SKO Pipeline Replacement

COMPANY: Target Energy Cooperation (TECO)

PROJECT TITLE: SKO Pipeline Replacement

CLIENT: PETRONAS SKO

LOCATION: Malaysia

YEAR: 2011

VESSEL: Derrick Lay Barge (DLB) Mas Mulia

SCOPE OF WORK:

MY INVOLVEMENT:

Install BAP-AA 12″ Riser (Stalk-on Method)

Reposition and Set-up at BAP-AA location
Connect Davits, Lift Pipeline to surface, Sidewalk & Lower down P/L
Diver Metrology (Riser)
Cleaning & Install 4 Nos of Riser Clamps
Fabricate riser (meanwhile)
Lift Pipeline to Surface, Secure and Erect Scaffolding
Stalk-on Riser
Weld/NDT/Wrap
Remove Scaffolding @ BAP-AA
Lowerdown Riser to Position
Close 4 nos. of clamps by Bolt Tensioning (at 4hours/clamp)
Flood Riser & Pipeline (meanwhile)
Reinstate Riser Guard
Final survey and derig
Pick-up anchors (deck anchor)
Sail to BADP-G

Install BADP-G 12″ Riser

Reposition and Set-up at BADP-G location
Remove Riser Guard
Diver Metrology
Cleaning & Install 2 nos of Riser Clamps
Fabricate Riser (meanwhile)
Preinstalled Riser
Remove Scaffolding @ BADP-G
Diver Metrology (Subsea Spool)
Fabricate Subsea Spool (meanwhile) Close 2 nos. of clamps by Bolt Tensioning (at 4hours/clamp)
Reinstate Riser Guard 8 hrs 21 Sep ’11 22 Sep ’11
Final survey and derig 9 hrs 21 Sep ’11 22 Sep ’11
Pick-up anchors (deck anchor)

Subsea Spool (Flange Tie-in) – BADP-G

Reposition and Set-up at BADP-G location
Spool tie-in & Install flange Protector
Final survey and derig
Pick-up anchors (deck anchor)
Sail to BNP-A location

Lay PL369 12″dia. BAP-B – BNP-A – 15.1km

Lay PL369 12″dia. BAP-B – BNP-A Pipeline (15.1km)
Lay PL BAP-B towards I/P Location
Reposition & Set-up at BAP-B
Bow string start-up
Commence lay pipe towards CP 2 [bend location up to KP13.6 – 1.5km
Continue pipeline installation towards TP 1 [KP2.6 – 11.0km]
Continue pipeline installation towards spool location(SP) [bend location up to KP0.0 – 2.6km (80 jts/day)]
Laydown at location
Remove ILC , X-ray Crawler, Buckle Detector
Install Laydown Head
Connect A & R Winch
Laydown head on bottom
De-rig A & R Cable, etc
Remove stinger
Pick-up anchors (deck anchor)
Sail to BAP-B location

12″ X 1.23KM BAP-AA TO BADP-G RISER INSTALLATION

INTRODUCTION

1.1 GENERAL

This procedure is produced to serve as a reference and guideline for the execution of the project that SUBCONTRACTOR undertake under the TRANSPORTATION AND INSTALLATION OF OFFSHORE FACILITIES FOR SKO PIPELINE REPLACEMENT PROJECT, CONTRACT

No.CH0/2009/DFIN/743, CONTRACT No.TLO/SK0/2010/055. This contract involves three parties, PETRONAS CARIGALI (COMPANY), TL Offshore (CONTRACTOR), and Target Energy Company (SUBCONTRACTOR).

This procedure details out the installation of 12″ diameter riser pipeline (PL365) from BAP-AA to BADP-G platform.

Target Energy Company has strict regulation in Health, Safety and Environment Management and committed to continuous safety improvement in the work place. The barge will be working under a permit to work (PTW) system to ensure the activities performed in a safe, effective and efficient manner in terms of safety. All barge crew will have mandatory training as stipulated by COMPANY.

Site conditions may warrant changes to offshore installation procedures and planning for the work to be taken in a safe expedient manner. In such event, CONTRACTOR ‘s Superintendent/Field Engineer shall consult with COMPANY Site Representative (CSR), the marine warranty surveyor (if available) and with its onshore management. Following agreement between all parties, this procedure may be revised to suit the prevailing installation conditions.

SCOPE OF WORK

The following riser installation scope of work shall be carried out by Diving/ Lay Barge Mas Mulia as described under this particular document.

RISER STALK–ON

Scope	Riser stalk-on KP	Pipe OD (inch)	Wall THK (mm)	Corrosion /THK (mm)	Concrete THK (mm )	Location
1	1.31	12″	13.1	5.5	40	BAP-AA

RISER INSTALLATION

Scope

Riser KP

Pipe OD (inch)

Wall THK (mm)

Corr./TH K

(mm)

Con’c

TH K

(mm)

Location

0.00

12″

13.1

5.5

BADP-G

The procedure contains the installation procedures required for offshore installation of riser sta lk-on by Mas Mulia and the installation methodology shall contain the followings as minimum :

– Riser fabrication plan
– Riser lifting analysis
– Installation aids
-Barge mooring plan/anchor pattern

The following part of the works will be subcontracted. The detailed scope of work and procedures will be submitted separately:

-Pigging and Hydrotest Procedure
-Pre installation survey Procedure
-Post installation survey procedure
-Pipeline NDT procedure
-Field joint coating & foam infilling procedure

MARINE EQUIPMENT

GENERAL

This section describes the Mas Mulia spread and support vessel to be utilized by CONTRACTOR for installation. Riser and spool pipe w ill be fabricated , loadout and transported from the fabrication yard facility in Kuantan, Malaysia to the site.

BARGE SPREAD

The Mas Mulia is a starboard side pipelay barge with a derrick crane maximum capacity of 190MT. The principal dimensions of 98.6m Length x 30.5m Beam x 6m Depth.

The pipelay equipment of Mas Mulia are consist of 4 welding station (manual fo r repair and automatic welding), 1NDT station, corrosion coating and infill form.

All diving supports and equipment are located to barge deck consist of diving control room, diving chamber and including 4 of 25 tonne and 2 of 50 tonne lifting davits.

A 150MT crawler crane operate on the port side open deck for general purpose lift including bringing pipe and materials onto the barge from vessel moored alongside.

The table gives data for the key equipment. The following elevation and plan drawing illustrate the Mas Mulia.

Feature	Mas Mulia
Barge Length	98.6m
Barge Breadth	30.5m
Accommodation	250 pax
Anchors	8 x 7 tonnes Delta flipper
Anchor cables	38mm x lOOOm
Pipelay capacity	60-inches dia meter
Tensioner +A/R winch	120tonne
Davits lifting	25 tonne (4 nos) I 50 tonne (2 nos)
Main Cranes (fixed)	190 tonne
Deck Crane (Crawler Crane)	150 tonne

BARGE LAYOUT

The Mas Mulia pipe ramp and location of diving equipment, we lding station, field joint application station, NDT station etc. is shown in drawing no.PL365/0P/008

The Mas Mulia spread will consist of the following:

Anchor Handling TUG (AHT)#l Boubon Liberity 254

Anchor Handling TUG (AHT)#2 Swissco Superior

Material and equipment barge Swiber 251

Tow Tug for Material and equipment Barge Swissco Superior

SUPPORT VESSEL

Following vessels will form part of the Mas Mulia as spool and riser. The nominated vessel are as follows:

Transporatation Barge Tiong Woon 37 + Tiong Woon 20

SUBCONTRACTOR

The following specialist contractor will be utilized:

Survey and positioning GEO info services sdn bhd

Non-Destructive Testing OAG inspection sdn bhd

ROV Alam Maritime Sdn Bhd

Diving Allied Marine & Equipment

MWS Berkat Global sdn bhd

Filled Joint Coating Duta Marine Sdn Bhd

GENERAL INFORMATION AND OFFSHORE MANAGEMENT

DESIGN RISER LOCATION

The riser description is shown in table below:

BAP-AA & BADP-G Multi-phase (Non-sour)

Description	BAP-AA	BADP-G
Platform Northing (ft)	1706661.00	1703905.00
Platform Easting (ft)	1550065.00	1553089.00
Platform Bearinq	12d57′	45d
Elevation at top of pup piece	EL(+)8873	EL( +)7558
Elevation at riser bend	EL(-)32610	EL(-)14837
Riser Diameter (ins)	12	12
Riser Type	Stalk-on	Riser spool
Pipeline Desiqn Bearinq	301d58’11”	321d59’01”
Riser better	1:10	1:8
Water Depth (mm)	32610	14837
No of clamps	EL(+)5881 (bearing clamp) EL(-)7771 (sliding clamp) EL(-)22044 (sliding clamp)	EL(+)3901 (bearing clamp) EL(-)4171 (sliding clamp)
Clamp Pre-insta lled	YES	Y ES
Riser Guard	YES	Y

WEATHER ESTIMATES AND FORECASTING

The installation barge barges are linked with the weather service from the special agency to receive all the pertinent weather information. Weather forecasts will be provided at least every 6 hours site-specific forecasts including monitoring and updating services. Also, the additional tropical storm/typhoon forecasts during storm threats will be provided on an urgent basis.

RISER INSTALLATION PROCEDURE

INTRODUCTION

The riser at BAP-AA and BADP-G will be installed after the pipeline installation . Portion of the risers can be prefabricated but the actual make-up assembly can only be completed upon divers measurement of the distance between actual laydown location to the proposed riser location.

The pipeline at BAP-AA will be lifted up by utilizing 4 nos. davits located at the barge port side. Refer dwg. No.PL365/ENG/GEN/026 for davit lift location. The pipeline at BADP-G will not be lifted up by davits. The riser at BADP-G will be installed first and will be linked to pipeline by subsea spool tie-in.

Details of the riser clamp locations at BAP-AA and BADP-G platform are shown in the drawing attached (PL365-BAP-AA-2050-01-0 and PL365-BADPG -2000-0 1-0).

PRE BARGE MOBILIZATION ACTIVITIES

Prior to arrival of Mas Mulia at the proposed location , Diving superintendent will ensure that all dive team members have reviewed the riser installation procedure. A meeting will be held with all members of the dive team onboard Mas Mulia.

The diving superintendent generates the dive plans in co-operation with the diving supervisor and field engineer.

All dive plans will be provided to and discussed with the dive team.

MATERIAL EQUIPMENT LIST FOR RISER INSTALLATION

The following materials and equipment are required for riser installation.

A: BOLT & NUT

BAP-AA 12″ RISER BOLT & NUT FOR RISER CLAMP

No.	Clamr:>_ Elevation	Bolt Size	Total Otv.	Remarks
1	EL(+)5881	M30	16 nos	Client supplied material
2	EL(-)7771	M30	12 nos	Client supplied material
3	EL(-)22044	M30	12 nos	Client supplied material

BADP-G 12″ RISER BOLT & NUT FOR RISER CLAMP

No.	Clamp Elevation	Bolt Size	Total Qty.	Remarks
1	EL(+)3901	M30	6 nos	Client supplied material
2	EL(-)4171	M30	12 nos	Client supplied material

Notes:

All bolts and nuts sha ll be type ASTM A193/ASTM 194 Grade B7/2H or equivalent.
All studs, nuts and washers sha ll be fluorocarbon coated .

