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PIPELINE INSTALLATION METHODOLOGY REPORT

PIPELINE INSTALLATION METHODOLOGY REPORT

Z12/112996-ENG-RPT-00005. Rev 02

Client: LOTOS PETROBALTIC S.A.


Project Number: Z12/112996
Project Name: B8 GAS PIPELINE INSTALLATION ENGINEERING

Date Revision Description of Revision Prepared Checked Approved

12.08.2016 02 Issued for Construction M. Morgan G. Cowie A. Cowie

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PIPELINE INSTALLATION METHODOLOGY REPORT

DOCUMENT COMMENT SHEET

CLIENT: Lotos Petrobaltic PROJECT: B8 Gas Pipeline Installation Engineering Date: 13.06.2016
Comments: The response to: Installation Engineering Report Document
Document Type: Report
Document No.: Z12/112996-ENG-PT-00005 Revision: 02 Date: 04.07.2016
Document Title: Pipeline Installation Methodology Report
Received by: M. Maciejewski Date: 13.06.2016 Transmittal No. CSL-OPS-P422-DTN-006

Item Reference Comment Comment Contractor’s


By Response
1. Section 2.0 Bullet point 4 reads “Deck crane suitable to support A. Wojcikowski Noted and will remove
Installation operations” reference to deck
(21.06.2016)
Vessel crane, we can review
LPB asks is it support crane, with limited lifting the need for it later,
capacity? There is hi potential risk that our vessel but it is not essential.
won’t be equipped with that kind of crane. Please find
attached example of reel weight

2. Section 3.2 Table of principle equipment for coiled pipe M. Maciejewski Noted, we will include
Equipment installation weights and envelope
(21.06.2016)
Spread dimensions
LPB comments
 Please compare items with deck plan
equipment list (DWG-00001)
 Please add basic information about
equipment i.e. weight, dimensions etc
 Please add all Zap-Lok equipment to the
table

3. Section 3.5.2 Note: if the pipeline designated for NACE sour service A. Wojcikowski Noted and will
Zap-Lok™ the Bell end is stress relieved using heating bands removed this note
(21.06.2016)
Belling Machine comment as not
Analysed pipeline is not going to be sour gases relevant within the
transported document.

4. Section 3.6 General comment M. Maciejewski Noted and will include


Render Unit (21.06.2016) photos of typical
 Do you have some photos with Render Unit? render unit design.

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PIPELINE INSTALLATION METHODOLOGY REPORT

Item Reference Comment Comment Contractor’s


By Response
5. Section 3.11 Paragraph reads “The stinger and A-frame module A. Wojcikowski The picture of the
Stinger shall provide the designed pipe installation chord and stinger was obtained
(21.06.2016)
radius specification on the 4” pipeline. The stinger from a design made by
shall allow for “real time” feedback on the roller loads GMC and was
and video monitoring of the tip end during representative of a
installation.” typical stinger. The A
frame shown is part of
the stinger deployment
General comments system.

 A-frame – It’s been changed since first


storyboard was presented. It changes Noted and will
approaching to the vessel with impact for rationalize pipe size
range of searching vessel on the market across all documents
 4” pipeline – Please check and use either 4”
ID (ND) or 4.5” OD Would not recommend
 Video Monitoring – Is it possible to utilise an ROV for stinger
ROV at least for tip end monitoring monitoring, the ROV
will be monitoring the
touch-down of the pipe
onto the seabed. We
suggest inclusion of a
subsea camera fitted to
the tip of the stinger, if
this is required

6. Section 4.1 Second paragraph, second sentence reads “A A. Wojcikowski Yes. We will add
Mobilisation procedure for the pre-qualification activities with comment in text to
(21.06.2016)
Operations detailed description of all tests and calibration clarify
exercises shall be provided for approval prior to the
tests.”

Would these prequalification procedures be supplied


by subcontractors?

7. Section 4.1 Fifth paragraph, second sentence reads “The client M. Maciejewski Seafastening design
Mobilisation shall secure the equipment onto the vessel deck in and application would
(21.06.2016)
Operations accordance with the approved seafastening design, be the responsibility of
equipment provider(s) will provide the fixings.” the installation
contractor, we will add
Who will design seafastening clarifying comment in
the text.

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PIPELINE INSTALLATION METHODOLOGY REPORT

Item Reference Comment Comment Contractor’s


By Response
8. Section 4.3 Third Bullet point reads “According to the project A. Wojcikowski Noted, we will add
Pipeline requirements and before bringing a pipe to the comment into text
(21.06.2016)
Installation assembly line, internal and external inspection shall be
Activities carried out on each coiled pipe, and the observed
unacceptable defects shall be reported. The
mechanical connector length of pipe internal diameter
shall be proved by gauging by using a gauging plate
designed as per vendor procedures.”

 This procedure’s gone through with Tenaris,


LPB will repeat it when unspooling pipe
during installation
 This Recommended Practice should be
implemented with its number in the project

9. Section 4.3.1 Fourth Paragraph reads “As a minimum, the following M. Maciejewski Agreed, we will review
Pipeline parameters shall be monitored, recorded in a this and revise to
(21.06.2016)
Installation continuous way, and made available to Company, with reflect what is possible.
Monitoring calibration against allowable areas defined above, for:”

I think that described monitoring parameters range is


typical for Installation Vessel, and will be hard to
achieve on typical PSV. Please consider what will be
the minimum for our job.

10. Section 4.3.1 Fourth paragraph, eleventh bullet point reads A. Wojcikowski We are assuming
Pipeline “Continuous monitoring at TDP” continuous monitoring
(21.06.2016)
Installation of touch-down point by
Monitoring Please inform what system is taken into consideration? ROV. It would be good
ROV? to discuss deployment
of ROV from
installation vessel or
other.

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PIPELINE INSTALLATION METHODOLOGY REPORT

Item Reference Comment Comment Contractor’s


By Response
11. Section 4.3.2 Second paragraph reads “Detailed seabed A. Wojcikowski Clarification given by
Pipelay Route characteristics shall be surveyed to allow adjustment LPB and amended
(21.06.2016)
of installation equipment, if necessary. The pre-lay wording within
survey shall also aim at collecting soil out of paragraph to the
straightness information, which shall be used to following.
specify the requested freespan reduction works.”
From the pre-lay survey
results, a freespan
Who decided about this?
assessment task shall
be performed in order
to evaluate the
required freespan
reduction works. When
processing freespan
assessment, it shall be
demonstrated whether
or not the pipe will
deflect and gain any
intermediate supports
under in-service
conditions. Also the
location of these
supports as well as
their suitability as
permanent supports
(integrity, susceptibility
to scour, etc.) shall be
fully assessed from the
pre-survey results.

12. Section 4.3.3 Second paragraph, first sentence reads “The initiation A. Wojcikowski The installation
Pipelay system will be installed in accordance with the contractor shall supply
(21.06.2016)
Initiation approved pipeline initiation procedure.” procedure. Wording
amended to reflect
Who will prepare and supply this procedure, in respect this.
to pipeline installation or in respect of using
installation equipment on vessel deck?

13. Section 5.2.3 Second paragraph reads “The chemical injection A. Wojcikowski Noted, we will remove
Chemical Details pumps are positive displacement pumps giving a reference to “positive
(21.06.2016)
prescribed output volume per stroke. The pumps will displacement”
be carefully chosen to ensure that their output can
comfortably achieve the dosage requirement in
relation to the anticipated pig speeds.”

Please, it’s hard to precisely as on side decided what


pumps shall be used. We know that it is important to
pump it continuousl, but pumping will be realised from
offshore platform and water will be supplied from
platform pumps. Especially when we need correct
chemical dosage, maybe water will be initially
prepared in platform storage tanks before we transfer
it to the pipeline

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PIPELINE INSTALLATION METHODOLOGY REPORT

Item Reference Comment Comment Contractor’s


By Response
14. Section 5.3 First paragraph, first sentence reads “Following A. Wojcikowski Noted, we will replace
Hydrostatic successful completion of flooding, cleaning and text to reflect your
(21.06.2016)
Strength Testing gauging operations, the pipeline shall be subjected to a comments
of Pipeline 24-hour hydrostatic strength test at TBA barg.”
System
This will be aligned with Polish recommended practice
and specification, all of these requirements from Polish
RP are attached in approved building project:
Fill up the pipeline with water and increase pressure
up to WP x 1.8 (24.8MPa) for 2 hours realized strength
test, after this timedecrease pressure to WP x 1.2
(16.6MPa) after stabilisation pressure keep this for 24
hours realized Hydrostatic pressure test (tightness
test)

15. Section 5.3.1 First paragraph reads “All pressure testing will be A. Wojcikowski Noted, we will replace
Pressure Testing carried out taking into consideration the requirements text to reflect your
(21.06.2016)
of pipeline design and client requirements. All comments
temporary equipment to be used shall be pressure
tested prior to operations commencing at a test
pressure of 1.1 x hydrostatic strength test pressure
(TBA barg).”

As comments above in item 14

16. Section 5.3.3 Third paragraph reads “Pressurisation shall A. Wojcikowski Noted and comment
Pressurisation recommence at a controlled rate until 95% of the test added to reflect
(21.06.2016)
pressure (TBA barg) has been achieved. Upon reaching inspection requirement
95% of the test pressure, the pressurisation shall
continue at a reduced rate to ensure the test pressure
is not exceeded. During pressurisation from 35 barg to
95% of the test pressure, the following parameters
shall be recorded at 5 barg intervals up to 50% of the
test pressure then at 2 bar intervals until the test
pressure is reached.”

All of these requirements shall be conducted according


to Investor representative inspector

17. General To get all information about equipment you have to M. Maciejewski Noted, we will
Comments - look for it in different documents and it takes time. accommodate your
(21.06.2016)
Document request
We should find in this document all sensual
information about equipment, please add information
from documents Z12/112996-ENG-RPT-00001, 2, 3 & 4
to this document. i.e Stinger dimensions etc
18. General All equipment should be described like Zap-Lok M. Maciejewski Noted and more
Comments - equipment (drawings, data etc.) information and details
(21.06.2016)
Document added as available for
equipment

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PIPELINE INSTALLATION METHODOLOGY REPORT

Item Reference Comment Comment Contractor’s


By Response
19. General We need some Quality Report (example) for Zap-Lok M. Maciejewski Noted and will include
Comments - connection for offshore job example Quality
(21.06.2016)
Document Control Reports for
Zap-LokTM Pipeline
Installation

20. General We are not happy with A-frame on stren, is it possible M. Maciejewski The example stinger
Comments - to go back to first drawing draft was obtained from a
(21.06.2016)
Drawings design made by GMC
and was representative
of a typical stinger.
The A frame shown is
part of the stinger
deployment system.

21. General Please add on drawing DWG-00001 “pipe path” M. Maciejewski Noted and will amend
Comments - (21.06.2016) drawing to incorporate
Drawings comment

22. General Why pipe is conducted down from reel, do you have M. Maciejewski Please clarify your
Comments - some analysis on this? requirements
(21.06.2016)
Drawings If your comment refers
I know that we spoke about this on meeting, but
to the 11m separation
please remind me?
between reel and
straightener, then yes,
we have done some
calculations to justify
this distance.

23. General Some stinger assembly drawings will be helpful for us. M. Maciejewski Noted. We will include
Comments - (21.06.2016) what we can, taking
Drawings into consideration the
intellectual property
rights of others.

