution and completion of the Permanent material and remedying of any
defects.
Specification : An explicit set of requirements to be satisfied by material, product or
services.
Procedure : A series of written steps to be carried out in a logical order for a defined
operation or a given situation.

4. PROJECT SCOPE OF WORK


Based on the scope of works, CONTRACTOR will perform:
Scope Of Work
o Fabrication & Erection ( Piping & Pipe Support )
o Painting & Sandblasting
Work Inspection
o WPS & PQR
o EBTKE Welder Certificate
o Field Test, such as : NDT, Hydro test
o Lifting Equipment & Operator EBTKE Certificate
Testing & Assist Commissioning

5. PROJECT SCHEDULE
The project schedule refers to the Baseline Schedule within the Main. Overall schedule progress updates will
be reported to CLIENT in weekly and monthly basis. Progress achievements are reported in weekly and
monthly basis to CLIENT. Mobilisasi 52 hari, brine pipeline 274 hari, brine hydrotest 52 hari
Baselines of schedule for this Project in 345 days (52 days mobilisation and 293 days for Project Execution
until Mechanical Completion), consist of Fabrication, Construction, Painting and sand blasting, Pre
Commissioning and Assist Commissioning follow schedule of client.

Days

75
52 293 days
days

mobilisation

Construction

Pre-Commissioning 52 days
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Assist Commissioning (Folow Client)

6. PROJECT ORGANIZATION
CONTRACTOR will assign the required personnel to execute the awarded project by CLIENT to meet the
Contract requirement and standard in satisfactory.

5.1 Project Organization Chart


Please refer to Appendix A for the Project Organization chart.

5.2 CONTRACTOR Key-personnel Role and Responsibilities


Project Manager
The Project Manager (PM) is the representative of CONTRACTOR which shall be valid from the effective
date of the contract up to the date of completion of the contractual obligations and will report to Project
Sponsor. Consequently, he shall be the focal point on all matters and actions related to the PROJECT.

The Project Manager will be responsible for the overall project execution and will establish the most
effective project task force for the execution of the PROJECT. He will communicate with CLIENT Project
Manager and implement the resolution of matters requiring judgment at the highest levels, including
decisions related to contractual matters. During Construction activities at site he will be back to back with
Construction Manager.

The Project Manager also responsible, within the allocated budget, for satisfying all contractual
commitments towards CLIENT while looking after the interests of CONTRACTOR and managing the risks
associated with the PROJECT.

The Project Manager is mandated to promote, conduct and monitor CONTRACTOR SHES Policy
objectives to enable work to be carried out safely. If necessary, he is responsible for the implementation
of remedial action in matters of health, safety and protection of the environment. Project Manager needs
to constantly reinforce the message that safety will not be compromised for any reason.

Construction Manager
The Construction Manager (CM) will report directly report to the Project Manager. His responsible and
duty as follow:
- Manage a team of construction specialists who perform the actual field construction works in
accordance with requirements contained in the approved Construction Plan, Drawings, Specifications
and Construction Procedures.
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- At the start of field construction work :


a. Review the project Execution Plan and Contract Agreement with CLIENT, to become familiar
with the details of the PROJECT, to-date progress of the project, significant milestone, and
various procedures.
b. Together with HSE Coordinator, reviews the forthcoming construction activities in the view of
any CLIENTs HSE regulation, such as but not to be limited to the work permit system,
emergency evacuation procedure, and HSE Plan.
c. Together with the QC Manager and the Project Engineer, reviews the forth coming construction
activities in the view of Site QA and QC, any design changes, and any non-conformity control
procedures to be complied with.
d. Together with Project Control, reviews the forthcoming construction activities in relation with
target progress and milestones of PROJECT.
e. Reviews the Temporary Facility Plan, makes sure that the plan has covered all required
construction aids and sufficient to support the safe and productive works.

- Initiates or reviews correspondences related to construction works, outgoing to CLIENT and


VENDOR.

- Attends regular scheduled meetings with CLIENTs Representatives to formally review the status of
construction, the present challenges of the work, and the planned works in the coming week(s) or
month(s).