B: RISER PIPE

BAP-AA 12″ RISER PIPE

No.	Pipe Size	Coating Type	Colour Code	Remarks	Total Qty.
1	323.9 OD X 13.1WT. API 5L- X65	12.7mm Neoprene over 0.5mm FBE		Riser section above splash zone coating	1
2	323.9 ID, 12.7mm, Neoprene over 0.5mm FBE	12.7mm Neoprene over 0.5mm FBE		Hanger Flange	1
3	323.9 OD X 13.1WT. API 5L- X65,5.7d 5D Bend c/w 500 tangent length	12.7mm Neoprene over 0.5mm FBE		Transition Bend	1
4	323.9 OD X 13.1WT. API 5L- X65, 12.7mm THK Neoprene coated over 0.5mm FBE	12.7mm Neoprene over 0.5mm FBE		Splash zone joint	2
5	323.9 OD X 13.1WT. API 5L-X65	0.5mm THK FBE		Subsea Riser	3
6	323 .9 OD X 13.1WT API 5L- X65, 85d SD bend c/w 500 tangent length	HSS		Bottom riser bend	1
7	323.9 OD X 13.1WT. API 5L-X65, 5 .5mm THK. AE and 40mm THK concrete (anodepipe)	5.5mm THK A. E and 40mm THK concrete		Subsea spool pieces	2

BADP-G 12″ RISER PIPE

No.	Pipe Size	Coating TYQ_e	Colour Code	Remarks	Total Qty.
1	323 .9 OD X 3.1WT. API SL- X65	12.7mm Neoprene over O.Smm FBE		Riser section above sp lash zone coating	1
2	323.9 ID, 12.7mm,Neoprene over OS mm FBE	12.7mm Neoprene over O .Smm FBE		Hanger Flange	1
3	323.9 OD X 13.1WT. API SL- X65,7 .Od 50 Bend 500 tang ent length with 12.7mm THK Neoprene over O.Smm FBE	12.7mm Neoprene over O.Smm FBE		Transition Bend	1
4	323.9 OD X 13.1WT. API SL- X65, 12.7mm THK Neoprene coated over O.Smm FBE	12.7mm Neoprene over O.Smm FBE		Splash zone joint	2
5	323 .9 OD X 13.1WT. API SL- X65	O.Smm FBE		Subsea Riser	1
6	323.9 OD X 13.1WT API SL- X65 , 83.4d SD bend 500 tangent length	HSS		Bottom riser bend	1

C: INSTALLATION AIDS AND OTHERS

No.	ITEMS	Required QTY
	INSTALLATION AIDS
1	Lifting Clamp for 12″ (ID 323.9mm)	2 nos
2	Stopp er Clamp for 12″ (ID 323.9mm)	2 nos
3	12″ knee brace c/w clamp & associated bolt + neoprene protection	2 nos
4	12″ bear clamp	2 nos
5	12″ External Clamp	2 nos
6	Swa bbing Rabbit 12″	1 no
7	Gauging plate for 12″	1 no
	OTHER ITEMS
1	Serviw rap	10 rolls
2	Stud Bolt M24 c/w nuts (ASTM A l93-B7) fo r all clamp c/w 2 nuts (ASTM A194-2H)- black	50 pes

3	Stud Bolt 1 V2″ dia. Stud bolt (ASTM A193-B7) for all knee brace c/w 2 nuts (ASTM A194-2 H)- black	20pcs
4	Rigging slings	1 lot
5	Holiday detector	1 no

D: EQUIPMENT AND TOOLS

No.	ITEMS	Required Qty.
1	Pneuma Hose x 40m	4
2	Pneuma Gauge panel	4

LOAD OUT AND TRANSPORTATION

The linepipe joints, riser/spool related materials and bends would all be transported from coating yard, kuantan and shall be loading to supply vessel and transport to site.

RISER INSTALLATION (STALK ON) AT BAP-AA PLATFORM

The rigid risers with diameter 12″ will be installed by adopting the “stalk-on” method. The existing riser guard has been removed by PLB Mas Mulia prior to laying of pipe. The pipeline end will be lifted to surface (barge deck level) by multiple davit lift lines and the riser will be welded/”stalk-o n” in sections and the riser – pipeline assembly wil l be lowered to sea-bed I into the clamps.

The following items will be verified by the lay barge prior to commenceme nt of the multiple side davit lift operations. These will be carried out using a combination of divers, ROV, Sector Scan and other mean .
-Pipeline corridor and heading
– General sector scan survey to confirm absence of anomalies and exposure of pipeline on the sea bed.
– Verify riser clamp integrity and ensure clamp gates are open to receiver.

PREPARATORY WORK

Check/confirm all riser clamps are in the open position
Check the clamp to the jacket flange bolts
Check and ensure correct and sufficient quantity of riser clamp bolts sup
Rig-up and check davits, including wire, block and load ce
Prepare 4 each 150ft, pneumo lines (include 1spare)
Prepare the bear clamp and other lifting aids such as knee braces and lifting clamps c/w bolts and nuts.
Prepare the rigging required for the davits lift, e. lifting sling, etc.
Check and prepare all hand tools required for tighten ing clamps
Divers to prepare equipment for connecting davits and taking
Prepare all necessary welding gears, NDT equipment and associated equipmen t for tie ins over the side .
Diver/ROV survey pipeline/riser route to ensure design corridor is clear of debris, existing pipelines and/ or power

SEQUENCE OF WORK

The scope of work covered by this installation procedure includes the following major activities:

Set up barge at platform, cut the bow string and sidewalk the pipeline to the proposed route if required.
Install two (2) riser sliding clamps (under water) and one (1) riser load bearing clamp (above water) for the 12″ dia. Riser at BAP-AA platform.
Lower davit block to pipeline at choking sling location.
Connect chocker sling to davits block and lift pipeline up as per field data book analysis for adjusting pipeline into designed route. (optional)
Attach metrology jig on pipeline and lower down pipeline to seabed as per field data book analysis.
Take riser measurement by diver’s metrology
Final fabricate expansion offset and riser make-up on deck.
Lift pipeline up to surface, cut pulling head laydown head and stalk-on weld expansion offset and vertical
Lower pipeline complete with expansion offset and riser
Close riser clamps and tighten
Flood the pipeline from BAP-AA platform to BADP-G platform
Remove installation aids and disconnect davits and choking slings from pipeline
Reinstate back existing riser guard
Video survey the completed works
De-rig from platform and pick up

Parameter	BAP-AA Platform
Platform Co-ordinates	N 1706660.9ft E 1550065.02ft
Location	East Face
Pipeline	BAP-AA to BADP-G
Riser Batter (apparent)	1:10
Number of clamps	EL( +) 5881 (load bearing clamp) EL(-)7771 (sliding clamp) EL(-) 22044 (sliding clamp)
Water Depth	33300mm
Top of splash zone	EL(+) 7712
Bottom of splash zone	EL(-) 3625mm
Pipe OD	323.9mm
Pipe WT	13.lmm
Riser pipe & bend specs	API 5L-X65
Riser corrosion coating	O.Smm thk FBE 12.7mm thk neoprene
Field joint coating	Serviwrap
Thickness of concrete coating	40mm
Weight in Air per joint (corrosion coated)	1.23MT
Weight in Air per joint (concrete coated)	2.93MT
Riser bend OD	323.9mm
Riser bend WT Riser bend radius (SD)	13.lmm 1620mm

MATERIAL AND EQUIPMENT

Refer to section 5.3 for detail description of the materials and equipment required of the job .

RISER CLAMP INSTALLATION

Riser clamp installation will be performed at BAP-AA and BADP-G Platform prior to commence of riser installation and riser stalk-on. The riser clamp related scope of work is stated as per the followings:

i) Underwater brace cleaning of riser clamp location
ii) Install riser clamp at the proposed location as per client’s AFC

Both saturation and air diver will be utilized for the installation of new riser clamps and removal of marine growth/obstruction on the jacket bracing. Air divers will operate up to a depth of 40M (130ft) while saturation divers will perform operations on deeper depth.

12″0 riser clamp installation at BAP-AA and BADP-G Platform
1. Prior to riser clamps installation, check all materials and ensure that all materials are in good condition and available
2. 3 nos and 2 nos, each of riser clamps w ill be installed at BAP-AA and BADP-G
3. Prior to installation, diver to clean jacket bracing from any marine growth using high pressure water jetting equipment at various clamp location.
4. Listed below are the elevations and clamp type fo r the riser clam

BAP-AA Platform

EL(+) 5881mm Load Bearing Clamp
EL(-) 7771mm Sliding clamp
EL(-) 22044mm Sliding clamp

BADP-G Platform

EL(+) 3901mm Load Bearing Clamp
EL(-) 4171mm Sliding clamp

DIVER MEASUREMENT/ PIPELINE RE-ALLIGNMENT

After relocation of the pipeline, an ROV survey will be carried out to verify the pipeline heading/alignment and position with respect to the jacket legs . An ROV survey also will be carried out to survey the riser location with clamps positioning and conditions. Using the if the pipeline needs further realignment. ROV sonar system, this will give an indication. The general methodology for pipeline re-alignment and diver measurements is as below.

ROV pre-survey of the pipelines at BAP-AA and BADP-G platform will determine the magnitude of pipeline misalignment from the proposed The magnitude is generally achieved by taking fixes with the ROV on the pipeline and comparing these to jacket leg coordinate and platform heading. Final barge positioning will be determined with respect to the surveyed pipeline.
With the 4 davits connected to choker sling on to pipelines as shown drawing no. PL365/0P/001, in accordance with the methods and procedures outlined in section 5.5.6.
The barge will then slowly move on anchors laterally to realign the pipeline (if required) Once the barge and pipeline are at predetermined location, the pipeline will be then gradually lowered to the seabed.
Once on seabed the alignment of the pipeline will be checked by means of the ROV and/or the USBL system. If necessary the pipeline will be lifted again and relocated until the desired location and heading are archived.
A measuring stake pre-installed and positioned at the mudline IP of the riser vertical bend to assist with final riser fabrication measurement. Th e stake was positioned on the centerline of the jacket mudline horizontal brace.
Diver will obtain the length measurement between pipeline pulling head girth weld and each measuring stake. Additional length and angular measurements to the stake and jacket leg/jacket panel brace will be required to obtain the final riser make-up. The diver shall verify the measuring table is in-line the pipeline heading and level on top of the pipeline.
– The metrology package consists of two aluminum tables that are designed, to be attached to the pipeline(s) with ratchet straps and align parallel to the pipeline axis. Both jigs are fitted with the protectors and one has a small diameter stainless steel cable and winch.
– The cable will be stretched taut between the two ji gs and the angles measured at the protectors.
– The distance between the metrology jigs wi ll be determined by marking the cable of the winch by attaching cable crimps.
Note: Below is sample of master jig equipment for metrology
In addition, the mudline to bottom of mud brace will be measured to confirm the riser vertical length make-up.
Based on the results of the diver measurements, the final riser dimensions can be confirmed for fabrication of the horizontal and vertical lengths and any bend angles in the riser
No final adjustments shall be made to the riser section until receipt of diver measurements.
FE (Field Engineer) to confirm and finalize the spool length

RISER FABRICATION

Prior to riser installation i.e. upon obtaining the measurement from divers, the pre-fabricated riser will be cut to suit with the actual length required on the fabrication barge. The completed riser shall be gauged with a rabbit prior to stalk-on.

Refer to drawing no.PL36S/OP/002 for riser fabrication make-up.

Notes:

All exposed field joints will be coated with corrosion protection materi
The mill joints numbers and length of each joint and their position in the riser will be recorded prior to welding . This will form part of the as-built data .
An external line-up clamp will be used for welding the per-fabricated riser during make up.
Clearly mark the pre-fabricated vertica l riser section with circumferential paint marks every Sft, from the IP of the vertical bend, e foot marks for aid during lowering of the riser.
Prepare adequate coating cutbacks on the riser section to allow for installation of bear clamp during stalk-on of the sections, approx . 3ft cutback is
Ensure all lifting clamps and temporary rigging attachments are not in the way of theCheck and confirm that the riser lifting clamps and knee braces are at the required clamps during installation of the riser.

BOW STRING CUT-OFF PROCEDURE

Prior to riser installation, bow string cable connected to jacket leg B2 on BAP-AA platform during pipelay works need to be cut-off. The bow string cut-off scope of work contains the following:

Launch the ROV to monitor the start-up head profile whether in offset or laydown position . If the start-up head in offset position, ROV to take fix the start-up head Field Engineer will verify the height distance of start-up head from seabed.
Barge crane to pick-up the load of the wire sling (pre-installed wire sling on 55MT shacke on start-up head) until reduce tension applied on the sacrificial sling
ROV to cut the sacrificial wire by using the cutter arm
Slowly lower down the start- up head on the seabed
ROV will take fix for start-up head coordinat Field Engineer and surveyor to confirm the start-up head location

RISER LIFT, STALK-ON AND SETTING PROCEDURE

Upon completion of the divers’ measurement and final adjustment to the riser, the pipeline will be lifted up from seabed utilizing 4nos of davits rigged up on the port side of the derrick barge.

