PIPELINE INSTALLATION METHODOLOGY REPORT

PIPELINE INSTALLATION METHODOLOGY REPORT

Z12/112996-ENG-RPT-00005 Rev 02 12.08.2016 Page 1 of 38


Z12/112996-ENG-RPT-00005. Rev 02 Client: LOTOS PETROBALTIC S.A. Project Number: Z12/112996 Project Name: B8 GAS PIPELINE INSTALLATION ENGINEERING

Date Revision Description of Revision Prepared Checked Approved

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



DOCUMENT COMMENT SHEET

CLIENT: Lotos Petrobaltic PROJECT: B8 Gas Pipeline Installation Engineering Date: 13.06.2016

Comments: The response to: Installation Engineering Report Document

Document Type: Report

Document No.: Z12/112996-ENG-PT-00005 Revision: 02 Date: 04.07.2016

Document Title: Pipeline Installation Methodology Report

Received by: M. Maciejewski Date: 13.06.2016 Transmittal No. CSL-OPS-P422-DTN-006

Item Reference Comment Comment By

Contractor’s Response

1. Section 2.0 Installation Vessel

Bullet point 4 reads “Deck crane suitable to support operations” LPB asks is it support crane, with limited lifting capacity? There is hi potential risk that our vessel won’t be equipped with that kind of crane. Please find attached example of reel weight

A. Wojcikowski

(21.06.2016)

Noted and will remove reference to deck crane, we can review the need for it later, but it is not essential.

2. Section 3.2 Equipment Spread

Table of principle equipment for coiled pipe installation LPB comments

Please compare items with deck plan equipment list (DWG-00001)

Please add basic information about equipment i.e. weight, dimensions etc

Please add all Zap-Lok equipment to the table

M. Maciejewski

(21.06.2016)

Noted, we will include weights and envelope dimensions

3. Section 3.5.2 Zap-Lok™ Belling Machine

Note: if the pipeline designated for NACE sour service the Bell end is stress relieved using heating bands Analysed pipeline is not going to be sour gases transported

A. Wojcikowski

(21.06.2016)

Noted and will removed this note comment as not relevant within the document.

4. Section 3.6 Render Unit

General comment

Do you have some photos with Render Unit?

M. Maciejewski

(21.06.2016)

Noted and will include photos of typical render unit design.





5. Section 3.11 Stinger

Paragraph reads “The stinger and A-frame module shall provide the designed pipe installation chord and radius specification on the 4” pipeline. The stinger shall allow for “real time” feedback on the roller loads and video monitoring of the tip end during installation.” General comments

A-frame – It’s been changed since first storyboard was presented. It changes approaching to the vessel with impact for range of searching vessel on the market

4” pipeline – Please check and use either 4” ID (ND) or 4.5” OD

Video Monitoring – Is it possible to utilise ROV at least for tip end monitoring

A. Wojcikowski

(21.06.2016)

The picture of the stinger was obtained from a design made by GMC and was representative of a typical stinger. The A frame shown is part of the stinger deployment system.

Noted and will rationalize pipe size across all documents

Would not recommend an ROV for stinger monitoring, the ROV will be monitoring the touch-down of the pipe onto the seabed. We suggest inclusion of a subsea camera fitted to the tip of the stinger, if this is required

6. Section 4.1 Mobilisation Operations

Second paragraph, second sentence reads “A procedure for the pre-qualification activities with detailed description of all tests and calibration exercises shall be provided for approval prior to the tests.” Would these prequalification procedures be supplied by subcontractors?

A. Wojcikowski

(21.06.2016)

Yes. We will add comment in text to clarify

7. Section 4.1 Mobilisation Operations

Fifth paragraph, second sentence reads “The client shall secure the equipment onto the vessel deck in accordance with the approved seafastening design, equipment provider(s) will provide the fixings.” Who will design seafastening

M. Maciejewski

(21.06.2016)

Seafastening design and application would be the responsibility of the installation contractor, we will add clarifying comment in the text.





8. Section 4.3 Pipeline Installation Activities

Third Bullet point reads “According to the project requirements and before bringing a pipe to the assembly line, internal and external inspection shall be carried out on each coiled pipe, and the observed unacceptable defects shall be reported. The mechanical connector length of pipe internal diameter shall be proved by gauging by using a gauging plate designed as per vendor procedures.”

This procedure’s gone through with Tenaris, LPB will repeat it when unspooling pipe during installation

This Recommended Practice should be implemented with its number in the project

A. Wojcikowski

(21.06.2016)

Noted, we will add comment into text

9. Section 4.3.1 Pipeline Installation Monitoring

Fourth Paragraph reads “As a minimum, the following parameters shall be monitored, recorded in a continuous way, and made available to Company, with calibration against allowable areas defined above, for:” I think that described monitoring parameters range is typical for Installation Vessel, and will be hard to achieve on typical PSV. Please consider what will be the minimum for our job.

M. Maciejewski

(21.06.2016)

Agreed, we will review this and revise to reflect what is possible.

10. Section 4.3.1 Pipeline Installation Monitoring

Fourth paragraph, eleventh bullet point reads “Continuous monitoring at TDP” Please inform what system is taken into consideration? ROV?

A. Wojcikowski

(21.06.2016)

We are assuming continuous monitoring of touch-down point by ROV. It would be good to discuss deployment of ROV from installation vessel or other.





11. Section 4.3.2 Pipelay Route

Second paragraph reads “Detailed seabed characteristics shall be surveyed to allow adjustment of installation equipment, if necessary. The pre-lay survey shall also aim at collecting soil out of straightness information, which shall be used to specify the requested freespan reduction works.” Who decided about this?

A. Wojcikowski

(21.06.2016)

Clarification given by LPB and amended wording within paragraph to the following.

From the pre-lay survey results, a freespan assessment task shall be performed in order to evaluate the required freespan reduction works. When processing freespan assessment, it shall be demonstrated whether or not the pipe will deflect and gain any intermediate supports under in-service conditions. Also the location of these supports as well as their suitability as permanent supports (integrity, susceptibility to scour, etc.) shall be fully assessed from the pre-survey results.

12. Section 4.3.3 Pipelay Initiation

Second paragraph, first sentence reads “The initiation system will be installed in accordance with the approved pipeline initiation procedure.” Who will prepare and supply this procedure, in respect to pipeline installation or in respect of using installation equipment on vessel deck?

A. Wojcikowski

(21.06.2016)

The installation contractor shall supply procedure. Wording amended to reflect this.

13. Section 5.2.3 Chemical Details

Second paragraph reads “The chemical injection pumps are positive displacement pumps giving a prescribed output volume per stroke. The pumps will be carefully chosen to ensure that their output can comfortably achieve the dosage requirement in relation to the anticipated pig speeds.” Please, it’s hard to precisely as on side decided what pumps shall be used. We know that it is important to pump it continuousl, but pumping will be realised from offshore platform and water will be supplied from platform pumps. Especially when we need correct chemical dosage, maybe water will be initially prepared in platform storage tanks before we transfer it to the pipeline

A. Wojcikowski

(21.06.2016)

Noted, we will remove reference to “positive displacement”





14. Section 5.3 Hydrostatic Strength Testing of Pipeline System

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

A. Wojcikowski

(21.06.2016)

Noted, we will replace text to reflect your comments

15. Section 5.3.1 Pressure Testing

First paragraph reads “All pressure testing will be carried out taking into consideration the requirements of pipeline design and client requirements. All temporary equipment to be used shall be pressure tested prior to operations commencing at a test pressure of 1.1 x hydrostatic strength test pressure (TBA barg).” As comments above in item 14

A. Wojcikowski

(21.06.2016)

Noted, we will replace text to reflect your comments

16. Section 5.3.3 Pressurisation

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

A. Wojcikowski

(21.06.2016)

Noted and comment added to reflect inspection requirement

17. General Comments - Document

To get all information about equipment you have to look for it in different documents and it takes time. We should find in this document all sensual information about equipment, please add information from documents Z12/112996-ENG-RPT-00001, 2, 3 & 4 to this document. i.e Stinger dimensions etc

M. Maciejewski

(21.06.2016)

Noted, we will accommodate your request


All equipment should be described like Zap-Lok equipment (drawings, data etc.)

M. Maciejewski

(21.06.2016)

Noted and more information and details added as available for equipment






We need some Quality Report (example) for Zap-Lok connection for offshore job

M. Maciejewski

(21.06.2016)

Noted and will include example Quality Control Reports for Zap-LokTM Pipeline Installation

20. General Comments - Drawings

We are not happy with A-frame on stren, is it possible to go back to first drawing draft

M. Maciejewski

(21.06.2016)

The example stinger was obtained from a design made by GMC and was representative of a typical stinger. The A frame shown is part of the stinger deployment system.


Please add on drawing DWG-00001 “pipe path” M. Maciejewski

(21.06.2016)

Noted and will amend drawing to incorporate comment


Why pipe is conducted down from reel, do you have some analysis on this? I know that we spoke about this on meeting, but please remind me?

M. Maciejewski

(21.06.2016)

Please clarify your requirements

If your comment refers to the 11m separation between reel and straightener, then yes, we have done some calculations to justify this distance.


Some stinger assembly drawings will be helpful for us. M. Maciejewski

(21.06.2016)

Noted. We will include what we can, taking into consideration the intellectual property rights of others.