- Overviews the overall day-to-day construction works and ensures that :


a. The Construction work force and VENDOR crews are working at allocated work places, under
adequate supervision and harmonious coordination, having enough manpower, materials,
equipment, tools, consumables, drawings, specifications, and correct instructions for the
required production.
b. The work is carried out in compliance with QC procedures, and in proper sequence to meet the
target progress and milestones in a safe and economic way.
c. The HSE Plan is implemented at actual field works and obeyed by all people: managers,
superintendents, supervisors, craftsmen and VENDORS.

- A lead of weekly staff coordination meetings to review the actual schedule of works being performed,
the forthcoming activities and targets, and highlighted the critical work schedule.

- Reviews the work schedules prepared by the construction work group or area team and VENDORS
and instruct if a corrective action is required, he shall be prepared to offer solutions to the Site
Management Team for further discussion.
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- Review and checks requisitions prepared by the construction group for construction tools, temporary
materials, additional manpower, material substitutions, prior to submit to the Project Manager for
approval.

- Reviews construction progress reports prepared by project control prior to Project Manager approval
for submittal to the Project Manager and or the CLIENT.

- Participate in the HSE inspections and audits. In case of an accident happened, the CM shall attend
the Emergency Response Team meeting conducted by HSE Coordinator.

- Reviews the constructability of any field design change proposed by Field Engineering.

- Approves time sheets of area/disciplinary superintendents and supervisors.

- Coordinates preparation of Close Out Report and review the reports, before submit to Project
Manager

HSE Coordinator
The HSE Coordinator will assist the Project Manager, who has a prime responsibility for the overall HSE
management and performance of the PROJECT during the entire project execution period. His major
roles and responsibilities are to:
- Establish the HSE Management Plan and incorporate regulatory and CLIENTs HSE policy and
requirements specified in the contract documents, and also CONTRACTORs HSE policy, objectives
and targets.

- Set up the project HSE programs, procedures, training materials, HSE audit programs, etc, including
modifying and / or improving CONTRACTORs standards, if necessary, to ensure that they meet HSE
goals and objectives.

- Fully participates in CONTRACTOR HSE Programs and Initiatives such as Hazard identification;
Observation and Intervention Programs.

- Promotes an Approaching Others no blame culture with each other CONTRACTOR personnel.

- Coordinate with the Project Engineer on HSE engineering activities to comply with the HSE
engineering program and requirements, such as hazard and effects management, incorporate HSE
requirement into engineering, conduct safety reviews including HAZOP (Hazard and Operability) and
Safety Integrity Level from a HSE point of view, monitor completeness and close-out matters raised
during engineering, etc.
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- Maintain a record of all documentation on HSE matters relating to PROJECT,

- Communicate and maintain close communication with the Site HSE Coordinator on HSE
requirements and information,

- Coordinate with CLIENTs HSE representatives as and when required.

- Prepare a Monthly HSE Report on the progress status of all activities included in the HSE
Management Plan; timely report on any HSE issue requiring action by the Project Management: Early
report on any conflict with the CLIENTs HSE representative on HSE matters requiring resolution at
the Contract Management level.

QA/QC Coordinator
The QA/QC Coordinator will report directly to the PM. He/she will be responsible to establish a Project
Quality (assurance) system in accordance with CLIENTs specification and CONTRATORs Quality
Management system as follows:
a. Define the measures to be put in place for quality planning, quality surveillance and quality
improvement.
b. Prepare schedule of Quality Audit and ensure its implementation.
c. Manage the execution of the quality surveillance activities.
d. Ensure satisfactory interface and communication with CLIENT quality representatives.
e. Prepare the Project Quality Plan, based on ISO 9001 : 2008 and CLIENTs Project requirements
f. Conduct External Quality Audit for VENDORs quality implementation.

Project Engineer
Project Engineer responsible to plan and administer all engineering related works within the project so as
to ensure the Project engineering target can be achieved. He will assign the required resources to
perform the Detail Engineering Design, Construction engineering, up to Final As-Built dossier.

He also has the responsibility to maintain communication and coordination with CLIENT Representatives,
attend coordination meetings with CLIENT, representing CONTRACTOR on engineering matters. He will
liaise with VENDOR Packages on technical matters for development of detail design and procurement.