ROV will survey the seabed area on the jacket face where the riser is to be installed to where the pipeline pullhead is located plus 2 joints back from ROV/divers wi ll check that all the subsea riser clamps are in the open position and tied-back also check the clamp to jacket flange bolts. They will also check the position and orientation of the clamps.
Diver will check the davits are in accordance with the choker arrangement as shown in drawing PL365/0P/001. Pneuma lines will also checked at the davit locations and big rig attachment points to ensure no fouling has occurred during the initial lift and realignment of the pipeline.
Once the rigging has been checked, the pipeline will be lifted based on the davit lift analysis in the field data book a nalysis. Refer to Appendix A for field data book extract for davit lift profile data.
Lift the pipeline to the surface, maintaining the pipeline profile as detailed in Field Data Book The ROV and pneuma gauges will be used to monitor the pipeline profile.
Dog-off the pipeline at the barge side to maintain cantilever support during stalk-on and lowering
Make the cut-off on the pre-fabricated riser section on the fabrication barge based on divers lowering.
Set-up scaffolds staging around the pipeline pullhead and ensures all required equipment is ready. Cut-off the pullhead and excess pipeline or add-on the required length to the horizontal of the riser section and install the bear clamp for riser stalk-on.
Using the derrick crane and /or deck crane, lift upright and stab the riser section into the bear
Weld out NDT
Take up the weigh t of the vertical section with the derrick crane, remove the securing line and return pipeline to its correct alignment. Use davits to lower the pipeline while using the derrick crane and tugger to support the vertical and cantilever sections respectively. Maintain the pipe profile using the davit and cantilever support. The pneuma lines and ROV will be used to monitor the profile.
Continue lowering the pipeline I riser During this operation, the riser tube turn need to be monitored as it the nearest point to the jacket and may foul the riser clamps if the stalk on is too long . ROV will continuously monitor the pipeline profile during the lowering activity.
Riser will have to be positioned in all the subsea clamps during the lowering activity. This may require diver assistance to use rigging line.
Once the riser is resting in the top clamp, the clamp wi ll be closed and loosely bolted. The riser will then be lowered until the hanger flange is seated on the top clamp.
ROV to survey that, the riser is correctly placed in the underwater clamps and check that the vertical riser bend is in the correct position relative to the seabed.
If all is clear, the riser clamps will be closed and bolts will be tightened using the diver’s hydraulic impact wrenches.
Perform ROV as-built survey of the installed riser .
De-rig all equipment and rigging from pipeline and riser.
To re-instate back existing riser guard back to location.

PIPELINE LIFTING AND LOWERING PROCEDURE

Various combination of parameter will be measured to confirm that the lift profile confirm to the pipeline lift analysis. Parameter values are given in tabular form for regular intervals of lift point Height off Bottom (HO B) as shown in the Field Data Book.

Document No. Title

TLO/S K0-055/PL365/ENG/04 Riser insta llation – Field data book fo r 12″ dia at BAP-AA platform (non-sour services)

The Field Data Book extract gives lift profile and tension at different intervals, however, during the actual lifting/ lowering the pipeline is lowered at lm intervals. Therefore, the intermediate va lues will be interpolated from that given in the field data book extracts. The controlling parameter i.e. Lift Point Elevation vs . davit load will be monitored to ensure the pipeline profile (i.e. sag bend stress) is within specification. As the multiple davit lift method is proposed for the lift, the elevation of the lift point will be monitored to ensure compliance to the Field Data Book recommendation.

Several monitoring facilities will be utilized during the lifting operation:

Pipeline Profile – Pneumo Gauges

Pneuma lines, used to measure depth from surface wi ll be attached to the davit lifting points on the pipeline. As the pipeline is being lowered down, pneuma gauges w ill give a series of readings for every attachment point during various lowering, stages, thus allowing confirmation that the pipe profile at a particular stage is within the bounds specified in Field Data Book.

Remote Operated Vehicle (ROV)

The ROV is equipped with a depth indicator and will be used during the pipeline lift operation to carry out the following functions:-

– Monitoring the pipeline profile at any point back to touchdown.
– Check to ensure rigging does not become entangled with any pneuma lines.
– Confirm integrity of each attachment point at various lifting stages.

RISER CLAMP BOLT AND TIGHTHENING

All bolts for riser clamps will be tightened using hydraulic impact w rench. All riser clamps stud-bolts shall be type ASTM A193/ASTM 194 Grade B7/2H or equivalent. A ll riser and brace clamp bolts, nut and washers shall be corrosion coated with fluorocarbon coating.

REMOVAL OF INSTALLATION AIDS

After tightening all the clamps, the following installation aids will be removed from the riser:

– Riser lifting clamps
– Knee brace and clamp
– Davit line and pneuma hose
– Choker sling

FLOODING

Once the installation riser is completed and prior to leaving BAP-AA Platform and tie-in spool at BADP-G Platform, the pipel ine sha ll be flooded with water in order to equalize with external pressure. The detailed procedure of the flooding is as follows :

Cut the knight cap on the top of riser
Arrange and pull fire water hose from PLB Mas Mulia
Add adequate quantity Black Smith Chemical for 1 year preservation into pipeline from top of riser.
Insert the fire water hose from top of rise r and flood the pipeline
Stop the flooding once the pipeline is fully flooded with the

SUMMARY OF DIVING AND ROV

The table below provides a summary of all the diving and ROV activities relevant to the riser installation scope of work .

Item	Description of ROV/Diving Task	Reference section in the is document
1	Divers to attach pneuma lines, davit block/big rig block to pre-installed chokers on the pipeline	Section 5 .5	Saturation Diving
2	ROV to inspect and confirm that the pre-installed chokers are still in their origina l positions on the pipeline. Indicated by circumferentia l point marks on either side of chokers.	Section 5 .5	ROV
3	Divers/ROV to perform debris survey of the riser route	Section 5.5	Saturation Diving or ROV
4	ROV to monitor profile of pipeline during lifting and lowering operations	Section 5.5	ROV

5	ROV to monitor the pipeline to touchdown during all lowering activities	Section 5.5	ROV
6	Diver to take measurement of expansion offset for riser stalk-on length	Section 5.5	Saturation Diving
7	Diver to tighten underwater riser clamps with hydraulic impact wrench and recover installation aids after riser installation	Section 5.5	Air dive and saturation dive
8	ROV to perform post installation survey of riser and pipeline	Section 5.5	ROV

RISER INSTALLATION AT BADP-G PLATFORM

The scope of work for the 12″ riser installation consists of the following:

Perform installation engineering analysis
Conduct metrology & fabricate the riser components at yard
Install riser clamp Transportation of riser from yard to field
Lift and lower down riser into clamp
Secure riser to the clamps & hydratight the clamp bolts
Conduct the final as-built survey

The material for the riser is supplied by COMPANY and these will be transported together with material for riser stalk-on in the same material barge.

The 12″ riser w ill be installed at the West side of the platform. Riser clamps installation works will be done first prior to installing of riser. The depth at the location is 14.837 m. The riser for BADP-G platform will be fabricated base on drawing (Riser general arrangement at BADP-G platform) and actual measurement taken at site by using taut wire (measuring from top of jacket and bottom of jacket by following the jacket batter).

Parameter	BADP-G Platform
Platform Co -ordinates	N 1703905.00ft E 1553089.00ft
Location	West Face
Pipeline	BAP-AA to BADP-G

Riser Batter (apparent)	1:8
Number of clamps	EL(+) 3901 load bearing clamp EL(-) 4171 sliding clamp
Water Depth	15100mm
Top of sp lash zone	EL(+) 6390mm
Bottom of splash zone	EL(-) 2310mm
Pipe OD	323.9mm
Pipe WT	13.lmm
Riser pipe & bend specs	API 5L-X65
Riser corrosion coating	O.Smm thk FBE 12.7mm thk neoprene
Field joint coating	Serviwrap
Thickness of concrete coating	40mm
Weight in Air per joint (corrosion coated)	1.29MT
Weight in Air per joint (concrete coated)	2.93MT
Riser bend OD	323 .9mm
Riser bend WT	13.lmm
Riser bend ang le	83 .ld
Riser bend radius (SD)	1620mm
Flange type	12″ RTJ WN Flange 600#, ASTM A694 F65 (1 nos)
Blind flange type	12″ Blind RTJ Flanges 600# ASTM A lOS

PREPARATORY ACTIVITIES

Check/confirm all riser clamps are in the open position
Check the clamp to the jacket flange bolts

Check and ensure correct and sufficient quantity of riser clamp bolts
Locate Air tugger on the platform
Prepare the lifting aids such as knee braces and lifting clamps c/w bolts and
Check and prepare all hand tools required for tightening clamps bolts.
Prepare all necessary welding gears, NDT equipment and associated equipment fo r tie ins over the
Diver/ROV survey pipeline/riser route to ensure design corridor is clear of debris, existing pipelines and/ or power cables.

SEQUENCE OF WORKS

The scope of work covered by this installation procedure includes the following major activities:

Set up barge at platform.
Final fabricate and riser make-up on deck
Lift up the riser and lower down to position
Remove installationClose riser clamps and tighten
Video survey the completed
De-rig from platform and pick up

Listed below are the steps for 12″ riser lifting, lower down to seabed and setting operation:

Item	Step
1	Prior to riser lifting, set and install all necessary rigging equipments on BADP-G platform i.e Air Tugger, snatch block and beam clamp (if required) Note: Grating at cellar deck will be temporarily removed if required.
2	Rig up the riser as per rigging drawing.
3	Lift the riser off the barge horizontally. The riser will be lifted from material barge and swing over the material barge deck towards to BADP-G platform using main crane.
4	At the water line, gradually upend the riser. Slowly pick up auxiliary hook and slack the main hook crane.
5	Move the riser towards the designated location using main crane
6	On the platform run the platform w inch wire and connect the winc h wire to the padeye on the kniqht cap.
7	Start transferring the load from crane to the platform tugger. Once load have been transferred, deploy air divers to disconn ect the crane wire and recover to deck. This load transfer will be visually verified by the ROV prior to divers entering the water.
8	ROV to monitor the bottom of the riser and using the top winch to pull the riser section if required to make any adjustment.

9	Position/align the riser hanger flange in the top of load bearing clamp, position the riser such that the premarked 12 and 6 o’cloc k position are running perpendicular to the platform brace. Install 5 t comealong at bottom section to secure the riser.
10	Deploy air diver to close the riser clamp
11	The diver/ROV wi ll survey the elevation of riser bend turn relative to the sea bed
12	Remove all the rigging gears

12″ BADP-G SUBSEA TIE-IN SPOOL INSTALLATION

SCOPE OF WORK

The following spool tie-in installation scope of work shall be carried out by Diving/Lay Barge Mas Mulia as described under this particular document .

SPOOL TIE-IN

Scope	Spool tie-in (KP)	Pipe OD (inch)	Wall THK (mm)	Corr./THK(mm)	Cone THK (mm)	Location
1	0.00	12″	13.1	5.5	40	BADP-G

This procedure contains the installation procedures required for offshore installation of spool tie-in by Mas Mulia and the installation methodology shall contain the followings as minimum :

Spool fabrication plan
Spool lifting analysis
Installation aids
Barge mooring plan/anchor patterns.

The following part of the works will be subcontracted . The detailed scope of work and procedures will be submitted separately:

Pipeline testing/pre-commissioning procedure
Pre-installation survey procedure
Post installation survey procedure
Pipeline NDT procedure
Field joint coating and foam infilling procedure

MARINE EQUIPMENT

GENERAL

This section describes the Mas Mulia spread and support vessel to be utilized by CONTRACTOR for installation . Spool pipe will be fabricated, loadout and transported from the fabrication yard facility in kuantan, Malaysia to the site.

BARGE SPREAD

The Mas Mulia is a starboard side pipelay barge with a derrick crane maximum capacity of 190MT (fixed Load) .The principal dimensions of 98.6m Length x 30.Sm Beam x 6m Depth .

The pipelay equipments of Mas Mulia are consist of 4 welding station (manual for repair and automatic welding), 1NDT station, corrosion coating and infill form.

All diving supports and equipments are located to barge deck consist of diving control room, diving chamber and including 4 of 25 tonne and 2 of 50 tonne lifting davits.

A crawler crane operate on the port side open deck for general purpose lift including bringing pipe and materials onto the barge from vessel moored alongside.

The tables gives data for the key equipment. The following elevation and plan drawing illustrate the Mas Mulia .

