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Subsea Pre-Commissioning Procedure
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Originator: : PT.TIMAS SUPLINDO COPI Group Owner: : Project Area: : Belanak Location: : Belanak General System: : General System Document Type: : Procedure Discipline / Subdiscipline: : Pipeline / Riser / Subsea Old COPI Document No.: : ‐
Document Title : Eastern Hub Mercury Removal ( EHMR ) – Water Project
Subsea Pre-commissioning Procedure COPI Doc No. : C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014
0B IFA 10-06-
13 Issued For Approval SS AW MBN
0A IFC 14-05-
13 Issued For Comment SS AW MBN
Rev Status Issue Date
Reason for Issue Prepared Checked Approved
Project Engineer
Project Manager
Contractor Approvals COPI Approvals
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 2 of 25
Printed initials in the approval boxes confirm that the document has been signed. The originals are held within Document Management.
Additional Approvers (If Applicable)
Name Designation Signature Date
Revision Sheet
REVISION DATE DESCRIPTION OF CHANGE
0A 14‐May‐13 Issued For Comment
0B 10‐June‐13 Issued For Approval
ConocoPhillips Indonesia Inc. Ltd
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 3 of 25
TABLES OF CONTENTS
DESCRIPTION PAGE
1.0 INTRODUCTION ............................................................................................................ 4
2.0 PIPELINE DETAILS ......................................................................................................... 7
3.0 PROJECT ORGANIZATION ............................................................................................. 8
4.0 SAFETY, HEALTH AND ENVIRONMENT .......................................................................... 9
5.0 OVERVIEW OF PROJECT PRELIMINARIES ..................................................................... 12
6.0 PERFORMANCE OF OPERATIONS ................................................................................ 14
7.0 INSPECTION AND TEST PLAN ...................................................................................... 16
Appendix A – Drawings .................................................................................................................. 21
Appendix B – Calculation ................................................................................................................ 22
Appendix C – Chemical Datasheet .................................................................................................. 23
Appendix D – Bi‐di Pig Drawings and Foam Pig Catalog................................................................... 24
Appendix E – NOV Factory Acceptance Test (FAT) Report ............................................................... 25
Appendix F – Reporting Format ...................................................................................................... 26
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 4 of 25
1.0 INTRODUCTION
1.1 General
The project concept is to install produced water reinjection facilities on the Belanak FPSO and Wellhead Platform A (WHP‐A) to inject produced water into four depleted Gabus Massive wells in the Belanak Field., located in the Natuna Sea Eastern Hub Block B PSC. The facilities are required to ensure compliance with the Belanak Operating Permit which stipulates a maximum mercury content of 10 µg/l in overboared produced water.
PT. Timas Suplindo has been awarded the contract to execute the Eastern Hub Mercury Removal (EHMR) Water Project under contract CS15869798 as EPCI contract for Subsea & Topsides Facilities
1.2 Purpose of this Document
The purpose of this document is to provide sufficient data for implementing pre‐commissioning work in line with international industry standards and to deliver a “fit for purpose” system and facilities. This document outlines the methodology for flooding, gauging, leak testing of subsea system. This procedure has been prepared as a working document to ensure that the operations shall be carried out in accordance with the specified project requirements.
1.3 References
The following documents have been referenced for the development of this procedure:
Rev Document Reference No. Document Title
2007 DNV‐OS‐F101 Submarine Pipeline Systems
2002 API 17 B Recommended Practice for Flexible Pipe
2002 API 17 J Specification for Unbinded Flexible Pipe
1 CPMS‐PPL‐EP‐004 Offshore Pipeline Hydrostatic Testing, Drying and Pre‐Commissioning
1 CPMS‐PPL‐EP‐022 Offshore Pipeline Pigging
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 5 of 25
1.4 Definitions and Abbreviations
Throughout this procedure, the following definitions will be used:
Definitions
Project EHMR Project
Company CONOCOPHILLIPS INDONESIA, Ltd
Contractor PT. Timas Suplindo
Subcontractor Offshore Construction Specialist
Vendor Any vendor supplying materials or equipment
Abbreviations
CFIM Company Free Issued Material
COG Center of Gravity
CSR Company Site Representative
DGPS Differential Global Positioning System
DNV Det norske Veritas
DP Dynamic Positioning
DSV Diving Support Vessel
FE Field Engineer
HP High Pressure
Hs Significant Wave Height
MBR Minimum Bending Radius
MMscfd Million standard cubic feet of gas per day
MWS Marine Warranty Surveyor
NDT Non Destructive Testing
P&ID Piping and Instrument Diagram
PSI Pounds per Square Inch
ROV Remotely Operated Vehicle
RTJ Ring Type Joint
SAT Diving Saturation Diving
HSE Health, Safety and Environment
SMYS Specified Minimum Yield Strength
SWL Safe Working Load
TBC To be Confirmed
TMS Tether Management System
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 6 of 25
TRA Task Risk Assessment
USBL Ultra Short Base Line
UT Ultrasonic Test
1.5 Flooding, Cleaning, Gauging and Leak testing Scope of Works
The actual scope of work for the Flexible pipelines are summarized below: Flooding equipments set‐up on DSV Ullswater
Fill treated fresh water and run foam pig upon completion of surface tie‐in 3000m flexible flowline with 1000m flexible flowline. Refer to "Flooding procedure" which shall be provided by Antares.
Flooding equipments set‐up on DSV Ullswater
Fill treated fresh water on Dynamic riser upon completion of dynamic riser pull‐in. Refer to document number C‐84514‐BK‐KK0‐PRO‐GN‐00‐0010;Dynamic riser Installation Procedure.
Gauging of subsea system (Rigid riser, Flexible flowlines, PLEM pipe spool and Dynamic Riser) from FPSO Dynamic Riser top of flange to WHP‐A Rigid Riser top of flange.
Leak testing of subsea system from FPSO Dynamic Riser top flange to WHP‐A Rigid Riser top flange by attached test blinds to each ends.
1.6 Acceptance Criteria
1.6.1 Pipeline Gauging
As per specification, pipeline shall be “No damage to one (1) of the gauge plates within the gauging run. In case of damage to both gauge plates, the gauging pigs shall be re‐run with new gauging plates of the same size”.
1.6.2 Pressure Testing
Leak test pressure hold of 6 hours. A pressure variation should there be any can be attributed to temperature fluctuation and shall be documented.
1.7 Procedural Changes
Site conditions may warrant changes to offshore installation procedures and planning for the work to be undertaken in a safe and expedient manner. In such an event, a Offshore Installation Manager, Captain, and Field engineer shall consult with COPI CSR, the marine surveyor and with its onshore management. Following agreement between all parties, any part of this procedure may be revised to suit the prevailing installation conditions. The site memo and/or technical query will be generated and documented.