He shall have access and good understanding of the CONTRACTORs Scope of Work and the CLIENTs
Project standards and requirements.
He is also to report to the CONTRACTORs Project Manager and coordinate between departments
(procurement, construction, etc.) of design, constructability and installation methods

Project Control
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The Project Control will be responsible to support the PM on controlling the project execution on schedule
and within budget. He/She shall produce and maintain accurate project schedule and understand
schedule resources loading. PCM will analyze variations, slipping task, impact of task changes, critical
path, and overall ability of project to deliver on time. PCM also responsible to tracking all expenditures,
analyze spending trends, prepare estimate final cost; recommend methods to keep the project under
budget and report to the Project Manager with recommend methods to keep the project under budget.
He/she shall prepare the monthly report and assemble data to consolidate.

6. HEALTH, SAFETY, ENVIRONMENT AND SECURITY


Safety, health, environmental and security will lead by the HSE Coordinator, CONTRACTOR will assign
dedicated person to arrange, manage and conduct the training.

Most personnel that directly involve on each work discipline, will be safety trained by Safety Officer at the
stockyard area and/or at work site. Basically, the training will cover the basic PPE requirement, introduction of
Emergency Response Plan, Muster Point, etc.

HSE Concern as below:


Excavation at industrial and High Population area
Hauling Material at detour road and ROW
Pipeline installation at ROW
Open cut work
Pre-commissioning work
Commissioning work
Reinstatement Work
Traffic management plan
Other works with high risk potential hazard.

CONTRACTOR will develop a working procedure for each activity and perform a risk assessment meeting to
assess the risk included in a certain activity. Any required safety training will be performed in accordance with
document Project HSE plan.

6.1 Safety Plan


Safety Plan is to act as a guideline to the project team for that need to be implemented during the project
execution to manage safety so that the objective No lost time accident with the focus on An injury and
Incident Free Work Place and safety shall not be compromised to achieve any other business objective:
Safety, Health and Environment are not affected and work crew performs their work in accordance with
well accepted safe working practices.
Equipment deployed for construction activities is certified, secured and safe.
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Adequate safety levels are maintained and environmental impacts are minimized and monitored during the
entire performance of the work.

The HSE team will assign a safetyman to each work location to manage the safety aspects on that location.
All members of the project team are considered to be part of the safety organization and will therefore be
responsible to work in a safe manner.

The HSE department will conduct safety and enhancement programs in order to pass safety knowledge and
motivation to all project members, such as: distribute safety booklets, perform safety inductions, safety
training, safety tool box meeting, and reward program.

All CONTRACTOR and VENDORs members within this project have the same commitment to Safety as per
the project motto, No Lost Time Accident.

The Safety Plan consists of several procedures such as:


Project HSE Plans
Emergency Response Plan
Incident Management Procedure
HSE inspection procedure
Emergency Response Procedures
Work permit Procedures

Safety Plan scope is applicable during the engineering, procurement, transportation, construction, systems
completions and start-up support of the pipeline by CONTRACTOR including, without limitation, providing all
project management, supervision, engineering services, procurement services, construction services,
consultations, equipment, materials, labors, construction tools, construction equipment, construction utilities,
construction supplies, systems completion materials and resources, temporary structures and facilities, and
transportation including, without limitation, hauling, unloading, and handling to, at, and from WORKSITE.

CONTRACTOR strongly believes that the workers are our most valuable resources and no phase of business
is more important than CONTRACTOR personal safety. CONTRACTOR believes that all accidents can be
prevented and that safety is an integral part of everyone's job. CLIENT, CONTRACTOR management and
workers are responsible for demonstrating safety leadership, providing a safe work environment and
promoting safety as a value.

CONTRACTOR core safety beliefs include:


All accidents are preventable
All injuries are preventable
Working safely is a condition of employment
All operating exposures can be safeguarded
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Trained workers to work safely is essential


Recognizing safe behaviors fosters better understanding of our policies, philosophy and practices

To contribute to safety improvement across the operation, CONTRACTOR share best practices and lessons
learned among industries / organizations and CLIENT. In addition, CONTRACTOR has a dedicated staff of
safety professionals, and construction team to support our philosophy.

