1.

GENERAL
1.1 SCOPE OF WORK
This procedure covers basic requirement for Hot Tapping of Piping Tie-in Work for Banyu
Urip Project

1.2 DEFINITIONS
Definitions within the content of this Piping-In Procedure :
a) “COMPANY” Shall be Mobile Cepu Limited
b) “CONTRACTOR” herein after refers as PT. Tripatra Engineers and Constructors.
c) “SUBCONTRACTOR” herein is the party, who perform the duties specified by
CONTRACTOR
d) “Hot Tap” is a method to make piping connection by drilling or cutting a pipe which
is carrying an under pressure fluid. The drilling or cutting will be done through a
valve stub that has been welded onto the line pipe and it has been pressure tested
before
e) “Hot Tapping Connection” is Stub (branch) is welded onto a line with cutting through
the line is still services on after making isolation part to line, tappingi is made
immediately.

1.3 CODES AND STANDARDS

All material and procedures shall be in accordance with this procedure, and as applicable
the latest edition of the following documents whic are made part of this procedure and
incorporated herein by refrence.
a. American National Standards Institute
ANSI Z49.1 Safety in Welding and Cutting
ANSI/AWSF4.1 Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers That Have Held
Hazardous Susbtances.
b. American Society of Mechanical Engineering (ASME)
ASME B31.3 Process Piping
ASME B31.8 Gas Transmission and Distribution Piping Systems
c. American Petroleum Instute (API)
API RP 2201 Safe Hot Tapping Practices in the Petroleum &
Petrochemical Industries.
API 1104 Welding of Pipelines and related Facilites
API 570 Piping Inspection Code (Inspection, Repair, Alteration,
and Rerating of in-service Piping Systems).
d. Occupational Safety and Health Standards (OSHA)
OSHA 1910.146 Permit-required confined spaces
OSHA 1910.147 The control of hazardous energy (lockout/tagout)
e. Project Specification
IDBC-TS-SPSAF-C0001 Project Specifi Safety Management Plan
IDBC-TS-SPSAF-C0003 Strategic Emergency Preparedness Plan

1.4 UNITS
The units which be applied as the measurement system shall be as mentioned in
documents and drawings. Nominal size of piping components shall be measured in
inches, for which the abbreviation is NPS

