Pipeline Repair Project Feed 2

PIPELINE REPAIR AT KP 110 – KP 133 KUALA TUNGKAL TO PANARAN TGI OFFSHORE PIPELINE 18th-June-08

FEED Handover Meeting Agenda 1.

Project Introduction

2.

Project Status

3.

MTO

4.

Procurement & Installation Specifications

5.

MR’s

6.

TBE/Table of Compliance

7.

Procurement Status

8.

Discussion and Close out

Project Introduction

KP 133.5

KP 110.5

Project Introduction 

Details of Damaged Section (KP110.5 to KP133.5) • Total of 19 buckles along the damaged section • Maximum deformation of buckle – 7.59% of OD • Water depth at damaged section – 35m

Design Basis of Replacement Pipeline DESCRIPTION

UNIT

PARAMETERS

Approximate Length

km

Approximately 23.0

Pipeline OD

mm

711.2 (28”)

Material

-

Carbon Steel

Line Pipe Specification

-

API 5L X65, manufactured to DNV OS-F101

Pipeline Wall Thickness

mm

15.9 (.625”)

Service

-

Dry Sales Gas

Pipeline Corrosion Allowance

mm

0.0

Internal Coating

-

80 micron DFT Epoxy Coating

External Corrosion Coating

-

3 Layer PE

External Corrosion Coating Thickness

mm

2.1

Concrete Weight Coating Thickness

mm

94

Design Pressure

Barg

113.8 (1650 psig)

Operating Temperature

°C

40.6

Hydrotest Pressure

Barg

136.7 (1983 psig)

Maximum Operating Pressure

Barg

103.4 (1500 psig)

Product Density

Kg/m3

63.0

Pressure Rating of Pipeline Components

-

ANSI Class 900

FEED OBJECTIVES 

Engineer a feasible repair method that can be executed by available installation contractors in the region



Develop a method based on use of industry proven equipment and procedures



Review the method with potential EPCC contractors to get feedback on their construction risks.



Develop a method which offers no or minimum stoppage of Gas to the consumers



Develop a method which enables restoring the gas flow to the full design pressure as early as possible



Conduct risk work shop and identify risks that should be managed by PMT



Identify long lead items for procurement so that repair work can be executed as early as practically possible

Schematic Diagram

MTO for Zero Downtime Method Hot Tap Tees Size

Material

Quantities

28 x 6”

ASTM A 694 F65

2

28 x 16”

ASTM A 694 F65

2

28 x 28”

ASTM A 694 F65

4

28” 28”, 90ºBends

5D Hot Induction Bends

API 5L X65

4+1spare

2 for Test bend and WPQT

Mechanical Connectors 28”

ASTM A 694 F65

2 Flanges

6” Pressurizing line

ASTM A 694 F65

4+1

Swivel type

16” Branch Line

ASTM A 694 F65

2+1

WN Flange

4+1

Swivel flange

8+1

Blind flange Misalignment flange

28” Pipeline

28” Pig Launcher/Receiver

ASTM A 694 F65

ASTM A 694 F65

4+1

WN Flange

6+1

Swivel flange

10+1

Blind flange

2+1

Misalignment flange

2

Swivel flange

MTO for Zero Downtime Method Testable Gaskets Size

Material

Quantities

28”

SS 316 Octagonal

4+1

Kamos Gasket

16”

SS 316 Octagonal

4+1

Kamos Gasket

Test Kit

SS316

2

Kamos

Weldolets 28 x 4 “

ASTM A 694 F65 / WPHY65

2+1

80XS

28 x 2”

ASTM A 694 F65 / WPHY65

2+1

80XS

16 x 4”

ASTM A 694 F65 / WPHY65

2+1

80XS

16 x 6”

ASTM A 694 F65 / WPHY65

2+1

80XS

2

Reducing Tee

4

90º

Barred Tee 28” x 16”

ASTM A 694 F65 / WPHY65 Elbow

16”

ASTM A 694 F65 / WPHY65 Subsea Ball Valves

2"

Body: A350-LF-2 / A352 LCC

2

Full Bore, RTJ x Welded End

4"

Ball & Seat: A182-F55 with WC coating

4

Full Bore, RTJ x Welded End

2

Full Bore, RTJ x Welded End

6”

Seat Spring: Inconel X750

MTO for Zero Downtime Method Expanding Gate Valves Size

Material

Quantities

16”

Body: A350-LF-2 / A352 LCC

2

Gate & Seat: A182-F55 with WC coating 28”

Seat Spring: Inconel X750

Reduced Bore, Welded end. Through conduit Double Block and Bleed

2

Full Bore, Piggable and welded end Through conduit Double Block and Bleed

Subsea Globe Valve 6”

Body: A350-LF-2 / A352 LCC Trim : A182-F55 with WC coating Stem packing : Flexible Graphite

2

RTJ X RTJ Welded bonnet

Material Specifications S/N

Activities TGI Specification

Status

Further Actions

Done

-

1.