6.2 Health Plan


Prevention is the key element used to minimize the severity of occupational injuries and illnesses. However,
unpredictable events do occur, and it is important that an emergency medical facility is defined so that prompt
and competent medical treatment is provided to an injured or ill worker.
CONTRACTOR will have designated 24 hours referral hospital or clinic, allocated at near the work site.

6.3 Environmental Management


CONTRACTOR confirms its commitment in performing the contractual works with the least possible impacts
on the environment and in absolute compliance with all Indonesian Regulations and CLIENT requirements.

CONTRACTOR will respect the environment by acting to minimize any impact which may arise from
construction operations; this includes assessing the types of materials and substances that are currently in
use and substituting them with more environmental frindly ones.

CONTRACTOR shall take note of all environmental issues and comply with all laws, rules and regulations
related to the environment. This shall include but not be limited to avoiding unnecessary felling or damaging of
trees, proper discharge of effluent, dust control, emission of noise, vibrations, fumes, waste, socioeconomic
surrounding the construction operation area, etc.

CONTRACTOR shall implement the Project Environment Management Plan in accordance with the conditions
stipulated in the Environmental Impact Assessment for the PROJECT. The environment management will
refer to document Environment Management Plan.

Environment is secured by several plans included at Project Environment Management Plan such as:
Waste Management Plan
Environmental Management Plan
Spill Prevention and Response Plan

6.4 Security Plan


CONTRACTOR will construct secure facilities at the work locations such as the site office, material storage,
site work shop and lay-down areas.

The CONTRACTOR Project office will follow existing Office owner security systems. Site facilities will be
designed as per site conditions and Contractual requirements.
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Security Expectation vs CONTRACTOR Strategy and Plan

NO Frame Work Result (Target) CONTRACTORs Strategy and Program

Entering the site office, working area or


Unauthorized person cannot
1 Workforce Control material storage will require a security
enter to project facilities
check.

All working areas including office will be


controlled by security guard, and all out
2 Controlled Asset No asset lost
going materials from storage, office, camp
will be control with permit

Security incident is no impact


Emergency
3 to continuity of the business Project HSE Plan
Response
work

CONTRACTOR will utilize local security at site during the commencement of construction. The local security
will be has security induction for a security system that will be implemented. All CONTRACTOR project team
members will be subject to checks before mobilization.

7. QUALITY MANAGEMENT SYSTEM


Detail of the Quality Management system refers to document Project Quality Plan.

The QA/QC department will be managed by the QA/QC Coordinator. The QA/QC Coordinator is responsible
for the implementation and monitoring of all inspection activities within the PROJECT. He shall delegate the
responsibility for project related inspections to nominated QC engineer and his organization. The QA/QC
Coordinator has responsibility (in-cooperation with the Construction Manager) to control conformance and
product with regards to inspection and test performed.

He shall ensure that all inspection and test are controlled and the records or other test documents are
maintained and updated to identify the status of inspection and testing. To get the Target for quality
performance CONTRACTOR will perform:

a) To satisfy the CLIENT and consistently achieve understanding of its expectation in satisfying contractual
requirements by the efficient use of the Project Quality Management System
b) Monitoring of Quality performance continually will get the effectiveness of the quality management system
through the use of the quality policy, quality assurance, quality objectives, audit results, analysis of data, corrective
and preventive actions and management review
c) CONTRACTOR will be prepare a specific project Quality Control Plan before the work commences, which
will define the arrangements and organization for Quality Control function applied to their scope of work.
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All elements or processes will be provide with an Inspection Test Plan by the CONTRACTOR before the
activities commences

7.1 Construction Approach


Related to construction activity, CONTRACTOR will put the field personnel to control of Quality Performance
and Measure for achieving targets. Each element or process of the scope of work that required for inspection
and testing during construction will be assessed for its quality level in accordance with approved ITP. During
construction stage, Quality Control system shall be started from the material storage and handling (refer to
document Material Handling, Storage and Preservation Procedure) until the material is installed and
functioning in accordance with the requirements of the project. The CONTRACTOR will prepare a specific
project QA/QC Plan for review by Construction Team before the work commences, which will define
arrangement and organization for quality control (QC) function applied to their scope of work.