24. General Please add details on estimated project personnel M. Maciejewski Noted and will include
Comments – requirements section for project
(21.06.2016)
Project personnel
Personnel

25. General Please add details on estimated project schedule M. Maciejewski Noted and will include
Comments – based upon installation of two (2) Reels per load-out section for project
(21.06.2016)
Project on vessel. schedule
Schedule

26. Section 4.3 Please add details on Concrete Mattresses somewhere M. Maciejewski Noted and will include
Pipeline in your document RPT-00005 (maybe in point 4.3 new section 4.3.6
(12.08.2016)
Installation Pipeline Installation Activities), with general Concrete Mattresses
Activities information i.e. that we are planning covering gas will be added tand
pipeline, your recommendation about when we should reference LPB
execute covering (just after pipe installation, documentation for
before/after commissioning) pipeline route and
mattress locations etc

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PIPELINE INSTALLATION METHODOLOGY REPORT

Item Reference Comment Comment Contractor’s


By Response
27. Section 3.11 Please add details about A-frame to be a fixed M. Maciejewski Noted and will amend
Stinger structure (without hydraulic servomotors) on stern if to include additional
(12.08.2016)
LPB get a vessel without an A-frame detail on stinger A-
frame to be fixed
structure as necessary

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PIPELINE INSTALLATION METHODOLOGY REPORT

REVISION RECORD SHEET

Date Revision Status Reason for Change(s)

12.08.2016 02 IFC See attached comments sheet(s)

04.07.2016 01 IFA See attached comments sheet(s)

13.06.2016 00 IFK Issued for Review

TABLE OF CONTENTS
1.0 INTRODUCTION ......................................................................................................................... 11
1.1 General ................................................................................................................................................ 11
1.2 Objective.............................................................................................................................................. 11
1.3 Abbreviations & Nomenclatures ......................................................................................................... 11
1.4 References ........................................................................................................................................... 11
2.0 INSTALLATION VESSEL ............................................................................................................... 12
2.1 Vessel Layout ....................................................................................................................................... 12
2.2 Project Personnel ................................................................................................................................ 13
2.3 Project Schedule .................................................................................................................................. 13
3.0 INSTALLATION AND EQUIPMENT .............................................................................................. 14
3.1 Installation Overview ........................................................................................................................... 14
3.2 Equipment Spread ............................................................................................................................... 14
3.3 Powered Reel Drive System................................................................................................................. 15
3.4 Pipeline Straighteners.......................................................................................................................... 17
3.5 Zap-Lok™ Connection System.............................................................................................................. 17
3.6 Render Unit ......................................................................................................................................... 19
3.7 Abandonment & Recovery Winch ....................................................................................................... 20
3.8 Turning Sheave .................................................................................................................................... 20
3.9 Hold-back Pipe Clamp .......................................................................................................................... 20
3.10 Tensioner ............................................................................................................................................. 20
3.11 Stinger.................................................................................................................................................. 21
4.0 COILED PIPE INSTALLATION ....................................................................................................... 22
4.1 Mobilisation Operations ...................................................................................................................... 22
4.2 Material ............................................................................................................................................... 23
4.3 Pipeline Installation Activities.............................................................................................................. 23
4.4 Demobilization of Vessel ..................................................................................................................... 27
4.5 Offshore Works Completion and Reporting ........................................................................................ 27
5.0 PIPE-LINE PRE-COMMISSIONING............................................................................................... 28
5.1 General ................................................................................................................................................ 28
5.2 Pipeline Hydrotest ............................................................................................................................... 28
5.3 Hydrostatic Strength Testing of Pipeline System................................................................................. 29
5.4 Pipeline De-watering and Drying ......................................................................................................... 31
APPENDIX A – DECK LAYOUT DRAWING Z12/112996-ENG-DWG-00001.............................................. 32
APPENDIX B – STORYBOARD DRAWINGS Z12/112996-ENG-DWG-00002 ............................................ 33
APPENDIX C – TENARIS COILED TUBING REEL DRAWING ..................................................................... 34

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PIPELINE INSTALLATION METHODOLOGY REPORT

APPENDIX D – ZAP-LOK™ 8000-12T PRESS ............................................................................................ 35


APPENDIX E – PROJECT SCHEDULE ........................................................................................................ 36
APPENDIX F – ZAP-LOK™ PIPE TALLY REPORT & END PREPARATION REPORT ...................................... 37
APPENDIX G – CONCRETE MATTRESSES ................................................................................................ 38

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PIPELINE INSTALLATION METHODOLOGY REPORT

1.0 INTRODUCTION
1.1 General
Lotos Petrobaltic S. A. is developing B8 Field and as part of this process, the gas pipeline (CPL) with
diameter of 4.5’’ (OD) would connect the offshore production centre and onshore heat plant. The
pipeline will transmit natural gas from Petrobaltic platform (B8 field) to Energobaltic CHP in
Wladyslawowo. The planned pipeline route length is approximately 80 km with maximum 87m water
depth.

1.2 Objective
The purpose of this report is to outline the method by with the pipeline will be installed from a DP
installation vessel using reels of coiled pipe and the Zap-Lok™ system to make the joints between each
reel.

1.3 Abbreviations & Nomenclatures

1.3.1 Abbreviations
Abbreviation Description
A&R Abandonment and Recovery
AHV Anchor Handling Vessel
CT Coiled Tubing
DP Dynamic Positioning
EEZ Poland exclusive economic zone
HOLD Document hold point requiring additional clarification information
HSE Health, Safety & Environment
km kilometre
NDE Non Destructive Examination
m Metre
OD Outer Dimension
PUP Pipe Utility Piece
QA Quality Assurance
ROV Remotely Operated Vehicle
TBC To Be Confirmed

1.4 References

1.4.1 Reference Documents


Document Title Document Number
Deck Layout Drawing Z12/112996-ENG-DWG-00001
Sequence drawings (storyboards) Z12/112996-ENG-DWG-00002 (7 sheets)

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PIPELINE INSTALLATION METHODOLOGY REPORT

2.0 INSTALLATION VESSEL


The installation vessel shall be of a typical dynamically positioned offshore construction support vessel
type that will provide a stable platform to perform the subsea pipeline installation. The vessel shall
need to support the proposed installation activities with suitable capabilities including;

 Dynamic positioning operations in accordance to IMCA standards


 Sufficient deck space and loading capability to support the installation equipment and
operation
 Suitable accommodation for marine and operations personnel
 Suitable handling aids to support operations, such as small cranes / hoists

A specific technical specification shall be provided to detail the appropriate vessel / marine
requirements. The following section details the vessel requirements from the pipeline installation
perspective.

2.1 Vessel Layout


In the base case, the deck layout is designed on having only 2 reels available on each load out for
installation. The installation vessel shall be able to accommodate the layout of equipment as shown in
Appendix A, the Deck Layout drawing, Z12/112996-ENG-DWG-00001 and this results in the need for a
vessel with a deck which can offer a minimum unobstructed length of 50m.

The installation contractor shall take into consideration the cost effectiveness of two (2) different
installation vessels.
I. A vessel suitable to accommodate two reels, necessitating frequent port calls for restocking
and;
II. A larger vessel, accommodating more reels, having the advantage of an increased time on site,
installing pipe and the possibility of restocking at sea, using ship to ship transfer of 35 tonne
reel (30 tonnes of pipe + reel weight 5 tonnes).

Other than running the pipe through a set of straightening rollers, to change the pipe profile from
curved to straight, it has been decided that there will be no other plastic deformation of the pipe during
the installation process. This decision establishes a minimum spacing between the aft most reel and
the straightening rollers, which has been calculated to be a minimum distance of 11m. This was
derived from a consideration of the pipe as cantilever, en-castre (built-in) at the straightening rolls and
deflected by the outer wraps on the reel. The pipe material conforms to API 5L grade X65, this
deflection would subject the pipe to a bending stress of 90% of its yield strength.

The coiled pipe installation equipment, including the reel drive system, is arranged so that it sits on its
own rail system and this feature contributes to minimizing the need to add additional structure to the
vessel in order to provide under deck strengthening.

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PIPELINE INSTALLATION METHODOLOGY REPORT

2.2 Project Personnel


The following is an estimate of required project personnel during the installation operations for the B8
Gas Pipeline.

Lotos Petrobaltic
Offshore Manager

Pipelay Supervisor
x2
Days / Nights

Tensioner Powered Reel Drive Zap-Lok Deck foreman Survey Obs ROV
Supervisor x 2 Supervisor x 2 Supervisor x 2 X2 Snr Surveyor x 2 Supervisor x 2

Tensioner PRD Technician / Zap-Lok Technician /


Rigger Surveyors Pilot / Techs
Technician / Operator Operator Operator
X2 X2 X2
x2 x2 X2

NOTE: Above personnel chart excludes any vessel marine crew

In view of the intermittent nature of the work, the crew will be in port every 2 – 3 days and the potential
for limited POB, it is suggested a multi-disciplined pipelay crew should be utilised and could be as
follows:

Tensioner 3 1 days, 1 nights and a senior who can bridge shifts


PRD 3 1 days, 1 nights and a senior who can bridge shifts
Zap-Lok™ 2 Pipe-lay supervisor oversee Zap-Lok™ operations, as these are so infrequent,
these personnel would not work shifts and when not busy could relieve the
PRD and Tensioner operators
Survey 2 1 days, 1 nights
ROV 4 2 days, 2 nights

Deck foreman 2 1 days, 1 nights


Riggers 2 1 days, 1 nights

2.3 Project Schedule


An estimate project schedule has been created based upon installation of pipelay equipment onto
vessel and laying two (2) CT reels per trip. A total of 38 reels will be installed, equating to 14 pipelay
operations trips, with port calls between each to off-load empty reels and load next full reels.

This schedule is attached in Appendix E

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PIPELINE INSTALLATION METHODOLOGY REPORT

3.0 INSTALLATION AND EQUIPMENT


3.1 Installation Overview
The pipe-line material is stored on a number of reels, each with approximately 1,800m of pipe. At least
2 reels, depending on the size of the installation vessel, would be stored on-board and the pipeline
would be laid by unreeling the pipe, starting with aft-most reel.

The pipe is lead off the underside of the reel to accommodate the layout of the Zap-Lok™ equipment
on deck. It is important that this system be installed parallel to the ship’s deck, insofar as this is possible
and for this reason the pipe cannot be led off the top of the reel.

Joints between successive reels of pipe would be made by the Zap-Lok™ process.

When the pipe had been unreeled from the initial reel the Zap-Lok™ system would secure the pipe end
while the reel drive system would disengage from the initial reel, move forward and engage the next
reel.

When the reel drive had engaged the next reel the new end would feed into Zap-Lok™ press, where
the pipe joint would be made. Laying would continue until all the pipe had been unwrapped from the
next reel and the process would continue until the end of the last reel had been reached.

At this point the last end would be sealed and a pull-head would be attached. The pull-head would be
connected to a pennant and buoy and carefully laid down onto the seabed, using an Abandonment
and Recovery (A&R) winch.

The vessel would transit to port to unload empty reels, re-stock with full reels, take on all necessary
supplies, change crew changes as required and return the field. On return to the field and the
completion of DP trials, the abandoned pipe end would be recovered and the laying process would
continue until the pipe had been unwrapped from the next reels.

The vessel would continue to lay pipe, transiting to port to restock until the pipe-line had reached the
target box adjacent to the platform. At this point the riser end termination would be attached,
together with a pull-head and the pipe would be laid down in preparation for connection to the
platform riser.

The pipeline would be integrity tested and leak tested using treated sea water. On completion of the
testing the pipe would be de-watered, dried and suspended until the riser would be connected.

3.2 Equipment Spread


The coiled pipe installation equipment spread required to install and connect each reel of coiled pipe
is described in this section. The principle of the installation equipment spread is to be able to mobilise
onto the installation vessel at a minimal cost each component that will work as a system to reel the
coiled pipe from the storage drum, straighten the pipe and then bring into the Zap-Lok™ connection
press to allow each reel of pipe to be connected. Thereafter the pipe shall pass through a tensioner
and then overboard via a stinger to support the pipeline during installation.

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PIPELINE INSTALLATION METHODOLOGY REPORT

The following table lists the principle equipment which shall be provided for the installation of the
coiled pipe from the installation vessel:

Item Qty Description Dimensions Weight


(m) (Tonnes)
1 2 Reel with product 5.9 X 2.8 X 5.9 35
2 1 Powered Reel Drive System 6 X 5.4 X 5 22
3 1 Pipeline Straighteners 1.5 X 1 X 1 6
4 1 Zap-Lok™ Connection System, inc Render 9X3X2 15
Unit
5 1 Zap-Lok™ pin/bell machine 6 X 2.4 X 2.5 10
6 1 Abandonment & Recovery Winch 0.5 X 2.4 X 2.0 8
7 1 Turning Sheave 1.0 x 1.0 x 1.5 1
8 1 Hold-back Pipe Clamp 1 x 1 x 0.5 0.5
9 1 Tensioner 6.4 X 3.4 X 0.5 15
10 1 Modular Stinger 8.0 X 3 X 3 10
11 1 Stinger deployment winch 3.2 X 3.7 X 2.6 10
12 1 Rigging/Control container 6 X 2.4 X 2.5 10
13 1 HPU 1.3 x 1.4 x 0.8 1.5

3.3 Powered Reel Drive System


The reel drive system shall be suitable to handle the specified loaded reel of coiled pipe via a drive
mechanism. The reel drive shall be installed onto a track system that shall allow the reel dive to be
dived along the tracks from one-reel position, to the other.

Figure 1. Typical Reel Drive

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PIPELINE INSTALLATION METHODOLOGY REPORT

The reel drive unit shall be suitable to accommodate the coiled pipe reels of which the specification
is as follows;

The reel dive shall be independently powered

3.3.1 Track System


The track system shall be laid onto the vessel deck with appropriate seafastening. The track will
accommodate the reel drive unit and be able to provide a controlled movement long the length of the
tracks to allow repositioning of the reel drive between the loaded reels.

3.3.2 Tower
The reel drive tower units (2) shall allow the loaded reel to be manoeuvred in both the vertical and
horizontal axis.

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3.3.3 Reel Drive Hub


The reel drive hob interface shall be able to lock onto the specific profile of each loaded reel. The
dimensions of the reels are provided in Appendix C.

3.3.4 Reel
The reel(s) are Tenaris designed and details are provided in Appendix C

3.4 Pipeline Straighteners


The supplied pipe straightener system will need to incorporate a large bending shoe that pre-bends
the pipe entering the straightener to a known, fixed radius in order to maintain the pipe straightener
at a constant setting as the reel is emptied of the pipe.

The pre-bend shoe also aligns the pipe with the face of the reel so that the pipe can be wound levelly
and smoothly on and off the reel. A movable bending shoe / set of rollers and fixed reaction shoe / set
of rollers are used to reverse the bend and straighten the pipe as it comes off the reel.

However, it may not be possible to accommodate the size of an aligner and for this reason it may be
necessary for the installation contractor to consider having only one straightening system and
employing accurate control of the reverse bend straightening rolls, in order to minimize deck space.