24. General Comments – Project Personnel

Please add details on estimated project personnel requirements

M. Maciejewski

(21.06.2016)

Noted and will include section for project personnel

25. General Comments – Project Schedule

Please add details on estimated project schedule based upon installation of two (2) Reels per load-out on vessel.

M. Maciejewski

(21.06.2016)

Noted and will include section for project schedule

26. Section 4.3 Pipeline Installation Activities

Please add details on Concrete Mattresses somewhere in your document RPT-00005 (maybe in point 4.3 Pipeline Installation Activities), with general information i.e. that we are planning covering gas pipeline, your recommendation about when we should execute covering (just after pipe installation, before/after commissioning)

M. Maciejewski

(12.08.2016)

Noted and will include new section 4.3.6 Concrete Mattresses will be added tand reference LPB documentation for pipeline route and mattress locations etc





27. Section 3.11 Stinger

Please add details about A-frame to be a fixed structure (without hydraulic servomotors) on stern if LPB get a vessel without an A-frame

M. Maciejewski

(12.08.2016)

Noted and will amend to include additional detail on stinger A-frame to be fixed structure as necessary



REVISION RECORD SHEET

Date Revision Status Reason for Change(s)

12.08.2016 02 IFC See attached comments sheet(s)

04.07.2016 01 IFA See attached comments sheet(s)

13.06.2016 00 IFK Issued for Review

TABLE OF CONTENTS

1.0 INTRODUCTION ......................................................................................................................... 11 1.1 General ................................................................................................................................................ 11 1.2 Objective .............................................................................................................................................. 11 1.3 Abbreviations & Nomenclatures ......................................................................................................... 11 1.4 References ........................................................................................................................................... 11

2.0 INSTALLATION VESSEL ............................................................................................................... 12 2.1 Vessel Layout ....................................................................................................................................... 12 2.2 Project Personnel ................................................................................................................................ 13 2.3 Project Schedule .................................................................................................................................. 13

3.0 INSTALLATION AND EQUIPMENT .............................................................................................. 14 3.1 Installation Overview ........................................................................................................................... 14 3.2 Equipment Spread ............................................................................................................................... 14 3.3 Powered Reel Drive System ................................................................................................................. 15 3.4 Pipeline Straighteners.......................................................................................................................... 17 3.5 Zap-Lok™ Connection System .............................................................................................................. 17 3.6 Render Unit ......................................................................................................................................... 19 3.7 Abandonment & Recovery Winch ....................................................................................................... 20 3.8 Turning Sheave .................................................................................................................................... 20 3.9 Hold-back Pipe Clamp .......................................................................................................................... 20 3.10 Tensioner ............................................................................................................................................. 20 3.11 Stinger .................................................................................................................................................. 21

4.0 COILED PIPE INSTALLATION ....................................................................................................... 22 4.1 Mobilisation Operations ...................................................................................................................... 22 4.2 Material ............................................................................................................................................... 23 4.3 Pipeline Installation Activities .............................................................................................................. 23 4.4 Demobilization of Vessel ..................................................................................................................... 27 4.5 Offshore Works Completion and Reporting ........................................................................................ 27

5.0 PIPE-LINE PRE-COMMISSIONING ............................................................................................... 28 5.1 General ................................................................................................................................................ 28 5.2 Pipeline Hydrotest ............................................................................................................................... 28 5.3 Hydrostatic Strength Testing of Pipeline System ................................................................................. 29 5.4 Pipeline De-watering and Drying ......................................................................................................... 31

APPENDIX A – DECK LAYOUT DRAWING Z12/112996-ENG-DWG-00001 .............................................. 32 APPENDIX B – STORYBOARD DRAWINGS Z12/112996-ENG-DWG-00002 ............................................ 33 APPENDIX C – TENARIS COILED TUBING REEL DRAWING ..................................................................... 34



APPENDIX D – ZAP-LOK™ 8000-12T PRESS ............................................................................................ 35 APPENDIX E – PROJECT SCHEDULE ........................................................................................................ 36 APPENDIX F – ZAP-LOK™ PIPE TALLY REPORT & END PREPARATION REPORT ...................................... 37 APPENDIX G – CONCRETE MATTRESSES ................................................................................................ 38



1.0 INTRODUCTION

1.1 General

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

1.2 Objective

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

1.3 Abbreviations & Nomenclatures

1.3.1 Abbreviations

Abbreviation Description

A&R Abandonment and Recovery

AHV Anchor Handling Vessel

CT Coiled Tubing

DP Dynamic Positioning

EEZ Poland exclusive economic zone

HOLD Document hold point requiring additional clarification information

HSE Health, Safety & Environment

km kilometre

NDE Non Destructive Examination

m Metre

OD Outer Dimension

PUP Pipe Utility Piece

QA Quality Assurance

ROV Remotely Operated Vehicle

TBC To Be Confirmed

1.4 References

1.4.1 Reference Documents

Document Title Document Number

Deck Layout Drawing Z12/112996-ENG-DWG-00001

Sequence drawings (storyboards) Z12/112996-ENG-DWG-00002 (7 sheets)



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

Dynamic positioning operations in accordance to IMCA standards

Sufficient deck space and loading capability to support the installation equipment and operation

Suitable accommodation for marine and operations personnel

Suitable handling aids to support operations, such as small cranes / hoists A specific technical specification shall be provided to detail the appropriate vessel / marine requirements. The following section details the vessel requirements from the pipeline installation perspective.

2.1 Vessel Layout

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

I. A vessel suitable to accommodate two reels, necessitating frequent port calls for restocking and;

II. A larger vessel, accommodating more reels, having the advantage of an increased time on site, installing pipe and the possibility of restocking at sea, using ship to ship transfer of 35 tonne reel (30 tonnes of pipe + reel weight 5 tonnes).

Other than running the pipe through a set of straightening rollers, to change the pipe profile from curved to straight, it has been decided that there will be no other plastic deformation of the pipe during the installation process. This decision establishes a minimum spacing between the aft most reel and the straightening rollers, which has been calculated to be a minimum distance of 11m. This was derived from a consideration of the pipe as cantilever, en-castre (built-in) at the straightening rolls and deflected by the outer wraps on the reel. The pipe material conforms to API 5L grade X65, this deflection would subject the pipe to a bending stress of 90% of its yield strength. The coiled pipe installation equipment, including the reel drive system, is arranged so that it sits on its own rail system and this feature contributes to minimizing the need to add additional structure to the vessel in order to provide under deck strengthening.



2.2 Project Personnel

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

Lotos PetrobalticOffshore Manager

Pipelay Supervisor x 2

Days / Nights

Powered Reel DriveSupervisor x 2

Zap-LokSupervisor x 2

TensionerSupervisor x 2

Tensioner Technician / Operator

x 2

PRD Technician / Operator

x 2

Zap-Lok Technician / Operator

X 2

Deck foremanX 2

RiggerX 2

Obs ROVSupervisor x 2

Pilot / TechsX 2

SurveySnr Surveyor x 2

SurveyorsX 2

NOTE: Above personnel chart excludes any vessel marine crew In view of the intermittent nature of the work, the crew will be in port every 2 – 3 days and the potential for limited POB, it is suggested a multi-disciplined pipelay crew should be utilised and could be as follows: Tensioner 3 1 days, 1 nights and a senior who can bridge shifts PRD 3 1 days, 1 nights and a senior who can bridge shifts Zap-Lok™ 2 Pipe-lay supervisor oversee Zap-Lok™ operations, as these are so infrequent, these personnel would not work shifts and when not busy could relieve the PRD and Tensioner operators Survey 2 1 days, 1 nights ROV 4 2 days, 2 nights Deck foreman 2 1 days, 1 nights Riggers 2 1 days, 1 nights

2.3 Project Schedule

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



3.0 INSTALLATION AND EQUIPMENT

3.1 Installation Overview

The pipe-line material is stored on a number of reels, each with approximately 1,800m of pipe. At least 2 reels, depending on the size of the installation vessel, would be stored on-board and the pipeline would be laid by unreeling the pipe, starting with aft-most reel. The pipe is lead off the underside of the reel to accommodate the layout of the Zap-Lok™ equipment on deck. It is important that this system be installed parallel to the ship’s deck, insofar as this is possible and for this reason the pipe cannot be led off the top of the reel. Joints between successive reels of pipe would be made by the Zap-Lok™ process. When the pipe had been unreeled from the initial reel the Zap-Lok™ system would secure the pipe end while the reel drive system would disengage from the initial reel, move forward and engage the next reel. When the reel drive had engaged the next reel the new end would feed into Zap-Lok™ press, where the pipe joint would be made. Laying would continue until all the pipe had been unwrapped from the next reel and the process would continue until the end of the last reel had been reached. At this point the last end would be sealed and a pull-head would be attached. The pull-head would be connected to a pennant and buoy and carefully laid down onto the seabed, using an Abandonment and Recovery (A&R) winch. The vessel would transit to port to unload empty reels, re-stock with full reels, take on all necessary supplies, change crew changes as required and return the field. On return to the field and the completion of DP trials, the abandoned pipe end would be recovered and the laying process would continue until the pipe had been unwrapped from the next reels. The vessel would continue to lay pipe, transiting to port to restock until the pipe-line had reached the target box adjacent to the platform. At this point the riser end termination would be attached, together with a pull-head and the pipe would be laid down in preparation for connection to the platform riser. The pipeline would be integrity tested and leak tested using treated sea water. On completion of the testing the pipe would be de-watered, dried and suspended until the riser would be connected.

