PIPELINE REPAIR AT KP 110 KP 133 KUALA TUNGKAL TO PANARAN TGI OFFSHORE PIPELINE

18th-June-08

FEED Handover Meeting Agenda

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Project Introduction Problem Definition Design Basis Pipeline Mechanical Design Pipeline Outline Installation Analysis Repair Methodology Cost Estimate and Schedule Valve Skid Design EIA Review HAZID & HAZOP Action Items Prof. Andrew Palmers Review Closeout Report Discussion and Close Out

Project Introduction

KP 133.5

KP 110.5

FEED OBJECTIVES
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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

Project Introduction
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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

Project Introduction

Design Basis of Replacement Pipeline

DESCRIPTION Approximate Length Pipeline OD Material Line Pipe Specification Pipeline Wall Thickness Service Pipeline Corrosion Allowance Internal Coating External Corrosion Coating External Corrosion Coating Thickness Concrete Weight Coating Thickness Design Pressure Operating Temperature Hydrotest Pressure Maximum Operating Pressure Product Density Pressure Rating of Pipeline Components UNIT km mm mm mm mm mm Barg C Barg Barg Kg/m3 PARAMETERS Approximately 23.0 711.2 (28) Carbon Steel API 5L X65, manufactured to DNV OS-F101 15.9 (.625) Dry Sales Gas 0.0 80 micron DFT Epoxy Coating 3 Layer PE 2.1 94 113.8 (1650 psig) 40.6 136.7 (1983 psig) 103.4 (1500 psig) 63.0 ANSI Class 900

Design Basis of Replacement Pipeline

Pipeline Mechanical Design

Pipeline Mechanical Design

Pipeline Mechanical Design

Pipeline Mechanical Design

Pipeline Mechanical Design

Pipeline Mechanical Design

Pipeline Mechanical Design

Pipeline Installation Analysis

Pipeline Installation Analysis

Final Repair Method

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Repair Method
Zero Downtime Method

Microsoft PowerPoint Presentatio

Schematic Diagram

Comparison Between Both Methods

Cost Flange Connections/ KaMos Gaskets Hot Taps STOPPLE Barred Tees 5D Bend Gate Valve Shut-down Time

Hardware Cost

Construction Cost

Total Cost

CM Reduced Downtime Zero Downtime Method

Nil

6 (4 in-place)

Nil

Nil

Nil

4 6 Wks

US$3.3

US$30M

US$33.3

8 (6 in-place)

2 x 28 2 x 16

Nil

US$9.6M

US$40M

US$49.6

Note: 1. 2. CM Conventional Method The hardware cost stated above includes 10% for transportation cost.

Comparison Between Both Methods

Reduced Downtime Method Advantages

Zero Downtime Method

No flange connections along the pipeline Involves less construction and diving work

Zero Shut-down time and any delay in construction will not disrupt flow to the consumers Restoration of full design pressure before completion of repair Equipment procured offers flexibility to switch to reduced down time method 6 flange connections Involves more construction / diving work 6 In-place hot-tap clamps

Disadvantages

Stoppage of gas supply to consumers for 4 to 6 weeks Delay in construction work will result in more stoppage of gas supply to consumers After commissioning sales gas will have some water till complete dryness is achieved Equipment procured does not offer flexibility to switch to zero down time method 4 In-place hot-tap clamps US$3.3M US$30.0M

Material Cost Construction Cost

US$9.6M US$40.0M

Comparisons of Risks
Reduced Downtime Method
1. 2. 3.

Zero Downtime Method

1. 2. 3.

Emergency Response Plan required Gas Freeing the abandoned pipeline Potential of buckling the pipeline during above water tie-in Presences of large amount of water and air pockets in the pipeline while restoring the flow Gas supply shut down time can increase due to construction delays Experienced Hot-tap contractor should be engaged

Emergency Response Plan required Gas Freeing the abandoned pipeline KaMOS gasket failure Experienced Hot-tap contractor should be engaged

4.

4.

5.

6.