3.5 Zap-Lok™ Connection System


The Zap-Lok™ joint is a widely used mechanical interference connection for pipeline use. The joint has
pressure, mechanical and fatigue strength suitable for the same service as welded joints, but the cost
of making and inspecting Zap-Lok™ joints is lower and installation rates are faster. Typical applications
include gathering and distribution systems, transmission lines and specialized pipe installations on land
and offshore. Thousands of kilometres of pipe have been joined using the Zap-Lok™ process under a
wide range of operating conditions. The Zap-Lok™ press machines have performed on virtually every
type of terrain, under severe weather conditions and in hostile environments. They have been used to
join offshore flowlines and injection lines for both internally and externally coated pipe.

The Zap-Lok™ process works on the basis of pre-forming a bell (female), or expanded area, which is
formed on one end of a pipe joint, and a pin (male) which is formed on the opposite end, Figure 1. This
part of the process can occur at various locations i.e. a Zap-Lok™ facility, pipe mill, or coating plant.
These end preparations are automatically controlled to specifications required for the Zap-Lok™ joint.
In the field, Zap-Lok™ field equipment is used to push together the bell end of one pipe joint and pin
end of another to form a metal-to-metal seal face. A specialised company specific Epoxy, known as
Zapoxy, is applied to each end to lubricate the joint during the pressing process as well as providing a
smooth bore and secondary seal.

Once the Zapoxy cures, the result is a metal-to-metal interference fit, with the connection made up of
the pipe itself, as can be envisaged by observation of the diagram below.

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Figure 1 - Zap-Lok™ Joint

The Zap-Lok™ process produces strong, permanent joints which can be used in the same pressure
service as welded lines. This allows the pipeline system design to be based on a joint strength of 100%.
Extensive independent evaluations under varied laboratory test conditions and in-service performance
records have proven the Zap-Lok™ joint to be strong, reliable and leak proof. There have been no
reported in-service failures over its entire 40-year history. The Zap-Lok™ method can be used to join
relatively thin wall pipe, down to Schedule 20, which cannot be easily welded. Additionally, the Zap-
Lok™ joint can carry corrosive fluid without the vulnerability of threaded couplings, or damaged
internal coating resulting from the high temperatures produced for a welded joint.

3.5.1 Zap-Lok™ Press


For offshore use the Zap-Lok™ 8000 12T Series Press will be used and incorporated into the Modular
Pipelay System®. The unit will be fitted with the data recorder unit that is set up to record various
clamping and squeezing pressures on the press to enable a confirmation of the integrity of each
connected joint to be given. The press shall be mounted onto the render unit which allows the Zap-
Lok™ press to “float” when the clamps are engaged onto the pipe during the connection process.

The Zap-Lok™ 8000 12T specification is included in Appendix D.

3.5.2 Zap-Lok™ Belling Machine


The base case connection system uses a belled end at the end of each pipe to be joined. For this
reason, the belling machine will need to be manipulated into position to prepare both the new reel
end and the end of the installed pipe. The installation contractor shall make provision to accommodate
this requirement safely.
The Zap-Lok™ end prep machine inserts a lubricated mandrel into one end of the pipe forms the bell
end. The mandrel is shaped to leave a bell end with a uniform taper and with a short lead-in flare. The
mandrel size is the same for all wall thicknesses (within API-5L tolerances) of a given pipe diameter.
The belling of pipe involves plastic deformation or cold-forming. Therefore, a lubricant must be used
to prevent galling between the mandrel and the pipe, to reduce the force required and to minimise
wear on the mandrel. Following belling, the lubricant must be removed and the soundness of the
belled end checked visually. Additional inspection using magnetic particle methods is recommended
when the amount of expansion strain is larger than 10%.

Inspection of a new mandrel for dimensions is required for monitoring of wear on the mandrel is
required. Each mandrel size has specified tolerances.

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3.5.3 Zap-Lok™ Pinning Machine


The pinning machine is likely to be needed to make pin ends on abandonment heads. The end of a
new reel will need to be provided with a pull-head. This is pulled into the Zap-Lok™ press and the end
cut off in preparation for making the belled end.

There is an opportunity to re-use this cut-off as a future abandonment head at least once, all that is
required would be to have a pin preparation made on the open end.

3.5.4 Zapoxy Mixing Unit


The Zap-Lok mixing unit is designed to provide a two-part mixing process of the Zapoxy lubricant
material. A Zapoxy mixing unit would be available and would normally be required when pipe is laid
using discrete lengths, where Zapoxy use would be frequent.

In this case, where the pipe-line is to be laid by the reel-lay method, there would only be need to
make joints infrequently, so it is anticipated that the Zapoxy compound could be mixed and applied
by hand.

3.5.5 Pipe Utility Pieces


The Feasibility Assessment report proposes a base case for Zap-Lok TM Jointing process in which each
of the pipe ends would be belled and a PUP, having a pin preparation at each end would be used to
make up the joint and the installation sequence drawings, in the Appendices, reflects this
arrangement.

3.6 Render Unit


The Render unit consists of a trolley mounted on rails which the Zap-Lok press is subsequently
mounted onto within the firing line. The render unit has two (2) main functions:

 Allow Zap-Lok press to render inboard or outboard relative to pipe end while making a pipe
connection, avoiding potential damage to Zap-Lok press or pipeline
 Aligning Zap-Lok press pipe clamps over pipe ends prior to making next connection

The Render unit is controlled via a hydraulic cylinder which drives the trolley forward or aft on the rails.
The hydraulic circuit is design to operate in “Drive” or “Float” mode via a changeover switch. When

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the Zap-Lok press is clamped onto the pipe ends when making a connection the render unit will be in
“float” mode which will allow the press to move relative to any movement of the outboard pipe end.
The following photo is an example of a render unit designed for offshore Zap-Lok™ Pipeline
installation operations.

Example of Render Unit

3.7 Abandonment & Recovery Winch


A 15Te Abandonment and Recovery (A&R) winch fitted with 300m of subsea wire should be provided.
The winch will be hydraulically powered and manually operated and used for the initiation and
laydown of the pipeline and if required abandonment.

3.8 Turning Sheave


A deck mounted turning sheave will be positioned on the deck to provide a pivot pint for the A&R
winch wire to be rigged to assist in pulling out the coiled pipe from the reel.

The turning sheave should be fitted with load cell in order to indicate the weight/load being taken on
the A&R winch during operations.

3.9 Hold-back Pipe Clamp


A hold back clamp will be provided to secure the coiled pipe around the exterior of the pipe to act as
a securing point of the pipe during installation.

3.10 Tensioner
Pipeline tension will be controlled during lay by a 5Te, 2 tracked (horizontal) tensioner as required in
accordance with the installation tension calculations, within the Pipeline Installation Analysis Report
Z12/112996-ENG-RPT-00003. All pipe tensioner units shall be equipped with a safety device that
ensures that it cannot be open while the product is under tension. It shall also be fitted with a squeeze
limitation device to ensure product integrity. The Tensioner will be provided with a control cabin and
HPU.

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3.11 Stinger
The stinger shall provide the designed pipe installation chord and radius specification on the pipeline,
as defined within report Z12-112996-ENG-RPT-00003 Pipeline Installation Analysis, section 4.1 as
follows:

 The stinger should a minimum of approximately 40m radius and 30m length in order to
maintain the pipeline within its yield strength during laying
 The spacing between roller boxes should be in the region of 5m. Spacing’s greater than this
may increase the local bending moment on the pipeline due to the larger span between roller
boxes.

Figure 8 is a representative sketch of a typical modular stinger.

The stinger shall be hinged so that it can be lowered into the water during pipe-lay operations and
lifted out of the water for transit and in port. If the installation vessel has no integral A-frame at the
stern then and suitable fixed A-frame structure shall be installed at the inboard end, which acts as a
lever arm during the deployment of the stinger. This A-frame structure does not require to be
independently hydraulically operated via servomotors, but must still have the ability to raise and lower
the stinger between operational and transit positions.

Figure 8 – Example of Typical Modular Stinger

One of the options for monitoring touch-down of the pipe-line would be to install a camera on the
stinger and monitor the departure angle of the pipe and compare it against tables which have been
constructed during the pipeline analysis.

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4.0 COILED PIPE INSTALLATION


4.1 Mobilisation Operations
The installation contractor shall develop a mobilisation manual, to ensure all requirements are met
and approved prior to mobilisation operations commencing.

Prior to shipping to the designated port of mobilisation and prior to mobilization, tests on all
installation equipment shall be performed, to demonstrate the suitability of the equipment for the
installation operation and prior to these tests, the installation contractor shall develop a procedure for
the pre-qualification activities, to include detailed description of all tests and calibration exercises
required.

Equipment provider(s) will undertake the mobilisation of the equipment in accordance with the
schedule and the approved project mobilisation plan.

The installation equipment shall be assembled into the specified component part at the quayside and
in the vicinity of the vessel berth. The client will provide the necessary quayside facilities and lifting
cranes for this to be performed.

The approved vessel layout drawing for the equipment spread shall be issued for installation including
mobilisation/demobilisation which illustrates the principal items to be supported on the vessel deck.
The client shall provide all lifting cranes to allow the pre-slung assemblies to be lifted from the quayside
onto the designated position on-board the vessel. Equipment suppliers shall specify weights and
positions of CoG for their equipment and sacrificial attachment points to facilitate sea-fastening.

In conjunction with the classification society for the vessel class issues, where applicable, the
installation contractor shall design suitable sea-fastening for all equipment and secure the equipment
onto the vessel deck in accordance with the approved sea-fastening design. The handling capacities
the pipe laying equipment shall be in excess of the maximum loads to be experienced during the
operation even during worst case scenarios. The structure of the vessel shall be strong enough to
support the specified equipment and where required, reinforcements shall be provided. The design of
such reinforcement shall be proven by calculation and approved by the relevant certifying authority.
Hook-up will be performed once all equipment has been sea-fastened.

At completion of the hook-up activities the equipment provider(s) shall perform a system test. This
pre-approved procedure shall be undertaken and witnessed by the client.

The mobilisation of the pipeline installation equipment onto the vessel and equipment are considered
to be fully accepted when:
 All control steps have been performed satisfactory
 The main systems of the vessel and equipment have been tested satisfactory according to the
referred international standards, client specifications and the Project Requirements
 All the documents and certificates requested by the client have been found on-board, have been
checked to be up to date and to prove a good management of the vessel, the qualified personnel
and the equipment mobilized on-board
 All HSE and other requirements are fulfilled
 Visual inspection of the different systems and areas of the vessel are satisfactory.

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4.2 Material
Specific care will be taken for the installation equipment and coiled pipe material; vendor handling
procedures shall be adhered to at all times.
 All coiled pipes, installation aids, equipment and other items arriving on site shall be thoroughly
inspected in accordance with the project requirements and industry specifications and/or
approved procedures. All items shall be accompanied by all necessary certifications.
 Any damaged item shall be repaired, or replaced if repair is not allowed or not possible.
 A list of the found damages indicating the reinstatement method or remedial measures performed,
shall be continuously maintained and available at all time.
 During pipes storage and transportation shall meet the criteria in accordance with the Zap-Lok™
connector storage and transport procedures.
 Handling, loading, shipping, storage and unloading shall be carried out in such a manner as to avoid
any damage to the line pipes and other material
 Materials shall be traceable and identifiable throughout the Project by means of certified markings
related to the authenticated material certificates
 Storage areas shall fulfil all requirements specified by the material’s suppliers.
 Certification, test and inspection reports generated throughout the manufacture of components
and assemblies shall be traceable to the completed assembly.

4.3 Pipeline Installation Activities


This section provides the minimum requirements to be fulfilled during the preparation, site
preparation and installation phases for normal and contingency conditions and shall be read in
conjunction with the DNV-OS-F101. All mechanical connection operations and inspection shall be
carried out in accordance with the project and vendor approved procedures for those mechanical
connectors.
 Unless otherwise stated by the project requirements, lay direction together with reason for
selected options shall be proposed and duly documented in the Construction Manual; as a
guideline, the lay direction shall minimise any possible interferences/clash with other activities.
 Installation of the pipelines shall conform strictly with all applicable laws and regulations. The
installation works shall also be performed in compliance with the applicable specifications and also
in compliance with the following guidelines:
o Stress in the pipelines shall be controlled during the lowering, laying and repairing to
prevent yielding, buckling or weakening of the pipe
o During the laying operations, equipment which will ensure the pipelines adequate
protection from external forces which might cause buckling, weakening or overstressing
of the pipe shall be provided as necessary
o All equipment used in handling and cradling coated pipe shall be of a type which will not
damage the coating
o Pipe shall be handled in a manner to prevent damage to the pipe walls and bevels. In lining
up the pipe, care will be taken so that pounding with a sledge hammer will not be
necessary.
o When laying operations are interrupted and abandonment of pipe is decided, the open
end of the laid pipe shall be securely closed and shall not be opened until laying is resumed.
o Any pipe end lowered in the water shall have watertight caps, installed with provisions for
flooding and dewatering.
o In case of accidental water ingress any sections, incriminated sections shall be swabbed or
pigged in a satisfactory manner before that section is tied into the line, according to the
dedicated procedure.