3.2 Equipment Spread

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



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

Item Qty Description Dimensions (m)

Weight (Tonnes)

1 2 Reel with product 5.9 X 2.8 X 5.9 35

2 1 Powered Reel Drive System 6 X 5.4 X 5 22

3 1 Pipeline Straighteners 1.5 X 1 X 1 6

4 1 Zap-Lok™ Connection System, inc Render Unit

9 X 3 X 2 15

5 1 Zap-Lok™ pin/bell machine 6 X 2.4 X 2.5 10

6 1 Abandonment & Recovery Winch 0.5 X 2.4 X 2.0 8

7 1 Turning Sheave 1.0 x 1.0 x 1.5 1

8 1 Hold-back Pipe Clamp 1 x 1 x 0.5 0.5

9 1 Tensioner 6.4 X 3.4 X 0.5 15

10 1 Modular Stinger 8.0 X 3 X 3 10

11 1 Stinger deployment winch 3.2 X 3.7 X 2.6 10

12 1 Rigging/Control container 6 X 2.4 X 2.5 10

13 1 HPU 1.3 x 1.4 x 0.8 1.5

3.3 Powered Reel Drive System

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

Figure 1. Typical Reel Drive



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

3.3.1 Track System

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

3.3.2 Tower

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



3.3.3 Reel Drive Hub

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

3.3.4 Reel

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

3.4 Pipeline Straighteners

The supplied pipe straightener system will need to incorporate a large bending shoe that pre-bends the pipe entering the straightener to a known, fixed radius in order to maintain the pipe straightener at a constant setting as the reel is emptied of the pipe. The pre-bend shoe also aligns the pipe with the face of the reel so that the pipe can be wound levelly and smoothly on and off the reel. A movable bending shoe / set of rollers and fixed reaction shoe / set of rollers are used to reverse the bend and straighten the pipe as it comes off the reel. However, it may not be possible to accommodate the size of an aligner and for this reason it may be necessary for the installation contractor to consider having only one straightening system and employing accurate control of the reverse bend straightening rolls, in order to minimize deck space.

3.5 Zap-Lok™ Connection System

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

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

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



Figure 1 - Zap-Lok™ Joint The Zap-Lok™ process produces strong, permanent joints which can be used in the same pressure service as welded lines. This allows the pipeline system design to be based on a joint strength of 100%. Extensive independent evaluations under varied laboratory test conditions and in-service performance records have proven the Zap-Lok™ joint to be strong, reliable and leak proof. There have been no reported in-service failures over its entire 40-year history. The Zap-Lok™ method can be used to join relatively thin wall pipe, down to Schedule 20, which cannot be easily welded. Additionally, the Zap-Lok™ joint can carry corrosive fluid without the vulnerability of threaded couplings, or damaged internal coating resulting from the high temperatures produced for a welded joint.

3.5.1 Zap-Lok™ Press

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

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

3.5.2 Zap-Lok™ Belling Machine

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



3.5.3 Zap-Lok™ Pinning Machine

The pinning machine is likely to be needed to make pin ends on abandonment heads. The end of a new reel will need to be provided with a pull-head. This is pulled into the Zap-Lok™ press and the end cut off in preparation for making the belled end. There is an opportunity to re-use this cut-off as a future abandonment head at least once, all that is required would be to have a pin preparation made on the open end.

3.5.4 Zapoxy Mixing Unit

The Zap-Lok mixing unit is designed to provide a two-part mixing process of the Zapoxy lubricant material. A Zapoxy mixing unit would be available and would normally be required when pipe is laid using discrete lengths, where Zapoxy use would be frequent. In this case, where the pipe-line is to be laid by the reel-lay method, there would only be need to make joints infrequently, so it is anticipated that the Zapoxy compound could be mixed and applied by hand.

3.5.5 Pipe Utility Pieces

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

3.6 Render Unit

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

Allow Zap-Lok press to render inboard or outboard relative to pipe end while making a pipe

connection, avoiding potential damage to Zap-Lok press or pipeline

Aligning Zap-Lok press pipe clamps over pipe ends prior to making next connection

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



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

Example of Render Unit

3.7 Abandonment & Recovery Winch

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

3.8 Turning Sheave

A deck mounted turning sheave will be positioned on the deck to provide a pivot pint for the A&R winch wire to be rigged to assist in pulling out the coiled pipe from the reel. The turning sheave should be fitted with load cell in order to indicate the weight/load being taken on the A&R winch during operations.

3.9 Hold-back Pipe Clamp

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

3.10 Tensioner

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



3.11 Stinger

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

The stinger should a minimum of approximately 40m radius and 30m length in order to maintain the pipeline within its yield strength during laying

The spacing between roller boxes should be in the region of 5m. Spacing’s greater than this may increase the local bending moment on the pipeline due to the larger span between roller boxes.

Figure 8 is a representative sketch of a typical modular stinger. The stinger shall be hinged so that it can be lowered into the water during pipe-lay operations and lifted out of the water for transit and in port. If the installation vessel has no integral A-frame at the stern then and suitable fixed A-frame structure shall be installed at the inboard end, which acts as a lever arm during the deployment of the stinger. This A-frame structure does not require to be independently hydraulically operated via servomotors, but must still have the ability to raise and lower the stinger between operational and transit positions.

Figure 8 – Example of Typical Modular Stinger

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



4.0 COILED PIPE INSTALLATION

4.1 Mobilisation Operations

The installation contractor shall develop a mobilisation manual, to ensure all requirements are met and approved prior to mobilisation operations commencing. Prior to shipping to the designated port of mobilisation and prior to mobilization, tests on all installation equipment shall be performed, to demonstrate the suitability of the equipment for the installation operation and prior to these tests, the installation contractor shall develop a procedure for the pre-qualification activities, to include detailed description of all tests and calibration exercises required. Equipment provider(s) will undertake the mobilisation of the equipment in accordance with the schedule and the approved project mobilisation plan.

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

The approved vessel layout drawing for the equipment spread shall be issued for installation including mobilisation/demobilisation which illustrates the principal items to be supported on the vessel deck. The client shall provide all lifting cranes to allow the pre-slung assemblies to be lifted from the quayside onto the designated position on-board the vessel. Equipment suppliers shall specify weights and positions of CoG for their equipment and sacrificial attachment points to facilitate sea-fastening. In conjunction with the classification society for the vessel class issues, where applicable, the installation contractor shall design suitable sea-fastening for all equipment and secure the equipment onto the vessel deck in accordance with the approved sea-fastening design. The handling capacities the pipe laying equipment shall be in excess of the maximum loads to be experienced during the operation even during worst case scenarios. The structure of the vessel shall be strong enough to support the specified equipment and where required, reinforcements shall be provided. The design of such reinforcement shall be proven by calculation and approved by the relevant certifying authority. Hook-up will be performed once all equipment has been sea-fastened. At completion of the hook-up activities the equipment provider(s) shall perform a system test. This pre-approved procedure shall be undertaken and witnessed by the client. The mobilisation of the pipeline installation equipment onto the vessel and equipment are considered to be fully accepted when: All control steps have been performed satisfactory The main systems of the vessel and equipment have been tested satisfactory according to the

referred international standards, client specifications and the Project Requirements All the documents and certificates requested by the client have been found on-board, have been

checked to be up to date and to prove a good management of the vessel, the qualified personnel and the equipment mobilized on-board

All HSE and other requirements are fulfilled Visual inspection of the different systems and areas of the vessel are satisfactory.



4.2 Material

Specific care will be taken for the installation equipment and coiled pipe material; vendor handling procedures shall be adhered to at all times. All coiled pipes, installation aids, equipment and other items arriving on site shall be thoroughly

inspected in accordance with the project requirements and industry specifications and/or approved procedures. All items shall be accompanied by all necessary certifications.

Any damaged item shall be repaired, or replaced if repair is not allowed or not possible. A list of the found damages indicating the reinstatement method or remedial measures performed,

shall be continuously maintained and available at all time. During pipes storage and transportation shall meet the criteria in accordance with the Zap-Lok™

connector storage and transport procedures. Handling, loading, shipping, storage and unloading shall be carried out in such a manner as to avoid

any damage to the line pipes and other material Materials shall be traceable and identifiable throughout the Project by means of certified markings

related to the authenticated material certificates Storage areas shall fulfil all requirements specified by the material’s suppliers. Certification, test and inspection reports generated throughout the manufacture of components

and assemblies shall be traceable to the completed assembly.

4.3 Pipeline Installation Activities

This section provides the minimum requirements to be fulfilled during the preparation, site preparation and installation phases for normal and contingency conditions and shall be read in conjunction with the DNV-OS-F101. All mechanical connection operations and inspection shall be carried out in accordance with the project and vendor approved procedures for those mechanical connectors. Unless otherwise stated by the project requirements, lay direction together with reason for

selected options shall be proposed and duly documented in the Construction Manual; as a guideline, the lay direction shall minimise any possible interferences/clash with other activities.