Feature	Mas Mulia
Barge Length	98 .6m
Barge Breadth	30.5m
A ccommodation	250 pax
Anchors	4 x 7 tonnes Delta flipperl4 x 8 tonnes Delta flipper
Anchor cables	38mm x 1000m I 45mm x 1000
Pipelay capacity	60-inches diameter
Tensioner +AIR winch	120 tonne
Davits lifting	25 tonne (4 nos) I 50 tonne (2 nos)
Main Cranes (fixed)	190 tonne
Deck Crane (Crawler Crane)	150 tonne

BARGE LAYOUT

The Mas Mulia pipe ramp and location of diving equipment , welding station, field joint application station, NDT station etc. is shown in drawing PL365/0P/008

The Mas Mulia spread will consist of the following:

Anchor Handling TUG (AHT) # l Boubon Liberity 254

Anchor Handling TUG (AHT) # 2 Epic Waja

Material and equipment barge Tiong Woon 32

Tow Tug for Material and equipment Barge Epic Waja

SUBCONTRACTOR

The following specialist contractor will be utilized:

Survey and positioning GEO info services sdn bhd

Non-Destructive Testing OAG inspection sdn bhd

ROV Alam Maritime Sdn Bhd

Diving Al lied Marine & Equipment

MWS Berkat Global Sdn Bhd

Filed Joint Coating Jurunature Sdn Bhd

MAJOR CONSTRUCTION EQUIPMENT

As part of Mas Mulia barge spread the following major shall be mobilized as part of spread.

Holiday Detector
Line-up clamp
Welding machine
X-ray machine
Diving equipment
Hydratight and tools Spanner wrench tool
Generator pump and hose (if required)

SPOOL TIE–IN/SPOOL INSTALLATION PROCEDURE

Taking into consideration the planned schedule of activities the DST ensure that dive plans are produced and are clearly understood by the diving supervisor (DS) and divers who will undertake the various tasks .

PRE BARGE MOBILIZATION ACTIVITIES

Prior to arrival of Mas Mulia at the proposed location, Diving superintenden t will ensure that all dive team members have reviewed the riser installation procedure . A meeting will be held with all members of the dive team onboard Mas Mulia.

The diving superintendent generates the dive plans in co-operation with the diving supervisor and field engineer.

A ll dive plans w ill be provided to and discussed with the dive team. JSA’s and risk assessment are to be discussed along with pre-shift toolbox talks.

Permanent materials and equipment that will be used during the installation activities will be checked and tested. A thread test of the hydratight reaction nuts will be checked on receipt of the permanent flange and bolts.

MATERIAL EQUIPMENT LIST FOR SPOOL TIE-IN

The following materials and equipment are required for spool piece installation.

S.No.	Description	Quantity
1	Line pipe for spool fabrication	4 nos (2 anode
1	Line pipe for spool fabrication	pipe)
1a	Bend 90d	2 nos
	Spool tie-ins equipment
2	Floqqing sQanner for 1.25″dia steel bolt	2 nos
3	Hammer wrenc h	1set
4	Hammer sledge	1set
5	Socket for 1.25″dia stud bolt	2
	Permanent materials
6	Stud bolt 1.25″ X 470 mmlg	20nos
7	12″ swivel flanqe #600 lb RTJ	2nos
8	Oval ring soft iron gasket R-57	2
9	Flange protector	2 nos
	Diving equipment
10	Riqqinq qear	1set
11	Water Jet (if required)	1set
12	Lift bag (if required)	1set
13	Hydratight tools	1set
14	Hydratight pump	1set
15	Hydraulic impact wrench	1set
16	Tommy Bar	1set
17	Metrology Jig	1set
18	Air dive control	1 lot
19	Sat dive control	1lot
20	Saturation Chamber	1lot
21	SAT system HPU	1lot
22	Diving Bell	1lot
23	Diving Gas	1lot
24	Divinq Oxyqen	1lot
25	Hydratight equipment (to suit all size of bolt)	1set
	Installation aids
26	Drift pin (all size)	1lot
27	Knee braces	1lot
28	Knee clamps	1lot
29	Bracing	1lot
30	Rigging equipment	1lot
	General
31	Field joint material	1lot
32	NDT equipment	1lot
33	ROV spread	1set

Notes:

All bolts and nuts shall be type ASTM A193/ASTM A194 Grade B7/2H or equivalent .
All studs, nuts and washers shall be fluorocarbon

SET-UP THE BARGE AT INITIATION LOCATION

Upon arrival of the Mas Mulia at location , the barge will be setting up at the initiation location . Before set-up, the onboard survey team will have previously noted all anomalies, detected from pre-installation survey operation and avoidance points and will have the same shown on the displayer on both Mas Mulia and tugboats.

Complete fabrication spool will be in place on deck material barge 250class. The material barge will be alongside with Mas Mulia prior to spool installation. 190 mt pedestal crane of Mas Mulia will be utilized to lifting and lowering the entire spool into the sea.

PIPELINES FLOODING OPERATION

According to subsea spool installation, all pipelines will be propelled by treated seawater from the temporary subsea launcher at BAP-AA platform to temporary subsea receiver at BADP-G SIDE for safe diving operations and to safeguard divers against suction. Refer to detailed procedure for pre-flooding will be in document no. TLOSKO-055/PL365/0PR/05.

TEMPORARY FLANGE PROTECTOR PULLING/LAYDOWN HEAD REMOVAL

Once the diver has confirmed that no suction can be heard through the 11/2-inch valve, the blind flange and pulling/laydown head can be removed.
The diver will require a hammer wrench, hydraulic impact wrench fitted with the appropriate size socket to assist with the removal of the bolts of flange .
Once complete remove all bolts, the diver will inform the diving Diving supervisor will inform crane operator to lower block of deck crane to water and diver will connect the slings.
The blind flange, pulling/lay-down head w ill be recovered to surface . The bolt and gasket will be secured in the works basket for recovery to surface, on completion.
Note: Hydra-Tight sea serpent equipment should be made ready in the event of any difficulty in loosening of the bolts.
The diver will inspect the permanent flange groove and face for any damaged
If the flange appears to be in good condition it will be protected, by securing a length of 2″ by 1″ wood planking (or suitable temporary protection) across the face of the flange in preparation of the spool installation.

Equipment requirements (Laydown Head Removal)

Item	Quantity
Hammer Wrench	1
Sledqe Hammer	1
Hydraulic impact wrench fitted with suita ble socket	1
Hydratigh pump	1
V4 inch rope (2m length)	1
Wood plankinq	1

SUB-SEA METROLOGY

It has been determined to use hard wire metrology table for this subsea metrology operation .

HARD WIRE METROLOGY TABLE

Hard wire metrology tables are specific ally designed and manufactured to obtain spool piece measurements for both flange connections and hyperbaric welded pipeline tie- ins.

The metrology package consists of two aluminium tables that are designed, to be attached to the pipeline with ratchet straps and aligned parallel to the pipeline axis.
Both jigs are f itted with protractors and one has small diameter stainless steel cable and winch.
The cable will be stretched taut between the two jigs and the angles measured at the protectors.
The distance between the metrology jigs will be determined by marking the cable of the winch by attaching cable
A video recording of the metrology table using the divers hat mounted camera will be carried Corroboration of obtained metrology information via videotape is extremely useful to backup and substantiate metrology data obtained. This video will be retained until the respective spool has been successfu lly installed.

SUB-SEA METROLOGY OPERATION

Utilize the “taut wire protectors maintenance and calibration notes” to set up the jig base plate to the pipeline diameter and “zero align” the units to each other.
Attach the crane line to the metrology jig rigging and install a tag line to the downline.
Note : The metrology jigs are sensitive and extreme care should be exercised in their handling and use. Rough handling can damage the mechanism and will affect their accuracy in obtaining metrology information.
Position the metrology jigs onto the pipeline as close to the flange faces as is practicable and release the crane wire. Note: The placement of each tab le (ex: Master table is located on the pipeline side of the tie-in etc)
. Check the level indicators on the tables (spirit level) for horizontal placement
Strap the metrology jigs securely to the pipeline using the ratchet
Note: Each table must be accurately center on the pipeline and level . Confirm with the divers hat camera and record.
Measure and record the distance (offset) from the centre point of each of the metrology tables to the respective flange face.
Loosen the pivot friction plate to allow the protector tables to rotate free
Run the wire from the meter table and attach to the slave table . The wire must feed through both jig ‘s vertical angle protector and wire -guide posts.
Use the cable winch to pre-tension the wire between the metrology
10. Inspect the cable between the metrology jigs and ensure that the cable is free running and clear of all obstructions .
Using the torque wren ch, tension the cable.
Re-inspect the bubble levels on both metrology jig s to ensure that the units have not rotated during cable tensioning.
Tighten the protector friction nuts to capture the pipeline angles.
Read the angle on the master table record in the dive log and video record
Read the angle on the slave table record in the dive log and video
Note:
– The metrology jig protector read from O to 180 with 90 being in line with the pipeline interline This feature ensures that the re is no confusion about the orientation of one j ig to the other one.
– The true offset angle must be calculated from zero point (in line with the pipeline) during topside calculations. It is critical however to establish the placement of the master and slave table (ex . Maste r table is located on the pipeline side of the tie-in etc) .
Place cable crimp onto the taut wire next to the centre wire -guide post to capture distance the two-metrology tables as measured from the centre posts.
Using the fiber glass ta pe measure take measurement along the taut wire from the centre post of the master table to the centre post of the slave table and record in the dive log.
Re-check spirit levels, measurement at table centre posts to respective flange faces .
Retrieve the metrology tables to surface, taking care with the handling .
Once the tables are retrieved on board the diving superintendent and field engineer will read off the angles on each table, pay out the winch w i re and tension to 35Nm (26ftlbs) and take the measurement. Compare topside measurements with diver measurements.
Note :
– The diving superintendent and field engineer will be in attendance during all metrology operations .
– The field engineer will be responsible for the calculations of the spool dimension
– If the visibility does not permit the direct reading of the protector on the metrology jigs, then this information can be read on the surface after the units are retrieved to the It is very important that the jigs are handled carefully to prevent rotation of the protector thereby giving erroneous angle information.
Once diver completed metrology, they will be passed the data to the field engineer and diving superintendent.
Field engineer will calculate the final length of the spool and pass to welder to fabricate final length of spool.

SPOOL DEPLOYMENT, ALIGNMENT AND FIT UP

The sub-sea spools will be deployed with the use of the deck crane. The spool wi ll be landed in close proximity for the final flange make up. All rigging in contact with the pipe coating will nylon webbing straps.

The spool will be pre-rigged on the deck of the derrick barge. Note:
-The general subsea spool lifting arrangement refer drawing no. PL365/0P/006
– The tag line will attached to riser flange and pipeline flange to align I guide the spool piece during installation.
The swivel flange faces will be protected, by securing a length of 2″ by 1″ wood planking across the face of the flange in preparation of the spool installation.
Lift bags maybe installed on the spool pieces to assist with the installation Field engineer onboard will calculate the buoyancy requirements and advise the lift bags to be used and their positions on the spool piece. Note:
– Prior to inflation of lift bags, the spool must be secured with hold back lines to the pipeline and platform to avoid excessive lift or tilt on the spool.
The spool piece will be lowered to approximately 5 meters above the seabed with aid of crane.
Once the diver has the spool piece in sight he will give instruction for the diving supervisor to direct the crane to assist with the orientation of the spool.
The diver will remove the flange protection from the riser flange and pipeline flange.
The diver with the aid of drift pins will align the flange bolt holes and bring the flanges close enough to start inserting the regular bolt.
Bolts w ill be inserted in the 9 O’clock to 6 O’clock and 6 O’clock to 3 O’clock flange bolt holes.
The diver will confirm that the flange faces and o-ring grooves are clear of any damage and or debris .
The diver will confirm that the gasket is free of damage or pitting prior to positioning between the flanges.
Note: Swivel flange shall be supp lied by Company
The diver wil l insert the gasket between the flange faces and install in the flange groove then tighten up on the existing bolts to firmly trap the gasket in the flange face A measurement (depth check) w ill be performed at the 12, 6, 3 and 9 O’clock locations to ensure the gasket is correctly installed.
Remaining bolts will be installed and tightened evenly with the aid of the hydraulic impact, drawing the flanges evenly together .
A measurement (depth check) will again be performed at the 12, 6, 3 and 9 O’clock locations to ensure the gasket are correct ly installed, additiona l gap between the flange faces will also be checked at the same clock
Items 5 to 14 will be repeated at the pipeline

Equipment requirements (Spool deployment, alignment and fit-up)

Description	Quantity
Rigging gear	1lot
Oval ring soft iron gasket	2 nos
Stud bolt	20 nos
Hydraulic impact c/w socket AF	1lot
Hammer wre nch	1
Tommy bar	1
Sledge hammer	1
Drift pin	3
12″ engineer rule	1
Tape measure	1
Lift bags	6 nos
A- Frame	2 nos

BOLT TENSIONING (SUB-SEA PIPELINE FLANGES)

Two pressures have been requested from supplie r for each application in the event that there are sufficient tools to perform a 100% tightening procedure or lack of access to both sides of the flange. Tensioning pressures will be provided in the following manner :

Pressure A (High Va lue)
Pressure B (Lower Value)

When using the 100% tightening method pressure B will be applied.
When using the 50% tightening method pressure A will be applied to the first 50% of stud bolts tensioned and pressure B will be app lied to the remaining 50% of stud bolts.