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 According to the project requirements and before bringing a pipe to the assembly line, internal
and external inspection shall be carried out on each coiled pipe in accordance with the
requirements of the Tenaris inspection procedure, and the observed unacceptable defects shall be
reported. The mechanical connector length of pipe internal diameter shall be proved by gauging
by using a gauging plate designed as per vendor procedures.
 All necessary precautions to keep the inside of the pipes free from dirt, waste and other foreign
matters shall be taken.
 The sequential marking/numbering of pipeline joints shall be done at the line up station and
touched up after the pipe has passed through the tensioning device. Proper recording and
maintenance in the pipe joint identification marks and numbers and of the sequence as-laid in
position shall be done.

4.3.1 Pipeline Installation Monitoring


An operational plan for the monitoring of the pipeline installation vessel and installation parameters
shall be produced. This plan shall be as simple as possible in order to immediately reflect or to confirm
any shift of the monitored parameters towards unsafe areas.

The operational plan and the pipeline installation monitoring system shall be fully described in the
Construction Manual with the aim to ensure that normal and contingency installation works are
conducted in a safe manner by giving the parameters to the Project.

The monitoring system shall be designed to provide instantaneous direct or indirect access to pipeline
buckling and collapse safety margin, pipeline as-laid versus initial routing gap, static and dynamic
deflections, fatigue, etc.

As a minimum, the following parameters shall be monitored, recorded in a continuous way, and made
available to Company, with calibration against allowable areas defined above, for:

 Pipe tension, tensioning devices setting and dead band


 Tensioner squeeze pressure and pay out/in speed
 Abandonment & Recovery winch cable tension
 Water depth
 Stinger: angle and loads in a mechanical supporting system
 Continuous monitoring at TDP: by ROV or Departure angle of pipe from stinger
 Horizontal distance from pipe departure at the vessel to TDP
 Wind speed and direction
Direct reading and processing of stored records from all required essential instrumentation, measuring
devices and video monitoring system shall be possible at the vessels bridge.

4.3.2 Pipelay Route


Before the commencement of pipe laying works, a pre-lay survey of the pipeline system installation
corridor and mooring anchors corridor (If applicable) shall be conducted according to the applicable
reference documents.

From the pre-lay survey results, a freespan assessment task shall be performed in order to evaluate
the required freespan reduction works. When processing freespan assessment, it shall be
demonstrated whether or not the pipe will deflect and gain any intermediate supports under in-service

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conditions. Also the location of these supports as well as their suitability as permanent supports
(integrity, susceptibility to scour, etc.) shall be fully assessed from the pre-survey results.

The location of freespan reduction supports, as well as the required pipeline lift-up height shall then
be specified so as to optimise the in-service stress/strain behaviour of the pipeline.

The construction route including expected pipeline service life displacement area shall be cleared of
any debris and obstructions assessed as hazards, in order to facilitate the proper and safe installation
of the pipelines, crossings and other.

4.3.3 Pipelay initiation


The installation contractor shall compile an initiation procedure and the initiation system will be
installed in accordance with this procedure. The initiation wire will be connected to the initiation
rigging; the initiation wire will be fed back to the pre-assembled initiation head connected to the first
section of pipeline assembled in the firing line.

4.3.4 Pipelay
The installation sequence of operation is shown in appendix B, the story board drawings Z12/112996-
ENG-DWG-00002 (7 Sheets).

The installation sequence is summarised below:

 Stage 1 - Pick up the Laid end in Shallow water at HDD section


 Stages 2 & 3 - Prepare and bell end of new reel
 Stages 4 – 8 - Pick up the Laid end and bring it onto the stinger and aboard at the stern of the
vessel
 Stage 9 - Bring the laid end into the tensioner and remove the pull head
 Stages 10 & 11 - Bell the laid end and withdraw the laid end into the tensioner
 Stage 12 - Pick up the PUP, install into rear clamp of Zap-Lok™ press
 Stage 13 - Bring Zap-Lok™ press and PUP forward, install new reel end into forward clamp of
Zap-Lok™ press, make up joint between new reel end and PUP and wait 5 minutes to cure Zap-
oxy compound
 Stage 14 - Open clamps, move Zap-Lok™ press aft, till in position to grip PUP in forward clamp
and close forward clamp
 Stage 15 - Tensioner advances pipe into Zap-Lok™ press, rear clamp closed joint made between
PUP and laid end, wait 5 minutes to cure Zap-oxy compound
 Stage 16 - Lay pipe
 Stages 17 – 26 - In General terms, repetition of the foregoing for the next reel.

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 Stage 27 - Port visit to unload empty reels, restock with full reels, take on bunkers and stores,
and carry out crew changes and any other requirements as they arise. Return to the field to
repeat the foregoing steps until the target box adjacent to the platform has been reached.

The process will be as follows and will be undertaken in accordance with the approved pipelay
installation procedures at all times.

4.3.5 Contingency
In case of contingency abandonment, an abandonment/recovery head shall be equipped for
localisation and easy recovery. Damage like buckles, collapses, denting, etc. on the pipeline system
components shall be repaired according to the contingency procedures. Prior to any repair, a detailed
underwater inspection and survey procedure to assess the extent of the damage and where the
pipeline is to be cut shall be implemented.

4.3.6 Concrete Mattresses


The installed pipeline shall be protected and stabilised on seabed by use of concrete mattresses. These
shall be positioned once pipeline has been installed and after commissioning. These mattresses may
be deployed from either the Pipeline Installation Vessel or alternative supporting vessel by use of a
concrete mattress lifting beam via crane or winch. It may be necessary to deploy some mattresses
during pipeline installation to ensure stability in shallow water areas where seabed is hard and currents
may induce movement of pipeline on seabed.

There will be an estimated 449 mattresses to be installed along the pipeline route. The pipeline route
has been divided into six (6) section and the locations and number of concrete mattresses to be
deployed in each section can be referenced in extract pages of the Calculation of Pipeline document
DP00315-OWR in Appendix G.

Installation of concrete mattress in areas of very soft seabed conditions (non-bearing ground) shall be
avoided to safeguard against sinkage of the mattresses and potential damage to the pipeline from the
weight of the mattress.

 Section 1
o Distance 6328 meters’ long
o 113 mats will be deployed, one every 50 meters
 Section 2
o Distance 12656 meters’ long
o 226 mats will be deployed, one every 50 meters
 Section 3
o Distance 7114 meters’ long
o 85 mats will be deployed, one every 50 meters
o Section consists of bearing and non-bearing ground
 Section 4
o Distance 23555 meters’ long
o No mats will be deployed
o Section consists of non-bearing ground and pipeline is predicted to sink into the soft
clay
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 Section 5
o Distance 6500 meters’ long
o 55 mats will be deployed, one every 50 meters
o Section consists of bearing and non-bearing ground
 Section 6
o Distance 19475 meters’ long
o No mats will be deployed
o Section consists of non-bearing ground and pipeline is predicted to sink into the soft
clay

The concrete mattress dimensions are 6m x 3m with an approximate weight of 8,145kg in Air and
4,667kg in water. Reference drawing 7027-ENG-DWG-0002 Rev 3 in Appendix G.

The Concrete Mattress Lifting beam shall be designed with the capacity for the single deployment of a
mattress and shall be hydraulically operated and can be reference in drawing FXT-EQU-ENG-LB-260515
Rev 0 in Appendix G.

4.3.7 Final surveys


Recording and mapping of all necessary data required to determine the as-laid and as-built position of
the pipeline and associated appurtenances shall be obtained and gathered for the preparation of as-
built drawings of the completed pipeline and appurtenances, as specified in the Construction Manual.

4.4 Demobilization of Vessel


On completion of the pipeline installation activities, the Installation equipment shall demobilise at
port. The removal of the equipment shall be included in the mobilisation manual and upon completion
of the activities.

4.5 Offshore Works Completion and Reporting


A quality conformance check list shall be completed after the completion of offshore pipeline
installation to ensure that all work conforms to requirements of the contract. Quality conformance
checks shall be witnessed by the client recorded on the quality conformance check list and shall cover
all aspects of the work. Reporting shall consist of;

 Final Acceptance documentation


 Final Documentation and As-Built
 Pipeline Design Report
 Pipeline Installation Design Report
 Installation Manual(s)
 Material Certificates
 Daily production and quality reports – See Appendix F for example of Zap-Lok™ Pipe Tally
Report and NOV End Preparation Report
 Tension strip charts
 Vessel daily reports including Job Safety Analysis (JSA) reports
 Accident/incident reports and non-conformance reports
 All relevant data form installation operations
 All Subcontractor reports

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5.0 PIPE-LINE PRE-COMMISSIONING

5.1 General

The purpose of this design guideline is to provide an outline to be followed when hydro testing
submarine pipelines for hydrocarbon service in the oil and gas industry.

The following section describes a typical flooding, cleaning and gauging method statement. Where
the text in following section mentions pigging it should be noted that it is normal practise NOT to use
pigs in lines of 4inch diameter and below due to the risk of getting a pig stick in the line.

In view of the bore and length of this pipe-line, consideration shall be given to using the alternative
technique of high velocity flushing instead of pigging.

The line could be flooded by high velocity flushing with treated seawater with a percentage overage
(TBA) to confirm the line is filled. The measure of internal condition of the pipe is achieved by
comparing actual back pressure with the theoretical value to confirm “true” bore of the line.

5.2 Pipeline Hydrotest

5.2.1 Flooding, Cleaning and Gauging of Pipeline System

The pipeline system shall be flooded, cleaning and gauged in accordance with the approved operation
procedure. See NOTE below.

Following deployment and connection of the downline, a connection test will take place to confirm
the integrity of the newly made subsea connection. Once the newly made connection is confirmed as
leak free, operations can commence.

The pipeline will be flooded, cleaning and gauged using up to 120%-line volume of chemically treated
and dyed seawater or potable water, inhibited and filtered as required to propel a 3 x bi-directional
pig train comprising of; cleaning pig, brush pig and gauge pig.

All pigs will be propelled at a typical speed of between 0.5m/s – 1.0 m/s as detailed below:

 Pump a minimum 250 linear metre slug of filtered, untreated seawater / potable water to act
as a lubricant
 Launch pig #1 (bi-directional flooding pig) followed by a minimum of 250 linear metres of
filtered, untreated seawater
 Launch pig #2 (bi-directional magnetic brush pig) followed by a minimum of 250 linear
metres of filtered, untreated seawater
 Launch pig #3 (bi-directional gauge pig) followed by 120%-line volume of filtered, untreated
seawater

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NOTE
For 4.5” OD pipelines it is NOT usual to use pigs, for fear of them becoming stuck. Instead, it is more
usual to dewater the pipeline by high velocity flushing with air / nitrogen.

5.2.2 Pigging Parameters


The pigging parameters shall be determined for each individual pipeline and applied for flooding,
cleaning and gauging operations

5.2.3 Chemical Details


All water entering the pipeline shall be filtered and any water that is to remain in the pipeline for any
length of time will be chemically treated with chemicals to be determined.

The chemical injection pumps will be carefully chosen to ensure that their output can comfortably
achieve the dosage requirement in relation to the anticipated pig speeds.

The volumetric flow rate of flooding water will be monitored from flowmeter readings and therefore,
if required, the setting of the chemical injection pumps may be adjusted to achieve the correct
chemical dosage rates.

The following information will be recorded at pre-determined intervals as a minimum;


 Time (hh:mm)
 Pressure (barg)
 Flow Rate (m3/min)
 Total Volume of Seawater Pumped (m3)
 Total Volume of Chemicals Pumped (Ltrs)
 Flooding Medium Temperature & Ambient Temperature (°c)

The following information will be calculated at 15 minute intervals throughout flooding operations:
 Velocity (m/s)
 Distance (km)
 Time to arrival (hh:mm)
 Chemical Concentration (ppm)

Following confirmation that the pig train has been received at the onshore pig receiver, the centrifugal
pumps shall be shut down and the downline will be recovered to the deck.

5.3 Hydrostatic Strength Testing of Pipeline System


Following successful completion of flooding, cleaning and gauging operations, the pipeline shall be
subjected to a 24-hour hydrostatic strength test. The pipeline shall be tested in accordance with
approved project and client specifications, aligned with Polish recommended practice and
specification, all of these requirements from Polish RP are attached in approved building project:

The temporary equipment shall be set up as per approved site layout and function tested as per the
approved operational procedures.

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The pipeline system shall be hydrostatically strength tested by means of a vessel based testing spread
connected to the designated tie-in point for both pressurisation and monitoring. The test will be
continually monitored by calibrated instrumentation and test equipment.

5.3.1 Pressure Testing


All pressure testing will be carried out taking into consideration the requirements of pipeline design
and client requirements. All temporary equipment to be used shall be pressure tested prior to
operations commencing at a test pressure of 1.1 x hydrostatic strength test pressure (TBA barg).

Fill up the pipeline with water and increase pressure up to WP x 1.8 (24.8MPa) for 2 hours realized
strength test, after this time decrease pressure to WP x 1.2 (16.6MPa) after stabilisation pressure keep
this for 24 hours realized Hydrostatic pressure test (tightness test)

Pressure recorders, pressure gauges and temperature recording equipment shall be in operation
during pressure testing activities and pressure relief valves shall be fitted for pressure testing the
temporary testing spread prior to strength testing operations.

5.3.2 Testing Parameters


The pipeline testing parameters shall be designed and approved the client and in accordance with the
standards and codes specified.