Installation of the pipelines shall conform strictly with all applicable laws and regulations. The installation works shall also be performed in compliance with the applicable specifications and also in compliance with the following guidelines:

o Stress in the pipelines shall be controlled during the lowering, laying and repairing to prevent yielding, buckling or weakening of the pipe

o During the laying operations, equipment which will ensure the pipelines adequate protection from external forces which might cause buckling, weakening or overstressing of the pipe shall be provided as necessary

o All equipment used in handling and cradling coated pipe shall be of a type which will not damage the coating

o Pipe shall be handled in a manner to prevent damage to the pipe walls and bevels. In lining up the pipe, care will be taken so that pounding with a sledge hammer will not be necessary.

o When laying operations are interrupted and abandonment of pipe is decided, the open end of the laid pipe shall be securely closed and shall not be opened until laying is resumed.

o Any pipe end lowered in the water shall have watertight caps, installed with provisions for flooding and dewatering.

o In case of accidental water ingress any sections, incriminated sections shall be swabbed or pigged in a satisfactory manner before that section is tied into the line, according to the dedicated procedure.



According to the project requirements and before bringing a pipe to the assembly line, internal and external inspection shall be carried out on each coiled pipe in accordance with the requirements of the Tenaris inspection procedure, and the observed unacceptable defects shall be reported. The mechanical connector length of pipe internal diameter shall be proved by gauging by using a gauging plate designed as per vendor procedures.

All necessary precautions to keep the inside of the pipes free from dirt, waste and other foreign matters shall be taken.

The sequential marking/numbering of pipeline joints shall be done at the line up station and touched up after the pipe has passed through the tensioning device. Proper recording and maintenance in the pipe joint identification marks and numbers and of the sequence as-laid in position shall be done.

4.3.1 Pipeline Installation Monitoring

An operational plan for the monitoring of the pipeline installation vessel and installation parameters shall be produced. This plan shall be as simple as possible in order to immediately reflect or to confirm any shift of the monitored parameters towards unsafe areas. The operational plan and the pipeline installation monitoring system shall be fully described in the Construction Manual with the aim to ensure that normal and contingency installation works are conducted in a safe manner by giving the parameters to the Project. The monitoring system shall be designed to provide instantaneous direct or indirect access to pipeline buckling and collapse safety margin, pipeline as-laid versus initial routing gap, static and dynamic deflections, fatigue, etc. As a minimum, the following parameters shall be monitored, recorded in a continuous way, and made available to Company, with calibration against allowable areas defined above, for: Pipe tension, tensioning devices setting and dead band Tensioner squeeze pressure and pay out/in speed Abandonment & Recovery winch cable tension Water depth Stinger: angle and loads in a mechanical supporting system Continuous monitoring at TDP: by ROV or Departure angle of pipe from stinger Horizontal distance from pipe departure at the vessel to TDP Wind speed and direction

Direct reading and processing of stored records from all required essential instrumentation, measuring devices and video monitoring system shall be possible at the vessels bridge.

4.3.2 Pipelay Route

Before the commencement of pipe laying works, a pre-lay survey of the pipeline system installation corridor and mooring anchors corridor (If applicable) shall be conducted according to the applicable reference documents. From the pre-lay survey results, a freespan assessment task shall be performed in order to evaluate the required freespan reduction works. When processing freespan assessment, it shall be demonstrated whether or not the pipe will deflect and gain any intermediate supports under in-service



conditions. Also the location of these supports as well as their suitability as permanent supports (integrity, susceptibility to scour, etc.) shall be fully assessed from the pre-survey results. The location of freespan reduction supports, as well as the required pipeline lift-up height shall then be specified so as to optimise the in-service stress/strain behaviour of the pipeline. The construction route including expected pipeline service life displacement area shall be cleared of any debris and obstructions assessed as hazards, in order to facilitate the proper and safe installation of the pipelines, crossings and other.

4.3.3 Pipelay initiation

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

4.3.4 Pipelay

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

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

Stages 2 & 3 - Prepare and bell end of new reel

Stages 4 – 8 - Pick up the Laid end and bring it onto the stinger and aboard at the stern of the

vessel

Stage 9 - Bring the laid end into the tensioner and remove the pull head

Stages 10 & 11 - Bell the laid end and withdraw the laid end into the tensioner

Stage 12 - Pick up the PUP, install into rear clamp of Zap-Lok™ press

Stage 13 - Bring Zap-Lok™ press and PUP forward, install new reel end into forward clamp of

Zap-Lok™ press, make up joint between new reel end and PUP and wait 5 minutes to cure Zap-

oxy compound

Stage 14 - Open clamps, move Zap-Lok™ press aft, till in position to grip PUP in forward clamp

and close forward clamp

Stage 15 - Tensioner advances pipe into Zap-Lok™ press, rear clamp closed joint made between

PUP and laid end, wait 5 minutes to cure Zap-oxy compound

Stage 16 - Lay pipe

Stages 17 – 26 - In General terms, repetition of the foregoing for the next reel.



Stage 27 - Port visit to unload empty reels, restock with full reels, take on bunkers and stores,

and carry out crew changes and any other requirements as they arise. Return to the field to

repeat the foregoing steps until the target box adjacent to the platform has been reached.

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

4.3.5 Contingency

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

4.3.6 Concrete Mattresses

The installed pipeline shall be protected and stabilised on seabed by use of concrete mattresses. These shall be positioned once pipeline has been installed and after commissioning. These mattresses may be deployed from either the Pipeline Installation Vessel or alternative supporting vessel by use of a concrete mattress lifting beam via crane or winch. It may be necessary to deploy some mattresses during pipeline installation to ensure stability in shallow water areas where seabed is hard and currents may induce movement of pipeline on seabed. There will be an estimated 449 mattresses to be installed along the pipeline route. The pipeline route has been divided into six (6) section and the locations and number of concrete mattresses to be deployed in each section can be referenced in extract pages of the Calculation of Pipeline document DP00315-OWR in Appendix G. Installation of concrete mattress in areas of very soft seabed conditions (non-bearing ground) shall be avoided to safeguard against sinkage of the mattresses and potential damage to the pipeline from the weight of the mattress.

Section 1 o Distance 6328 meters’ long o 113 mats will be deployed, one every 50 meters

Section 2 o Distance 12656 meters’ long o 226 mats will be deployed, one every 50 meters

Section 3 o Distance 7114 meters’ long o 85 mats will be deployed, one every 50 meters o Section consists of bearing and non-bearing ground

Section 4 o Distance 23555 meters’ long o No mats will be deployed o Section consists of non-bearing ground and pipeline is predicted to sink into the soft

clay



Section 5 o Distance 6500 meters’ long o 55 mats will be deployed, one every 50 meters o Section consists of bearing and non-bearing ground

Section 6 o Distance 19475 meters’ long o No mats will be deployed o Section consists of non-bearing ground and pipeline is predicted to sink into the soft

clay The concrete mattress dimensions are 6m x 3m with an approximate weight of 8,145kg in Air and 4,667kg in water. Reference drawing 7027-ENG-DWG-0002 Rev 3 in Appendix G. The Concrete Mattress Lifting beam shall be designed with the capacity for the single deployment of a mattress and shall be hydraulically operated and can be reference in drawing FXT-EQU-ENG-LB-260515 Rev 0 in Appendix G.

4.3.7 Final surveys

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

4.4 Demobilization of Vessel

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

4.5 Offshore Works Completion and Reporting

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

Final Acceptance documentation

Final Documentation and As-Built

Pipeline Design Report

Pipeline Installation Design Report

Installation Manual(s)

Material Certificates

Daily production and quality reports – See Appendix F for example of Zap-Lok™ Pipe Tally Report and NOV End Preparation Report

Tension strip charts

Vessel daily reports including Job Safety Analysis (JSA) reports

Accident/incident reports and non-conformance reports

All relevant data form installation operations

All Subcontractor reports



5.0 PIPE-LINE PRE-COMMISSIONING

5.1 General

The purpose of this design guideline is to provide an outline to be followed when hydro testing submarine pipelines for hydrocarbon service in the oil and gas industry. The following section describes a typical flooding, cleaning and gauging method statement. Where the text in following section mentions pigging it should be noted that it is normal practise NOT to use pigs in lines of 4inch diameter and below due to the risk of getting a pig stick in the line. In view of the bore and length of this pipe-line, consideration shall be given to using the alternative technique of high velocity flushing instead of pigging. The line could be flooded by high velocity flushing with treated seawater with a percentage overage (TBA) to confirm the line is filled. The measure of internal condition of the pipe is achieved by comparing actual back pressure with the theoretical value to confirm “true” bore of the line.