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 7 of 25
2.0 PIPELINE DETAILS
2.1.1 Dynamic Riser and Flexible flowlines
Description
Parameter Units 3642NKT001 3642NKT002 3642NKT003
Dynamic Riser Flexible Flowline Flexible Flowline
Pipe OD mm 218.1 214.1 206.1
Pipe ID mm 139.7 139.7 139.7
Length Approx m 358 1000 3014
Volume Approx m3 5.49 15.33 46.22
Design Pressure psi 3600 3600 3600
Test Pressure (1.1 DP) psi 3960 3960 3960
2.1.2 Rigid Riser
Parameter Units Rigid Riser
Pipe OD mm 168.3
Pipe ID mm 139.76
Length Approx m 95
Volume Approx m3 1.46
2.1.3 PLEM Pipe spool
Parameter Units PLEM Pipe Spool
Pipe OD mm 168.3
Pipe ID mm 139.76
Length Approx m 12.8
Volume Approx m3 0.20
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 8 of 25
3.0 PROJECT ORGANIZATION
Day Shift Night Shift Field Engineer One Field Engineer would be in overall charge of the operation. His duties include:
Overall co‐ordination Providing continuity between shifts Ensuring adherence to all procedures/permits Collating and presenting all handover documentation Responsible for all matters concerning safety, quality and technical and operational
activities
Supervisor Reporting to the Field Engineer will be supervisor who will look after the night shift. His duties would include:
Liaising with Client Shift Supervisor Adherence to permits that may be in place Preparing all logs and reports of work carried out Implementation of all safety and quality measures Ensuring compliance with working procedure
Mechanic / Technician Reporting to the project engineer and the shift supervisor will be Mechanic/Technician working 12‐hour shifts. Their main function is to carry out the service in a safe and expedient manner. Such duties would include:
Operating all equipment safely Liaising with mechanical and pipe fitters Carrying out preparation work on systems to be tested
Timas Site Rep
OCS Pre‐Com Engineer
OCS Management Team
Mechanic Supervisor
Technician
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 9 of 25
4.0 SAFETY, HEALTH AND ENVIRONMENT
4.1 General
Subcontractor's target for the project is zero injuries and incidents. All personnel will be trained in Subcontractor's HSE systems. Briefings and inspections will be conducted before, during and after the operations. Onsite a bunding will be installed around any containers/tanks, containing hazardous liquids, fuel storage areas and machines. Any waste will be disposed off in accordance with appropriate procedures. Subcontractor is committed to providing a safe environment for its employee’s, clients and third parties to work in and this will not be compromised by any other factor. Subcontractor consider safety to be an inherent value associated with everything it does and Subcontractor will not jeopardize own or our colleagues well‐being for any reason. Subcontractor believe that all accidents and injuries are preventable and regard the promotion of health and safety as an obligation and mutual objective for all employees at all levels, whether working offshore, customer land locations or our premises. Our target is that no employee gets injured. All personnel involved in pre‐commissioning shall be pre‐briefed on the operating procedures and the potential hazards in a pre‐mobilization Job Safety Analysis (JSA). The JSA shall be reviewed prior to commencing any operation activities during pre‐commencement tool box talk. A walk through shall be conducted to inspect the arrangement of the equipment on site prior to commencing of operations. Subcontractor personnel shall adhere and conduct all activities in accordance with site and client operating procedures (including the permit to work system). Applicable permit for using of site fire water shall be applied prior to use. Contractor site representative shall liaise with Company Site Representative when applying for such permits. The contractor field engineer shall be responsible for ensuring all permit requirements are fully complied with. The immediate vicinity around the work area shall be cordoned off with signage stating “Pre‐Commissioning On‐Going, All Unauthorized Personnel Please Keep Off”.
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 10 of 25
4.2 Tool Box Talk
A Tool Box Safety Talk shall be conducted on‐site before each new phase of operations. The talk shall outline the work to be carried out and shall include but not limited to the following:
Sequence, co‐ordination and details of work to carried out
Hazards/control measures/emergency response contingency plans
Safe areas/escape routes/muster points
Barriers and signs
4.3 Personnel Safety
All personnel shall wear personal protective equipment (PPE) provided for their use. Protective safety hard hat, steel toe safety boots and flame retardant coveralls shall be the minimum safety clothing worn at all times when on‐site. All personnel shall carry safety glasses, ear protection and gloves with them at all times and use them in the appropriate situations. Waterproof jacket and trousers shall be worn in adverse weather conditions. Contractor personnel shall wear ear defenders at all times when running diesel powered equipment with a sound power level in excess of 85 dB(A). Portable eye wash available on‐site shall be properly identified prior any commencement of any phase of the works scope.
4.4 System Safety
Pre‐commissioning involves the application of pressure and volume displacement to confined structures such as pipelines and there is a risk of failure and subsequent release of pressure energy. The following safety rules shall be adhered to at all times:
Never open a pig trap or flange unless you have checked by carefully opening vent valves to ensure there is no pressure in the system.
Make sure no one or any equipment is in line with the route of the pig passage and ensure the launcher/receiver is well secured.
Be aware of the pressure in the hose, valve, gauges and fittings.
Never attempt any remedial work on any equipment and system under pressure.
Never apply pressure to an untested hose, test them before connecting to the pipeline or system.
Always secure hoses to prevent whipping in the event of failure.
Always checked that no low pressure fitting or instruments have been used in the rig up or system.
Always check that all connection is fully secure.
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 11 of 25
4.5 Equipment Safety
All equipment shall be located when onsite in a manner which leaves suitable and safe escape routes. Equipment shall be positioned so as to leave 0.6m access in between, in order to minimize:
• Prevent trip hazards • Prevent damage to hoses • Protect all personnel and site equipment in the event of hose failure (i.e. away from
access routes) etc.
4.6 Environmental Control
All equipment with the potential for spill causing environmental damage will have drip pans or tarpaulin sheets installed to contain any spillage. Drip tray or tarpaulin sheets shall be utilised for retrieval of pig. Contractor has written approval from the relevant Indonesia government agencies having authority and jurisdiction for environmental matters for the use of the test chemical and its disposal. (Clariant brand)
4.7 Actions in the event of Emergency
In the event of an emergency during operations, all equipment shall be shut down immediately. The power and air supply to the test equipment container shall be properly isolated. If a system is under pressure at the time of an emergency, the injection point must be closed as soon as pumping has stopped. Non return valves (NRV) shall be fitted to injection points of systems to ensure that pressure is contained in the event of hose failure. Work permits (if any) are to be returned to the permit office/control room. Personnel shall proceed to their allocated emergency muster point in accordance with the vessel on‐going response procedure.
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 12 of 25
5.0 OVERVIEW OF PROJECT PRELIMINARIES
5.1 Water Supply
Flooding and gauging work scope shall make use of available fresh water from DSV Ullswater approximate 83 m3 (including 20% contingency of total subsea pipeline volume). DSV Ullswater shall be positioned on DP on port side of FPSO. The water hose shall be laid across FPSO from DSV Ullswater to Pre‐com spread location.
5.2 Instrumentation
Instruments supplied will be calibrated to traceable reference standards no more than 6 months prior to mobilization and shall conform to the following levels of accuracy:
● Hydrostatic pressure gauges ............................................................................ +0.01%, 0.25% ● Pressure Transducers ...................................................... +0.2%, sensitivity better than 0.1% ● Pressure Chart Recorders ........................................................................... 24 hour type, +1% ● Flow Meters ........................................................................ +1%, sensitivity better than 0.1% ● Temperature Probes, Recorders, Read‐out devices .......... +10C, sensitivity better than 0.10C ● All other measuring equipment ....................................................................................... +1 % Any pressure retaining equipment shall be tested to at least 10% over maximum possible working pressure during function test at OCS base.
5.3 Chemicals
Multi Treat 5549R being a cocktail of biocide and corrosion inhibitor will be injected to the pipeline at a dosage of 500 ppm and SeaDye of Clariant brand will also be injected at 50 ppm. The chemical dosage is sufficient to protect the pipeline for 3‐6 months. Chemical MSDS and TDS are provided in appendix C section.
5.4 Pigs
Bi‐di Pig to be used will be in‐pipe brand, having four sealing discs and two guiding discs. The number of pigs to be used for base case (gauging) will be as follows: DSV Ullswater
2 no. Foam pig on 3000m+1000m flexible flowline on 3000m flexible line at WHP‐A end and 1000m flexible line at PLEM end.
FPSO
1 no. Foam pig on Dynamic riser at PLEM end
1 no. Bi‐ directional gauging pig (subsea system)
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 13 of 25
Prior to back loading of any pigs into the pig launcher, dimensions of gauging plate will be checked and a photographic record of pig loading taken.