5.3.3 Pressurisation
Pressurisation of the pipeline will commence at a rate of 1 barg per minute until 35 barg is reached.
The following parameters shall be recorded at 1 bar intervals throughout this stage of pressurisation:

 Time (hh:mm)
 Pressure (barg)
 Total Volume Injection (Ltrs)
 Δ Volume Injected

A 30-minute hold period will commence, where a visual gross leak check will be completed both
topside and subsea. At this point the air content will be calculated using the extrapolation method, if
the air content is acceptable (0.2% for pigged pipelines) operations will re-commence. If the test limit
is exceeded, it shall be documented that the amount of air will not influence the accuracy of the test
significantly.

Pressurisation shall recommence at a controlled rate until 95% of the test pressure (TBA barg) has been
achieved. Upon reaching 95% of the test pressure, the pressurisation shall continue at a reduced rate
to ensure the test pressure is not exceeded. During pressurisation from 35 barg to 95% of the test
pressure, the following parameters shall be recorded at 5 barg intervals up to 50% of the test pressure
then at 2 bar intervals until the test pressure is reached.
All of these requirements shall be conducted according to Client representative inspector.

The following parameters shall be recorded at the above bar intervals throughout this stage of
pressurisation:
 Time (hh:mm)
 Pressure (barg)

Z12/112996-ENG-RPT-00005 Rev 02 12.08.2016 Page 30 of 38


PIPELINE INSTALLATION METHODOLOGY REPORT

 Total Volume Injection (Ltrs)


 Δ Volume Injected (Ltrs)
 Ambient Temperature (°c)
 Subsea Temperature (°c)

During pressurisation, pressure versus volume injected readings shall be plotted using a chart recorder.
In the event of any deviation from the apparent linearity or any significant difference between the
theoretical and actual curve values, the test shall be suspended and checks shall be carried out to
determine and rectify the cause.

The following parameters shall be recorded at the above bar intervals throughout this stage of
pressurisation:

5.3.4 Stabilisation & Hold Period


Upon reaching 100% of the test pressure, the pipeline shall be isolated and a stabilisation period shall
commence. Should the pipeline pressure drop below the test pressure, pressure shall be increased at
a rate of 0.1 barg per minute until 100% of test pressure is reached. This process shall continue until
pipeline pressure is stabilised.

A hold period of 24-hour shall commence. The following parameters shall be recorded at 30 minute
intervals:

 Time (hh:mm)
 Test Pressure (barg)
 Ambient Temperature (°c)

5.3.5 Test Acceptance


The hydrostatic strength test shall be considered successful when the pressure has been held for a 24-
hour hold period and if no variation occurs during the hold period which cannot be accounted for by
temperature change.

5.3.6 Depressurisation
Upon confirmation that the system pressure test is acceptable and complete, the pipeline shall be
depressurised in a steady, safe and controlled manner ensuring not to exceed a depressurisation rate
of 2 barg/min until the pipeline reaches ambient atmospheric pressure.

5.4 Pipeline De-watering and Drying

5.4.1 De-watering and Drying


Future tie-in operations between the pipe-line and the platform riser are beyond the scope of this
report.

In view of the need to pressure test the connection between the pipe-line and the riser, the client may
decide to leave de-watering and drying of the line until after this connection has been made and
successfully tested.

For this reason this report does not address these requirements.

Z12/112996-ENG-RPT-00005 Rev 02 12.08.2016 Page 31 of 38


PIPELINE INSTALLATION METHODOLOGY REPORT

APPENDIX A – DECK LAYOUT DRAWING Z12/112996-ENG-DWG-00001

INTENSIONALLY BLANK

Z12/112996-ENG-RPT-00005 Rev 02 12.08.2016 Page 32 of 38


67308 (+3 REELS DECK LENGTH)
47905

10

11 11
4 30955

3000

2845
13108
Pipe Path 1 1
7 3
1000
9 5
8
6
13 2 4318
5903
9000 1654 11000
1500 1500 1000
12 11

CLIENT: SUBJECT: SCALE REV DATE DRAWN CHECKED APPROVED


- draft 02.06.16 S.D. M.M. G.C.
LOTOS PETROBALTIC B8 PIPELINE INSTALLATION Z12/112996-ENG-DWG-00001 01 04.07.16 S.D. M.M. G.C.
SHEET:
DECK PLAN 1 of 1
PIPELINE INSTALLATION METHODOLOGY REPORT

APPENDIX B – STORYBOARD DRAWINGS Z12/112996-ENG-DWG-00002

INTENSIONALLY BLANK

Z12/112996-ENG-RPT-00005 Rev 02 12.08.2016 Page 33 of 38


PIPELINE INSTALLATION METHODOLOGY REPORT

APPENDIX C – TENARIS COILED TUBING REEL DRAWING

INTENSIONALLY BLANK

Z12/112996-ENG-RPT-00005 Rev 02 12.08.2016 Page 34 of 38


PIPELINE INSTALLATION METHODOLOGY REPORT

APPENDIX D – ZAP-LOK™ 8000-12T PRESS

INTENSIONALLY BLANK

Z12/112996-ENG-RPT-00005 Rev 02 12.08.2016 Page 35 of 38


ZAP-LOK 8000-12 (T) PRESS

Weight = 18,000 lbs.

Specifications

NPS / DN 6” - 12” (150 mm - 300 mm)


OD [inches (mm)] 6 5/8” - 12 3/4”(168.27 mm - 323.85 mm)
Dimensions 160” x 80” x 85”
[L x W x H] (4.06 m x 2.03 m x 2.16 m)
Weight 18,000 lbs., 8,164.66 kg, 9.00 short tons (US),
8.03 long tons (UK), 8.16 tonnes (MT)
Power Zap-Lok 8000 HPU

32
PIPELINE INSTALLATION METHODOLOGY REPORT

APPENDIX E – PROJECT SCHEDULE

INTENSIONALLY BLANK

Z12/112996-ENG-RPT-00005 Rev 02 12.08.2016 Page 36 of 38


ID Task  Task Name Duration Start Finish b '17 06 Mar '17 13 Mar '17 20 Mar '17 27 Mar '17 03 Apr '17 10 Apr '17 17 Apr '17 24 Apr '17 01 May '17 08 M
Mode W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T
1 Lotos Petrobaltic ‐ B8 Gas Pipeline Installation using Zap‐Lok 32.21 days Mon  Fri 05/05/17
Connection 03/04/17

2 Commence operational activities 0 days Mon 03/04/17 Mon 03/04/17 03/04


3 Pipelay equipment onto vessel ‐ Installation and Testing 1.67 days Mon 03/04/17 Wed 05/04/17

4 Pre‐install shallow water anchors 0.67 days Mon 03/04/17 Tue 04/04/17

5 Load Coiled Pipe Reels 0.33 days Wed 05/04/17 Wed 05/04/17

6 Full function test of Pipelay equipment 0.67 days Wed 05/04/17 Thu 06/04/17

7 Transit to field / DP Trials 0.5 days Thu 06/04/17 Thu 06/04/17

8 Pipelay Operations 29.04 days Thu 06/04/17 Fri 05/05/17

9 Pipelay Ops 1 1.79 days Thu 06/04/17 Sat 08/04/17

10 Pick‐up pre‐installed anchors 8 hrs Thu 06/04/17 Thu 06/04/17

11 Pick‐up abandoned Coiled Pipe End 4 hrs Thu 06/04/17 Fri 07/04/17

12 Zap‐Lok Connection of first reel to laid pipe end 3 hrs Fri 07/04/17 Fri 07/04/17

13 lay coiled pipe @ 200m/hr 9 hrs Fri 07/04/17 Fri 07/04/17

14 Zap‐Lok connection first reel tail end to second Reel new  4 hrs Fri 07/04/17 Fri 07/04/17


end

15 Lay coiled pipe @200m/hr 9 hrs Fri 07/04/17 Sat 08/04/17

16 Temporary abandon coiled pipe with pennant and buoy 6 hrs Sat 08/04/17 Sat 08/04/17

17 Port Call # 01 ‐ Tranit to port, reload reels & transit to field 0.75 days Sat 08/04/17 Sun 09/04/17

18 Pipelay Ops 2 ‐ Repeat tasks 10 ‐ 15 1.5 days Sun 09/04/17 Mon 10/04/17

19 Port Call # 02 0.75 days Mon 10/04/17 Tue 11/04/17

20 Pipelay Ops 3 ‐ Repeat tasks 10 ‐ 15 1.5 days Tue 11/04/17 Wed 12/04/17

21 Port Call # 03 18 hrs Wed 12/04/17 Thu 13/04/17

22 Pipelay Ops 4 ‐ Repeat tasks 10 ‐ 15 1.5 days Thu 13/04/17 Sat 15/04/17

23 Port Call #04 0.75 days Sat 15/04/17 Sat 15/04/17

24 Pipelay Ops 5 ‐ Repeat tasks 10 ‐ 15 1.5 days Sat 15/04/17 Mon 17/04/17

25 Port Call #05 0.75 days Mon 17/04/17 Tue 18/04/17

26 Pipelay Ops 6 ‐ Repeat tasks 10 ‐ 15 1.5 days Tue 18/04/17 Wed 19/04/17

27 Port Call #06 ‐ including 6 hrs for vessel bunkering 1 day Wed 19/04/17 Thu 20/04/17

28 Pipelay Ops 7 ‐ Repeat tasks 10 ‐ 15 1.5 days Thu 20/04/17 Sat 22/04/17

29 Port Call #07 0.75 days Sat 22/04/17 Sat 22/04/17

30 Pipelay Ops 8 ‐ Repeat tasks 10 ‐ 15 1.5 days Sat 22/04/17 Mon 24/04/17

31 Port Call #07 0.75 days Mon 24/04/17 Tue 25/04/17

32 Pipelay Ops 9 ‐ Repeat tasks 10 ‐ 15 1.5 days Tue 25/04/17 Wed 26/04/17

33 Port Call #07 0.75 days Wed 26/04/17 Thu 27/04/17

34 Pipelay Ops 10 ‐ Repeat tasks 10 ‐ 15 1.5 days Thu 27/04/17 Fri 28/04/17

35 Port Call #07 0.75 days Fri 28/04/17 Sat 29/04/17

36 Pipelay Ops 11 ‐ Repeat tasks 10 ‐ 15 1.5 days Sat 29/04/17 Mon 01/05/17

37 Port Call #07 0.75 days Mon 01/05/17 Mon 01/05/17

38 Pipelay Ops 12 ‐ Repeat tasks 10 ‐ 15 1.5 days Mon 01/05/17 Wed 03/05/17

39 Port Call #07 0.75 days Wed 03/05/17 Thu 04/05/17

40 Pipelay Ops 13 ‐ Repeat tasks 10 ‐ 15 1.5 days Thu 04/05/17 Fri 05/05/17

41 Transit to port 1 day? Fri 05/05/17 Sat 06/05/17

42 Remove pipelay equipment from vessel 2 days Sat 06/05/17 Mon 08/05/17

Task Summary External Milestone Inactive Summary Manual Summary Rollup Finish‐only


Project: CSL‐OPS‐P422‐SCHD‐001_
Split Project Summary Inactive Task Manual Task Manual Summary Deadline
Date: Tue 05/07/16
Milestone External Tasks Inactive Milestone Duration‐only Start‐only Progress

Page 1
PIPELINE INSTALLATION METHODOLOGY REPORT

APPENDIX F – ZAP-LOK™ PIPE TALLY REPORT & END PREPARATION REPORT

INTENSIONALLY BLANK

Z12/112996-ENG-RPT-00005 Rev 02 12.08.2016 Page 37 of 38


ZAP-LOK PIPE TALLY REPORT

Client: Chevron Thailand E&P Ltd. Report No.:


Project: Chevron 2016 Installation Campaign Pipe Size: 10" OD x 0.500" WT
Location: Gulf of Thailand Date: 06 April 2016
Pipeline: PL50/2 10"BABLI Shift: Day
Material: API 5L X42 Page: 1 of 1

Zap-Lok Installation Equipment


Press Model: 8000-12T Press Serial No. Press Test Pressure: 2800psi
HPU Model: 8000 HPU Serial No. HPU Working Pressure: 2800psi
Mixer Model: Mixer Serial No. Pipe Clamp Pressure: 2800psi
Zapoxy Type: 136 Zapoxy Batch No. Press Stroke Pressure: 2800psi

Pipe Data Coating Type Zap-Lok Connection


QC Clamp
No. Insertion Effective Comments
Pipe No. Heat No. Length (M) Type Thickness Verified Marks (Y
Depth (M) Length (M)
(Y/N) / N)

Flange 01 A694 F52 600# 800073 12.20 - - - - - 12.20

Anode Installed, Shrink wrap


001 12.20 FBE 14-16 Mils 0.381 Y Y 11.82
applied
002 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
003 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
004 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
005 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
006 12.20 FBE 14-16 Mils 0.381 Y N 11.82 Shrink wrap applied
007 12.20 FBE 14-16 Mils 0.381 Y N 11.82 Shrink wrap applied
008 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
009 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
010 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
011 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
012 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
013 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
014 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
015 12.20 FBE 14-16 Mils 0.381 Y N 11.82
016 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
017 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
018 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
019 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
020 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
021 12.20 FBE 14-16 Mils 0.381 Y Y 11.82 Shrink wrap applied
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Total Laid This Sheet (M): 260.40

NOTE: The above length of pipe is based on measurements taken from tally sheet manifest

CORTEZ SUBSEA SOLSTAD OFFSHORE CHEVRON THAILAND E&P LTD.