8. PRE-CONSTRUCTION ACTIVITIES
The objective of the Preconstruction activities is to ensure that the facilities which are required during main
construction execution are sufficient and adhering to the following criteria:
The quantity, size and condition of facilities are sufficient, safe and secure.
Optimization of the local content.
All project, government laws and standard practice quality requirements are met.

8.1 Site Office, Houses, Equipment Yard and Stock Yard


The site office for CLIENT and CONTRACTOR staff will be located close to the Construction site.
CONTRACTOR will assign the open area for line pipe and permanent material stock yard at closest location
to the work site, when possible, the fabrication work shop and equipment yard will be at same location with
the line pipe stock yard. CONTRACTOR housing for staff will not be far from the office, construction team will
be accommodated in some local houses rented according to the area they will be working on. Detail as
tabulated below:

Description Facility Location


Fabrication workshop Open area, container office, The Location will be notified
and container warehouse information later
Major Equipment Open Area The Location will be notified
Parking Area information later
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Line Pipe & Permanent Open Area Warehouse and other


Material temporary storage located at
the closest site location as
number of length required to be
laid

Personnel home stay Proper Rented houses from The location will be as close as
local. the working area.
Site office All proper CONTRACTOR and The Location will be notified
CLIENT office requirements. information later.

8.2 Mobilization
CONTRACTOR will mobilize Material, Manpower and Equipment based on the latest pre-construction
schedule.

8.3 Permit
CONTRACTOR will obtain all regulatory permits from local governments before constructing the facilities.
Below is the list of the requirement permits:
Principal permit
Permit to Install (PTI) Pipeline work
Permit to Operate ( PTO) Pipeline work
Road Crossing.
Hydrostatic test water disposal.
Drainage or ditch crossing.
River Crossing.
Existing crossing.
Those permits must be obtained at least 2 weeks before start construction.

9. PIPELINE CONSTRUCTION

9.1 Receiving, Transport, Hauling & Handling of Main Coated Pipe


Prior to handing over of free issued pipe from CLIENT to CONTRACTOR at Coating yards, visual inspection
shall be conducted for damaged pipe (dent), size, quantity, pipe no, heat no, and coating. The result of
inspection result of free issue material will be signed by CONTRACTOR, Coating yard representative, and
CLIENT on the Material Receiving Report (MRR) as documentation for hand over material from CLIENT to
CONTRACTOR.
CONTRACTOR will be responsible for receiving the CLIENT Free-Issue Materials. After receiving such
Materials by CLIENT, CONTRACTOR shall be solely responsible for care and custody of handed over
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materials from CLIENT until CONTRACTOR has completed all work which is known to be outstanding at the
completion date stated in the handover of Custody Transfer Certificate for the Works. The line pipe load out
tally sheet shall be signed off on a daily basis by CONTRACTOR and CLIENT Representatives.
All pipe transport vehicles shall be equipped with wooden saddles covered with rubber or other soft material
so that no scratching or damage can occur to the pipe coating. When storing or transporting pipe, each joint
shall be separated using non-abrasive material (no nylon).
When transporting the CLIENTs Free-Issued Material from Coating yard to the lay-down area, the
CONTRACTOR will use sufficient amount of flat bed trailers loaded with a maximum of pipes.

9.2 Pre-Construction Survey


Pre-construction survey work shall be done prior to commencement of the construction work.This work will
covers the ROW survey works, staking outthe pipeline route and ROW boundaries prior to the
construction/boring phase.The objective is to provide specific data for the construction team on ROW
condition, crossings, obstacles, environment, and community.

9.3 Mainline Spread


The Mainline spread is a major pipeline installation spread consists of several crews divide by one (1)
spreads to perform each sequential work. The crew will be:
- Clearing and grading crew
- Stringing crew
- Line-up Welding crew
- NDE crew
- Painting and Sandblasting Crew
- Reinstatement crew

The Mainline spread will perform the pipeline installation, the sequence will be as follow:

9.3.1 Clearing
The ROW shall be cleared as necessary by removing trees, bush and undergrowth. Bush and trees
shall be felled parallel to the right of way to minimize damages to structures and trees on adjacent
properly, and then removed from ROW. Stumps and other debris shall be cleared from the spoil area
so that the spoil bank from the ditching operations will not contain any foreign matter that might
become mixed with the excavated soil. Debris shall be disposed of in a manner approved by
CLIENT.