5.5 Gauge Plates
Recommended Gauging plate size is 129.8mm dia x 10mm thick. Refer to Appendix E; NOV Factory Acceptance Test (FAT) Report
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 14 of 25
6.0 PERFORMANCE OF OPERATIONS
6.1 Gauging
Upon the construction has been completed. The subsea system will be cleaned and gauged from a temporary launcher on FPSO to a temporary receiver on WHP‐A using treated fresh water. The launcher and receiver will be sufficiently sized to contain only 1 foam pig or 1 Bi‐di pig at a time. Spread of equipment will be set‐up on FPSO and hoses will be connected to pig launcher. Upon completion of all preparation works, the initial cleaning and gauging will commence in the below detailed sequence.
Subsea system: • Introduction of chemically treated fresh/portable water in flooding the flexible flow line.
Additional, 20% of pipeline line volume will be pumped to ensure full pipeline length has been flooded in preparation for Leak testing. Once the desired volume has been achieved, the operation has deemed to be completed.
The approaching of the pigs to the receiver will be indicated by variations on the chart of the pressure recorder. However, in case no clear signs are noted, an extra volume of approx. 20% of pipeline volume will be pumped. Upon the last pig being received, the pump spread will be stopped and the system will again be depressurized to ambient conditions. All injection and discharge valves will be set in closed position.
Once gauging and flooding have been performed to the subsea system (Dynamic Riser, Pipe spool, Flexible flowline and Rigid riser), the pig receiver and launcher shall be removed. The pig received/retrieved will be inspected together with the Contractor and Company. The gauging plate re‐measured and data will be recorded as well as photograph will be taken. The gauging of pipeline shall then be signed off on the plate and on the gauging log by all parties. During cleaning, gauging and flooding the following parameters will be recorded and logged at regular interval. • Pipeline pressure behind pig train .............................................................................. bar / psi • Volume of water injected ahead, between & behind pigs ............................................ m3/gal • Volume and dosage of chemicals (once applicable) .................................................. Ltr/ppm • Pig speed ............................................................................................................................ m/s
6.2 Leak testing
Subsea system: Once subsea termination have been completed, the hydrostatic testing will be performed as per requirements using chemically treated fresh/portable water from FPSO Dynamic riser test flange to WHP‐A Rigid riser test flange at each end. Before commencement of operations, if and where applicable, all temporary pumping pipework will be walked through and inspected together with Contractor and Company representatives.
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 15 of 25
• Top up and vent all pipework. • Hold for 15 minutes for stabilization and leak check. • Continue pressurization to 100% of test pressure at a rate of about 0.1 barg./min (1.45
psi/min). • Once 100 % of test pressure has been achieved. Approximate 50 psi will be added to the
test pressure to allow for stabilization. • Hold for approx. 6 hours for stabilization and leak check. Upon attaining the specified test pressure, the pumping equipment will be isolated from the pipeline by removal and plugging. During the pressurization phases above, the dedicated test engineer will maintain a graph of pressure verse volume and any criteria not conforming to standard expectancies, which indicate leaks or other problem areas will be immediately brought to the Contractor's attention. Upon completion of an adequate post pressurization stabilization period for test medium, the test pressure hold period will be started. The pipeline test pressure will be held for a period of at least six (6) consecutive hours. During the pressurization and hold period phases, if and where applicable, the following parameters will be recorded and logged: Note: For Flexible flow line, air inclusion shall be accepted at 0.5% of the pipeline volume & 6
hours hold shall be deemed acceptable. As an alternative pressurization of flexible flowline shall may also be performed at 5 bar/min interval.
• Pressurization rate .....................................................................................................barg/min • Flow injection rate ................................................................................... Liter /barg (Liter/psi) • Volume of water injected .................................................................................................. Liter • Volume of chemicals added .............................................................................................. Liter • Injection water temperature ................................................................................................. °C • Seabed temperature ............................................................................................................ °C • Ambient temperature ........................................................................................................... °C • Pipeline pressure ...................................................................................................... barg / psi • Pressure versus volume plot ................................................................................................... ‐ • Pressure / temperature versus time graph ............................................................................. ‐ The specified hold period will only be terminated when written acceptance has been obtained from the Contractor and the specification criteria have been successfully attained. Upon receipt of written acceptance of the controlled test, the pressure will be released from the system in a controlled and safe manner.
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 16 of 25
7.0 INSPECTION AND TEST PLAN
7.1 Gauging
ID ID Activity Responsible Verified Approve
1 Carryout a pre‐job safety meeting with all personnel in attendance.
OCS Timas COPI
2 Carry out site operations safety checklist, request Permit to Work and rig up equipment as per operational layout.
OCS Timas COPI
3
Ensure that all hoses are tied down at regular intervals to prevent whipping in the event of failure. Also ensure hoses are clearly visible and clear of walkways. Erect safety barriers.
OCS Timas COPI
4 On WHP‐A, the temporary 6" #1500 Ball valve shall be installed between Rigid riser and Pig receiver
Timas Timas COPI
5 Inspect Receiving Head OCS Timas COPI
6 Inspect Launching End OCS Timas COPI
7 Connect flooding hose to the temporary launcher head
OCS Timas COPI
8
Once finished connection to the temporary pig launcher has been prepared, start the flooding pump and fill the hose with treated fresh water to confirm injection & flow of water.
OCS Timas COPI
9
Connect the flooding hose into the WECO connection on the temporary launcher head. Technician should at this point standby in preparation to operate the valves.
OCS Timas COPI
10 Start flooding spread, ensure all instruments are online and working.
OCS Timas COPI
11 Launch Bi‐di Pig with gauging plate OCS / Timas ‐ COPI
12
Inject water behind the Bi‐di Pig. This water is required chemical treatment Pipeline Length Volume Pig Purpose6" 4500 m ~ 69 m3 Gauging This stage chemically treated water will be introduced until the pig has been confirmed to be received on the receiving end. Flooding spread pumps will be run to maintain the flowrate to run the pig at speed of about 0.5 m/s. Simultaneously the chemical injection pumps will be run to maintain 500 ppm (Multi Treat) & 50 ppm (Sea Tracer Dye)
OCS Timas COPI
13 During gauging, the parameters in the Recording Section as below will be recorded and logged at 30 minute intervals.
OCS Timas COPI
14
The receipt of the pig train at the receiving end of the Rigid riser will be indicated by a increase in the flowrate and pressure. If there is no clear indication of the pig being received then flooding should
OCS Timas COPI
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 17 of 25
ID ID Activity Responsible Verified Approve
continue until 120% (83 m3) of the theoretical flexible flowline volume has been pumped behind the last pig in the train. If there is very positive indication then flooding can conclude.
15
Prior to retrieve pig(s) from Pig receiver, the temporary 6" #1500 Ball valve shall be 100% closed and re‐open (100%) again upon completion of pig retrieval.
Timas OCS COPI
16 Acceptance & completion report shall be signed off. To include valve status check sheet.
Timas OCS COPI
17 Once Pigs have been retrieved, gauge plates will be inspected and photographed.
OCS Timas COPI
18 Gauge plate certificate will then be signed off Timas OCS COPI
Note: Temporary 6" #1500 Ball valve shall be removed prior to install test blind on rigid riser at WHP‐A
7.2 Leak testing
Description
Design Pressure (DP) 3,600 psi
Pipeline System Leak test (PLT = 1.1 DP) 3,960 psi
75% Test Pressure 2,970 psi
95 % Test Pressure 1,980 psi
Holding Period 6 hours
ID ID Activity Responsible Verified Approved
1 Carryout a pre‐job safety meeting with all personnel in attendance.
OCS Timas COPI
2 Carry out site operations safety checklist, request Permit to Work and rig up equipment as per operational layout.
OCS Timas COPI
3
Ensure that all hoses are tied down at regular intervals to prevent whipping in the event of failure. Also ensure hoses are clearly visible and clear of walkways. Erect safety barriers.