Name

Signature

CSL-OPS-P459-FOR-0001 Rev B 06/04/2016 Page 1


End Preparation Daily Quality Control Report
JOB INFORMATION

Date 23/4/2016 End User Chevron Thailand WO# 019-16-01


Pipe Vendor CUEL Mftr MITA (Marubeni)

Pipe Size / Grade 10-3/4" X42 Wall Thickness 0.500"

ERW/SMLS ERW Type 2 or 4 2

OPERATOR INFORMATION

EP Station Bredero shaw Kuantan Beller Operator Steven Galvan Pinning Operator Mike Gambino

Inspector Nick Benoot Rinse Bredero Shaw Forklift Operator Bredero Shaw

EQUIPMENT INFORMATION

Beller Clamping Pressure 3100 Bead Roller 10"-12" Type 2 (3150-2) Pinning Clamping Pressure 2000

Mandrel Number 10.14 Backing Roller 10"-12" Type 2 (3148-1) Mandrel OD Spec 10.572

QUALITY CONTROL GUIDELINES (Pipe should be supplied as per API 5L latest edition with 30 degree Bevel)

Steel Inspection Bell Inspection

E
 Check pipe stencils and heat numbers  Check for splitting  Check for scratches

Pipe Inspection  Lubricant completely removed

 Check for squareness  Check for ovality


PL  Check for dog legging

 Check for excessive rust  Check for pitting Pin Inspection

 Weld Flash OD < = .015”  Weld Flash ID < = .015”  Check for Bevel Damage  Check for Sharp Edges
AM

Reworks/Rejects Cells Color Filled Lubricant

Zap-Lok Vendor  100% Liqui-Lube Check for foreign particles

PRODUCTION SUMMARY

Total # of Joints Processed Today 225 Total Joints


EX

(-) # Reworks

(-) # Rejects
0
0
Complete & Ready
225
END PREP PRODUCTION COMMENTS

Today production went well and we had no issues with the pipe or machinery. We prepped 225 joints with no reworks or rejects, so the estimated pipes left in
the order is around 460 joints for completion. We will continue production on Monday 4-25-16, as Sunday is an off day for the workers. The belling tool grip
mark readings measured for the first 5 joints of the day were #1 .001", #2 .001", #3 .000", #4 .001", #5 .004". Close to the end of the shift the heat numbers
began to change from the last several reported heat numbers. Also the drill hole was made this morning for the UT calibration standard procedure, and the
approval was confirmed to cut and re-bevel the calibration joint which at this point is the only rework we have for the order.

Report By Nick Benoot

www.nov.com/tuboscope Chevron-ZL-100-01 Rev.3 4/21/16


NOV Tuboscope Zap-Lok Headquarters NOV Tuboscope Zap-Lok End Prep
18660 East Hardy Road 39 Gul Ave
Houston, Texas 77073 Singapore 629679
United States Phone: +65 9733-0665
Phone: +1 713 849 4932 Email: mark.wallace@nov.com
End Prep QC 2 ⅜" - 12 ¾" LL -
ZAP-LOK SPECS

Tolerances for Wall Thickness Grade x-42 and higher ( -12.5% to +15% of Specified Wall Thickness)
Wall Thickness Low High Wall Thickness Low High
0.154 0.135 1.177 0.300 0.263 0.345

0.156 0.136 0.179 0.322 0.281 0.370

0.188 0.164 0.216 0.337 0.295 0.387

0.203 0.178 0.233 0.365 0.319 0.419

0.216 0.189 0.248 0.375 0.328 0.431

0.218 0.191 0.250 0.406 0.356 0.466

0.219 0.191 0.251 0.432 0.378 0.496

0.237 0.208 0.272 0.500 0.437 0.575

0.250 0.218 0.287 0.562 0.491 0.519

E
0.276 0.242 0.317 0.594 0.519 0.683

0.280 0.245 0.322 0.625 0.549 0.718


PL
Pipe Groove Groove Type 2 Type 4 Bell Flare
Pin End OD Bell Depth Bell ID
Diameter Depth Location Angle Angle Angle
AM

0.815" 3°
2 ⅜" .015" Min 2°- 5° 6°- 9° 2.360" - 2.437" 3 3/4" 2.280" - 2.340"
1.065" 5°
0.815" 3°
2 ⅞" .020" Min 2°- 5° 6°- 9° 2.860" - 2.937" 5 7/8" 2.780" - 2.840"
1.065" 5°
0.815" 3°
3 ½" .020" Min 2°- 5° 6°- 9° 3.485" - 3.562" 5 7/8" 3.397" - 3.457"
1.065" 5°
0.815" 3°
4 ½" .020" Min 2°- 5° 6°- 9° 4.485" - 4.552" 5 7/8" 4.388" - 4.453"
1.065" 5°
1.00" 8°
EX

6 ⅝" .040" Min 2°- 5° 8°- 15° 6.610" - 6.687" 9.5" 6.489" - 6.549"
1.250" 12°
1.00" 8°
8 ⅝" .040" Min 2°- 5° 8°- 15° 8.610" - 8.687" 10.5" 8.386" - 8.521"
1.250" 12°
1.500" 8°
10 ¾" .040" Min
1.900"
8°- 10° 8°- 15° 10.719" - 10.843" 11.5" 10.465" - 10.626"
12°
1.500" 8°
12 ¾" .040" Min
1.900"
8°- 10° 8°- 15° 12.719" - 12.843" 13" 12.423" - 12.603"
12°

www.nov.com/tuboscope Chevron-ZL-100-01 Rev.3 4/21/16


© 2014 National Oilwell Varco
NOV Tuboscope Zap-Lok Headquarters NOV Tuboscope Zap-Lok End Prep All rights reserved
18660 East Hardy Road 39 Gul Ave
Houston, Texas 77073 Singapore 629679
United States Phone: +65 9733-0665
Phone: +1 713 849 4932 Email: mark.wallace@nov.com
Belling Tool Parts Reference List
Equipment Mandrel Part # Description Slip Part # Description

5500 Belling Tool 2" 2754 Nose Piece 2" 2 Slips needed
None Spacer Bolts - (4) 5/8" x 1 3/4" Grade 8 SHCS
2755 Flare Ring
5500 Belling Tool 2 1/2" 2757 Nose Piece 2 1/2" 2 Slips needed

2752 Spacer Bolts - (4) 5/8" x 1 3/4" Grade 8 SHCS


2758 Flare Ring
5500 Belling Tool 3" 2759 Nose Piece 3" 2 Slips needed
2752 Spacer Bolts - (4) 5/8" x 1 3/4" Grade 8 SHCS
2760 Flare Ring
5500 Belling Tool 4" 2761 Nose Piece 4" 2 Slips needed
2752 Spacer Bolts - (4) 5/8" x 1 3/4" Grade 8 SHCS
2762 Flare Ring
8000-12 Belling Tool 4" 2761 Nose Piece 4" 6 Slips needed
2752 Spacer Bolts - (6) 5/8" x 4 1/2" Grade 8 SHCS

E
2762 Flare Ring
4" Mandrel Adaptor
8000-12 Belling Tool 6" 2747
2740
Nose Piece
Spacer
PL 3044 6 Slips needed
Bolts - (6) 5/8" x 3 1/2" Grade 8 SHCS
2748 Flare Ring
6" Mandrel Adaptor
8000-12 Belling Tool 8" 3004 Nose Piece 3043 6 Slips needed
AM

3003 Spacer Bolts - (6) 5/8" x 2 1/2" Grade 8 SHCS


3002 Flare Ring
Back Stop Plate
8000-12 Belling Tool 10" 3007 Nose Piece 10" 2 Slips needed
3006 Spacer Bolts - (4) 5/8" x 3" Grade 8 SHCS
EX

3005 Flare Ring


Back Stop Plate
8000-12 Belling Tool 12" 3010 Nose Piece 12" 2 Slips needed
3009 Spacer Bolts - (4) 5/8" x 3" Grade 8 SHCS
3008 Flare Ring
Definitions: SHCS - Socket Head Cap Screw

www.nov.com/tuboscope Chevron-ZL-100-01 Rev.3 4/21/16


NOV Tuboscope Zap-Lok Headquarters NOV Tuboscope Zap-Lok End Prep
18660 East Hardy Road 39 Gul Ave
Houston, Texas 77073 Singapore 629679
United States Phone: +65 9733-0665
Phone: +1 713 849 4932 Email: mark.wallace@nov.com
Pinning Tool Parts Reference List
Equipment Part # Description Part # Description

5000 Pinning Tool (2") 3079-1 Bead Roller 3079-1 HW Bead Roller (Heavy Wall)
3078-1 Finish Roller 3077-1 Turn Down Roller - Type 2
3080-1 Turn Down Roller - Type 4

5000 Pinning Tool (2 ⅞") 3079-2 Bead Roller 3078-2 Finish Roller
3077-2 Turn Down Roller - Type 2 3080-2 Turn Down Roller - Type 4

5000 Pinning Tool (3") 3079-3 Bead Roller 3079-3 HW Bead Roller (Heavy Wall)
3078-3 Finish Roller 3077-3 Turn Down Roller - Type 2
3080-3 Turn Down Roller - Type 4

5000 Pinning Tool (4") 3079-4 Bead Roller 3079-4 HW Bead Roller (Heavy Wall)
3078-4 Finish Roller 3077-4 Turn Down Roller - Type 2
3080-4 Turn Down Roller - Type 4

E
8000-12 Pinning Tool (6∕8") 3105-1 Bead Roller - Type 2 3151-1 Bead Roller - Type 4

8000-12 Pinning Tool (6") 3146 Backing Roller 3154 Backing Roller Shaft Bracket

3090-2
PL
7000 Pinning Tool (6") Bead Roller 3091-1 Finish Roller
3088-1 Turn Down Roller - Type 2 3089-1 Turn Down Roller - Type 4

8000-12 Pinning Tool (8") 3147 Backing Roller 3119-1 Backing Roller Shaft Bracket
AM

7000 Pinning Tool (8") 3090-3 Bead Roller 3050-2 HW Bead Roller (Heavy Wall)
3091-2 Finish Roller 3088-2 Turn Down Roller - Type 2
3089-2 Turn Down Roller - Type 4

8000-12 Pinning Tool (10") 3150-2 10"/ 12" Type 2 Bead Roller
3150-2 HW New 10"/ 12" Type 2 Bead Roller (Heavy Wall)
EX

3151-2 10"/ 12" Type 4 Bead Roller


3151-2 HW New 10"/ 12" Type 4 Bead Roller (Heavy Wall)
3148-1 10"/ 12" Backing Roller Type 2
3148-2 10"/ 12" Backing Roller Type 4
3119-2 10"/ 12" Backing Roller Shaft Bracket
3119-2 HW New 10"/ 12" Backing Roller Shaft Bracket (Heavy Wall)

www.nov.com/tuboscope Chevron-ZL-100-01 Rev.3 4/21/16


NOV Tuboscope Zap-Lok Headquarters NOV Tuboscope Zap-Lok End Prep
18660 East Hardy Road 39 Gul Ave
Houston, Texas 77073 Singapore 629679
United States Phone: +65 9733-0665
Phone: +1 713 849 4932 Email: mark.wallace@nov.com
End Preparation Daily Quality Control Report
JOB INFORMATION

Date 23/4/2016 End User Chevron Thailand WO# 019-16-01


Pipe Vendor CUEL Mftr MITA (Marubeni)

Pipe Size 10-3/4" X42 Wall Thickness 0.500"

ERW/SMLS ERW Type 2 or 4 2

OPERATOR INFORMATION

Cutting Operator Bredero Shaw Kuantan Transfer Operator Bredero Shaw Kuantan

REWORKS/REJECTS

NOTE: TRANSFER JOINT & HEAT NUMBERS ONTO CUT PIECES OF PIPE
Length Remaining
Joint # Reject or Rework Heat # Description of Defect
Removed Length

E
PL
AM
EX

Signature Nick Benoot

www.nov.com/tuboscope Chevron-ZL-100-01 Rev.3 4/21/16


NOV Tuboscope Zap-Lok Headquarters NOV Tuboscope Zap-Lok End Prep
18660 East Hardy Road 39 Gul Ave
Houston, Texas 77073 Singapore 629679
United States Phone: +65 9733-0665
Phone: +1 713 849 4932 Email: mark.wallace@nov.com
End Prep QC 2 ⅜" - 12 ¾" WO# 019-16-01

Bell I.D. Max 10.626 Bell I.D. Minimum 10.47 Pin O.D. Max 10.843 Pin O.D. Minimum 10.719
Joint # Pipe # Heat # Pin End O.D. Wall Thickness Groove Depth Groove Location Pin End Angle Grip Marks Bell I.D. Flare Angle 100% Visual Insp.
1 20300 36480 10.762 0.488 0.052  10 0.001"/0.025mm 10.562  
2 20361 36480 0.001"/0.025mm 
3 20358 36480 0 
4 20359 36480 0.001"/0.025mm 
5 20348 36477 0.004"/0.1mm 
6 20372 36481 
7 20298 36480 
8 20299 36480 
9 20305 36480 
10 20354 36480 10.765 0.48 0.06  10 10.562  
11 20363 36480 
12 20373 36481 
13 20353 36480 
14 20371 36481 
15 20388 36481 
16 20428 36481 
17 20437 36481 
18 20431 36481 