5.2 Pipeline Hydrotest

5.2.1 Flooding, Cleaning and Gauging of Pipeline System

The pipeline system shall be flooded, cleaning and gauged in accordance with the approved operation procedure. See NOTE below. Following deployment and connection of the downline, a connection test will take place to confirm the integrity of the newly made subsea connection. Once the newly made connection is confirmed as leak free, operations can commence. The pipeline will be flooded, cleaning and gauged using up to 120%-line volume of chemically treated and dyed seawater or potable water, inhibited and filtered as required to propel a 3 x bi-directional pig train comprising of; cleaning pig, brush pig and gauge pig. All pigs will be propelled at a typical speed of between 0.5m/s – 1.0 m/s as detailed below:

Pump a minimum 250 linear metre slug of filtered, untreated seawater / potable water to act as a lubricant

Launch pig #1 (bi-directional flooding pig) followed by a minimum of 250 linear metres of filtered, untreated seawater

Launch pig #2 (bi-directional magnetic brush pig) followed by a minimum of 250 linear metres of filtered, untreated seawater

Launch pig #3 (bi-directional gauge pig) followed by 120%-line volume of filtered, untreated seawater



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

5.2.2 Pigging Parameters

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

5.2.3 Chemical Details

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

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

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

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

Time (hh:mm)

Pressure (barg)

Flow Rate (m3/min)

Total Volume of Seawater Pumped (m3)

Total Volume of Chemicals Pumped (Ltrs)

Flooding Medium Temperature & Ambient Temperature (°c) The following information will be calculated at 15 minute intervals throughout flooding operations:

Velocity (m/s)

Distance (km)

Time to arrival (hh:mm)

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

5.3 Hydrostatic Strength Testing of Pipeline System

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



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

5.3.1 Pressure Testing

All pressure testing will be carried out taking into consideration the requirements of pipeline design and client requirements. All temporary equipment to be used shall be pressure tested prior to operations commencing at a test pressure of 1.1 x hydrostatic strength test pressure (TBA barg). Fill up the pipeline with water and increase pressure up to WP x 1.8 (24.8MPa) for 2 hours realized strength test, after this time decrease pressure to WP x 1.2 (16.6MPa) after stabilisation pressure keep this for 24 hours realized Hydrostatic pressure test (tightness test) Pressure recorders, pressure gauges and temperature recording equipment shall be in operation during pressure testing activities and pressure relief valves shall be fitted for pressure testing the temporary testing spread prior to strength testing operations.

5.3.2 Testing Parameters

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

5.3.3 Pressurisation

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

Time (hh:mm)

Pressure (barg)

Total Volume Injection (Ltrs)

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

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

Time (hh:mm)

Pressure (barg)



Total Volume Injection (Ltrs)

Δ Volume Injected (Ltrs)

Ambient Temperature (°c)

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

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

5.3.4 Stabilisation & Hold Period

Upon reaching 100% of the test pressure, the pipeline shall be isolated and a stabilisation period shall commence. Should the pipeline pressure drop below the test pressure, pressure shall be increased at a rate of 0.1 barg per minute until 100% of test pressure is reached. This process shall continue until pipeline pressure is stabilised. A hold period of 24-hour shall commence. The following parameters shall be recorded at 30 minute intervals:

Time (hh:mm)

Test Pressure (barg)

Ambient Temperature (°c)

5.3.5 Test Acceptance

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

5.3.6 Depressurisation

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

5.4 Pipeline De-watering and Drying

5.4.1 De-watering and Drying

Future tie-in operations between the pipe-line and the platform riser are beyond the scope of this report. In view of the need to pressure test the connection between the pipe-line and the riser, the client may decide to leave de-watering and drying of the line until after this connection has been made and successfully tested. For this reason this report does not address these requirements.



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

INTENSIONALLY BLANK

90001500

67308

1000

15001654

1000

1

2

3

4

5

7

8

10

6

309551111

11

11000

13108

9

47905

2845

(+3 REELS DECK LENGTH)

12

43185903

13

3000

1Pipe Path

CLIENT: SUBJECT: SCALE-

REV DATE DRAWN CHECKED APPROVED

B8 PIPELINE INSTALLATIONDECK PLAN

S.D.02.06.16

SHEET:1 of 1

draft

Z12/112996-ENG-DWG-00001LOTOS PETROBALTICM.M. G.C.

S.D.04.07.1601 M.M. G.C.



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

INTENSIONALLY BLANK



APPENDIX C – TENARIS COILED TUBING REEL DRAWING

INTENSIONALLY BLANK



APPENDIX D – ZAP-LOK™ 8000-12T PRESS

INTENSIONALLY BLANK

Weight = 18,000 lbs.

ZAP-LOK 8000-12 (T) PRESS

Specifications

NPS / DN 6” - 12” (150 mm - 300 mm)OD [inches (mm)] 6 5/8” - 12 3/4”(168.27 mm - 323.85 mm)Dimensions 160” x 80” x 85”[L x W x H] (4.06 m x 2.03 m x 2.16 m)Weight 18,000 lbs., 8,164.66 kg, 9.00 short tons (US),

8.03 long tons (UK), 8.16 tonnes (MT)Power Zap-Lok 8000 HPU

32



APPENDIX E – PROJECT SCHEDULE

INTENSIONALLY BLANK

ID Task Mode

Task Name Duration Start Finish

1 Lotos Petrobaltic ‐ B8 Gas Pipeline Installation using Zap‐LokConnection

32.21 days Mon 03/04/17

Fri 05/05/17

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

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

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

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

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

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

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

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

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

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

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

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

14 Zap‐Lok connection first reel tail end to second Reel new end

4 hrs Fri 07/04/17 Fri 07/04/17

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

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

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

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

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

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

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

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

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

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

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


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

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

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


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


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

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

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


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

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

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

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

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

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

03/04

W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M Tb '17 06 Mar '17 13 Mar '17 20 Mar '17 27 Mar '17 03 Apr '17 10 Apr '17 17 Apr '17 24 Apr '17 01 May '17 08 M

Task

Split

Milestone

Summary

Project Summary

External Tasks

External Milestone

Inactive Task

Inactive Milestone

Inactive Summary

Manual Task

Duration‐only

Manual Summary Rollup

Manual Summary

Start‐only

Finish‐only

Deadline

Progress

Page 1

Project: CSL‐OPS‐P422‐SCHD‐001_Date: Tue 05/07/16



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

INTENSIONALLY BLANK

2800psi

2800psi

2800psi2800psi

Pipe No. Heat No. Length (M) Type ThicknessInsertion

Depth (M)

QC

Verified

(Y/N)

Clamp

Marks (Y

/ N)

Effective

Length (M)

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

001 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

002 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

003 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

004 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

005 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

006 12.20 FBE 14-16 Mils 0.381 Y N 11.82

007 12.20 FBE 14-16 Mils 0.381 Y N 11.82

008 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

009 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

010 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

011 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

012 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

013 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

014 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

015 12.20 FBE 14-16 Mils 0.381 Y N 11.82

016 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

017 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

018 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

019 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

020 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

021 12.20 FBE 14-16 Mils 0.381 Y Y 11.82

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

Signature

Client:

Location:

Zapoxy Type:

Chevron Thailand E&P Ltd.

Chevron 2016 Installation Campaign

Gulf of Thailand

PL50/2 10"BABLI

API 5L X42

Mixer Model: Mixer Serial No.

HPU Model:

10" OD x 0.500" WT

06 April 2016

Day

1 of 1

Press Model:

Zap-Lok Installation Equipment

Pipe Size:

Date:

Shift:

Page:

Project:

Material:

Pipeline:

Pipe Clamp Pressure:136 Zapoxy Batch No. Press Stroke Pressure:

8000-12T Press Serial No. Press Test Pressure:

Report No.:

HPU Working Pressure:8000 HPU Serial No.

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Anode Installed, Shrink wrap

applied

Shrink wrap applied

No. Comments

Zap-Lok ConnectionPipe Data Coating Type

ZAP-LOK PIPE TALLY REPORT

CHEVRON THAILAND E&P LTD.SOLSTAD OFFSHORECORTEZ SUBSEA

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Shrink wrap applied

Name

260.40Total Laid This Sheet (M):

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

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

Date End User

Pipe Vendor Mftr

Pipe Size / Grade Wall Thickness

ERW/SMLS Type 2 or 4

EP Station Beller Operator Pinning Operator

Inspector Rinse Forklift Operator

Beller Clamping Pressure Pinning Clamping Pressure

Mandrel Number Mandrel OD Spec

Steel Inspection Bell Inspection

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

Pipe Inspection Lubricant completely removed

Check for squareness Check for ovality Check for dog legging

Check for excessive rust Check for pitting Pin Inspection

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

Reworks/Rejects Cells Color Filled Lubricant

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

Report By

www.nov.com/tuboscope

NOV Tuboscope Zap-Lok Headquarters NOV Tuboscope Zap-Lok End Prep

18660 East Hardy Road 39 Gul Ave

Houston, Texas 77073 Singapore 629679

United States Phone: +65 9733-0665

Phone: +1 713 849 4932 Email: [email protected]

EQUIPMENT INFORMATION

3100

Nick Benoot

Bredero shaw Kuantan Steven Galvan

Bredero Shaw

Mike Gambino

Bredero Shaw

End Preparation Daily Quality Control Report

WO# 019-16-01

OPERATOR INFORMATION

Chevron Thailand

MITA (Marubeni)

2

JOB INFORMATION

CUEL

0.500"

ERW

23/4/2016

10-3/4" X42

10.572

2000

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

Backing Roller

Bead Roller

10.14 10"-12" Type 2 (3148-1)

10"-12" Type 2 (3150-2)

PRODUCTION SUMMARY

225Total # of Joints Processed Today

(-) # Reworks

(-) # Rejects

0

0

Total Joints

Complete & Ready 225

Nick Benoot

mark readings measured for the first 5 joints of the day were #1 .001", #2 .001", #3 .000", #4 .001", #5 .004". Close to the end of the shift the heat numbers

the order is around 460 joints for completion. We will continue production on Monday 4-25-16, as Sunday is an off day for the workers. The belling tool grip

END PREP PRODUCTION COMMENTS

approval was confirmed to cut and re-bevel the calibration joint which at this point is the only rework we have for the order.