OCS Timas COPI
4 Install "Leak Test" Test Blinds for both ends OCS Timas COPI
6 WHP‐A End: Technician to survey the blind flange. OCS Timas COPI
7 FPSO (Pressurization) End: Technician to survey the blind flange
OCS Timas COPI
8 Connect the Leak Test hose & instrumentation hose to test flange.
OCS Timas COPI
9
Once finished connection to the test flange has been prepared, start the Leak Test pump and fill the hose with treated fresh/portable water to confirm injection & flow of water. Bleed residual air. Once injection &
OCS Timas COPI
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 18 of 25
ID ID Activity Responsible Verified Approved
Leak Test spread has been proven to be leak free, stop pumping. As necessary perform pressurization of test spread.
10
Connect the pressurization hose into the 1" ball valve (BFV 01) connection on the blind flange. Technician should at this point standby in preparation to operate the valves.
OCS Timas COPI
11 Start Leak Test spread, ensure all instruments are online and working.
OCS Timas COPI
12
Techinician open BFV 01, BFV 02 to bleed residual air (tentative for 2 mins), on Blind flange. Once bleeding of residual air has been completed, close BFV 02.
OCS / Timas Timas COPI
13
Engage the pressurising pump and commence pressurising the system to 35 barg (507.5 psi) at a rate not to exceed 5 barg per min. Record readings of time, pipeline/flowline pressure, and volume injected at 1 Barg intervals.
OCS Timas COPI
14
At 35 barg pressure (507.5 psi), calculate the volume of air entrapped in the pipeline. If the volume of air is > 0.5% of the pipeline volume, then depressurize the pipeline to ambient and depressurize. If the volume of air is < 0.5% of the pipeline volume. Pressurization can resume.
OCS Timas COPI
15 Continue pressurization to 75 % of test pressure at a rate not exceeding 1.0 barg./min (14.5 psi/min).
OCS Timas COPI
16 Hold for 15 minutes for stabilization and leak check. OCS Timas COPI
17
Continue pressurization to 100 % of test pressure at a rate not exceeding 0.25 barg/min (3.625 psi/min). Note: Approximately 50 psi will be pumped in to allow for stabilization.
OCS Timas COPI
19
Hold for approx. 4 hours for stabilization and leak check. Once pressure has been stabilized, isolate the pressurization line & commence 6 hours hold. Stabilization period may be subject for change due to length & condition of system on test.
OCS Timas COPI
20 Record Pressure & Temperature reading every 30 minutes.
OCS Timas COPI
21 As necessary should it be required to add or remove water due to pressure fluctuation it shall be noted by Contractor & Company.
OCS Timas COPI
22
Once the 6 hours hold period has been successful and acceptance of the test shall be signed off. Depressurize the pipeline at a rate of not exceeding 3 bar/min (43.5 psi/min).
OCS Timas COPI
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 19 of 25
ID ID Activity Responsible Verified Approved
24 Once the pressure has been put into ambient and declared safe, remove the hoses installed in the blind flanges.
OCS Timas COPI
25 Sign off acceptance certificates & valve status check sheet.
OCS Timas COPI
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 20 of 25 APPENDICES
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 21 of 25
Appendix A – Drawings
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
A A
B B
C C
D D
E E
F F
G G
H H Built-in angle 11° Azimuth 315 °N MWL
BS Flange 5.5” WIR Bend stiffener length 2.951m
5.30m Fully loaded draught
Detail A
MWL 90.0m
Detail A
Midship PLEM
Detail B
Mudline
FPSO keel
21.90m
Bend stiffener flange
Fully loaded draught, 16.60m
56.90m
Bend stiffener flange
5.5” WIR Touchdown point
PLEM flange
5.5” WIR Touchdown point
15.02m 222.93m
5.5” Riser System Configuration Riser/view plan: azimuth 315 °N, perpendicular to the FPSO bow-aft direction
Detail B View plan: Azimuth 315.67 °N, perpendicular to the PLEM flange Residual tension: ~50kN at PLEM interface
Midship PLEM
EF length 1.226m
1.40m
15.02m
6 No. BR Elements assemblies, nominal length 2.420m
5.5” WIR Touchdown point
Flange interface
BR steel work length, to first element face 0.427m
Detail B, oblique view Detail A, oblique view
Nominal Configuration: Fully loaded draught – 16.60m Pipe content density, minimum operation – 956kg/m3
No marine growth Zero FPSO offset
Belanak FPSO
Note that hang-off details are given in 3642-DWG-HO-100 Rev.3.
This document contains confidential information. All rights are owned by National Oilwell Varco Denmark I/S. No use or disclosure is to be made without prior written permission of National Oilwell Varco Denmark I/S. .
Client Projection method
Project
EASTERN HUB MERCURY REMOVAL - WATER Standard tolerance
- Title
GA Drawing, Riser Configuration
Part No.
- Client Doc No.
Location: COPI Group Owner:
System No.: Document type:
Discipline/ SUB-Discipline: K-Pipelines/Risers – K0
Rev. Date Description By Chk Appr Proj
0A Issued for Comments ELI PDR MSN AGC
ID-F-BK-P-SCH003-B01-0003
12-Feb-2013
Area Code:
Size State
Released
Sheet
1/2
Drawing No.
3642-DWG-CONF-100
PDM Ver. Scale
FP-Belanak FPSO Projects B01 A4-Water Injection
BK – Belanak
- N/A -
0B Issued for Approval ELI PDR MSN AGC 09-Apr-2013
01 Issued for Construction ELI RLF MSN AGC 16-Apr-2013
1
1
2 3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
A A
B B
C C
D D
E E
F F
G G
H H
2
315.67°N
315.00°N
Center of Belanak FPSO 636 318.27 E 460 587.99 N (WGS 84)
PLEM ref. point 636 093.24 E 460 840.39 N (WGS 84)
Top View of Riser System Configuration, nominal
56.90m +9/-5*
Bend stiffener flange
5.5” WIR Touchdown point
PLEM flange
5.5” WIR Touchdown point
15.02m
222.93m
Detail A
PLEM tie in flange 636 097.30 E 460 835.65 N (WGS 84)
Detail A
225.00°N
* The touchdown point – BS flange horizontal distance is given for three conditions: Nominal: As described on page 1(Nominal Configuration). 56.90m Compressed System: Minimum water level, fully loaded draught, max pipe length. 51.90m Stretched System: Maximum water level, ballasted draught. 65.90m
Riser Section DescriptionSectionLength[m]
Acc. Length From End A
[m]
1.226 1.226
0.700 1.926
2.951 4.877
349.004 353.881
2.847 356.728
1.226 357.954
Total [m] 357.954
A Topside End-Fitting
Spool Piece
Bend Stiffener
Bare Flexible Pipe
Bend Restrictor
B Subsea End-Fitting
This document contains confidential information. All rights are owned by National Oilwell Varco Denmark I/S. No use or disclosure is to be made without prior written permission of National Oilwell Varco Denmark I/S. .
Client Projection method
Project
EASTERN HUB MERCURY REMOVAL - WATER Standard tolerance
- Title
GA Drawing, Riser Configuration
Part No.
- Client Doc No.
Location: COPI Group Owner:
System No.: Document type:
Discipline/ SUB-Discipline: K-Pipelines/Risers – K0
Rev. Date Description By Chk Appr Proj
0A Issued for Comments ELI PDR MSN AGC
ID-F-BK-P-SCH003-B01-0003
12-Feb-2013
Area Code:
Size State
Released
Sheet
2/2
Drawing No.
3642-DWG-CONF-100
PDM Ver. Scale
FP-Belanak FPSO Projects B01 A4-Water Injection
BK – Belanak
- N/A -
0B Issued for Approval ELI PDR MSN AGC 09-Apr-2013
01 Issued for Construction ELI RLF MSN AGC 16-Apr-2013
F
1 2
D
E
3 4
C
A
1 2
B
3 4
5 6 7
F
8
D
E
5 6
C
7
A
8
B
Scale Size
Title
Project
Client
Drawing No.