E
19 20384 36481
20 20362 36480 10.755 0.501 0.06  10 10.567  
21 20410 36480 
22 20425 36481 
23 20426 36481
PL 
24 20411 36480 
25 20427 36481 
26 20331 36480 
27 20332 36480 
AM

28 20389 36481 
29 20381 36481 
30 20432 36481 10.76 0.503 0.063  10 10.563  
31 20408 36481 
32 20492 36481 
33 20406 36481 
34 20491 36481 
EX

35 20407 36481 
36 20445 36481 
37 20480 36481 
38 20404 36481 
39 20430 36481 
40 20429 36481 10.771 0.495 0.06  10 10.56  
41 20619 36477 
42 20439 36481 
43 20440 36481 
44 20438 36481 
45 20479 36481 
46 20433 36481 
47 20595 36477 
48 20680 36477 
49 20671 36477 
50 20452 36481 10.765 0.494 0.051  10 10.563  
Signature Nick Benoot

www.nov.com/tuboscope Chevron-ZL-100-01 Rev.3 4/21/16


NOV Tuboscope Zap-Lok Headquarters NOV Tuboscope Zap-Lok End Prep
18660 East Hardy Road 39 Gul Ave
Houston, Texas 77073 Singapore 629679
United States Phone: +65 9733-0665

Phone: +1 713 849 4932 Email: mark.wallace@nov.com


End Prep QC 2 ⅜" - 12 ¾" WO# 019-16-01

Bell I.D. Max 10.626 Bell I.D. Minimum 10.47 Pin O.D. Max 10.843 Pin O.D. Minimum 10.719
Joint # Pipe # Heat # Pin End O.D. Wall Thickness Groove Depth Groove Location Pin End Angle Bell I.D. Flare Angle 100% Visual Insp.
51 20436 36481 
52 20434 36481 
53 20681 36477 
54 20676 36477 
55 20675 36477 
56 20605 36477 
57 20502 36481 
58 20531 36477 
59 20435 36481 
60 20593 36477 10.773 0.495 0.055  10 10.547  
61 20673 36477 
62 20538 36477 
63 20662 36480 
64 20501 36481 
65 20590 36477 
66 20537 36477 
67 20591 36477 
68 20536 36477 

E
69 20592 36477
70 20674 36477 10.775 0.49 0.052  10 10.548  
71 20559 36480 
72 20467 36481 
73 20526 36481
PL 
74 20520 36481 
75 20519 36481 
76 20506 36481 
77 20557 36477 
AM

78 20508 36481 
79 20529 36477 
80 20465 36481 10.754 0.491 0.056  10 10.554  
81 20453 36481 
82 20513 36481 
83 20507 36481 
84 20566 36477 
EX

85 20521 36481 
86 20204 36480 
87 20249 36480 
88 20201 36480 
89 20248 36480 
90 20247 36480 10.572 0.494 0.059  10 10.559  
91 20489 36481 
92 20376 36481 
93 20375 36481 
94 20374 36481 
95 20224 36480 
96 20417 36480 
97 20380 36481 
98 20488 36481 
99 20367 36481 
100 20366 36481 10.76 0.502 0.055  10 10.564  
Signature Nick Benoot

www.nov.com/tuboscope Chevron-ZL-100-01 Rev.3 4/21/16


NOV Tuboscope Zap-Lok Headquarters NOV Tuboscope Zap-Lok End Prep
18660 East Hardy Road 39 Gul Ave
Houston, Texas 77073 Singapore 629679
United States Phone: +65 9733-0665

Phone: +1 713 849 4932 Email: mark.wallace@nov.com


End Prep QC 2 ⅜" - 12 ¾" WO# 019-16-01

Bell I.D. Max 10.626 Bell I.D. Minimum 10.47 Pin O.D. Max 10.843 Pin O.D. Minimum 10.719
Joint # Pipe # Heat # Pin End O.D. Wall Thickness Groove Depth Groove Location Pin End Angle Bell I.D. Flare Angle 100% Visual Insp.
101 20409 36480 
102 20454 36481 
103 20416 36480 
104 20365 36480 
105 20415 36480 
106 20418 36481 
107 20385 36481 
108 20379 36481 
109 20414 36481 
110 20448 36481 10.759 0.491 0.052  10 10.564  
111 20468 36481 
112 20403 36481 
113 20402 36481 
114 20419 36481 
115 20378 36481 
116 20462 36481 
117 20446 36481 
118 20455 36481 

E
119 20469 36481
120 20456 36481 10.761 0.504 0.057  10 10.559  
121 20463 36481 
122 20386 36481 
123 20401 36481
PL 
124 20392 36481 
125 20391 36481 
126 20618 36481 
127 20395 36481 
AM

128 20394 36481 


129 20393 36481 
130 20514 36481 10.754 0.496 0.052  10 10.57  
131 20612 36481 
132 20582 36477 
133 20390 36481 
134 20515 36481 
EX

135 20396 36481 


136 20583 36477 
137 20584 36481 
138 20614 36481 
139 20617 36481 
140 20613 36481 10.76 0.495 0.051  10 10.565  
141 20565 36477 
142 20548 36481 
143 20610 36481 
144 20558 36477 
145 20496 36481 
146 20615 36481 
147 20606 36477 
148 20490 36481 
149 20549 36481 
150 20547 36481 10.76 0.49 0.053  10 10.567  
Signature Nick Benoot

www.nov.com/tuboscope Chevron-ZL-100-01 Rev.3 4/21/16


NOV Tuboscope Zap-Lok Headquarters NOV Tuboscope Zap-Lok End Prep
18660 East Hardy Road 39 Gul Ave
Houston, Texas 77073 Singapore 629679
United States Phone: +65 9733-0665

Phone: +1 713 849 4932 Email: mark.wallace@nov.com


End Prep QC 2 ⅜" - 12 ¾" WO# 019-16-01

Bell I.D. Max 10.626 Bell I.D. Minimum 10.47 Pin O.D. Max 10.843 Pin O.D. Minimum 10.719
Joint # Pipe # Heat # Pin End O.D. Wall Thickness Groove Depth Groove Location Pin End Angle Bell I.D. Flare Angle 100% Visual Insp.
151 20449 36481 
152 20494 36481 
153 20495 36481 
154 20616 36481 
155 20497 36481 
156 20528 36477 
157 20685 36477 
158 20672 36477 
159 20684 36477 
160 20683 36477 10.765 0.494 0.059  10 10.554  
161 20556 36477 
162 20562 36481 
163 20561 36481 
164 20560 36480 
165 20518 36481 
166 20458 36481 
167 20511 36481 
168 20686 36477 

E
169 20677 36477
170 20555 36477 10.762 0.499 0.056  10 10.556  
171 20451 36481 
172 20517 36481 
173 20450 36481
PL 
174 20487 36481 
175 20441 36481 
176 20546 36477 
177 20512 36481 
AM

178 20552 36481 


179 20551 36481 
180 20533 36477 10.763 0.496 0.059  10 10.551  
181 20510 36481 
182 20500 36481 
183 20521 36481 
184 20539 36477 
EX

185 20540 36477 


186 20553 36480 
187 20457 36481 
188 20509 36481 
189 20464 36481 
190 20461 36481 10.757 0.496 0.052  10 10.568  
191 20485 36481 
192 20466 36481 
193 20486 36481 
194 20679 36477 
195 20516 36481 
196 20620 36477 
197 20543 36477 
198 20554 36477 
199 20532 36477 
200 20472 36481 10.758 0.49 0.056  10 10.557  
Signature Nick Benoot

www.nov.com/tuboscope Chevron-ZL-100-01 Rev.3 4/21/16


NOV Tuboscope Zap-Lok Headquarters NOV Tuboscope Zap-Lok End Prep
18660 East Hardy Road 39 Gul Ave
Houston, Texas 77073 Singapore 629679
United States Phone: +65 9733-0665

Phone: +1 713 849 4932 Email: mark.wallace@nov.com


End Prep QC 2 ⅜" - 12 ¾" WO# 019-16-01

Bell I.D. Max 10.63 10.47 Pin O.D. Max 10.843 Pin O.D. Minimum 10.719
Joint # Pipe # Heat # Pin End O.D. Wall Thickness Groove Depth Groove Location Pin End Angle Bell I.D. Flare Angle 100% Visual Insp.
201 20473 36481 
202 20474 36480 
203 20678 36477 
204 20475 36480 
205 20525 36481 
206 20587 36477 
207 20604 36477 
208 20542 36477 
209 20550 36481 
210 20541 36477 10.76 0.496 0.059  10 10.562  
211 20611 36481 
212 20588 36477 
213 20352 36480 
214 20345 36477 
215 20413 36481 
216 20589 36477 
217 10229 17323 
218 A10085 20534 

E
219 10248 17323
220 A10096 20534 10.761 0.498 0.06  10 10.564  
221 10197 17323 
222 A10113 20534 
223 10241 17323
PL 
224 A10039 17319 
225 10199 17323 
226
227
AM

228
229
230
231
232
233
234
EX

235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
Signature Nick Benoot

www.nov.com/tuboscope Chevron-ZL-100-01 Rev.3 4/21/16


NOV Tuboscope Zap-Lok Headquarters NOV Tuboscope Zap-Lok End Prep
18660 East Hardy Road 39 Gul Ave
Houston, Texas 77073 Singapore 629679
United States Phone: +65 9733-0665

Phone: +1 713 849 4932 Email: mark.wallace@nov.com


PIPELINE INSTALLATION METHODOLOGY REPORT

APPENDIX G – CONCRETE MATTRESSES

INTENSIONALLY BLANK

Z12/112996-ENG-RPT-00005 Rev 02 12.08.2016 Page 38 of 38


Project No.

DP00315

CALCULATION OF PIPELINE

3 Calculations with the use of AutoPIPE


To determine the maximum unsupported length of the pipeline, proper calculations were performed. The
pipeline model included mounted 8-ton stabilizing mats. Calculations showed that maximum acceptable
unsupported length of the pipeline is 50 meters.

Pic. 3.1. Model view

In case of pipeline scouring on the length of 50 meters, the maximum stress ratio of the material is 0.72.
The maximum deflection of the pipe occurs midway between mats and is 2182 mm.

Analyzing the geotechnical data provided by Lotos Petrobaltic it was found that, maximum scouring depth
may be up to 800mm. To modeled this case, possibility of pipeline deflection in unsupported point was
limited up to 800 mm in vertical axis. In case of total scouring on entire analysis lengths (50m), pipeline
will be laid on scouring seabed. Maximum stress ratio will be 0.54. The highest value of stress will take
place at the end of the mat. (as is marked on picture 3.2)

Project name Location Project No.


Executive pipeline project B8-W•adys•awowo. Seam B8 – Elektrociep•ownia W•adys•awowo DP00315

TECHNICAL DOCUMENTATION LOTOS Petrobaltic S.A.


Documentation archival No. Documentation No. Page Pages Rev.

DP00315-OWR 13 73 0
Project No.

DP00315

CALCULATION OF PIPELINE

Pic. 3.2. Stress in the described system

Pic.3.3. Displacements in the described system

Project name Location Project No.


Executive pipeline project B8-W•adys•awowo. Seam B8 – Elektrociep•ownia W•adys•awowo DP00315

TECHNICAL DOCUMENTATION LOTOS Petrobaltic S.A.


Documentation archival No. Documentation No. Page Pages Rev.

DP00315-OWR 14 73 0
Project No.

DP00315

CALCULATION OF PIPELINE

After the calculation of the maximum unsupported length of the pipeline, strength calculations for pipeline
were performed taking into account the trawl impact. Forces related with the trawl impact were calculated
in section 1.

Strength calculations have shown that maximum distance between mats is 50 meters, for the section
where pipeline scouring and trawl impact may occur. The 8-ton mats were assumed in the calculation.

Pic. 3.4. Model view

If unsupported section will be hit by trawl ( what is the most worst case in all analysis) the value of
maximum stress ratio will be 0.8. The highest value of stress will take place at the end of the mat. ( as is
marked on picture 3.5). When trawl will hook pipeline, pipeline will move 2789 mm in the direction of the
force caused from trawl. This is shown on picture 3.6.

Project name Location Project No.


Executive pipeline project B8-W•adys•awowo. Seam B8 – Elektrociep•ownia W•adys•awowo DP00315

TECHNICAL DOCUMENTATION LOTOS Petrobaltic S.A.


Documentation archival No. Documentation No. Page Pages Rev.

DP00315-OWR 15 73 0
Project No.

DP00315

CALCULATION OF PIPELINE

Pic. 3.5. Stress in the described system

Pic.3.6. Displacements in the described system

Project name Location Project No.


Executive pipeline project B8-W•adys•awowo. Seam B8 – Elektrociep•ownia W•adys•awowo DP00315

TECHNICAL DOCUMENTATION LOTOS Petrobaltic S.A.


Documentation archival No. Documentation No. Page Pages Rev.

DP00315-OWR 16 73 0
Project No.

DP00315

CALCULATION OF PIPELINE

Strength calculation taking into account initial temperature of fluid service was performed. Analysis
contained in description DP00315 point 7 shows that temperature of 4 stC will be reached in point
located 1500 m from riser flange (for maximum value of the flow). Initial temperature of fluid service was
introduced to the model according to the chart below.