2. SAFETY CONSIDERATIONS
With reference to the list of safety document below :
 a. IDBC-TS-SPSAF-000001 Project Specific Safety Management Plan
b. IDBC-TS-SPSAF-000003 Strategic Emergency Preparedmess Plan
c. IDBC-TS-SPSAF-000004 WORKSITE Specific Health Plans
d. IDBC-TS-SPSAF-000005 Spill Prevention and Response Plan
e. IDBC-TS-SMSAF-000001 Upstream Safety Manual
The following consideration should be incorporated in all planning activities and
issue of excecution documentation.
a. Pre-job execution
 Correct Job Safety Assesment (JSA) shall be done before executing the work
and communicating to all crew on daily basis
 Correcr JEA (Job Environmental Analysis) shall be done prior to execute the
work and recorded in the JSA (Job Safety Analysis) format.
 Approved permit to work (PTW) shall be obtained prior to work execution.
b. Equipment & Tools Inspection
 All equipment shall pass pre-mobilization inspection
- Gas detector
- First Aid Kit (P3K)
- Fire Extinguisher (APAR)
- Hot tap machine
- Pressure Gauge
- Drain valve
- Adaptor flange
- Test. Pump assembly / Hand Pump assembly
- Hand Tools, Hammer, Pipe wrench, Adjustable wrench and others tool
- Hose, Water & Spill Cans
 All equipment shall be completed with standard operating procedure
c. Man Power Qualification
 All workers shall pass medical assessment prior to site mobilization
 All workers shall receive induction and required trainning for doing the job
 All workers shall be competent to perform the job properly in the safe
manner
 Operation shall only be executed on the presence of proper supervision
 SHE personnel shall be assigned to monitor the compliance of all regulation
d. Personal Protective Equipment (PPE) shall be worn as appropriate
 Safety helmet (mandatory)
 Safety shoes (mandatory
 Safety goggles (mandatory)
 Safety gloves (mandatory)
 Working clothes that cover upper arm, body ang leg (to ankle)
 Other personnel protective equipment as required by the job.
e. Safety program shall be implemented but not limited to the following
requirement
 Emergency system to anticipate any possible emergency including first aid
system and incident reporting
 Fire prevention and control system
 Environmental and waste management system.
f. Safety practice shall be implemented but not limited to the following
requirement
 A safety and toolbox meeting shall be conducted prior to commencement of
the work
 All construction equipment to be inspected by CONTRACTOR HSE, COMPANY
HSE, and tagged as approved prior to use.
 SUBCONTRACTOR Safety Officer shall in attendance at all time when doing
Tie-In Work
 SUBCONTRACTOR shall provide daily clean up of construction areas and
reinstallation of safety barricades
 Gas detection shall be performed prior to commence the work
 Fire-fighting equipment shall stand by close to the working area location
 Barricade the Hot Tap area to keep the people away.
g. Working at Height
All personnel working in elevated areas where fall exposure exist shall wear an
approved body harness with two (2) lanyards (shock absorbing type) and be tied
off to a structure, lifeline, or aprroved fall arresting device, including, but, not
limited to, the following circumstances
 When working at height greater than six (6) feet (1,8 meters ) above the
surrounding ground or WORK surface
 Within six (6) feet (1,8 meters) of the edge of elevated floors or roofs (greater
than six [6] feet) or wire rope railing
 When removing floor planks, hole covers, grating, or others from the last
panel in a temprorary floor
 On slooping roofs
 In precarious positions (lening or off balance) at any elevation
 On any type of suspended scaffolding
 In areas exposed to sharp, protruding, or unprotected objects where the
potential for injury exist
 Personnel working from or travelling in powered work platforms or personnel
lifting/ hosting devices
 When there is potential or entering a situation where fall protection is
required, inlcuding while on any scaffolding all personnel shall be required to
wear an approved full body harness and two lanyards (shock absorbing type)
h. Manual Lifting
SUBCONTRACTOR shall comply with the minimum requirements outlined below.
 Provide all personnel with training for manual lifting
 Required the use of Task Based Hazard Analysis (i.e JSA) for complex manual
lifting scenarios involving several workers
 Promote the use of Personal Risk Assessment (i.e. Last Minute Risk
Assessment [LMRA]) for simplistic manual lifting scenarios involving one
worker
 Require additional assistance, wether mechanical or manual, when a load
cannot be safely handled
 Required additional coordination by a person (not physically involved in the
lifting proccess) for those situations where several workers are involved in
the lifting procces
  Encourage the use mechanical lifting equipment for manual lift performed by
several wokers
 Require the use of gloves when lifting objects which may injure hands or
require additional grip
 Requirements for personnel making the lift
 Evaluate the estimated weight, centre of gravity, and dimensions of the
object to be lifted before performing the lift
 Verify that the route is clear and free from obstacles before performing the
lift
 Verify a clear view of the route before performing the lift
 Position close to the load, keeping feet firmly on the floor
 Squat down with back straight, bend knees, and maintain tight stomach
muscles
 Verify the weight of the object is manageable for the individual and a firm
grip is in place before handling the load
 Stand up slowly, using leg strength, holding the load close to the body,
 Do not twist while carrying the load, lead movements with feet
 Avoid standing for extended periods of time while holding heavy loads
 Do not changes grip while carrying heavy loads; if necessary, rest the load on
firm support before changing grip
 Lower the load slowly, using leg strength rather than back muscles
i. Electrical Safety
 Electrically conductive parts of enclosure, structures, and electrical
equipment that could become energized shall be effectively bonded and
grounded. This includes electrical equipment cabinets and metal housings
that may become enegized if the conductor insulation becomes defective or if
fault occurs in the equipment
 Portable electric hand tools shall an equipment grounding conductor or be
double insulated, of heavy duty construction, and approved for use by
competentn personnel
 Grounding system shall be maintained by qualified workers. Ground wires
shall not be altered except by a qualified worker performing repairs or
troubleshooting. Workers shall use Earth Leak Circuit Breaker (ELCB) for
circuits on which portable eletrical quipment is used, such as hand tools,
portable lights, and heat guns, ELCB shall be tested by a competent personnel
approved by COMPANY. ELCB protection is required for electrical portable
hand tools used inside a vessel or in wet areas. Some portable ELCBs are not
waterproof and may allow nuisance tripping of the circuit. Long sets of
extension cords and fan motors also may cause nuisance tripping of the
circuit.
 Distribution cables should be arranged so that they are not tripping hazards
and cannot be damaged by traffic
 Extension leads, if on reel shall be fully unwound before use to avoid
overheating of the cable
 Extension leads shall not be coiled on the ground as the leads overheating

3. GENERAL REQUIREMENTS
 a. HAZID managed by COMPANY (operation) to be attended and accepted prior to
starting work.
b. The Supplement HAZID of the work shall be implemented by CONTRACTOR and
SUB CONTRACTOR
c. Hot Tapping Piping Tie-In Procedures shall be approved by CONTRACTOR and
COMPANY before commencement the work.
d. Job Safety Analysis shall be provided prior to the Tie-in work and shall be
approved by CONTRACTOR and COMPANY
e. Work procedure and Job Safety Analysis shall be induced to all personnel
involved in Tie-in work
f. Work Permit shall be obtained prior execution the work
g. All equipment for Hot Tapping Tie-In work shall be inspected, approved and
certified by authorized Inspector
h. Person who are engaged for Hot Tapping work shall be qualified
i. All welding works shall be performed in accordance with Project Specification
Doc No ADBC-TS-KPZZZ-C02006 for Welding
j. Person who are engaged for welding including tack welding and support welding
work shall be passed the qualification test stipulated in Project Specification
k. The SUB CONTRACTOR shall responsible for the supervision of all Hot Tapping
Tie-In Pipe work
l. Tie-in work shall be done only at specified tie-in point
m. Tie-in shall clearly marked with tie-in tag number identical to tie-in list
n. Special consideration shall be given to any tie-in work done on piping which has
contained hazardous substances