Client Doc No.
This document contains confidential information. All rights are owned by National Oilwell Varco Denmark I/S.No use or disclosure is to be made without prior written permission of National Oilwell Varco Denmark I/S.
State
Part No.
Rev. Date By Chk Appr Proj
Standard Tolerance
Description
PDM Ver.
Projectionmethod
Sheet
Location: COPI Groupowner:
Discipline/SUB-Discipline:
System No.: Area Code:Documenttype:
9200
4400
5000
5898
9355
6000 6000
700
1096
R2500
1400
1600
Te NOV Reel
40.0
NOV Cradle 4.5
Empty pipe incl. all equipment 207.5
Packing Rigging 2.0
Total weight 254.0
3642-DWG-PCK-200D.2Released1/1A21:50
K-Pipelines/Risers - K0BK -
BelanakA4-Water InjectionB01ProjectsFP-Belanak
FPSO
ID-F-BK-P-SCH003-D06-0003
General Packing Arrangement
Flowline - WHPA
-EASTERN HUB MERCURY REMOVAL - WATER
0A 12-Feb-13 CHR JBM BJP AGC
1 19-Apr-13 Issued for Construction CHR JBM BJP AGC
SECTION B-B SECTION A-A
Notes: 1. Pipe Info: 5.5" WIF NKT Pipe Serial No.: 3642NKT003 Pipe OD: 206.1 mm Pipe length: 3014 m MBR: 1.59 m 2. The reel can be lifted using a standard spreader beam. 3. Pipe and end fittings secured to reel using lever hoists. For rigging details refer to: 3642-DWG-LPP-200/ID-F-BK-P-SCH003-D06-0005 4. 5 Te Hold Back Wire 50 m. 5. Hold Back Wire Bracket placed on spoke. 6. First end off reel 3642NKT003B 7. End fitting to be packed in rubber and foam to protect pipe and end fitting. 8. Expanded polystyrene support blocks. 9. Actual winding of pipe may be slightly different. 10. Weight info:
FRONT ISO VIEW BACK ISO VIEW
FR
ON
T
Note 9
Note 7
Note 8
Note 6
Note 7
Note 5
Note 4
F
1 2
D
E
3 4
C
A
1 2
B
3 4
5 6 7
F
8
D
E
5 6
C
7
A
8
B
Scale Size
Title
Project
Client
Drawing No.
Client Doc No.
This document contains confidential information. All rights are owned by National Oilwell Varco Denmark I/S.No use or disclosure is to be made without prior written permission of National Oilwell Varco Denmark I/S.
State
Part No.
Rev. Date By Chk Appr Proj
Standard Tolerance
Description
PDM Ver.
Projectionmethod
Sheet
Location: COPI Groupowner:
Discipline/SUB-Discipline:
System No.: Area Code:Documenttype:
5600
5000
6000 6000
700
5898
9355
9200
16003200
700
1000
4573
79
992
700
R31
00
Te NOV Reel
40.0
NOV Cradle 4.5
NOV Dividerring 4.5
Empty pipe 3642NKT001 incl. all equipment 35.2
Empty pipe 3642NKT002 incl. all equipment 89.1
Packing Rigging 4.0
Total weight 177.3
Pipename
NOV pipeSerial No.
Pipe ODPipe
LengthMBR
5.5 WIR 3642NKT001 218.1 mm 358 m1.59 m
5.5 WIF 3642NKT002 214.1 mm 1000 m
3642-DWG-PCK-100E.2Released1/1A21:50
K-Pipelines/Risers - K0BK -
BelanakA4-Water InjectionB01ProjectsFP-Belanak
FPSO
ID-F-BK-P-SCH003-D06-0002
General Packing Arrangement
Riser / Flowline - PLEM
-EASTERN HUB MERCURY REMOVAL - WATER
0A 12-Feb-13 Issued for Comment CHR BDJ BJP AGC
1 19-Apr-13 Issued for Construction CHR JBM BJP AGC
Note 8
SECTION B-B SECTION A-A
Notes: 1. Pipe Info: 2. The reel can be lifted using a standard spreader beam. 3. Pipe and end fittings secured to reel using lever hoists. For rigging details refer to: 3642NKT001: 3642-DWG-LPP-100/ID-F-BK-P-SCH003-D06-0001 3642NKT002: 3642-DWG-LPP-101/ID-F-BK-P-SCH003-D06-0004 4. 5 Te Hold Back Wire 50 m. 5. Hold Back Wire Bracket placed on spoke. 6. First end off reel 3642NKT001A /3642NKT002B 7. End fitting to be packed in rubber and foam to protect pipe and end fitting. 8. Expanded polystyrene support blocks. 9. Actual winding of pipe may be slightly different. 10. Weight info:
FRONT ISO VIEWBACK ISO VIEW
SECTION C-C
CoG
FR
ON
T
FR
ON
T
Note 7
Note 8
Note 9
Note 6Note 7
3642NKT0023642NKT001
3642NKT001A
3642NKT002B
Note 5
Note 4
3642NKT002A Dividerring
Identical Polystyrene ramps
Note 5Note 4
Note 2
3642NKT001B
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 22 of 25
Appendix B – Calculation
Project Name
Project Number
Pipeline Reference
Company
Contractor
Subcontractor
Location
Scope of Work
Start Point
End Point
Enter Pipeline Data 6"
Section 1 Section 2 Section 3Outer Diameter 168.3 mm mm mmWall Thickness 14.27 mm mm mmInternal Diameter 139.76 mm 0 0Length 4500 m m mDesign Pressure 3600 PSI PSI PSITest Pressure 273.10 barg 0 barg 0 bargTest Pressure (DP x 1.1) 3960 PSI 0 PSI 0 PSIWater Depth / Elevation 90 m m m
NOTE DNV: TP = 1.25 DP; ASME: 1.4 DP
CALCULATION
Eastern Hub Mercury Removal ( EHMR ) – Water Project
R1812
6" 4.5KM FLEXIBLE FLOWLINE - FPSO TO WHP-A
CONOCOPHILLIPS INDONESIA, Ltd
PT. Timas Suplindo
OFFSHORE CONSTRUCTION SPECIALISTS (OCS)
Belanak Field, Indonesia
Gauging and Leak Testing
Belanak FPSO
Wellhead Platform A (WHP-A)
OFFSHORE CONSTRUCTION SPECIALISTS PTE LTD.
SUBSEA PRE-COMMISSIONING
;
Volume per meter 0.01534 m30.00 m3
0.00 m3
0.54 ft3 0.00 ft3 0.00 ft3
4.05 Us gal 0.00 Us gal 0.00 Us gal
Pipeline Volume 69.03 m30.00 m3
0.00 m3
2437.94 ft3 0.00 ft3 0.00 ft3
18237.07 Us gal 0.00 Us gal 0.00 Us gal
Total Volume 69.03 m3
2437.94 ft3
18237.07 Us gal
Launching Sequence
Lubrication / Flushing 300 m 4.60 m3162.53 ft2 1215.80 Us gal
Post Pig 1 m 0.00 m3 0.00 ft3 0.00 Us gal
Post Pig 2 m 0.00 m3 0.00 ft3 0.00 Us gal
Post Pig 3 m 0.00 m3 0.00 ft3 0.00 Us gal
Post Pig 4 m 0.00 m3 0.00 ft3 0.00 Us gal
Post Pig 5 m 0.00 m3 0.00 ft3 0.00 Us gal
Post Pig 6 m 0.00 m3 0.00 ft3 0.00 Us gal
Post Pig 7 m 0.00 m3 0.00 ft3 0.00 Us gal
Post Pig 8 m 0.00 m3 0.00 ft3 0.00 Us gal
Flooding
Distance Volume Equivalent
Project Name
Project Number
Pipeline Reference
Company
Contractor
Subcontractor
Location
Scope of Work
Start Point
End Point
CALCULATION
Eastern Hub Mercury Removal ( EHMR ) – Water Project
R1812
6" 4.5KM FLEXIBLE FLOWLINE - FPSO TO WHP-A
CONOCOPHILLIPS INDONESIA, Ltd
PT. Timas Suplindo
OFFSHORE CONSTRUCTION SPECIALISTS (OCS)
Belanak Field, Indonesia
Gauging and Leak Testing
Belanak FPSO
Wellhead Platform A (WHP-A)
OFFSHORE CONSTRUCTION SPECIALISTS PTE LTD.