The final operating pressure for the system is reached when the pump is stopped and the gauge needle settles back into a static position corresponding to the pressure required.

PERMANENT FLANGE PROTECTOR INSTALLATION

Flange protectors will be installed on each of the sub-sea flanges to prevent fouling of anchor wires and such like.

The draw ing of general flange protector wil l be shown detailing the design of the flange protectors that will be installed. Refer to drawing no. PL365/ FAB/020.

The flange protector plates and ring plate complete with nuts and bolts will be kept in the basket and lowered to the diver by using of the deck crane.
The diver will position of the basket proximity of the flange to which it is to be installed and then release the crane for recovery to surface.
The subsea bolt will place to the hole of subsea flange and locked by first nut.
Installed the ring plate with flange protector plate to bolt and locked by second nut
The bolts wil l be Tighten ing carried out with the underwater impact wrench.

KNEE BRACE CLAMP REMOVAL

Completion of spool installation activities wil l be knee brace clamp removal. Deploy diver to dismant le the bolt and nut at knee brace clamp using underwater impact wrench. Knee brace will be attached with deck crane and recover to the surface.

12″ X 15.1km BAP-B TO BNP-A PIPELINE INSTALLATION

SCOPE OF WORK

Following is the scope of works related to BADP-G to BAP-AA 12″ diameter pipeline installation.

Transportation and installation engineering.
Transportation of linepipes and bends from coating yards to field locations.
Perform pre-lay and post lay survey.
Locate and determine burial condition of existing pipeline to be crossed. Remove riser guard at BAP-AA
Lay new pipeline from BAP-AA platform to propose laydown location at BADP-G platform.
Install riser and spool
Reinstalled riser guard at BAP-AA
Perform detailed engineering for pipeline installation and provide al l materials for pipeline installation aids.
Fabricate and install pipeline crossing

The final scope of work of pipelay may be revised as required to suit the agreed offshore installation schedule with PCSB

TECHNICAL DATA

General
Starting Point From	BAP-AA
Pipeline Lay Down	BADP-G
BAP-AA Platform Center Coordinate	E 1550065.00
	N 1706661.00
BADP-G Platform Center Coordinate	E 1553089.00
	N 1703905.00
Proposed Pipeline Start-up Coordinate	E 1550148.70
	N 1706638.04
Proposed Pipeline Laydown Coordinate	E 1553126.84
	N 1704077.48
Start-up Method	Bowstring start up
Pipelay Tension	lSMT
W ater Depth (MSL Depth)	Start-up Location	Lay-down Location
	33m	15m
Pipeline Details
Outside Diameter (OD)	323 .90mm
Wa ll Thickness	13.lmm
Concrete Thi ckness	40 mm
Estimated new pipeline length	1.239km
Grade	X65
Average line pipe length	12 .20m

Estimated number of joints	102
Estimated number of anodes	15
Line pipe w eight per joint (MT)	DRY 2 .9 MT SUBMERGED 1.3 MT

Design Pressure	96.8 barg
Design Temperatur e	70 uC
System Hydrotest Pressure	145.2 barg
Pipelay Tensio n (Installation)	15MT
Start-up Tension (Installation)	15MT

VESSEL AND MAJOR EQUIPMENT

PIPELAY BARGE SPECIFICATION

PIPELAV BARGE
NAME	MAS MULIA
LENGTH OVERALL	98.6m
BREADTH	30.5m
DEPTH OPERATING DRAFT	6m 4m
TENSIONER	2 nos horizontal, 60MT each
STINGER LENGTH	40m (TRUSS STINGER)
A/R WINCH	120MT

Please refer APPENDIX D and E for stinger function test and A/R winch and Tensioner certificate

ROV

A Work-Class ROV system will be provided onboard the pipelay barge. The ROV system will be a free flying type and will be used to assist in the pipe lay and subsea tie in monitoring activities. Sufficient crew will be available onboard to opera te the vehicle on a 24 hour basis. Ancillary equipment on the ROV will include pan and tilt cameras, sector scan sonar, cutting heads as well as robotic manipulators.

The activities required of the ROV will include the following:

Pipe lay start-up, profile monitoring, touch-down and lay dow n monitoring.
Cutting of lay down sacrificial cable
Installation monitoring and positioning of subsea tie-in spool
Removal of abandonment pipeline section.

AIR DIVING AND SATURATION DIVING

An in-house air diving spread, manned by in-house personnel will be available onboard the barge. The air divers will perform stinger monitoring, ballasting, and visual checks during pipelay operations. The air diver will also help the stinger installation process. Saturation system spread will be available onboard pipelay barge. The saturation system will be fielding a 12 man system. The system w ill have three (3) men bell capabilities. Du ring the pipelay operation, the SAT system will be on standby for contingency wet buckle of the pipeline.

EQUIPMENT AND INSTALLATION CHECKLIST

Listed in the tables below are the portable equipment and installation aids that will be used to execute this project.

START-UP HEAD CHECKLIST

Start–Up Head
Item	Description	Quantity	Remar ks
1	12″ Pipeline Start Up Head	1ea

LAYDOWN EQUIPMENT CHECKLIST

Laydown
Item	Description	Quantity	Remarks
1	12″ Laydown Head	1ea
2	55 T Shackle	3 ea
3	Sacrificial Sling 2 1/2″ x 20ft c/w close spelter socket at one end and 2 ft soft eyw at one end	lea

EMERGENCY LAY DOWN CHECKLIST

Emergency Laydown Head
Item	Description	Quantity	Remarks
1	12″ Emergency laydown head	1ea
2	55MT Shackle	1ea
3	Sacrificial Sling 2 1/2″ x 20ft	lea

BOWSTRING START-UP RIGGING CHECKLIST

Bowstring Start Rigging
Item	Description	Quantity	Remarks
1	1-1/2″ X 30m lg. Bowstring Sling	1	Drawing no: PL36S/ PRC/ 016- SECTION 12.S
2	1-1/2″ X 1S.Sm lg. Startup Cable Sling	1
4	11/2″ X 3m lg. Sacrificial Sling	1
s	SST Crosby Shackle	2
6	3ST Crosby Shac kle	4

LINEPIPE EQUIPMENT CHECKLIST

Line Pipe Equipment
Item	Description	Quantity	Remarks
1	JBBS W elding Equipment	S unit
2	ROV Unit c/w lift Rigging and Spreader Bar	1Unit
3	Survey Equipment	1Lot
4	Lift Rigging & spreader frame for Stinger	1lot
5	12″ Internal Line Up Clamp	2 ea.
6	12″ Swa bbing Brush (Cleaning Rabbit)c/w circular nylon/neoprene brush	2 ea .
7	12″ External Line Up Clamp	2 ea .
8	12″ External Bevelling Band	2 ea .
9	40ft Reach Rod	2 ea
10	Pipeline NDT Equipment	1Lot

12	Jeep Meter	1ea .
13	Holiday Detector and spring coil	2 Sets
14	Impact W rench	2 ea
15	%” x 2000 ft Long Wire Cable	1ea
16	5T Air Tugger	1ea
17	Load Cell with Gauge Readout	1unit
18	12″ Pipe Facing Machine	2 ea
19	Impact Socket 1-7/8″ AF X 1″ Drive	2 ea .

LINEPIPE HANDLING CHECKLIST

Line Pipe Handling Rigging
Item	Description	Quantity	Remarks
1	Pipe Lifting Spreader Bar	1ea	Drawing no: PL365/ FAB/0 12- SECTION 10 .8
2	1V4″ dia. X 30ft Sling c/w 3 ft soft eye both end	2 ea
3	1 1/4 ” dia . x 8ft sling c/w 4ft soft ey e one end & thimble eye other end	2 ea
4	%” dia. X 20 ft long sling c/w extra heavy wi re rope thimble one end & 3ft soft eye other end	2 ea
5	8.5 t shackle	2 ea

SURVEY

INTRODUCTION

The primary survey system used throughout this section of installation program is similar during the pipelay mode. A comp uterized barge navigational system will be utilized to graphically display the current location and heading of the laybarge and her anchors in relation to the permanent structures and pipelines in the vicinity. The position and heading of the anchor handling tugs will also be displayed. The tugs will a lso have a telemetry system on board that is interfaced with the laybarge’s navigational computer. The primary requirement for survey during this stage is to determine the location and identify the laid pipeline, aside from that it also required to conduct an as built of the installed spool once its completed.

UNDERWATER POSITIONING

Underwater positioning w ill be done using an Ultra Short Base Line (USBL) acoustic tracking system. The system consists of acoustic beacons which are typically fitted on the ROV or a subsea handling frame. The beacons a re interrogated by a hydrophone suspended under the keel of the vessel. The return signals are then used to determine the heading, depth and distance of the beacon.

The systems are integrated with the barge navigational system and can be displayed graphically on the screen for better operational purposes . This allow accurate underwater reading as long as its within the specified range from the hydrophone. This system is then supplemented by the ROV sonar if visibility is bad.

PRE –LAY SURVEY

A pre-engineering I debris survey wa s performed to determine the pipe routing installation corridors . The results of this pre-survey have been incorporated in the pipeline route and alignment drawings .

INSTALLATION SURVEYING

During the course of the pipelay, the main survey activities will consist of barge track control, anchor running and ROV tracking. All these activities are run from the control tow er, using the barge navigation system. A monitor is installed for the anchor w inch operator s in the co ntrol tow er, showing the design location of the pipeline with the image of the lay barge and her anchor overlaid. The lay barge position is updated in real time, allowing the operators to move the lay ba rge on line and on heading during the pipeline operation. When laying in a curve, a suitable run line will be plotted depending on the depth of the water and the pipeline touch down distance behind the stern. The barge w ill be tracked along the run line to ensure that the pipeline is laid in the required curve . The touchdown location of the pipeline is recorded by the surveyor based on the theoretical layback of the pipeline from engineer ing studies. This theoretical layback distance is verified during the regular ROV profile checks.

ROV TOUCHDOWN SURVEYING

The ROV will dive to check touchdown position of the laid pipe w hether it still on the proposed route. Once ROV on the touch down position, it will run back 3 or more joints to take fix on the pipeline joint.

AS LAID SURVEY

Upon the comp letion of the laying of the pipeline, an as-laid survey will be conducted using side scan sonar. This survey will confirm the as-la id position of the pipelines and locate any potential free spans. Any free spans detected will be recorded, tabulated and compared to the allowable free span length along the pipeline route. COMPANY will advise in writing which spans require rectification.

SURVEY AND INSTALLATION TOLERANCES

The location and heading of the pipeline at the platform end will be checked using the ROV’s USBL system following laydown. The following installation tolerances wil l be maintained during the pipelay activity:

The pipeline will be laid in a corridor 30 m wide, ±15 m either side of the intended pipeline route.
Between 450 m to 150 m from riser – decreasing gradually from ± 15 m to±
Within 150 m from the riser± 3m .
Where the pipeline is installed adjacent to an existing pipeline, a minimum separation of 15m sha ll be maintain, except at the platform approach.