began to change from the last several reported heat numbers. Also the drill hole was made this morning for the UT calibration standard procedure, and the

Today production went well and we had no issues with the pipe or machinery. We prepped 225 joints with no reworks or rejects, so the estimated pipes left in

Chevron-ZL-100-01 Rev.3 4/21/16

EXAMPLE

Tolerances for Wall Thickness Grade x-42 and higher ( -12.5% to +15% of Specified Wall Thickness)


© 2014 National Oilwell Varco

NOV Tuboscope Zap-Lok Headquarters NOV Tuboscope Zap-Lok End Prep All rights reserved





0.154 0.135 1.177 0.300 0.263 0.345

End Prep QC 2 ⅜" - 12 ¾" LL -

ZAP-LOK SPECS

Wall Thickness Low High Wall Thickness Low High

0.136 0.179 0.322 0.281 0.370

0.216 0.189 0.248 0.375 0.328 0.431

0.203 0.178 0.233 0.365 0.319 0.419

0.188 0.164 0.216 0.337 0.295 0.387

0.156

0.219 0.191 0.251 0.432 0.378 0.496

0.218 0.191 0.250 0.406 0.356 0.466

0.250 0.218 0.287 0.562 0.491 0.519

0.237 0.208 0.272 0.500 0.437 0.575

0.280 0.245 0.322 0.625 0.549 0.718

0.276 0.242 0.317 0.594 0.519 0.683

Bell DepthBell Flare

AngleBell ID

2 ⅜" .015" Min 0.815"

1.065"2°- 5° 6°- 9° 2.360" - 2.437" 3 3/4"

Pipe

Diameter

Groove

Depth

Groove

Location

Type 2

Angle

Type 4

AnglePin End OD

3°

5°2.280" - 2.340"

2 ⅞" .020" Min 0.815"

1.065"2°- 5° 6°- 9° 2.860" - 2.937" 5 7/8" 3°

5°2.780" - 2.840"

3 ½" .020" Min 0.815"

1.065"2°- 5° 6°- 9° 3.485" - 3.562" 5 7/8" 3°

5°3.397" - 3.457"

5 7/8" 3°

5°4.388" - 4.453"

6 ⅝" .040" Min 1.00"

1.250"2°- 5° 8°- 15° 6.610" - 6.687" 9.5"

4 ½" .020" Min 0.815"

1.065"2°- 5° 6°- 9° 4.485" - 4.552"

8°

12°6.489" - 6.549"

8 ⅝" .040" Min 1.00"

1.250"2°- 5° 8°- 15° 8.610" - 8.687" 10.5" 8°

12°8.386" - 8.521"

10 ¾" .040" Min1.500"

1.900"8°- 10° 8°- 15° 10.719" - 10.843" 11.5" 8°

12°10.465" - 10.626"

13" 8°

12°12.423" - 12.603"12 ¾" .040" Min

1.500"

1.900"8°- 10° 8°- 15° 12.719" - 12.843"

Chevron-ZL-100-01 Rev.3 4/21/16

EXAMPLE

5500 Belling Tool 2" 2754 2"

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

2755

5500 Belling Tool 2 1/2" 2757 2 1/2"

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

2758

5500 Belling Tool 3" 2759 3"


2760

5500 Belling Tool 4" 2761 4"


2762

8000-12 Belling Tool 4" 2761 Nose Piece 4"

2752 Spacer

2762 Flare Ring

4" Mandrel Adaptor

2747 3044

2740

2748

6"

3004 3043

3003

3002

Back Stop Plate

3007 10"

3006

3005

Back Stop Plate

3010 12"

3009

3008







Chevron-ZL-100-01 Rev.3 4/21/16

Spacer

Flare Ring

None

Equipment Mandrel Part # Description Slip Part # Description

8000-12 Belling Tool 6" Nose Piece

8000-12 Belling Tool 12"

Spacer

Flare Ring

Nose Piece

6 Slips needed8000-12 Belling Tool 8" Nose Piece

Spacer

Flare Ring

Belling Tool Parts Reference List

Flare Ring

Nose Piece

Spacer

Nose Piece

Flare Ring

Nose Piece

Spacer

Flare Ring

Nose Piece

Spacer

2 Slips needed

2 Slips needed

2 Slips needed

2 Slips needed

8000-12 Belling Tool 10"

Flare Ring

Spacer

6 Slips needed


6 Slips needed

Spacer Bolts - (6) 5/8" x 3 1/2" Grade 8 SHCS

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

Definitions: SHCS - Socket Head Cap Screw

Flare Ring

Mandrel Adaptor

2 Slips needed

2 Slips needed


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

Nose Piece

EXAMPLE

5000 Pinning Tool (2") 3079-1 Bead Roller 3079-1 HW Bead Roller (Heavy Wall)

3078-1 Finish Roller 3077-1 Turn Down Roller - Type 2

3080-1 Turn Down Roller - Type 4

5000 Pinning Tool (2 ⅞") 3079-2 Bead Roller 3078-2 Finish Roller

3077-2 Turn Down Roller - Type 2 3080-2 Turn Down Roller - Type 4







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

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

7000 Pinning Tool (6") 3090-2 Bead Roller 3091-1 Finish Roller

3088-1 Turn Down Roller - Type 2 3089-1 Turn Down Roller - Type 4

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




8000-12 Pinning Tool (10") 3150-2 10"/ 12" Type 2 Bead Roller

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

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

3151-2 HW New 10"/ 12" Type 4 Bead Roller (Heavy Wall)

3148-1 10"/ 12" Backing Roller Type 2

3148-2 10"/ 12" Backing Roller Type 4

3119-2 10"/ 12" Backing Roller Shaft Bracket

3119-2 HW New 10"/ 12" Backing Roller Shaft Bracket (Heavy Wall)







Equipment Part # Description Part # Description

Pinning Tool Parts Reference List

Chevron-ZL-100-01 Rev.3 4/21/16

EXAMPLE

Date End User

Pipe Vendor Mftr

Pipe Size Wall Thickness

ERW/SMLS Type 2 or 4

Cutting Operator Transfer Operator

Signature







Chevron-ZL-100-01 Rev.3 4/21/16

ERW 2

OPERATOR INFORMATION

Bredero Shaw Kuantan Bredero Shaw Kuantan

REWORKS/REJECTS

End Preparation Daily Quality Control ReportJOB INFORMATION

WO# 019-16-0123/4/2016 Chevron Thailand

CUEL MITA (Marubeni)

0.500"

NOTE: TRANSFER JOINT & HEAT NUMBERS ONTO CUT PIECES OF PIPE

Joint # Reject or Rework Heat #Length

Removed

Remaining

LengthDescription of Defect

10-3/4" X42

Nick Benoot

EXAMPLE

Bell I.D. Max 10.626 Bell I.D. Minimum Pin O.D. Max Pin O.D. Minimum

Pipe # Heat #

20300 36480

20361 36480

20358 36480

20359 36480

20348 36477

20372 36481

20298 36480

20299 36480

20305 36480

20354 36480

20363 36480

20373 36481

20353 36480

20371 36481

20388 36481

20428 36481

20437 36481

20431 36481

20384 36481

20362 36480

20410 36480

20425 36481

20426 36481

20411 36480

20427 36481

20331 36480

20332 36480

20389 36481

20381 36481

20432 36481

20408 36481

20492 36481

20406 36481

20491 36481

20407 36481

20445 36481

20480 36481

20404 36481

20430 36481

20429 36481

20619 36477

20439 36481

20440 36481

20438 36481

20479 36481

20433 36481

20595 36477

20680 36477

20671 36477

20452 36481

Signature







Joint # Pin End O.D. Wall Thickness Groove Depth Groove Location

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

10.47 10.843 10.719

Pin End Angle Bell I.D. Flare Angle 100% Visual Insp. Grip Marks

2

1 10.762 0.488 0.052 10 0.001"/0.025mm

0.001"/0.025mm

10.562

3 0

0.001"/0.025mm

0.004"/0.1mm

6

5

4

7

10 10.765 0.48 0.06 10 10.562

9

8

11

13

12

14

15

17

16

18

19

10 10.567

21

20 10.755 0.501 0.06

22

23

25

24

26

27

29

28

30 10.76 0.503 0.063 10 10.563

31

33

32

34

35

37

36

38

39

10 10.56

41

40 10.771 0.495 0.06

42

43

45

44

46

47

49

48

Chevron-ZL-100-01 Rev.3 4/21/16

Nick Benoot

50 10.765 0.494 0.051 10 10.563

EXAMPLE


Pipe # Heat #

20436 36481

20434 36481

20681 36477

20676 36477

20675 36477

20605 36477

20502 36481

20531 36477

20435 36481

20593 36477

20673 36477

20538 36477

20662 36480

20501 36481

20590 36477

20537 36477

20591 36477

20536 36477

20592 36477

20674 36477

20559 36480

20467 36481

20526 36481

20520 36481

20519 36481

20506 36481

20557 36477

20508 36481

20529 36477

20465 36481

20453 36481

20513 36481

20507 36481

20566 36477

20521 36481

20204 36480

20249 36480

20201 36480

20248 36480

20247 36480

20489 36481

20376 36481

20375 36481

20374 36481

20224 36480

20417 36480

20380 36481

20488 36481

20367 36481

20366 36481

Signature

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






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

10.47 10.843 10.719

Groove Location Pin End Angle Bell I.D. Flare Angle 100% Visual Insp. Joint # Pin End O.D. Wall Thickness Groove Depth