SUBSEA PRE-COMMISSIONING
Gauge Plate InformationGauge Plate Sizing 129.80 mm Gauge Plate Quantity 2Gauge Plate Thickness 10 mm
Refer to Appendix E; NOV Factory Acceptance Test (FAT) Report
Pig Speed [m/sec] m3/hr m3/min m3/sec ft3/min Us gpm Minutes Hours Days0.1 5.52 0.09 0.00 3.25 24.32 750.00 12.50 0.520.2 11.05 0.18 0.00 6.50 48.63 375.00 6.25 0.260.3 16.57 0.28 0.00 9.75 72.95 250.00 4.17 0.17
Flooding Projection Summary Duration
TIO
NS
Gauging
0.4 22.09 0.37 0.01 13.00 97.26 187.50 3.13 0.130.5 27.61 0.46 0.01 16.25 121.58 150.00 2.50 0.100.6 33.14 0.55 0.01 19.50 145.90 125.00 2.08 0.090.7 38.66 0.64 0.01 22.75 170.21 107.14 1.79 0.070.8 44.18 0.74 0.01 26.00 194.53 93.75 1.56 0.070.9 49.71 0.83 0.01 29.26 218.84 83.33 1.39 0.061 55.23 0.92 0.02 32.51 243.16 75.00 1.25 0.05
1.5 82.84 1.38 0.02 48.76 364.74 50.00 0.83 0.032 110.46 1.84 0.03 65.01 486.32 37.50 0.63 0.033 165.68 2.76 0.05 97.52 729.48 25.00 0.42 0.02
Line Volume 69.03 m3 Contingency 20.00%
Pressurization Volume 1.22 m3 Total Volume to Treat + Contingency 84.30 m3
Total Volume to Treat 70.25 m3
Required Volume BaseDescription Dosage m3 L L
Cocktail Chemical 550 0.05 46.36 38.64Corrosion Inhibitor 0.00 0.00 0.00Biocide 0.00 0.00 0.00Oxygen Scavenger 0.00 0.00 0.00Dye 50 0.00 4.21 3.51
Multitreat 5549R 0 0 0 Tros Seadye
Pig Speed [m/sec] m3/hr m3/min ft3/min Us gpm L/min L/min L/min L/min L/min0.1 5.52 0.09 3.25 24.32 0.05 0.000 0.000 0.000 0.0050.2 11.05 0.18 6.50 48.63 0.10 0.000 0.000 0.000 0.0090.3 16.57 0.28 9.75 72.95 0.15 0.000 0.000 0.000 0.0140.4 22.09 0.37 13.00 97.26 0.20 0.000 0.000 0.000 0.0180.5 27.61 0.46 16.25 121.58 0.25 0.000 0.000 0.000 0.0230.6 33.14 0.55 19.50 145.90 0.30 0.000 0.000 0.000 0.0280.7 38.66 0.64 22.75 170.21 0.35 0.000 0.000 0.000 0.0320.8 44.18 0.74 26.00 194.53 0.41 0.000 0.000 0.000 0.0370.9 49.71 0.83 29.26 218.84 0.46 0.000 0.000 0.000 0.0411 55.23 0.92 32.51 243.16 0.51 0.000 0.000 0.000 0.046
1.5 82.84 1.38 48.76 364.74 0.76 0.000 0.000 0.000 0.0692 110 46 1 84 65 01 486 32 1 01 0 000 0 000 0 000 0 092
Summary
Chemical Injection Rate
Chemical Name
Multitreat 5549R
Tros Seadye
ES
TIM
AT
ED
DU
RA
T
Chemical Injection
2 110.46 1.84 65.01 486.32 1.01 0.000 0.000 0.000 0.0923 165.68 2.76 97.52 729.48 1.52 0.000 0.000 0.000 0.138
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 23 of 25
Appendix C – Chemical Datasheet
REVISION DATE: January 2009
SAFETY DATA SHEET
MULTITREAT 5549R
1 IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND COMPANY/UNDERTAKING
PRODUCT NAME MULTITREAT 5549R
PRODUCT NO. MT5549R
APPLICATION BIOCIDE OXYGEN SCAVENGER
Clariant Oil ServicesSUPPLIER
Howe Moss Place, Kirkhill Industrial Estate,
Dyce,
AB21 0GS Aberdeen (SCOTLAND)
+44 1224 797400
+44 1224 770118
2 COMPOSITION/INFORMATION ON INGREDIENTS
EC No. CAS-No.Name Content Classification
233-469-7 10192-30-0AMMONIUM BISULPHITE 10-30% Xi;R36/37/38. R31.
Coco alkyl dimethyl benzyl ammonium chloride 10-30% Xn;R22. C;R34. N;R51/53.
The Full Text for all R-Phrases are Displayed in Section 16
3 HAZARDS IDENTIFICATION
Contact with acids liberates toxic gas. Causes burns. Harmful to aquatic organisms, may cause long-term adverse effects in the aquatic
environment.
CLASSIFICATION C;R34. R31,R52/53.
4 FIRST-AID MEASURES
INHALATION
Fresh air and rest. Get medical attention if any discomfort continues. In contact with acids this product may liberate toxic gas. If inhaled
seek medical attention.
INGESTION
Rinse nose, mouth and throat with water. DO NOT INDUCE VOMITING! NEVER MAKE AN UNCONSCIOUS PERSON VOMIT OR
DRINK FLUIDS! Get medical attention immediately!
SKIN CONTACT
Immediately remove contaminated clothing. Rinse immediately with plenty of water. Get medical attention immediately.
EYE CONTACT
Make sure to remove any contact lenses from the eyes before rinsing. Promptly wash eyes with plenty of water while lifting the eye lids.
Get medical attention immediately. Continue to rinse.
5 FIRE-FIGHTING MEASURES
EXTINGUISHING MEDIA
Water spray. Foam, carbon dioxide or dry powder.
SPECIFIC HAZARDS
Fire creates: Hydrogen chloride (HCl). Nitrous gases (NOx). Sulphurous gases (SOx).
PROTECTIVE MEASURES IN FIRE
Full protective equipment including suitable respiratory protection
6 ACCIDENTAL RELEASE MEASURES
PERSONAL PRECAUTIONS
Wear suitable protective clothing to prevent skin contact. Use respiratory protection in confined areas.
ENVIRONMENTAL PRECAUTIONS
Take appropriate steps to prevent discharges to drains and watercourses. Causes depletion of oxygen in watercourses.
/ 41
REVISION DATE: January 2009
MULTITREAT 5549RSPILL CLEAN UP METHODS
Absorb with vermiculite or dry sand. Collect spillage in containers, seal securely and deliver for disposal according to local regulations.
Flush area with plenty of water. Do not let washing down water contaminate ponds or waterways. Inform Authorities if large amounts are
involved.
7 HANDLING AND STORAGE
USAGE PRECAUTIONS
Avoid spilling, skin and eye contact.
STORAGE PRECAUTIONS
Store in tightly closed original container in a cool, dry well-ventilated place. Do NOT use container made of: polyethylene Mild Steel.
8 EXPOSURE CONTROLS/PERSONAL PROTECTION
PROTECTIVE EQUIPMENT
HAND PROTECTION
Impermeable material.
