Project Execution Plan

NO DOCUMENT :

PT. TEGMA ENGINEERING

TE-PEP-PR-JTB-001

PROJECT EXECUTION PLAN

LUMUT BALAI GEOTHERMAL FCRS AND POWER PLANT 1 X 55 MW PROJECT

A

Rev.

25/05/2016

Date

Description

Prepared by

Checked by

Approved by

KONTRAKTOR

Approved by KLIEN

LUMUT BALAI GEOTHERMAL FCRS AND POWER PLANT 1 X 55 MW PROJECT Date : 25/05/2016

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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

6.

7.

5.1

PROJECT ORGANIZATION CHART ........................................................................................................................................ 7

5.2

CONTRACTOR KEY-PERSONNEL ROLE AND RESPONSIBILITIES .......................................................................................... 7

HEALTH, SAFETY, ENVIRONMENT AND SECURITY ..................................................... 11 6.1

S AFETY PLAN ...................................................................................................................................................................11

6.2

HEALTH PLAN ...................................................................................................................................................................13

6.3

ENVIRONMENTAL M ANAGEMENT ........................................................................................................................................13

6.4

SECURITY PLAN ................................................................................................................................................................13

QUALITY MANAGEMENT SYSTEM ................................................................................. 14 7.1

8.

9.

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

PRE-CONSTRUCTION ACTIVITIES .................................................................................. 15 8.1

SITE OFFICE, HOUSES, EQUIPMENT Y ARD AND STOCK Y ARD ...............................................................................................15

8.2

MOBILIZATION ..................................................................................................................................................................16

8.3

PERMIT 16

PIPELINE CONSTRUCTION .............................................................................................. 16 9.1

RECEIVING, TRANSPORT, H AULING & H ANDLING OF M AIN COATED PIPE ...............................................................................16

9.2

PRE-CONSTRUCTION SURVEY ...........................................................................................................................................17

9.3

M AINLINE SPREAD ............................................................................................................................................................17

9.3.1

Clearing.......................................................................................................................................................17

9.3.2

Hauling and Stringing ................................................................................................................................17

9.3.3

Pi pe S upport Ins tallation ........................................ ...................... ...................... ..................... ..................18

9.3.4

Line-up Welding .........................................................................................................................................18

9.3.5

NDE

9.3.6

6.

.............................................................................................................................................................19

Mainline S ection Ti e-in ... ...... ... ... ... ... ...... ... ... ... ...... ... ... ... ...... ... ... ... ... ...... ... ... ... ...... ... ... ... ... ... ...... ... ... ... ...... .19

9.4

P AINTING AND SANDBLASTING ............................................................................................................................................19

9.5

REINSTATEMENT ...............................................................................................................................................................20

PRE-COMMISSIONING AND COMMISSIONING .............................................................. 20 6.1

6.2

PRE-COMMISSIONING .......................................................................................................................................................20

6.1.1

Cleaning, Gauging and Water Filling ........................................................................................................20

6.1.2

Pres s urization and Holding Time ................... ...................... ...................... ....................... ..................... ...21

6.1.3

Testing ........................................................................................................................................................21

COMMISSIONING ...............................................................................................................................................................21



7.

APPENDIX ......................................................................................................................... 22 APPENDIX-A: PROJECT ORGANIZATION CHART .................................................................................................................23 APPENDIX-B: PROJECT SCHEDULE ......................................................................................................................................24 APPENDIX-C: MANPOWER AND EQUIPMENT LOADING ......................................................................................................25



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 CONTRACTOR’s plan, methodo logies, 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

:

material 

Temporary

All material/facilities and its associated work under the Contract Package which to be designed, executed, and completed by CONTRACTOR.

:

All temporary material/facilities of every kind required on Site for the



material

execution and completion of the Permanent material and remedying of any defects.



Spec ification

:

An explicit set of requirements to be satisfied by material, product or services.



Procedur e

:

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: 





5.

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

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 52

75 days

293 days

mobilisation Construction Pre-Commissioning

52 days



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.



-

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 CLIENT’s 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 CLIENT’s 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.



-

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 CLIENT’s HSE policy and requirements specified in the contract documents, and also CONTRACTOR’s HSE policy, objectives and targets.

-

Set up the project HSE programs, procedures, training materials, HSE audit programs, etc, including modifying and / or improving CONTRACTOR’s stan dards, 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 wi th 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.



-

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 CLIENT’s 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 CLIENT ’s 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 CLIENT ’s specification and CONTRATOR’s 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 CLIENT’s 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 CONTRACTOR’s Scope of Work and the CLIENT’s Project standards and requirements. He is also to report to the CONTRACTOR’s Project Manager and coordinate between departments (procurement, construction, etc.) of design, constructability and installation methods



Project Control



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 ach ieve 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.





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 Safet y 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





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.



Security Expectation vs CONTRACTOR Strategy and Plan NO

1

Frame Work

Result (Target)

Workforce Control

Unauthorized person cannot enter to project facilities

2

Controlled Asset

No asset lost

3

Emergency Response

Security incident is no impact to continuity of the business work

CONTRACTOR’s Strategy and Program Entering the site office, working area or material storage will require a securit y check. All working areas including office will be controlled by security guard, and all out going materials from storage, office, camp will be control with permit

Project HSE Plan

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.



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 Fabrication workshop

Major Equipment Parking Area

Facility

Location

Open area, container office,

The Location will be notified

and container warehouse

information later

Open Area

The Location will be notified information later



Line Pipe & Permanent

Open Area

Material

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

Personnel home stay

Site office

Proper Rented houses from

The location will be as close as

local.

the working area.

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



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 CLIENT’s 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



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 CLIENT’s 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.



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 dent’s 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 day’s 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.



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 data’s 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



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 re ports of the test are prepared by CONTRACT OR 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.



7.

APPENDIX Appendix-A

: Project Organization Chart

Appendix-B

: Project Schedule

Appendix-C

: Manpower and Equipment Loading



APPENDIX-A: PROJECT ORGANIZATION CHART



APPENDIX-B: PROJECT SCHEDULE



APPENDIX-C: MANPOWER AND EQUIPMENT LOADING

Project Execution Plan

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