51

52

53

54

55

56

57

58

59

10 10.547 60 10.773 0.495 0.055

61

62

63

64

65

66

67

68

69

10 10.548 70 10.775 0.49 0.052

71

72

73

74

75

76

77

78

79

10 10.554 80 10.754 0.491 0.056

81

82

83

84

85

86

87

88

89

10 10.559 90 10.572 0.494 0.059

91

92

93

94

95

96

97

98

99

Nick Benoot

10 10.564 100 10.76 0.502 0.055

EXAMPLE


Pipe # Heat #

20409 36480

20454 36481

20416 36480

20365 36480

20415 36480

20418 36481

20385 36481

20379 36481

20414 36481

20448 36481

20468 36481

20403 36481

20402 36481

20419 36481

20378 36481

20462 36481

20446 36481

20455 36481

20469 36481

20456 36481

20463 36481

20386 36481

20401 36481

20392 36481

20391 36481

20618 36481

20395 36481

20394 36481

20393 36481

20514 36481

20612 36481

20582 36477

20390 36481

20515 36481

20396 36481

20583 36477

20584 36481

20614 36481

20617 36481

20613 36481

20565 36477

20548 36481

20610 36481

20558 36477

20496 36481

20615 36481

20606 36477

20490 36481

20549 36481

20547 36481

Signature







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

10.47 10.843

101

Joint # Pin End O.D. Wall Thickness

Groove Location Pin End Angle Bell I.D. Flare Angle 100% Visual Insp. Groove Depth

103

102

105

104

107

106

109

108

111

110 10.759 0.491

10 10.564 0.052

113

112

115

114

117

116

119

118

121

120 10.761 0.504

10 10.559 0.057

123

122

125

124

127

126

129

128

131

130 10.754 0.496

10 10.57 0.052

133

132

135

134

137

136

139

138

141

140 10.76 0.495

10 10.565 0.051

143

142

145

144

147

146

10.719

10 10.567

Nick Benoot

150 10.76 0.49 0.053

149

148

EXAMPLE


Pipe # Heat #

20449 36481

20494 36481

20495 36481

20616 36481

20497 36481

20528 36477

20685 36477

20672 36477

20684 36477

20683 36477

20556 36477

20562 36481

20561 36481

20560 36480

20518 36481

20458 36481

20511 36481

20686 36477

20677 36477

20555 36477

20451 36481

20517 36481

20450 36481

20487 36481

20441 36481

20546 36477

20512 36481

20552 36481

20551 36481

20533 36477

20510 36481

20500 36481

20521 36481

20539 36477

20540 36477

20553 36480

20457 36481

20509 36481

20464 36481

20461 36481

20485 36481

20466 36481

20486 36481

20679 36477

20516 36481

20620 36477

20543 36477

20554 36477

20532 36477

20472 36481

Signature







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

10.47 10.843 10.719

151

Joint # Pin End O.D. Wall Thickness


153

152

155

154

157

156

159

158

161

160 10.765 0.494

10 10.554 0.059

163

162

165

164

167

166

169

168

171

170 10.762 0.499

10 10.556 0.056

173

172

175

174

177

176

179

178

181

180 10.763 0.496

10 10.551 0.059

183

182

185

184

187

186

189

188

191

190 10.757 0.496

10 10.568 0.052

193

192

195

194

197

196

199

198

10 10.557

Nick Benoot

200 10.758 0.49 0.056

EXAMPLE

Bell I.D. Max 10.63 Pin O.D. Max Pin O.D. Minimum

Pipe # Heat # Pin End O.D.

20473 36481

20474 36480

20678 36477

20475 36480

20525 36481

20587 36477

20604 36477

20542 36477

20550 36481

20541 36477 10.76

20611 36481

20588 36477

20352 36480

20345 36477

20413 36481

20589 36477

10229 17323

A10085 20534

10248 17323

A10096 20534 10.761

10197 17323

A10113 20534

10241 17323

A10039 17319

10199 17323

Signature







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

10.47 10.843 10.719

201

Joint # Wall Thickness


203

202

206

205

204

209

208

207

210 0.496

10 10.562 0.059

213

212

211

215

214

218

217

216

221

220 0.498

10 10.564 0.06

219

222

224

223

227

226

225

230

229

228

233

232

231

234

236

235

239

238

237

242

241

240

245

244

243

246

247

Nick Benoot

250

249

248

EXAMPLE



APPENDIX G – CONCRETE MATTRESSES

INTENSIONALLY BLANK

Project No.

DP00315

CALCULATION OF PIPELINE

Project name Executive pipeline project B8-W�adys�awowo.

Location Seam B8 � Elektrociep�ownia W�adys�awowo

Project No. DP00315

TECHNICAL DOCUMENTATION LOTOS Petrobaltic S.A.

Documentation archival No. Documentation No. Page Pages Rev.

DP00315-OWR 13 73 0

3 Calculations with the use of AutoPIPE

To determine the maximum unsupported length of the pipeline, proper calculations were performed. The

pipeline model included mounted 8-ton stabilizing mats. Calculations showed that maximum acceptable

unsupported length of the pipeline is 50 meters.

Pic. 3.1. Model view

In case of pipeline scouring on the length of 50 meters, the maximum stress ratio of the material is 0.72.

The maximum deflection of the pipe occurs midway between mats and is 2182 mm.

Analyzing the geotechnical data provided by Lotos Petrobaltic it was found that, maximum scouring depth

may be up to 800mm. To modeled this case, possibility of pipeline deflection in unsupported point was

limited up to 800 mm in vertical axis. In case of total scouring on entire analysis lengths (50m), pipeline

will be laid on scouring seabed. Maximum stress ratio will be 0.54. The highest value of stress will take

place at the end of the mat. (as is marked on picture 3.2)

Project No.

DP00315




Project No. DP00315



DP00315-OWR 14 73 0

Pic. 3.2. Stress in the described system

Pic.3.3. Displacements in the described system

Project No.

DP00315




Project No. DP00315



DP00315-OWR 15 73 0

After the calculation of the maximum unsupported length of the pipeline, strength calculations for pipeline

were performed taking into account the trawl impact. Forces related with the trawl impact were calculated

in section 1.

Strength calculations have shown that maximum distance between mats is 50 meters, for the section

where pipeline scouring and trawl impact may occur. The 8-ton mats were assumed in the calculation.

Pic. 3.4. Model view

If unsupported section will be hit by trawl ( what is the most worst case in all analysis) the value of

maximum stress ratio will be 0.8. The highest value of stress will take place at the end of the mat. ( as is

marked on picture 3.5). When trawl will hook pipeline, pipeline will move 2789 mm in the direction of the

force caused from trawl. This is shown on picture 3.6.

Project No.

DP00315




Project No. DP00315



DP00315-OWR 16 73 0

Pic. 3.5. Stress in the described system

Pic.3.6. Displacements in the described system

Project No.

DP00315




Project No. DP00315



DP00315-OWR 17 73 0

Strength calculation taking into account initial temperature of fluid service was performed. Analysis

contained in description DP00315 point 7 shows that temperature of 4 stC will be reached in point

located 1500 m from riser flange (for maximum value of the flow). Initial temperature of fluid service was

introduced to the model according to the chart below.

Project No.

DP00315




Project No. DP00315



DP00315-OWR 18 73 0

Pic. 3.7 Displacements in the described system

Pic. 3.8 Displacements in the described system

Project No.

DP00315




Project No. DP00315



DP00315-OWR 19 73 0

The performed analysis show that set temperature in pipeline does not affected on exceeding of

allowable stressed. The highest deflection in analysis system equal 4.67 mm.

Strength analysis and deflation analysis for point where pipeline outlet on surface of seabed from HDD

drilling was performed. For 12st angle of outlet pipeline from HDD drilling occurs pipeline deflection.

Deflection cause laying the pipeline on the seabed right behind outlet point. With such a deflection stress

ration equal 0.96.

Pic. 3.9 � HDD Model View

Project No.

DP00315




Project No. DP00315



DP00315-OWR 20 73 0

Pic. 3.10 - Displacements in the described system

Project No.

DP00315




Project No. DP00315



DP00315-OWR 21 73 0

4 Division of the pipeline sections

Because of variable characteristic of Batlic seabed and different various load ranges, pipeline has been

divided into six section:

The section 1 is 6328 meters long. The starting point is located in P1 point. The finishing point of the section

one I located 36,8 meters before the V-217/14 point. In this section 113 mats will be laid every 50 meters .

The mats are 6 meters long.

Loads included in the calculations:

- scouring

- see current velocity of 0,75 kn

- waving

Section 1 consist of bearing ground.

The section 2 is 12656 meters long. The starting point is located 36,8 meters before V-217/14 point. The

finishing point of the section 2 is located 1,6 meters before V-178/14 point. In this section 226 mats will be laid

every 50 meters. The mats are 6 meters long.


- scouring


- waving

- trawl impact

Section 2 consist of bearing ground.

The section 3 is a 7114,1 meters long. The starting point is located 1.6 meters before V-178/14 point. The

finishing point of the section 3 is located 68 meters before V157/14 point. In this section 85 mats will be laid

every 50 meters. The mats are 6 meters long. Section 3 consist of bearing and non-bearing ground.