EYE PROTECTION
Use approved safety goggles or face shield.
HYGIENE MEASURES
When using do not eat, drink or smoke. DO NOT SMOKE IN WORK AREA! Wash at the end of each work shift and before eating, smoking
and using the toilet. Promptly remove any clothing that becomes contaminated. Wash promptly if skin becomes contaminated. Use
appropriate skin cream to prevent drying of skin.
9 PHYSICAL AND CHEMICAL PROPERTIES
APPEARANCE Liquid
COLOUR Clear Yellow
ODOUR Mild (or faint). Sulphur dioxide.
RELATIVE DENSITY 1.00 – 1.10 25 pH-VALUE, DILUTED SOLUTION 4 - 7 10
VISCOSITY Less than 50 cps 25
10 STABILITY AND REACTIVITY
STABILITY
No particular stability concerns.
MATERIALS TO AVOID
Oxidising agents and acids
HAZARDOUS DECOMPOSITION PRODUCTS
Contact with acids liberates toxic gas. Sulphurous gases (SOx).
11 TOXICOLOGICAL INFORMATION
INHALATION
Contact with acids liberates toxic gas.
INGESTION
Causes burns.
SKIN CONTACT
Causes burns.
EYE CONTACT
Causes burns.
12 ECOLOGICAL INFORMATION
ECOTOXICITY
Causes depletion of oxygen in watercourses. Degrades to form sulphates in the natural environment. Harmful to aquatic organisms, may
cause long term adverse effects in the aquatic environment for a continuous high concentration disposal.
/ 42
REVISION DATE: January 2009
MULTITREAT 5549R
BIOACCUMULATION
Log Pow < 3
DEGRADABILITY
Readily Biodegradable; >60%
13 DISPOSAL CONSIDERATIONS
DISPOSAL METHODS
Dispose of waste and residues in accordance with local authority requirements.
14 TRANSPORT INFORMATION
UK ROAD CLASS 8
PROPER SHIPPING NAME CORROSIVE LIQUID, N.O.S (alkyl dimethyl benzyl ammonium chloride)
1760UN NO. ROAD IIIUK ROAD PACK GR.
Class 8: Corrosive substances.ADR CLASS 80 Corrosive or slightly
corrosive substance.
HAZARD NO. (ADR)
2XHAZCHEM CODE 1760UN NO. SEA
8IMDG CLASS IIIIMDG PACK GR.
F-A, S-BEMS Yes.MARINE POLLUTANT
1760UN NO. AIR 8ICAO CLASS
IIIAIR PACK GR.
15 REGULATORY INFORMATION
LABELLING
Corrosive
CONTAINSCoco alkyl dimethyl benzyl ammonium chloride
RISK PHRASES
R31 Contact with acids liberates toxic gas.
R34 Causes burns.
R52/53 Harmful to aquatic organisms, may cause long-term adverse effects in the aquatic
environment.
SAFETY PHRASES
S26 In case of contact with eyes, rinse immediately with plenty of water and seek medical
advice.
S45 In case of accident or if you feel unwell, seek medical advice immediately (show label
where possible).
S24/25 Avoid contact with skin and eyes.
S36/37/39 Wear suitable protective clothing, gloves and eye/face protection.
S60 This material and its container must be disposed of as hazardous waste.
/ 43
REVISION DATE: January 2009
MULTITREAT 5549RUK REGULATORY REFERENCES
The Approved Supply List
STATUTORY INSTRUMENTS
Chemicals (Hazard Information and Packaging) Regulations.
APPROVED CODE OF PRACTICE
Safety Data Sheets for Substances and Preparations.
GUIDANCE NOTES
The Approved Classification & Labelling Guide
16 OTHER INFORMATION
ISSUED BY
SPS
REVISION DATE January 2009
REV. NO./REPL. SDS GENERATED Rev 1 / November 2006
SDS NO. O 797
RISK PHRASES IN FULL
Harmful if swallowed.R22
Contact with acids liberates toxic gas.R31
Causes burns.R34
Irritating to eyes, respiratory system and skin.R36/37/38
Toxic to aquatic organisms, may cause long-term adverse effects in the aquatic environment.R51/53
/ 44
Product Bulletin
Clariant Oil Services www.clariantoil.com
MULTITREAT 5549R SCAVENGER Description MULTITREAT 5549R is an aqueous solution of oxygen scavenger, biocide and corrosion inhibitor. It is based on a combination of ammonium bisulphite and amine, and is classified as readily biodegradable (>60% in 28 days). This product has already been approved by Lemigas (Indonesia R&D Center for Oil and Gas Technology) as material for hydrostatic test in seawater. Application MULTITREAT 5549R is used to prevent corrosion in oilfield pipelines and process facilities that are filled with water during hydrostatic testing operations or temporary mothballing of facilities. The product controls the propagation of corrosion-causing sulphate reducing bacteria (SRB), scavenges oxygen (which can also cause severe corrosion) and forms a protective film on the metal surfaces. The treatment rate depends on the source of water used and the length of testing / mothballing. Typical doses for seawater are shown below: Duration of test Dose rate (ppm) < 3 months 400 - 500 3 - 12 months 500 - 700 1 - 5 years 700 - 1000 Typical properties*
• Appearance (QPI 1) Clear Colourless to Yellow Liquid • Specific Gravity @ 25°C (QPI 2) 1.0 - 1.1 • pH 10% (QPI 3) 4 - 7 • Viscosity @ 25°C (QPI 4) Less than 50 cps
o * these do not constitute a specification
Handling** MULTITREAT 5549R is a corrosive liquid and should be handled with care. Avoid contact with skin and eyes. Wear appropriate safety clothes to minimise skin and eye contact. Consult MSDS for further details. ** Refer to MSDS for specific safety and health hazards.
This information is based on our present state of knowledge and is intended to provide general notes on our products and their uses. It should not therefore be construed as guaranteeing specific properties of the products described or their suitability for a particular application. Any existing industrial property rights must be observed. The quality of our products is guaranteed under our General Conditions of Sale.
PB-MULTITREAT 5549R-A4-January 09
Exactly your chemistry.
SEADYE/1Exactly your chemistry.The information in this publication corresponds to the present state of our knowledge and intends to describe our products and their possible applications. It is notintended to guarantee the suitability of particular product characteristics for a specific use. Any existing industrial rights are to be taken into consideration. Quality isguaranteed in accordance with our general conditions of sale.
Clariant Oil ServicesInternet: www.clariantoil.com
[Product Bulletin]SEADYE – LEAK DETECTION DYE
DescriptionSEADYE is a solution of the dye compound fluorescein in aqueous solution. The fluorescein dye is present asthe sodium salt, rendering it water-soluble.
ApplicationSEADYE is particularly recommended for systems where leaks and flow paths are required to be checked. Thefluorescent colour can be seen visually and with optical instruments if the system is under water.
SEADYE should be injected neat into the flowing water stream at 50 to 100 ppm depending on the potentialproblem to be checked. At these concentrations, the alkalinity of the product will be buffered by the salts inseawater.
Typical properties** (these do not constitute a specification)
Appearance Red liquidSpecific Gravity 1.07 – 1.10 at 25ºCpH (20 g/l) 7.0 – 11.0Viscosity < 10 cps at 25ºCFlash Point Above 65ºCPour Point Minus 5ºCSolubility Soluble in water and brines
HandlingSEADYE is irritant to the skin and eyes. Wear neoprene gloves, safety goggles and protective clothing. Consultproduct MSDS prior to handling.