4. PREPARATION
4.1 GENERAL PREPARATION AND SAFETY PRECAUTIONS
Hot Tapping Tie-in work locations shall be analyzed for the appropriate
safeguards and types of personal protective equipment available during the
work. The following are factors that require consideration for Tie-in work :
a. The work location must be gas free, and precautions should be taken to
prevent ignition of flammable or cumbustible materials.
b. Provision should alse made to ensure that Hot Tapping operations inside a
confined space does not create a hazard to personnel.
c. Only qualified personnel are allowed to perform Hot Tapping Tie-In work.
Qualified personnel must be capable of anticipating, recognizing and
evaluating employee exposure to hazardous substance or other unsafe
conditions. These personnel should be capable of specifying the necessary
control or protective action or both, for worker safely.
d. Truck shall be used to transport the Hot Tapping Tie-in equipment to location
and MIGAS Certificate Crane shall be used to take the Hot Tapping equipment
off the truck at the designated Tie-in required.
e. All equipment shall be inspected by Operations minimum 1 day before start
of the work. The equipment shall be certified by authorize department.
f. To manage the Hot Tap equipment delivery including Crane acces way/road
of the existing OPF Plant.
 g. Install all the ladder, scaffolding, walkway and safety net at designated
working area.
h. To placed the Potable Power Generating Unit atposition minimum 5 (five)
meters away from the existing flange connections, extension welding cable is
preferred to accomodate the Hot Tapping machine and power generating
safety aspect.
i. Finding and Tagging the designated Hot Tapping Tie-In point by using
Engineering Drawing.
j. All the existing facilities which is potential damaged due to the effect of Hot
Tapping Tie-In work shall be covered and/or protected.
k. Hot tapping tie-in work locations shall be analyzed for the appropriate
safeguards and types of personal protective equipment available during the
work. The following are factors that require consideration for Tie-In work :
i. The work location must be gas free, and precautions should be taken to
prevent ignition of flammable or conbustible materials.
ii. Provisions should also be made to ensure that Hot Tapping operations
inside a confined space does not create hazard to personnel.
l. Only qualified personnel are allowed to perform Hot Tapping Tie-In work.
Qualified personnel must be capable of anticipating, recognizing, and
evaluating employee exposure to hazardous, substances or other unsafe
conditions. These personnel should be capable of specifying the necessary
control of protective action or both, for worker safely.
m. All equipment shall be inspected by COMPANY minimum 1 day before start
the work. The equipment shall be certified by authorized department.
n. Install all the ladder, scafolding, walkway, and safety net at designated
working area.
o. To placed the Potable Power Generating Unit at position minimum 5 (five)
meters away from the existing flange connections, extension welding cable is
preferred to accomodate the Hot Tapping machine and power generating
safety aspect.
p. Finding and tagging the designated Hot Tapping Tie-In point by using
Engineering Drawing.
q. All the existing facilities which is potential damaged due to the effect of Hot
Tapping Tie-In work shall be covered and/or protected.

4.2 TIE IN PACKAGE

Before execution work of tie-in package that shown information and status of
tie-in. Tie-in package shall include, not limited to following items:
 Tie-in information, such as
 Tie-in number
 Tie-in size
 Type of tie-in
 Drawings
 Line number
 Fluid service

 Sign-off block for approval at each identified tie-in

 4.3 HOT TAPPING
Stub (branch) is welded onto a line with cutting through the line is still service on
after making isolation part to line, tapping is made immediately.

4.4 TIMING CLASSIFICATION

Tie-in shall be given a timing classification whn the connection construction can
be performed and Hot Tap can be executed at any time, required only the
issuance of proper permitting

4.5 INSPECTION AND TESTING PRIOR TIE-IN ACTIVITIES

 All existing piping shall be inspected to ensure weld ability and minimun wall
thickness
 All pipe contents shall be verified
 Valves in the line should be closed and locked. Line should be disconnected
and drained.
 The open end of pipe sections not being worked on should be blanked off.
 Only certified and qualified personnel shall be allowed to undertake the
examinations. All personnel qualification shall be subjected ro approval by
the COMPANY.
 CONTRACTOR shall provide documentation which includes as-built drawing
and photograph of the Hot-Tap Tie-In work.

5. WORK METHODOLOGY
5.1 HOT TAPPING TIE-IN WORK ACTIVITIES
5.2 REFERENCE DRAWING
5.3 WORK PROCEDURE

6. APPENDIX 1 – HOT TAP SCHEMATIC

7. APPENDIX 2 - HOT TAP WORK CHECK LIST (BEFORE CUTTING)
8. APPENDIX 3 – HOT TAP WORK CHECK LIST (BEFORE REMOVE CUTTING MACHINE)
9. APPENDIX 4 – HOT TAP WORK CHECK LIST (AFTER REMOVE CUTTING MACHINE)