INSTALLATION OVERVIEW

Remove riser guard at BAP-AAMobilize PLB to BAP-AA Set-Up at BAP-AA
Bowstring Start-Up
Normal lay & Laydown at KP
Set-Uo at BADP-G
Install Riser and spool
Metrology(Dog leg spool)
Move & Set-Up at BAP-AA
Install Riser stalk-on at BAP-AA
Reinstate Riser Guard Flooding PL 365 from BAP-AA
Move & Set-Up at BADP-G
Spool Tie-in (Dog Leg Spool)
Demob & sailto BNP-A

LOADOUT AND TRANSPORTATION

GENERAL

The line pipe joints and other material will be loaded onto barge. The loadout of the linepipes will be carried out at Kuantan Port facility. Upon completion of the loadout, the tie downs and seafastening will be carried out to the satisfaction of PCSB and the appointed third party surveyor . Refer to Document No.: TLOSK0-055/PL365 /M R/Ol for further details on stowage plan and other related information.

LOADOUT CHECKLIST

COMPANY will provide CONTRACTOR a detailed checklist prior for the pipes being loaded out from the company approved facility. The checklist will be submitted to CONTRACTOR at least two (2) weeks before and after the loadout has been carried out.

PRE-LOADOUT

Prior to loadout from the coating yard, inspection l ist included in Document No.: TLOSK0 – 055/PL365/MR/Ol will be reviewed and completed either by the Field Eng ineer or Loadout Engineer assigned for the operations . Any areas of potentia l concern will be highlighted to PCSB. The loadout list for each loadout is also detailed in the above document. Particular attention will be given to:

End condition of linepipes
Condition of linepipes coating
Linepipes magnetic properties
Concrete and anti-corrosion coat cutback

LOADOUT AND TRANSPORTATION

Load out checklist for the 12″ line pipes is shown in the Document No. : TLOSK0- 055/PL365/MR/Ol . General arrangement and sea fastening detail for load out of the pipeline and miscellaneous items are also included in the above report.

The line pipe coating has been contracted to WASCO yard in Kuantan by PCSB. Custody transfer to OIC is based on ex-tackle arrangement .

A detailed review of all components and material loaded out will be conducted and checked against the load out list as described in the checklist. TECo shall check any discrepancies in the quantity and conditions of the line pipes prior to load out and if any discrepancies found, TECo shall highlight to PCSB representative to give sufficient time for WASCO to rectify. The proposed load-out arrangement of the line pipes on the pipe haul barge is shown in drawing no. PL365/PL/003, PL365/PL/004, PL365/PL/005 . Drawing no. PL365/PL/002 shows the tie-down lashing arrangement of line pipes on the transportation barge.

Upon completion of load out and accepted by MWS, TECo load-out engineer shall provide a copy of the revised stowage plan (if any) to the barge and office .

Prior to departure of each transportation barge from the respective load-out location, a three-day weather outlook will be obtained from the meteorologi cal service provider and forwarded to the tugboat captain for his information.

STINGER OPERATING PROCEDURE

GENERAL

The stinger can either be brought out to the offshore site aboard a barge, or towed out from the pipe load out base or the nearest harbour when the weather permits. TECo w ill be bring the stinger to the offshore site aboard a barge.

The spa re stinger will genera lly be kept at the material barge ready to be installed to the barge should it be required. A lso, when the pipeline has been abandoned and the stinger been unhitched, the stinger w ill be taken under tow by a tug until the weather moderates sufficiently for rehitching. The stinger should never be towed at more than 3 knots.

Prior to the stinger being tow ed out all the ballast tanks shall be blown empty . The stinger w ill be towed using a single towing wire shackled to a pair of padeyes on the top chords of the stinger tip. A single wire shou ld be used rather than a bridle since it is found in practice that bridles often get caught up in the rollers and horns at the tip of the stinger.

STINGER-BARGE HITCH

The Stinger-Barge hitches are designed to satisfy the following operational requirements.

Installation and removal of the stinger as a routine procedure in calm sea, defined as a meter maximum wave height.
As an emergency procedure, abandonment of the stinger in the sea states defined in Section 2.2.

The procedure requires the availability of pull-in -winches or equivalent rigging using existing davits. Description of the step-by-step procedures for connecting and disconnecting the stinger to and from the barge are as follows:

Head the barge into the sea and current
Lift the stinger to astern of the barge by the barge crane and lower it into the sea.
Release the lifting cables from the pair of lifting padeyes which are further away from the barge stem of the stinger using diver. Attach towing cables from the tug to the aft end of the stinger and keep the cables taut and the stinger in the proper position for pull-in.
Lift the stinger hitch using the crane until the stinger hitch is approximately two meters below the seawater
Make sure the closure plates, wedge, locking and kickout plates on the hitch box are in the proper receiving position.
The stinger is lifted by the barge crane until the hitch slots are one meter above the barge receiver The stinger is then lifted into the hitch. A tug shall maintain some tension on the tow cables to prevent stinger from slamming into the barge stern.
The stinger is lowered by the barge crane along the guide plates and adjusted such that both the slots come in lin The operator has to make sure that the kick out wedge is in the “DOWN” position, the closure plate in fully “OPEN” position and the locking wedge in fully “OPEN” position prior to lowering the stinger into the hitch box.
With the pin put in place, lower the closure plate to fully “CLOSE” position and lower the locking wedge in fully “C LOSE” position.
Disconnect the crane and tug
Connect the buoyancy control air lines, va lve actuator control lines, pneumo line and cables for cameras and ligh Flood the buoyancy tanks accordingly to su it the laying operation .
The stinger hook up procedure is illustrated in Figures 3A to 3F.

NORMAL DISCONNECTION

Under calm weather and sea co nditions w ith maximum wave heights of less than one meter, the stinger is disconnected from the barge according to the follow ing step-by-step procedure.

The barge is headed into the seas and currents. Deballast all tanks, disconnect all cables and hoses.
Connect all the lifting slings to the barge crane hook,and all shackles to the respective lifting padeyes as shown in the attachment procedure
Position the tug aft of the stinger and attach the tow cables from the tug to the aft end of the The tow line should be slightly taut.
Move the locking wedge and the closure plate to the fully “OPEN” Retract the hydraulic cylinder for the kick-out wedge to move the kick-out wedge to the “UP” position.
As the stinger is separated from the hitch, the tug exerts a back pull to cause a rapid increase of distance to approximately five meters between the stin ger and the barge.
Slack off the tug cable and lift the stinger onto the transportation barge.

EMERGENCY DISCONNECTION

The procedure for abandoning the stinger under emergency conditions is similar to that for routine disconnection except for the use of the barge crane.

Head the barge into the seas and currents.
Deballast all buoyancy tanks.
Disconnect all cables, umbilical hose and lines.
Attach the stinger tow line to t he tug.

PIPE RAMP ACTIVITIES

GENERAL

The pipeline will be laid using a S-lay method. This section outlines the activities that will take place from the offloading of the line pipe, through the preparations for welding, to the completion of the pipeline field joints before the pipeline is laid out of the stern of the lay barge.

LINE PIPE HANDLING

The line pipe w ill be delivered on pipe haul
After the barge is brought alongside and the lashings removed,
Pipe w ill be lifted off the barge onto the deck of the lay barge and either used directly or stock. Note: Line pipe handling offshore will be in accordance with the drawing no. PL365/FAB/012.

PIPELINE PREPARATION FOR WELDING

Following steps shall be followed for line pipe preparation :

The line pipe color code w ill be checked and the joint will be visual ly inspected on board the lay barge for any obvious deform ities, e. out of roundness, end-bev el, corrosion and concrete coating damage. If any pipes a re found to be unacceptable, the line pipe w ill be repaired if possible or reje cted and another joint used .
The steel swabbing rabbit mounted with cup brush will then be pulled through the length of the line pipe to remove any loose mill scale and other foreign materi This is done at the longitudin a l conveyor before the pipes enter the ready rack . The debris w ill be blown out using compressed air after th e rabbit has been removed.
After each pipe joint has been re-beveled, the bare pipe ends w ill be mechanica lly buffed to remove surface scale. Also, any minor damage to the end- bevel will be ground smooth.
The pipe number, heat number, length, concrete coating thickness, whether plain or anode joint and any pertinent remarks w ill be recorded on the pipe tally sheet which w ill be submitted at completion of pipeline. Refer to A PPENDIX B for the proposed pipe tally sheet.
The bare ends of the pipe w ill also be pre-heated for welding .

PIPELINE WELDING

The line pipe is transferred laterally into the line up station and aligned with the last joint of the pipeline in station one (bead stall). Fit up will be accomplished using an internal line up clamp. Hydraulic rams will be used to move the new joint of pipe on the line up rack in three dimensions to align the bevels. W hen a good fit up is achieved, the internal line up clamp will be engaged, and welding will commence . The internal line up clamps can be released when the root weld is finished.

The proposed stat ion arrangements on the lay barge and the we ld deposition in each station are as follows:

Station	Main Process
Station 1	Bead Stall Fit-up, Root Pass, Hot Pass
Station 2	Fill Pass
Station 4	Fill and Capping
Station 5	NDT/Weld Repair
Station 6	Corrosion Wrapping/ Foam Infill

PIPELINE NOT AND REPAIR WELDING

Pipeline NDT for w eld acceptance will be done by internal x-ray located mainly at Station 5 . The allowable length of gouge is based on the maximum moment observed at weld repair location.

Serviwrap M30B Application

Primer will not be required with the Serviwrap M30B proposed for the pipelines temperature ranges when they are utilised on concrete weight coated lines under a joint filling material . The following procedure will be adopted for the application.

As specified in the Serviwrap M30B Datasheet, total weld area, including exposed corrosion coat will be power-wire brushed to remove all rust, weld spatter, insecure mill scale, dirt, dust and other deleterious matter and to be cleaned and dry . The mention work took place in Station No. 6 which is after the NDT station
450mm wide Serviwrap M30B, a cold-appl ied type, will be app lied in a single continuous layer, cigarette wrap style, centring on the line of the It shall commence at the 11 o’clock position and proceed in a clockwise direction through 420 degrees, terminating at the 1o’clock position. Th e 450mm-wide Serviwrap sha ll overlap onto itself by 213mm.
150 mm w ide strips will be applied in a single continuous layer, cigarette wrap style; one at each extremity of the 450 mm wide Serviwrap tapewrap, overlapping the yard corrosion coating by 50mm and it shall terminate with a minimum of 150mm end lap onto itself
Application of Serviwrap will take place on a clean, dry, firm surface, employing sufficient hand tension to assure a smooth, wrinkle free application . A small hand roller will be used to run over Serviwrap for finishing (in order pushing out any trapped air).
After application, the surface will be holiday tested at 15 kV for Serviwrap M30B to check for voids/air pockets between the pipe surface and Serviw rap . If holiday is detected, the Serviwrap will be removed and Step 1to 5

Foam (HDPF) Addition

The field joints infill will be done with High Density Polyurethane Foam (HDPF-10). This will be performed in Station No.6. HDPF-10 joi nt fill material is cellular plastic rigid polyuretha ne foam with dry density of 101b/rt3 and a compressive strength of 4001b.g/in 2 . The material system consists of two liquid components (Part-A and Part- B) which when blended, reacts w ithin seconds, rises as it changes state to solid form and completely fills the joint annulus w ith expendab le sleeve .

Following is a step by step procedure:

Mould Joint: Upon arrival of the joint in Station 6, position the mandrel over the girth weld so that the distance between the mandrel ends and the pipe end are approx imately Place the end sleeve for the bottom plastic weld over the mandrel. Attach the magnetic wire rack on lower edge of mandrel. Overlap and tighten the other end of sleeve around field joint on top leads. Place pressure pad on top of the sleeve overlap. Lock toggle clamps on top of pressure pad. Approximately 60 seconds .
Fusion of Serviwrap: Charge welding element for approximately 12 Unlock toggle clamps; remove pressure pads, wire rack, and mandrel . Approximately 30 seconds.
Securing I Moulding: Install nylon belts with ratchets on both ends of sleeve to secure to the concrete If reusable molds are used, position mold over sleeve and tighten with nylon straps and ratchets otherwise proceed with material in joint annulus. Average pour is 30 seconds or less.
Material Injection: The injection nozzle is inserted into the injection Operator will then inject liquid material in joint annulus. Average pour is 30 seconds or less.
Reaction: The liquids materials react, rise and change state to solid completely filling the cavity or The reaction time is approximately 60 seconds.
Remove nylon straps and ratchets I reusable mold after curing approximately 2 Field joint is now complete. Total cycle time approximately 5 minutes or less. Refer to Appendix H for manufacturer’s data sheets for HDPF product application

PIPELINE INTERNAL EQUIPMENT

The following equipment will be installed inside the pipeline:

EQUIPMENT Pneumatic internal line-up clamp	12″ PIPELINE Set to 323.9mm ID
Internal x-ray crawler	Required
Stop Trolley	Required (see details in drawing PL365/PRC/012 and PL365/FAB/006)
Cooper Tube (sleeved on stop trolley cable)	Required (Drawing details PL365/ PRC/002)

Reach Rod

The reach rod is 1″ x 40′ long stainless steel tube supplying air to control the internal line up clamp. The rod sticks out of the open end of the pipeline and is connected to the front of the clamp . The clamp is activated by manually turning the rod at the open end of the pipeline which actuates a press button switch on the clamp . This extends the internal dogs that grip the pipe in position for welding.