Project name Location Project No.


Executive pipeline project B8-W•adys•awowo. Seam B8 – Elektrociep•ownia W•adys•awowo DP00315

TECHNICAL DOCUMENTATION LOTOS Petrobaltic S.A.


Documentation archival No. Documentation No. Page Pages Rev.

DP00315-OWR 17 73 0
Project No.

DP00315

CALCULATION OF PIPELINE

Pic. 3.7 Displacements in the described system

Pic. 3.8 Displacements in the described system

Project name Location Project No.


Executive pipeline project B8-W•adys•awowo. Seam B8 – Elektrociep•ownia W•adys•awowo DP00315

TECHNICAL DOCUMENTATION LOTOS Petrobaltic S.A.


Documentation archival No. Documentation No. Page Pages Rev.

DP00315-OWR 18 73 0
Project No.

DP00315

CALCULATION OF PIPELINE

The performed analysis show that set temperature in pipeline does not affected on exceeding of
allowable stressed. The highest deflection in analysis system equal 4.67 mm.

Strength analysis and deflation analysis for point where pipeline outlet on surface of seabed from HDD
drilling was performed. For 12st angle of outlet pipeline from HDD drilling occurs pipeline deflection.
Deflection cause laying the pipeline on the seabed right behind outlet point. With such a deflection stress
ration equal 0.96.

Pic. 3.9 – HDD Model View

Project name Location Project No.


Executive pipeline project B8-W•adys•awowo. Seam B8 – Elektrociep•ownia W•adys•awowo DP00315

TECHNICAL DOCUMENTATION LOTOS Petrobaltic S.A.


Documentation archival No. Documentation No. Page Pages Rev.

DP00315-OWR 19 73 0
Project No.

DP00315

CALCULATION OF PIPELINE

Pic. 3.10 - Displacements in the described system

Project name Location Project No.


Executive pipeline project B8-W•adys•awowo. Seam B8 – Elektrociep•ownia W•adys•awowo DP00315

TECHNICAL DOCUMENTATION LOTOS Petrobaltic S.A.


Documentation archival No. Documentation No. Page Pages Rev.

DP00315-OWR 20 73 0
Project No.

DP00315

CALCULATION OF PIPELINE

4 Division of the pipeline sections


Because of variable characteristic of Batlic seabed and different various load ranges, pipeline has been
divided into six section:

The section 1 is 6328 meters long. The starting point is located in P1 point. The finishing point of the section
one I located 36,8 meters before the V-217/14 point. In this section 113 mats will be laid every 50 meters .
The mats are 6 meters long.

Loads included in the calculations:

- scouring

- see current velocity of 0,75 kn

- waving

Section 1 consist of bearing ground.

The section 2 is 12656 meters long. The starting point is located 36,8 meters before V-217/14 point. The
finishing point of the section 2 is located 1,6 meters before V-178/14 point. In this section 226 mats will be laid
every 50 meters. The mats are 6 meters long.

Loads included in the calculations:

- scouring

- see current velocity of 0,75 kn

- waving

- trawl impact

Section 2 consist of bearing ground.

The section 3 is a 7114,1 meters long. The starting point is located 1.6 meters before V-178/14 point. The
finishing point of the section 3 is located 68 meters before V157/14 point. In this section 85 mats will be laid
every 50 meters. The mats are 6 meters long. Section 3 consist of bearing and non-bearing ground.

Loads included in the calculations:

- scouring

- see current velocity of 0,75 kn

- waving

- trawl impact

Project name Location Project No.


Executive pipeline project B8-W•adys•awowo. Seam B8 – Elektrociep•ownia W•adys•awowo DP00315

TECHNICAL DOCUMENTATION LOTOS Petrobaltic S.A.


Documentation archival No. Documentation No. Page Pages Rev.

DP00315-OWR 21 73 0
Project No.

DP00315

CALCULATION OF PIPELINE

The section 4 is 23555,2 meters long. The starting point is located 68 meters before V157/14 point., The
finishing point of the section 4 is located 136 meters beyond V-083/14 point. There are no mats located in
this section because of non-bearing ground. The pipeline is submerged in the non-bearing ground.

The section 5 is 6500,8 meters long. The starting point is located 136 meters beyond the V-083/14 point.
The finishing point of the section 5 is located 54,4 meters before the V-062/14 point. In this section 25 mats
will be laid every 50 meters . The mats are 6 meters long. Section 5 consist of bearing and non-bearing
ground.

Loads included in the calculations:

- scouring

- see current velocity of 0,75 kn

- waving

- trawl impact

The section 6 is 19475,2 meters long. The starting point is located 54,4 meters before V-062/14 point. The
finishing point of the section 6 is located in B8-2/5 point. There are no mats located in this section because of
non-bearing ground. The pipeline is submerged in the non-bearing ground. From point B8 2/5 occurs
temperature different from 4 degrees according to chapter DP00315-OSC picture 4.

Project name Location Project No.


Executive pipeline project B8-W•adys•awowo. Seam B8 – Elektrociep•ownia W•adys•awowo DP00315

TECHNICAL DOCUMENTATION LOTOS Petrobaltic S.A.


Documentation archival No. Documentation No. Page Pages Rev.

DP00315-OWR 22 73 0
Project No.

DP00315

CALCULATION OF PIPELINE

4.1 Section 1

The section 1 is 6328 meters long. The starting point is located in P1 point. The finishing point of the section
one I located 36,8 meters before the V-217/14 point. In this section 113 mats will be laid every 50 meters .
The mats are 6 meters long.

Project name Location Project No.


Executive pipeline project B8-W•adys•awowo. Seam B8 – Elektrociep•ownia W•adys•awowo DP00315

TECHNICAL DOCUMENTATION LOTOS Petrobaltic S.A.


Documentation archival No. Documentation No. Page Pages Rev.

DP00315-OWR 23 73 0
NOTES:
6.0 x 3.0 x 0.3 m X300, FLXMAT G.A. 1. ALL DIMENSION IN mm UNO
2. LATERAL ROPES Ø18 mm POLYPROPYLENE (PP), RATED TO 4.8 t
BREAKING STRENGTH (MINIMUM)
3. SIDE LIFT ROPES Ø22 mm POLYPROPYLENE (PP), RATED TO 7.0 t
BREAKING STRENGTH (MINIMUM)
4. LIFTING ROPES ARE DESIGNED ACCORDING TO DNV RULES FOR

(APPROX)
LOTOS PETROBALTIC
PLANNING AND EXECUTION OF MARINE OPERATIONS (1996) Pt: 2,

2555
Ch: 5 & 6
5. CONCRETE DENSITY: 2400 kg/m³
APPROVAL 6. VOLUME PER MATTRESS: 3.39 m³
7. CONCRETE MATTRESS WEIGHT: 8,145 kg (AIR), 4.667 kg (SUB)
SPREADER BEAM
7027-ENG-DWG-0002 R3
File No............................................. 8. ALL BLOCKS ARE ENCASED IN 3 mm PP
FIXED END QUICK RELEASE 9. EACH BLOCKS ARE 500(L) x 500(W) x 300(H) mm
END

Client PO No. ................................. 3.5 m LGTH


SOFT WEBBING SLING
Signed.............................................
MTO - PER MATTRESS
Name............................................... NO DESCRIPTION QTY UOM COMMENTS
m FOR SIDE LIFT ROPES

(APPROX)
1 Ø 24 mm PP ROPE 49.2
Date.................................................

3279
2 Ø 18 mm PP ROPE 78.6 m FOR LATERAL ROPES
3 FM150T (BLACK) 40 PCS FLXMAT TOP SHELL
FM150T (YELLOW) FLXMAT TOP CL
4 32 PCS
MARKER SHELL
5 FM150B (BLACK) 72 PCS FLXMAT BASE SHELL
BLOCK DETAILS: X300
SCALE 1:10 1NO. LIFT PP ROPES
500 CAST THRU EA. BLOCK

6.0 x 3.0 x 0.3 m FLXMAT 2NO. LATERAL PP ROPES


GENERAL LIFTING ARRANGEMENT CAST THRU EA. BLOCK
SIDE LIFT OF 6.0 x 3.0 x 0.3 m, X300 FLXMAT
Ø22 mm POLYPROPYLENE ROPE, B/S 7.0 t

500
340 mm LIFTING APEX, SIDE LIFT
APPROX. 8.2 m, 6NO. PER MAT
(REMAINING ROPES NOT SHOWN FOR CLARITY) SPLICE
APPROX 0.5m
6000
5
41
340

Ø18 mm POLYPROPYLENE ROPE, B/S 4.8 t


LATERAL ROPES
APPROX. 13.1 m, 6NO. PER MAT
(REMAINING ROPES NOT SHOWN FOR CLARITY)

300
YELLOW TOP SHELL
CENTRELINE MARKING
3000

CLIENT :

3 03/06/15 ISSUED FOR CLIENT'S APPROVAL SZ DM


2 18/05/15 RE-ISSUED FOR BID - CHANGED TO X300 SZ DM DM
1 13/05/15 ISSUED FOR BID SZ DM DM
0 09/04/15 ISSUED FOR CLIENT'S INFOMATION SZ DM DM
REV. DATE DESCRIPTION DRN. CHK. APD.

F L X M A T
6 4 B Q U E E N S T R E E T , S I N G A P O R E 1 8 8 5 4 3
PLAN WE B SI T E : WW W . FL X M A T . C O M , E M A I L : I N F O @ FL XM A T . C OM
500 ©2015 by FLXMAT Ô All rights reserved. This document is confidential and may contain copyright material protected by law. If you
have received it in error, no copyright or confidentiality is lost and you may not disclose or use this document but please notify us. No
part of this document may be reproduced or transmitted in any form or by any means without prior written permission of FLXMAT Ô.
PROJECT TITLE :
300

LOTOS PETROBALTIC S.A.


PIPELINE STABILISATION - WATER INJECTION
LINES B8 FIELD
ELEVATION SIDE DRAWING TITLE :
6.0 x 3.0 x 0.3 m, X300, FLXMAT G.A.
DRAWING No. : REV. SCALE SIZE
7027-ENG-DWG-0002 3 AS SHOWN A1
NOTES:
1. ALL DIMENSION IN mm UNO
2. ALL FABRICATION, WELDING AND NDT TO BE IN ACCORDANCE
WITH DNV 2.7-3 PORTABLE OFFSHORE UNITS
3. SHACKLES AND WIRE SLINGS PROVIDED BY 7SEAS
4. 6NO. QUICK CONNECT (QC) MECHANISM EACH SIDE OF BEAM,
12NO. TOTAL
5. ESTIMATED WEIGHT OF BEAM: 700 kg

6.0 m LIFTING BEAM


SCALE 1:10
MTO
1.1 NO. DESCRIPTION QTY COMMENTS
2.3
1.2 1.3 1.6 1.1 PIN PLATE 1 12
1.2 PIN PLATE 2 12
1.3 BAR LOCK PLATE 24
1.4a FRONT BAR 2
1.4b CENTRE BAR 2
1.5d 1.4c END BAR 2
2.7 1.5a RELEASE HANDLE 1
1.5a 1.5b PIN - PIVOT 1
2.8 2.4
1.5b 1.5c PIN - END BAR 1
2.6 1.4a 1.4b 1.4c 2.2 1.5d HANDLE PIVOT 2
2.5
1.6 M10 x 45 CSK SCREW 48
1.7 GREEN PIN SHACKLE 12
713

1.8 M8 x 55 HEX BOLT & NUT 6 LINK 1.4 a,b, c &


2.1 MAIN BEAM 1
TRANSPONDER BUCKET +
2.1 2.2 2
1.8 1.5c 2.9 ROV HANDLE
525
2.3 BEAM FEET 2
QUICK CONNECT (QC) MECHANISM 2.4 MAIN PADEYES 2
CLOSE POSITION
SCALE 1:16 2.5 CYLINDER CONNECTOR 1
2.6 CYLINDER BRACKET 1
96 2.7 CONNECTOR PIN 1
2.8 BRACKET PIN 1
2.9 M16 x 30 HEX BOLT & NUT 4 FASTEN 2.2 TO2.1
CLIENT :

114
250 1000
QUICK CONNECT (QC) MECHANISM
OPEN POSITION
0 26/06/15 ISSUED FOR LOTOS APPROVAL SZ DM
SCALE 1:16
MANUAL HANDLE DIRECTION A 28/05/15 ISSUED FOR INTERNAL REVIEW SZ
LOTOS PETROBALTIC APPROVAL REV. DATE DESCRIPTION DRN. CHK. APD.

HYDRAULIC CYLINDER DIRECTION


FXT-EQU-ENG-LB-260515
File No.............................................
Client PO No. ................................. 114 STROKE LENGTH: 114 mm
7 S E A S P T E L T D
Signed............................................. 6 4 B Q U E E N S T R E E T , S I N G A P O R E 1 8 8 5 4 3
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PROJECT TITLE :

Date................................................. CONCRETE MATTRESS


114 6.0 m LIFTING BEAM
DRAWING TITLE :

QUICK CONNECT (QC) MECHANISM LIFTING BEAM - HYDRAULIC RELEASE


SCALE 1:8 DRAWING No. : REV. SCALE PAGE
FXT-EQU-ENG-LB-260515 0 AS SHOWN 1 OF 1