Line Pipe

2.

Flanges, Bolts, Nuts, Gaskets and Fittings

29780-00-SU-SPC001

Done

-

3.

Subsea DBB Expandable Gate Valves / Gate Valves

29780-00-SU-SPC003

Done

-

4.

5D Induction Bends

Done

5.

Subsea Mechanical Connectors & Hot Tap Assembly

29780-00-SU-SPC004 29780-00-SU-SPC005

Done

EPC

Contractor to attend all FAT testing for both mechanical connectors and hot tap assemblies EPC

Contractor to perform mock testing at the works followed by full mock up before the actual installation works 6.

Field Welding and NDT

29780-00-SU-SPC002

Done

EPC Contractor to prepare welding and NDT procedures

7.

Installation

29780-00-SU-SPC007

Done

EPC Contractor to develop installation procedures.

8.

Survey and Monitoring

Done

-

9.

Hydrotest, Gauging and Pigging

29780-00-SU-SPC008 29780-00-SU-SPC009

Done

EPC to develop site procedures. Final HAZOP and HAZID need to be performed.

10.

Construction Materials

----

Not Done

All non-long lead and construction materials to be procured by EPC Contractor

Material Requisitions S/N

Activities

Status

Further Actions

1.

Line Pipe

TGI

Done

-

2.

Flanges, Bolts, Nuts, Gaskets and Fittings

29780-00-SU-RFQ-0003

Done

-

3.

Subsea DBB Expandable Gate Valves / Ball Valves

29780-00-SU-RFQ-0002

Done

-

4.

5D Induction Bends

29780-00-SU-RFQ-0001

Done

-

5.

Subsea Mechanical Connectors & Hot Tap Assembly

29780-00-SU-RFQ-0004

Done

-

TBE/Table of Complinace S/N

Activities

Status

Further Actions

1.

Line Pipe

TGI

--

-

2.

5D Induction Bends

TGI

--

-

3.

Flanges, Bolts, Nuts, Gaskets and Fittings

TGI

Done

-

4.

Subsea DBB Expandable Gate Valves / Ball Valves

TGI

Done

-

5.

Subsea Mechanical Connectors & Hot Tap Assembly

TGI

Done

-

Project Status – Procurement 

Steel Plate and Line Pipe Manufacturing Inspection • AnYang Steel Plate Mill audit – Done • Line Pipe Manufacture Kick-off meeting and Mill audit – ????



All non-long lead items & consumables to be supplied by EPC Contractor and subjected to PMT’s approval – status ????



Specifications and MRs for Long Lead Items Preparation – Done • Long lead items are identified in the MTO Report

Project Status – Procurement  S/N

Procurement Assistance Activities

Status

Further Actions

Float MR

TBE

1.

Flanges, Bolts, Nuts, Gaskets and Fittings

Done

Done

-

2.

Subsea Double Expandable Gate Valves / Gate Valves

Done

Done

-

3.

5D Induction Bends

-

-

Specifications and MRs issued to TGI. TGI to send out for quotations – Status unknown ???

4.

Subsea Mechanical Connectors & Hot Tap Assembly

Done

Done

PMT to ensure EPC Contractor attend all FAT testing and perform mock testing before actual repair works

Project Status – Procurement  S/N 1.

Procurement Assistance Activities

Selected Vendor

Further Actions

PT Bakrie

28” Line Production status to be updated by TGI.

Line Pipe

Status of 16” pipe to be informed by TGI ???? 2.

5D Induction Bends

-

-

3.

Coating & Anodes

4.

Flanges, Bolts, Nuts, Gaskets and Fittings

Oceanering

TGI to update the staus

5.

Subsea Double Expandable Gate Valves / Globe/Ball Valves

BEL Valves

-

6.

Subsea Mechanical Connectors & Hot Tap Assembly

BrederoShaw -Batam

OCEANERING

Specifications and MRs issued to TGI. Awaiting TGI to send out for quotations. TGI to update the status ???? TGI to update the status ?????

PMT to ensure EPC Contractor attend all FAT testing and perform mock testing before actual repair works

Project Status – Procurement 

Balance Procurement Items S/N

Activities

1.

Line Pipe

Small bore pipes like 6”,4”, 2” etc to be procured by EPC contractor

2.

Small Bore valves

¾” 2 “

3.

Flanges, Bolts, Nuts, Gaskets and Fittings

Small bore and miscellaneous items to be procured by EPC contractor

5.

Barred Tee

6.

Structurals for Skid assembly

To be confirmed by TGI ????? To be Procured by EPC contractor

Discussion and Close Out