A 3/4″ tugger line is attached to the forward end of the reach rod to pull it back towards the bow of the barge at the end of each pull. This also pull the internal line up clamp, stop trolley, and the buckle detector along the pipeline.

Internal Line Up Clamp

The internal line up clamp secures the pipe joint for welding. Two sets of dogs are used, the first set of dogs are engaged on the open pipeline end. The second set engages on the new piece of pipe brought into the pipe tunnel after the pipe has been spaced and aligned. A minimum of two internal line-up clamps will be available onboard the barge. One will be used for normal pipelay operations with the other on standby. The internal line up clamps will have copper shoes and ceramics coating.

RISER GUARD REMOVAL

GENERAL

This section details the sequence to remove the riser guard at BAP-AA prior to installing the bow string and riser stalk on. Upon completion of riser installation, the riser guard will be reinstalled at the same location.

Setup PLB as per anchor pattern in drawing Geomatic /SK0/11/0GE0/339.
Launch ROV to monitor riser guard removal
Erect scaffolding at riser guard area at BAP-AA, jacket leg B2 and (+) 2160.
Rig-up 2 sets of tuggers at barge stern, rig-up snatch blocks at BAP-AA for horizontal adjustment.
Rig-up lifting slings & shackles to the riser
Lower crane main block, connect riser gua rd lifting slings to crane main
Divers to cut bolts on riser guard clamp s at (-) 1760mm. Open up clamps with hinge still intact.
Minimise slack on lifting Riggers to cut riser guard bolts with torch. Ensure cut bolts /nuts/ washers do not drop into the sea . Hinge bolt shall remain intact . Open up clamp.
Bring riser guard aboard material Refer drawing no PL365/PRC/030

RISER GUARD RE-INSTALLATION

The riser guard reinstallation is essentially the reverse of the riser guard removal. The riser guard will be reinstalled after riser stalk on at BAP-AA completed.

Setup barge at riser guard removal
Lift riser guard from material barge & lower down into the water .
Boom down slowly & control the rise r guard alignment using tugger
Bolt up riser guard clamps at EL (-) 1760mm with new bolts/ nuts/washers .
Bolt up riser guard clamps at EL (+ ) 2160mm with new bolts/nuts/washers. 6 . Derig slings, remove all tuggers from BAP-AA to bring aboard

BOWSTRING START-UP

GENERAL

For pipeline start up initialization, lay barge w ill be positioned herself in accordance w ith the approved anchor pattern. Refer to drawing number TBA for detail of anchor pattern . The barge w ill be backed up to the BAP-AA platform for the installation of the bowstring on B2 jacket leg.

Following the bowstring rigging installation on jacket, lay barge w ill move ahead to install the stinger. The linepipe will then push to the stern up until the end of the stinger. Bowstring rigging drawing presented in drawing no. PL365/ PRC/016.

Limiting seastate for bowstring and pipeline installation will be 2 metre significant wave height.

Following this, the lay barge will be moved ahead to the position as shown in anchor pattern. The stinger w ill be installed and checked for its readiness at the stern of the barge. From this position, the line pipes w ill then be pushed out of the stinger and the start up cable attached to the pipeline start up head.

LAY BARGE PREPARATION WORKS

Prior to commencement of pipeline initiation, the following preparation works must be completed.

The stinger is to be set back into the hitch and all hoses and cables are connected. The stinger is then to be pre-ballasted for the bowstring startup.
Adjust the barge tension machine shoes to suite the total OD of the pipeli
Confirm roller height.
Check the readiness of the pipe rack, transfer rack and the line up
Check that the sufficient length of cables is installed on the abandonment and recovery winch
Check the availability and the readiness of the internal and external line up clamps
Check the availability and the readiness of the (size) stop trolley cable and the pigable stop trolley
Prepare the linepipes handling equipments such as shackles, slings and spreader bar.
Check the availability and the readiness of the bow string startup rigging.
Check the availability and the readiness of the pipeline laydown head and
Check the availab ility and the readiness of the field joi nt materials
Check the readiness of the HDPF equipment
Checks the readinesses of the dark room and radiation survey have been done at x-ray station.
Check the availability and the readiness of the paint and brushes for pipeline marking
Check survey contractor has equipment, person nel and all information required for the pipeline startup and pipelay .
Check NDT contractor has equipment, personnel and all information required for the pipeline startup and
Fill pipe tunnel and ready rack w ith 12″ line pipe.
Install rigging on startup Please refer drawing start-up head draw ing no.PL365/FAB/003
NOTE: Brief diving crew on the bow string installation and familia rize personnel with their equipment that they are going to use.

BOWSTRING INSTALLATION AND START-UP

The basic philosophy to be adopted for the bowstring startup of the 12″ pipeline may be summarized into the following steps:

Relocate PLB to facilitate installation of bow string
Push pipe to the end of stinger and attach the startup cable to the startup
Proceed with pipeline

Bowstring Installation

The bow string configuration is as shown in drawing number PL365/PRC/016. It consists of two chocker slings which are attached to the jacket leg at elevations EL (+) 5782 and (-) 12290. These chokers secure the single vertical bow sling to the jac ket. The upper elevation chocker sling is to have a gunny sack wrapp i ng to prevent damage to jacket paint work. When secured, one end of the start-up cable is shackled to the bow string (free running) and the other end is to be shackled into the startup head of the pipeline.

The following steps are to be followed for bow string insta llation:

Transfer the upper elevation chocker rigging to the jacket and install to leg B2
Note:
–Wrap choker sling in gunny sack to prevent damage to jacket paint
– Place the 35 ton shackle on top of jacket for future connection of bow string
Lift top of bow string to jacket and connect to top of jacket chocke r. The bottom end of the bow string is to remain at the stern of the barge.
Secure stern tugger line to the bottom eye of the bow string
Secure a tag line of sufficient length to the bottom end of the bow string for temporary attachment to the jacket leg
Lift bottom end of the bow string rigging with the derrick crane boom tugger and swing over to the jacket location .
Deploy diver to the work site on the brace of the jacket and establish a down line.
Lower bow string rigging to the diver
When the rigging is within reach, the diver is to collect the tag line and secure the rigging to the jacket brace.
Diver to re-route the stern tugger line around jacket brace and connect to the chocker sling eye ensuring the line first passes through the eye of the bow string.
Come up on the stern tugger line. This will pull the chocker sling around the jacket leg and bring the eye of the chocker sling to the eye of the bowstring.
Shackle the eye of the chocker to the eye of the bowstring.
De-rig the stern tugger line. Slack off and de-rig the derrick boom tugger line.
Cut the tag line securing the rigging to the jacket and diver to return to surface.
Note:
i) Ensure diver is clear of bow string when cutting the tug line
ii) If the weather conditions are favourable, the diver may opt to man handle the choker sling and dispense with the tugger
Lift startup sling and attach to the bowstring at the upper elevation. Both eyes are temporarily tied to the top of the jacket.

Connection of Startup Cable

Pull the stern tugger line out with a dive boat to the end of the stinger and pass the eye through the end of the pre-attached pulling head shackles
Continue pulling the tugger line to the jacket
Pass the eye of the tugger line to the jacket and attach to the eye of the start up sling that is loose. Come up on the tugger line and cut free the temporary manila securing This will bring the startup sling to the pulling head.
When the startup cab le is at the pulling head, shackle them together.
With all startup rigging installed, ballast the stinger down and prepare for pipeline initiation .

Anchor Pattern for Start-up Initiation

The anchor pattern for PLB for BAP-AA location is presented in drawing number Geomatic/SK0/11/0GE0/339 initiation anchor pattern.

Start-up of Pipelay

The PLB will applying tension and maintaining the stinger profile accordance with table of the stinger and tension control for 12″ pipeline startup. Please refer APPENDIX C for analysis.

BOWSTRING CUT OFF PROCEDURE

After completion of the pipelaying installation, lay barge will proceed to the BAP-AA platform. Prior to subsea spool installation, the bowstring rigging that is attached to the jacket leg B2 will need to be removed .

The following are step by step procedure for bowstring removal:-

Launch the ROV to monitor the start-up head profile weather in offset or laydown position. If the start-up head in offset position, ROV to take fix the star t-up head position. Field Engineer will verify the height distance of start-up head from seabed.
Barge crane to pick-up the load of the wire until reduce tension applied on the sacrificial sling (pre-insta lled wire sling on SST shackle on start up head).
ROV to cut the sacrificial wire by using the cutter arm.
Slowly lower down the start-up head on the seabe
ROV will ta ke fix the start-up head coordinate. Field Engineer and Surveyor to confirm the start-up head location.

PIPELAY OPERATION

GENERAL

This section outlines the pipelay activities following the completion of the bow string startup until the end of the pipeline at the BADP-G location.

During the pipelay operations, the following works will encompass the lay parameter monitoring .

Stinger Check – Diver
ROV Check – ROV
Lay Tension – Tower
Pipe Ta lly Sheets – Field Engineer
DPR – Barge Administrator

PIPELINE ROUTE AND ALINGMENT

PL365-BADPG-0005 -01-0 in Appendi x A .The pipeline route shall be laid as per AFC Pipeline Alignment Sheet Drawings no

ANCHOR PATTERN AND BARGE SETUP

The PLB w ill typ ically use an eight (8) anchor mooring spread and will use more if site conditions dictate to perform the . The anchor pattern and barge setup fo r bow string startup are as detail ed in Section 10. It is noted that the pipeline startup barge hea ding is different from the pipeline route heading. Following pipeline initiation and pipeline laydown, the anchors w ill be run in such a manner as to allow the lay barge to pull ahead and maintain the pipeline heading .

The anchor pattern will be planned on the survey computer and anchor positions will be sent to the master of the A HT on their navigation computers. The A HT w ill steam from the location of the old anchor to the new under the visual guidance of the barge anchor foreman as w ell as with the assistance of the bull’s eye target on the navigation screen. Please refer d raw ing no . Geomatic/SK0/ 11/0GE0/339 rev .O for barge approach at BA P-AA

PIPELINE LAYDOWN

The procedure for the laydown of the pipeline is as per the pipeline laydow n procedure app ended in draw ing PL365/ PRC/ OOS. A n emergency laydown head w ill be fabricated and used for pipeline abandonment in the event adverse weather conditions do not permit continuation of pipelay. Refer to drawing no.PL365/PRC/007 for details of emergency laydown procedure and drawingno.PL365 /FAB/002 for emergency laydown head and rigging arrangement.

To ensure the pipeline is laid down with in the specified designated area, the coordinates of the bead stall and the theoretical pipeline growth on the lay down will be used to calculate the required pipeline length.