9.3.2 Hauling and Stringing


The CONTRACTOR will be responsible for obtaining hauling permits and authorizations from
regulating authorities. The CONTRACTOR will ensure that all roads, bridge and other transportation
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infrastructure are capable of handling transportation loads and dimensions, a survey for traffic route
will be conducted prior to start the work. Only approved pipe end hooks and lifting belt which will not
damage bevels shall be used for lifting pipe. All booms, hooks, supports, skids and tie-downs used
in handling or storing the pipe shall be properly padded to prevent damage to pipe and pipe
insulation.
Certified lifting equipment with sufficient power shall be used to maintain safe pipe hauling and
stringing activity.
Pipe will be strung in a manner so as to minimize joint overlap and accumulation of pipe, to leave
gaps for access at roads and tracks, where necessary to accommodate landowner local access,
farming or livestock activities and local access. Pipe will be set on skids; pipe set directly on the
ground will not be permitted. No pipe may be rolled off a truck.
Pipe shall be strung according to approved alignment sheet. In case of discrepancy between the
alignment sheet and actual requirement, CONTRACTOR shall propose the revised alignment sheet
for obtaining CLIENTs No Objection. Each revision shall be recorded in accordance with the field
change notice procedure

9.3.3 Pipe Support Installation


By coordinating with civil work crew, pipe support installation will perfomed to lay down line
pipe (if the pipe support is ready) before line up welding or parallel.

9.3.4 Line-up Welding


Procedures and welders must be approved by CLIENT before commencing any welding. During
welding, welding speeds, voltage, and amperage shall not vary from the setting used in WPS. Any
other change in essential variables shall be qualified as a new procedure. The welding qualification
will be performed at the work shopin lay down/stock yard area or other CONTRACTOR assigned
location.

External clamp will be used for production welding, except for tie-ins and other locations where they
are not practical. The line-up clamps shall not be removed until the completion of root pass. When
external line-up clamps are used, clamp may be removed when equivalent of 50% of the root bead
equally spaced in four quadrants around the weld joint has been completed.

During fit-up, pipe lifting will be performed by using lifting frame or backhoe loader.

Welding progression shall be vertically down for all passes, except for tie-in welds. Manual welding
shall be performed by a minimum of two (2) welders for each pass, one (1) on each side of the
welding joint. Weld deposits shall be made simultaneously so as to keep heat input uniform.
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During the welding process, care shall be taken to protect the coated pipe at either side of the weld
from damage due to weld spatter.

The welding production performance and productivity will be controlled by the Quality Coordinator in
order to anticipate and overcome missed production target. Under performed welders will be warned
and given opportunity to re-train.

The records and reports will be prepared accordingly as requirement for the final documentation and
certification

If for any reason a section of pipe has to be cut out of the pipe string, due to unacceptable dents or
arc strikes. A pipe pup shall be inserted and welded into the line having the same minimum
dimensions as that of the cut out portion.

Night caps shall be installed on the ends of each pipe string at the ends of days work to prevent the
entrance of foreign matters.

9.3.5 NDE
The NDE crew will follow the mainline welding crew; NDE crew will start work at the mid day until
night in order to keep the NDE result a day after welding production. The CONTRACTOR shall be
responsible for completing 100% radiographic inspection of all welding joints to the satisfaction of
the CLIENT. Radiography shall be in accordance with API 1104 and document Radiographic Test
Procedure. CONTRACTOR will nominate a Third Party NDE CLIENT, the NDE CLIENT profile is
subject to be reviewed and approved by CLIENT.

9.3.6 Mainline Section Tie-in


Tie-in welds are those which defined as being closure welds, connecting any break in the mainline
left un-welded for construction handle-ability purpose. The tie-in will be performed by separate small
tie-in crew.

All tie-ins shall be performed in a manner that will result in stress-free piping. CONTRACTOR will
supply sufficient equipment to provide adequate slack in the line and so as not to overstress the pipe
by excessive bending while lifting. Pulling and straining to accumulate sufficient lap for a tie-in will
not be tolerated. If there is insufficient lap, then a pup of approved length is to be installed.