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 24 of 25
Appendix D – Bi‐di Pig Drawings and Foam Pig Catalog
iNPIPE PRODUCTS™ Foam Pig Data Sheet
International Pipeline Products Ltd, Walkerville Industrial Estate, Catterick Garrison, North Yorkshire, England, DL9 4RRTel: (+44) 01748-834 577 Fax: (+44) 01748-834 121 - E-mail: [email protected] - [email protected]
Registered in England 1852899
Foam Pig Data Sheet
iNPIPE PRODUCTS™ manufacture a comprehensive range of foam pigging products which are designed for a variety of pipeline pigging applications including:
• Available in 4 standard densities of foam, Low Density (1.5-2lb/Cu.ft), Medium Density (5-7lb/Cu.ft), Heavy Density (8-10lb/Cu.ft) and Extra Heavy (20lb/Cu.ft)
• Therangeincludesanumberofdifferentfinishesdesignedforspecificapplications.TheseincludeBareFoam,FullyCoated, Criss Cross, Silicone Carbide and both Wire & Nylon Brushdesigns
• Foam pigs can be adapted to include transmitter cavities ,tow loops, gauge plates and encapsulated magnets for tracking
• Dual densities are available on request• Sizes ranging from 1/2” to 74”
Features:
Nominal Size A B C
2 58 86 113
3 82 117 149
4 108 163 205
6 159 240 304
8 212 318 402
10 266 375 450
12 318 460 580
14 350 550 695
16 403 605 750
18 454 680 850
20 504 752 950
22 552 818 1028
24 609 912 1140
26 660 1000 1260
28 707 1062 1334
30 765 1145 1423
32 810 1229 1546
34 850 1260 1586
36 909 1370 1710
38 970 1435 1795
40 1020 1515 1895
42 1066 1600 2005
44 1100 1600 2005
46 1225 1825 2286
48 1237 1780 2250
ProvingSwabbingDryingWipingDe-watering
ScrapingProduct RemovalDebris RemovalCleaningAggressive Cleaning
• Maintenance free, disposable product• Capable of travelling long distances• Can be customised to meet client requirements • Can reduce through a pipeline by up to 50% in diameter • Capable of negotiating short radius 90° bends and elbows• Able to traverse bends, mitres, tees and various valve
configurations• Can be used on pipelines not originally designed for pigging
activities
Benefits:
Standard Foam Dimensions
A comprehensive range of additional moulds are available to suit client specificpipeschedules.Dimensionsareapproximationsinmm.
International Pipeline Products Ltd, Walkerville Industrial Estate, Catterick Garrison, North Yorkshire, England, DL9 4RRTel: (+44) 01748-834 577 Fax: (+44) 01748-834 121 - E-mail: [email protected] - [email protected]
Registered in England 1852899
• Proving: Ensuring that pig travels from one end of pipeline to the other
• Swabbing: Removing moisture from pipeline until dry• Drying: Initial drying of pipeline prior to air drying and
vacuum drying• Wiping: Removal of small particles/debris from pipe wall
Pig Application Key:
Foam Pig Selection Matrix:
• De-Watering: Removing water from pipeline • Scraping: Abrasive cleaning of the pipeline• Product Removal: Removal of product from pipeline• Debris Removal: Removing debris from pipeline
Foam Pig Data Sheet
International Pipeline Products Ltd, Walkerville Industrial Estate, Catterick Garrison, North Yorkshire, England, DL9 4RRTel: (+44) 01748-834 577 Fax: (+44) 01748-834 121 - E-mail: [email protected] - [email protected]
Registered in England 1852899
Solution:
• Long run standard duty foam (LRSD)• Cleaninginepoxycoatedline(NFB)• Front pulling/handling rope (PF-F)• Transmitter cavity (TF-T)
Foam Pig Selection Example:
Foam Pig Data Sheet
Purpose: Cleaning (Debris Removal)
Pipeline Size & Length:
20” x 30km
Wall Thickness: 15.09-26.19mm (Sch 40-Sch 80)
Pipeline Material: API 5L Gr x 60. C.Steel w/internal epoxy coating
Barred Tees: YesAdditional Requirements:
Front pulling/handling rope requiredEM transmitter cavity required
Pulling Facility(Front, Rear, Dual)
Ref: PF-F/R/D
Double Nose
Ref: DN
Double Dish
Red: DD
NonFerrousBrush(For use on internally coated pipelines)Ref:NFB
Extra Long(Extended sealing applications)Ref: ExL
MaxiBrush(Total Coverage)
Ref:MB
Gauge Plate Facility
Ref: GPF
Tracking Facility(Transmitter or Magnet insert)Ref: TF-T/M
Maxi-Silicone Carbide(Total Coverage)
Ref: MSC
Single Spiral(Econo Pig)
Ref: SS
Extra Short(Ballvalve-Launch&Receiving facilities)Ref: ExS
By-PassFacility(Pluggable)
Ref:BPF
Foam Pig Extras:
In conjunction with the standard range of foam pigs iNPIPE PRODUCTS™ also offer a large range of special pig options to cater for a wide range of pigging applications:
REF: 20” LRSD-NFB-PF-F-TF-T
Client Reference List:
Foam Pig Data Sheet
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 25 of 25
Appendix E – NOV Factory Acceptance Test (FAT) Report
EASTERN HUB MERCURY REMOVAL - WATER (EHMR-W) Page 13 of 28
Factory Acceptance Test (FAT) Procedure Doc. no. 3642-DOC-FAT-100 Rev. 3
This document contains confidential information. All rights (including copyright, confidential information, trade secrets, and design rights) are owned by National Oilwell Varco Denmark I/S No use or disclosure is to be made without the prior written permission of National Oilwell Varco Denmark I/S. All rights reserved.
TM-ENG-028 Rev 17
5 GAUGE TESTING/PIGGING The gauge test is not applicable for the following cases:
• Pipes with reduced ID in both end-fittings/flanges, i.e. the above gauge disc criteria cannot be fulfilled.
• For smooth bore pipes, i.e. pipes with no internal carcass, a foam pig will be used for filling of the pipe.
Table 5-1 Gauge testing
Description Pipe No Gauge testing Min. gauge disc OD (mm)
5.5” WIR
5.5” WIF Plem
5.5” WIF Wellhead
3642NKT001
3642NKT002
3642NKT003
YES
YES
YES
129.8
129.8
129.8
5.1 GAUGE TESTING A bi-directional pig will be used during filling of the pipe in order to minimise the amount of trapped air. The pig will remain in the flexible pipe section during the hydrostatic pressure test. The pig will be equipped with a gauge disc capable of detecting any unacceptable obstruction. The gauge disc is made of aluminium with a thickness between 5 to 10 mm and is equipped with radial cuts with a spacing of 30° or 45°. The clearance between ID of the pipe and the OD of the gauge disc shall not exceed 10 mm, for pipes with an ID of less than 200 mm. For pipes with an ID of more than 200 mm, the gauge disc shall have an OD of no less than 95% of the pipe’s ID, ref. to Table 3-1.
5.2 ACCEPTANCE CRITERIA The acceptance criterion is the gauge disc/pig showing no sign of damage after having passed through the bore of the pipe. Minor scratches and scuffs are acceptable.
Procedure Subsea Pre‐commissioning Procedure C‐84514‐BK‐KK0‐PRO‐GN‐00‐0014 Rev.0B ConocoPhillips Indonesia Inc.Ltd Page 26 of 25
Appendix F – Reporting Format
Project Name Report No.
Discipline Document Type
Originator NATA Accreditation No. 19122
Revision date
Page 1 of 1
LEAK TESTING ACCEPTANCE CERTIFICATE
Project Name:
Date:
Client:
Time:
Location:
Operational Description:
Pipeline Description:
Pipeline ID
Length (Actual) Wall Thickness
Location of Test Equipment
Test Pressure
Initial Test Pressure at Test Location
Final Test Pressure at Test Location
Initial Subsea Temperature at Test Location
Final Subsea Temperature at Test Location
Duration of Hold Period
Description of Leak (if any)
Remarks
Detail OCS Engineer Timas Representative COPI Representative
Name
Date
Signature