- scouring


- waving

- trawl impact

Project No.

DP00315




Project No. DP00315



DP00315-OWR 22 73 0

The section 4 is 23555,2 meters long. The starting point is located 68 meters before V157/14 point., The

finishing point of the section 4 is located 136 meters beyond V-083/14 point. There are no mats located in

this section because of non-bearing ground. The pipeline is submerged in the non-bearing ground.

The section 5 is 6500,8 meters long. The starting point is located 136 meters beyond the V-083/14 point.

The finishing point of the section 5 is located 54,4 meters before the V-062/14 point. In this section 25 mats

will be laid every 50 meters . The mats are 6 meters long. Section 5 consist of bearing and non-bearing

ground.


- scouring


- waving

- trawl impact

The section 6 is 19475,2 meters long. The starting point is located 54,4 meters before V-062/14 point. The

finishing point of the section 6 is located in B8-2/5 point. There are no mats located in this section because of

non-bearing ground. The pipeline is submerged in the non-bearing ground. From point B8 2/5 occurs

temperature different from 4 degrees according to chapter DP00315-OSC picture 4.

Project No.

DP00315




Project No. DP00315



DP00315-OWR 23 73 0

4.1 Section 1

The section 1 is 6328 meters long. The starting point is located in P1 point. The finishing point of the section

one I located 36,8 meters before the V-217/14 point. In this section 113 mats will be laid every 50 meters .

The mats are 6 meters long.

NOTES:1. ALL DIMENSION IN mm UNO2. LATERAL ROPES Ø18 mm POLYPROPYLENE (PP), RATED TO 4.8 t

BREAKING STRENGTH (MINIMUM)3. SIDE LIFT ROPES Ø22 mm POLYPROPYLENE (PP), RATED TO 7.0 t

BREAKING STRENGTH (MINIMUM)4. LIFTING ROPES ARE DESIGNED ACCORDING TO DNV RULES FOR

PLANNING AND EXECUTION OF MARINE OPERATIONS (1996) Pt: 2,Ch: 5 & 6

5. CONCRETE DENSITY: 2400 kg/m³6. VOLUME PER MATTRESS: 3.39 m³7. CONCRETE MATTRESS WEIGHT: 8,145 kg (AIR), 4.667 kg (SUB)8. ALL BLOCKS ARE ENCASED IN 3 mm PP9. EACH BLOCKS ARE 500(L) x 500(W) x 300(H) mm

BLOCK DETAILS: X300SCALE 1:10

PROJECT TITLE :

DRAWING TITLE :

©2015 by FLXMAT All rights reserved. This document is confidential and may contain copyright material protected by law. If youhave received it in error, no copyright or confidentiality is lost and you may not disclose or use this document but please notify us. Nopart of this document may be reproduced or transmitted in any form or by any means without prior written permission of FLXMAT .

F L X M A T6 4 B Q U E E N S T R E E T , S I N G A P O R E 1 8 8 5 4 3W E B S I T E : W W W . F L X M A T . C O M , E M A I L : I N F O @ F L X M A T . C O M

SIZESCALEREV.37027-ENG-DWG-0002 A1

DRAWING No. :AS SHOWN

REV. DATE DESCRIPTION DRN. CHK. APD.

CLIENT :

6.0 x 3.0 x 0.3 m, X300, FLXMAT G.A.

6.0 x 3.0 x 0.3 m X300, FLXMAT G.A.

2NO. LATERAL PP ROPESCAST THRU EA. BLOCK

LOTOS PETROBALTIC S.A.PIPELINE STABILISATION - WATER INJECTION

LINES B8 FIELD

ISSUED FOR CLIENT'S INFOMATION09/04/150 SZ DM DM

300

500

500

Ø22 mm POLYPROPYLENE ROPE, B/S 7.0 t340 mm LIFTING APEX, SIDE LIFTAPPROX. 8.2 m, 6NO. PER MAT(REMAINING ROPES NOT SHOWN FOR CLARITY)

340

PLAN

6000

3000

Ø18 mm POLYPROPYLENE ROPE, B/S 4.8 tLATERAL ROPESAPPROX. 13.1 m, 6NO. PER MAT(REMAINING ROPES NOT SHOWN FOR CLARITY)

ELEVATION SIDE

MTO - PER MATTRESS

NO DESCRIPTION QTY UOM COMMENTS

1 Ø 24 mm PP ROPE 49.2 m FOR SIDE LIFT ROPES2 Ø 18 mm PP ROPE 78.6 m FOR LATERAL ROPES3 FM150T (BLACK) 40 PCS FLXMAT TOP SHELL

4 FM150T (YELLOW) 32 PCS FLXMAT TOP CLMARKER SHELL

5 FM150B (BLACK) 72 PCS FLXMAT BASE SHELL

SPLICEAPPROX 0.5m

415

1NO. LIFT PP ROPESCAST THRU EA. BLOCK

300

500

YELLOW TOP SHELLCENTRELINE MARKING

ISSUED FOR BID13/05/151 SZ DM DM

2555

3279

(APP

ROX)

(APP

ROX)

3.5 m LGTHSOFT WEBBING SLING

FIXED END QUICK RELEASEEND

GENERAL LIFTING ARRANGEMENTSIDE LIFT OF 6.0 x 3.0 x 0.3 m, X300 FLXMAT

6.0 x 3.0 x 0.3 m FLXMAT

SPREADER BEAM

RE-ISSUED FOR BID - CHANGED TO X30018/05/152 SZ DM DM

LOTOS PETROBALTIC

APPROVAL

File No.............................................

Client PO No. .................................

Signed.............................................

Name...............................................

Date.................................................

ISSUED FOR CLIENT'S APPROVAL03/06/153 SZ DM

7027-ENG-DWG-0002 R3

PROJECT TITLE :

DRAWING TITLE :

©2015 by 7SEAS Pte Ltd All rights reserved. This document is confidential and may contain copyright material protected by law. If youhave received it in error, no copyright or confidentiality is lost and you may not disclose or use this document but please notify us. Nopart of this document may be reproduced or transmitted in any form or by any means without prior written permission of 7SEAS.

7 S E A S P T E L T D6 4 B Q U E E N S T R E E T , S I N G A P O R E 1 8 8 5 4 3W E B S I T E : W W W . 7 S E A S G R P . C O M , E M A I L : S A L E S @ 7 S E A S G R P . C O M

SCALEREV.0

DRAWING No. :AS SHOWN

REV. DATE DESCRIPTION DRN. CHK. APD.

CLIENT :

NOTES:1. ALL DIMENSION IN mm UNO

2. ALL FABRICATION, WELDING AND NDT TO BE IN ACCORDANCE

WITH DNV 2.7-3 PORTABLE OFFSHORE UNITS

3. SHACKLES AND WIRE SLINGS PROVIDED BY 7SEAS

4. 6NO. QUICK CONNECT (QC) MECHANISM EACH SIDE OF BEAM,

12NO. TOTAL

5. ESTIMATED WEIGHT OF BEAM: 700 kg

PAGE1 OF 1FXT-EQU-ENG-LB-260515

LIFTING BEAM - HYDRAULIC RELEASE

CONCRETE MATTRESS6.0 m LIFTING BEAM

MTO

NO. DESCRIPTION QTY COMMENTS

1.1 PIN PLATE 1 121.2 PIN PLATE 2 121.3 BAR LOCK PLATE 24

1.4a FRONT BAR 21.4b CENTRE BAR 21.4c END BAR 21.5a RELEASE HANDLE 11.5b PIN - PIVOT 11.5c PIN - END BAR 11.5d HANDLE PIVOT 21.6 M10 x 45 CSK SCREW 481.7 GREEN PIN SHACKLE 121.8 M8 x 55 HEX BOLT & NUT 6 LINK 1.4 a,b, c &2.1 MAIN BEAM 1

2.2 TRANSPONDER BUCKET +ROV HANDLE 2

2.3 BEAM FEET 22.4 MAIN PADEYES 22.5 CYLINDER CONNECTOR 12.6 CYLINDER BRACKET 12.7 CONNECTOR PIN 12.8 BRACKET PIN 12.9 M16 x 30 HEX BOLT & NUT 4 FASTEN 2.2 TO2.1

2.2

1.5a

2.31.1

1.2 1.3

1.4a2.6 1.4b 1.4c2.4

1.5c

1.5b

1.5d

1.6

2.1

2.5

114

96

250 1000

2.8

2.7

713

525

HYDRAULIC CYLINDER DIRECTION

MANUAL HANDLE DIRECTION

QUICK CONNECT (QC) MECHANISMSCALE 1:8

114

114 STROKE LENGTH: 114 mm

QUICK CONNECT (QC) MECHANISMOPEN POSITION

SCALE 1:16

QUICK CONNECT (QC) MECHANISMCLOSE POSITION

SCALE 1:16

1.8 2.9

6.0 m LIFTING BEAMSCALE 1:10

28/05/15A ISSUED FOR INTERNAL REVIEW SZ

26/06/150 ISSUED FOR LOTOS APPROVAL SZ DM

LOTOS PETROBALTIC APPROVAL

File No.............................................

Client PO No. .................................

Signed.............................................

Name...............................................

Date.................................................

FXT-EQU-ENG-LB-260515