Prior to field cutting of pipe for a tie-in, the coating of the both mainline section shall be stripped off
for a width of 200 millimeters in a smooth, even band with the proposed cut located in the center.

9.4 Painting and sandblasting


Painting and sandblasting will be performed after NDE test complete.
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9.5 Reinstatement
The ROW and any temporary access road, lay-down area, and waterway shall be reinstated back
to their original conditions. Any existing utilities or facilities dismantled during construction shall be
put back to its place or reinstated as soon as the pipeline has been laid and backfilled. The
reinstatement crew also will install the pipeline accessories such as pipeline markers, warning sign,
and kilometer point.

10. PRE-COMMISSIONING AND COMMISSIONING

10.1 Pre-Commissioning
Prior Pre-Commissioning activities such as Cleaning, Gauging and Water filling and testing
activities started, the Test Package, Procedure, Equipment datas and the measuring Instruments
shall be properly calibrated and certified.
Temporary pig launcher and receiver will be fabricated by CONTRACTOR. For test header, the test
header is subject to certified by third party. The design of test header will be in accordance with the
same standard and code applied for the pipeline hydrotest.
6.1.1 Cleaning, Gauging and Water Filling
Setting the Temporary Launcher & Temporary Receiver.
Planning of the location for the temporary launcher and temporary receiver will be ready in
advance prior start of pre-commissioning.

The temporary launcher & receiver are pre-fabricated at the fabrication yard and will have been
pressure tested. It is then delivered to each destination. Test instruments and test manifolds are
also mobilized.

Install the launcher / receiver by welding or flange connection. Install the drain valves at the
highest elevation or at the pig receiver if there are no other connections.

All supporting equipment will be set-up close to the launcher position and all hose connected to
the test cabin at Launcher station

Cleaning Line Pipe


Insert the pig, which is bi-directional type with the brush and gauging plate mounted into
Launcher. The water will be filled first prior pig run as enough for liquefied and remove any debris
in the internal pipe surface. The pig will run to clean inside the pipeline base on the specification
and may-require series of pig runs for CLIENT acceptance.

Gauging
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The gauging pig will be a bi-directional brush pig mounted with aluminium disc with minimum
diameter 95% of the pipe internal diameter.
This pig is to ensure the installed line pipe has no found buckle or dented.

Water filling.
After the Cleaning and the Gauging Pig has been accepted, the pig will be used for water filling.
The water will fill full to the entire pipeline testing section.

All the above activities will be executed based on the approved procedure and specification, and
subject of regular inspection and acceptance by CLIENT.

6.1.2 Pressurization and Holding Time


After test section full of water, the water pressurization will commence using suitable High Pressure
Pump up to maximum 95 % the test pressure requirement.

The pressure will be maintained and monitored through the Pressure gauge installed in the manifold
to the range of 1 bar per minutes. And if the pressure reached to 95 % test pressure, the high point
valves will open and drain to ensure there is no air gap any more in the pipe. With the measurement
control will count the volume of the water in the pipeline and subject of CLIENT witness.

6.1.3 Testing
All testing equipments will be prepared, complete with all valid certificates prior commencement of
pressure test.

The test pressure will be to 1.25 of Maximum Operating Pressure for pipeline located in location
classes 2 and the maximum hoop stress during testing is less than 95% of the specified minimum
yield strength of the pipe material.

The test pressure will be hold for 24 hours and recorded by Chart Recorder and also local gauge
readings by the test engineer.
All quality records and reports of the test are prepared by CONTRACTOR for CLIENT and Authorize
government approval. These reports will be compiled as part of the final job report.

6.2 Commissioning
The completed commissioning phase will be carried out after the pre-commissioning stage when the testing
has been completed. CLIENT will perform the commissioning and CONTRACTOR will assist by supplying
staff the organization such as (manager, engineers, planners, drafting specialists) and assist to coordinate
and expedite equipments, tools and parts deliveries that are required for commissioning activities.
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7. APPENDIX
Appendix-A : Project Organization Chart
Appendix-B : Project Schedule
Appendix-C : Manpower and Equipment Loading
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APPENDIX-A: PROJECT ORGANIZATION CHART


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APPENDIX-B: PROJECT SCHEDULE


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APPENDIX-C: MANPOWER AND EQUIPMENT LOADING