Following is the step by step procedure for pipeline laydown:

The ROV wi ll be deployed prior to reaching the lay The ROV shall be positioned over the field weld w ith the pipe on the seabed just beyond touchdown. The weld joint number on either side of the weld w ill be identified and noted. A co ordinate can be obtained from the ROV and the same can be compared with the coordinate at the line-up station at that instant. By comparing the horizontal distance from the co-ordinates at touchdown and at the line-up station with the exact length of pipe between the two points the actual gain can be established.
The ROV will be equipped with a USBL beacon which is tracked by survey package on board PLB Mas Mulia. The real time positioning of the ROV will be visible on the co mputer graphics display onboard. Severa l fixes w ill be made to obtain an average location coordinate of the ROV on the field joints for comparison w ith the coordinate position on the bead stall on the lay barge.
The length of the pipe remaining to be welded can be established by calculating the distance between the line-up station and the laydown coordinates and subtracting the actual.
Once the length to touchdown is determined, the number and length of the final joint w ill be established. The last joint in the pipeline wi ll have an anode installed.
Prior to the last joint being welded, the internal pipeline equipment w ill be removed in the following sequence:
i) Internal line-up clamp – Is being removed after the root has been completed on last one joint
ii) Internal Gamma Crawler – Removed after the last butt have been gamma rayed
iii) Stop trolley and cable – After crawler is removed
The last joint is then to be stalked on and weldeded. Concurrent with the last joint being welded out of the following activities will be done:
i) Ensure there is free access for the A&R winch cable to be routed from the sheave to the laydown head
ii) Prepare and install the laydown head onto the pipeline flange
iii) Attach the A&R cab le to the lay down head 2 1/2″ lay down sling is installed between the laydown head and the A&R cabl This is a sacrificial sling that will be cut later using the ROV following conformation of the location that the lay down head is within the target box.
iv) Secure single point lift rigging to 12″ laydown This will be used if the pipeline needs to be moved after laydown is completed and the laydown cable has been disconnected.
When the last joint reaches the bow side of the tensioner, the load on the tension machines will be transferred to the laydown When all of the loads have been taken from the tensioner, the top tracks will be raised to allow the pipeline lay down head to pass through .
The remaining field joints and anode attachments will be completed as per normal pipelay operations.
On completion of all field joints coating and anode attachment, the barge wil l then be moved ahead while simultaneously paying out on the lay down winch
When the pipeline has been la id down, the barge w ill back up over the pulling head l The ROV wi ll be deployed and positioned over the pipeline flange to estab lish an as-laid position.
The ROV will then cut the 2 1/2″ X 20ft sacrificia l sling shackled to the laydown head and the laydown cable will be recovered.

PIPELINE CROSSING

INTRODUCTION

This section describes the installation procedure for concrete mattresses.

Mattresses

The concrete mattress will be installed at BADP-G location. Coordinate for mattress E 1553086.04, N 1704051.14. Refer Drawing no. ENG/GEN/0 17

MATERIALS AND EQUIPMENTS

Refer to Table 12.2 for the materials and equipment required. The rigging arrangements for the installation of concrete mattress are shown in PL365/ PRC/013.

Item	Description	Qty
1	Lifting Frame c/w Webbing Sling (for Mattress)	1set
2	Spreader bar 8″ dia. SCH 80 x 20ft lg (for mattress)	1set
3	Lifting sling: • 11/2″ 0 x 25 ft cjw eye at both end- 6 no’s • 13/4″ 0 x 25 ft c/w eye at both end – 4 no’s • 13/4″ 0 x 70 ft cjw eye at both end – 2 no’s • 13/4″ 0 x 100ft c/w eye at both end – 4 no’s	1lot
4	USBL Beacon – transponder with completely charged	2 no’s
5	25 MT Shackles	10 no’s
6	12 MT Shackles	26 no’s
7	35 MT Shackles	12 no’s
8	Bitumen Mattress	2 no’s

PREPARATORY WORKS

The following preparations are required prior to the installation of the concrete mattress:-

Paint all temporary supports for easy identification
Paint all edges (of concrete mattress) about 1ft wide and mark corners A, B, C and D for easy
Mark the centrelines on the concrete
MPI the padeyes of the lifting frame and spreader
Attach air tugger lines to spreader bar for orientation
Install a high-powered USBL beacon on the Air
Function test Air Diver underwater broco
Locate and identify route of the existing pipelines by Air
Test and calibrate all electronics including USBL beacons and Hydrophones.
Ensure beacons are complete with extended life battery pack (freshly charged).

INSTALLATION PROCEDURE

The concrete mattress will be positioned with reference to the surveyor’s navigation screen and Air Diver. The position and orientation of the items will be monitored using a short baseline acoustic positioning system.

Two survey transponders/ high-powe red beacons will be installed at lifting frame to mar k the corridor/windows. The Air Diver will be used to provide a visual display of the setting of the items . A third survey beacon will be installed on the Air Diver in order to provide a check on the item position prior to its release. A check on the survey system will be done to ensure USBL beacons are referring to the same co -ordinate system as th e barge navigation system.

When the barge is located within the location, set-up the
Air Diver will be deployed to examine the seabed conditions e. scar marks, depression, etc. at proposed locations.
Air Diver w ill establish visual contact with the existing pipeline and takes fixesalong the pipeline for SOm on each side of the anticipated crossing point (where applicable) .
Based on the positioning carried out by Air Diver (if visible), the pipeline route, crossing co-ordinates and intersection angles w ill be verified prior to deployment of the concrete mattress .
If the existing pipeline is not visible, client-supplied coordinates will be utilized
Surveyor w ill determine a target box calculated for the positions, enter it into the navigation software and shown on the navigation display.
Lift up th e concrete mattress using crawler crane and lower it down until approx 5m off the sea bed. Air Diver will constantly monitor the lowering process and tuggers will be used to orientate the items to the required orientation and coordinates
Once the concrete mattress is w ithin the ta rget box, place it onto A ir Diver will check the heading and take minimum three (3) fixes. This is to double-check the positions given out by the beacons.
Upon confirmation by the Field Engineer and Surveyor, the temporary support, sleeper, and mattress will be released on the seabed by Air Diver either by cutting the slings or dislodging the release lever on the lifting frame.
Note: A ir Diver to keep monitoring the slings until the lifting frame etc. recovered.
During the pipe lay, maneuver the pipeline until it is directly on the centreline of the new ly-installed mattresses (Air Diving to check it visual ly or use sonar if the visibility is poor).

PIPELAY CONTINGENCY PROCEDURE

DRY BUCKLE

A pipeline is said to have suffered a dry buckle if it is dented beyond acceptable limits, but the pipe has not opened up and allow ed any ingress of water (i.e., the inside of the pipeline is dry).

There are two types of dry buckle, minor buckle and severe buckle. A minor buckle is when it is considered safe to back up the barge and cut out pipe joints until the damaged pipe is removed. A severe buckle exists when it is determined that backing up the barge will cause further damage to the pipeline i.e. the buc kled section cannot support the recovery tension while passing through the tension machines, or a w et buckle or a complete shearing of the pipeline may result.

The following procedures will be followed for each of the above cases. Refer drawing no. PL365/PRC/O 10

Minor Buckle

a) The gamma crawler and stop trolley will be removed
b) The barge will be backed up and successive joints of pipe cut off until the buckled joint is forward of the tension machines.
c) The damaged joint will be cut out and the end of the pipeline re-bevelled
d) The internal pipeline equipment will be re-inserted and normal pipelay will re-commence.
Note: The undamaged pipe joints cut out may be re-bevelled and re-used .

Severe Buckle

The gamma craw ler and stop trolley will be removed
The laydown head will be welded on to the pipeline, and the pipeline abandoned .
W hen laying the pipeline down the rigging for a single point lift will be pre-installed onto the pipeline
The barge will be re-positioned for a single point pipeline lift on the pipel ine.
The pipeline w ill then be raised to the surface, the pipeline will secure to the barge and approximately one jo int of pipeline w ill be removed.
The procedure will be repeated until the damaged pipe is remove.
After the final cut is made, weld on the laydown head, and lower the pipe to the The laydown cable may be pre-attached at this stage.
Reposition the barge and recover the pipeline
Resume normal pipelay when the laydown head is removed

WET BUCKLE

This refers to a pipeline buckle where the pipeline has been flooded with seawater. The wet buckle repair procedure is outlined as follows:

Cease all barge movement and pipelay
Field Engineers, Superintendent and CSR notified immediately
Deploy ROV to inspect pipeline from end of stinger to touch down point on seabed
Determine location and type of buckle, namely:
– Case A- Pipeline buckled but not broken off
– Case B- Pipeline buckled, broken off and lying on seabed
Remove internal line-up clamp and the X -ray crawler from inside the pipeline, (and X-ray stop trolley if possible).
Under the direction of the Superintendent, commence moving the barge astern whilst simultaneously retrieving as many joints as possible up through the stern Cut out the jo ints and remove from the tunnel.

CASE A

Retrieve pipe until in the option of the Superintendent, it is not safe to bring the buckle up the stinger
Fit and weld the emergency laydown head onto the end of the pipeline. Meanwhile, shackle the A &R cable to the laydown head .
Upon completion of welding, abandon the pipeline using the Abandonment Procedure detailed in DWG . PL365/ PRC/00
Proceed to step (b) of Case B

Case B

Retrieve all pipes in the stinger
Reposition lay barge for a multiple davit lifts of the pipeline.
Deploys the diver with cutting equipment to cut out all the buckled section. After that, cut two diametrical ly opposite holes approximately 44.5mm (1- 3/4″) dia, from the open end of the pipeline. Insert a stopper pin (1-1/4″ dia. x 500mm long) through th e two holes cut in the pipeline and secure it. This will stop and trap the dewatering pig. Upon completion, rig-up all davit lines to the pre-installed choker slings in preparation for multiple davit lifts.
Connect the air hose and open the ball valve at the start-up head, Commence de-watering the pipeline with the dewatering pig (i.e. a bi-di pig).
Continue pumping air into the pipeline until the dewatering pig arrives at the stopper
Deploy ROV to bottom to visual ly confirm the pig
Cease pumping air while maintaining the pressure in the pipeline at a minimum of 8bar (116psi).
Recover the pipeline using the multiple davit lifts .
As the pipeline breaks the surface, open inlet valve to de-pressurize the pipeline Upon confirmation, lay barge to secure the pipeline at either port or starboard side.
Remove stopper pin and recover the bi-di pig.
Cut and re-bevel the end of the pipeline.
Weld a pulling head to the pipeline and attach a marker buoy.
Lower pipeline to the seabed using the reverse of the dry davit lift procedure and disconnect lowering cab l
Pay out the recovery line with 2 ea 55T shackles at the end
Diver to shackle recovery line to pulling head and detach marker buoy pennant Use crane and strip out block to position recovery line in stinger.
Perform recovery of pipeline
Once the pull head reaches the bead stall, it w ill be removed and the pipeline re-bevelled.
Resume pipelaying operation, only after determining the reason for the buckle and taking corrective steps.

FAILURE OF MOORING SYSTEM

The barge mooring system is a reliable mechanism and rarely is there a requirement to stop pipelay activities. However, the following contingency procedures w ill be adopted in instances of mooring failure such as presented below.

Anchor Winch Failure

During normal pipelay operations an eight-anchor spread will be used. The barge is equipped with a twelve-anchor spread which provides for one contingency anchor on each corner of the barge. The anchor associated with the broken down winch w ill be moved forward and deployed in wet storage to keep pace with pipelay activities. It is to be noted that this anchor w ill not be a load-bea ring anchor. Upon completion of anchor winch repair, the anchor will be put back into the pipelay anchor pattern.

Anchor Cable Failure

The barge is equip ped w ith a twelve-anchor spread which provides for one contingency anchor on each corner of the barge.

Depending on the length of anchor cable broken, the anchor cable remaining on the winch will either have a new socket poured or be stripped off the drum and recovered . The segment of the anchor cable attached to the anchor w ill be moved ahead to keep pace with pipelay activities and retrieved when convenient. Following this,a new anchor cable will be installed on the anchor winch.

FAILURE OF TENSIONING SYSTEM

The pipelay barge is equipped with dual pipe tensioning system.In case there is failure of one of the machines, the tension shall be transferred over to other system until the fa ult is identified and corrected. Note in the event of a failure the machines wi ll apply brake set mode so tension on the pipe will be maintained .

FAILURE OF POSITIONING SYSTEM

The barge positioning system is normally reliable. In case, due to certain reasons, there is a minor failure in the system, then the backup positioning systems wi ll be used . Should a failure occur such that the pipeline cannot be laid withi n the installation tolerances, pipelay will stop until the system is reinstated .

RECOVERY OF LOST ILC

The internal line up clamp is held in the pipe ramp by a cable that is spooled onto a w inch at the bow. In the event the internal line up clamp gets lost down the pipeline, winch at bow will spool up and retrieve the ILC. Refer Dwg.Internal Pipeline Equipment Rigging Arrangement PL365/PRC/012.