Shut-Down Time for Reduce Downtime Method

Overall Schedule for Zero Downtime Method Best Scenario

Overall Schedule for Zero Downtime Method - Realistic

Potential EPCC Contractors

Pipelay Cal Dive Saipem Global Acergy Technip Subsea 7
  

Subsea
    

Valve Skid Design

Valve Skid Design

Valve Skid Design

Valve Skid Design

EIA Action Plan

EIA Action Plan

EIA Action Plan

HAZID & HAZOP Action Items

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HAZID Action Items HAZOP Action Items

Adobe Acrobat 7.0 Document

Adobe Acrobat 7.0 Document

Dr Andrew Palmers Review and Actions Required

Dr Andrew Palmers Review and Actions Required

Dr Andrew Palmers Review and Actions Required

Project Status Engineering

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S/N
1. 2.

Pipeline Mechanical Design

Activities Status
Done Done

Further Actions
EPC Contractor to check suitability of the available 16 pipe from Stockist. For a !6 dia 11.1 mm thick a 40mm concrete is required. EPC Contractor to proposed method to ensure stability of pipeline if 16 pipe is not concrete coated. EPC Contractor to check suitability of the available 6 pipe from Stockist. EPC Contractor to ensure stability of piping during operation. No CP is proposed for the temporary piping as it is exposed to sea water for a short period only. There is enough margin on the anodes provided on the permanent facilities to take care of the temporary piping. EPC Contractor to perform detailed dynamic lay analysis based on their proposed pipe laybarge EPC Contractor to perform pre-engineering survey and update the Bottom Roughness Analysis. Span rectification if required. EPC Contractor to perform final HAZOP and HAZID and update overall schematic.

28 Pipe WT and Concrete Thickness 16 Pipe WT and Stability

3.

Small Diameter Pipings, WT and Stability Cathodic Protection Design

Done

4.

Done

5. 6.

Pipelay Analysis Bottom Roughness

Done Done

7.

Overall Schematic

Done

Project Status Engineering

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S/N
1.

Installation Methodologies
Activities Status
Done

Further Actions
EPC Contractor to develop a detailed execution plan and procedures for this method -

Zero Downtime Method

2.

Reduced Downtime Method

Done

3.

Comparisons between Methods

Done

4.

HAZID and HAZOP

Done

EPC Contractor to perform HAZID and HAZOP based on the execution plan and procedures developed by EPC Contractor

Project Status Engineering

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S/N
1.

Valve Skid Design

Activities Statue
Done
fEPC

Further Actions
Contractor to carry out detailed design of Valve Skids .

Piping Analysis - Caesar II Model Structural Analysis - SACS Model Drawings

2.

Done

3.

Done

Contractor to re-check installation analysis and design installation aids based on the final skid design and equipment / vessel proposed for installation.
fEPC

fEPC

Contractor to develop detailed fabrication drawings.

Project Status Engineering

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S/N
1. 2.

Material Specifications
Activities Status
Done Done

Further Actions
-

Flanges, Bolts, Nuts, Gaskets and Fittings Subsea DBB Expandable Gate Valves / Gate Valves 5D Induction Bends Subsea Mechanical Connectors & Hot Tap Assembly

3. 4.

Done Done
fEPC Contractor to attend all FAT testing for both mechanical connectors and hot tap assemblies

Contractor to perform mock testing before the actual installation works 5. 6. Field Welding and NDT Construction Materials Done Not Done EPC Contractor to prepare welding and NDT procedures All non-long lead and construction materials to be procured by EPC Contractor

fEPC

Project Status Engineering

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S/N
1.

Installation Specifications
Activities Status
Done

Further Actions
EPC Contractor to develop all necessary installation procedures

Pipeline Installation

2.

Survey and Monitoring

Done

EPC Contractor to develop detail survey and monitoring procedures. EPC Contractor develop detail pre-commissioning procedures. Final HAZOP and HAZID need to be performed

3.

Pipeline Cleaning, Gauging, Pigging and Hydrotest

Done

Project Status Engineering

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S/N
1.

Drawings
Activities Status
Done

Further Actions
EPC Contractor to update based on pre-engineering survey and identify locations where span rectification is required
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Pipeline Alignment

2.

Tie-in Arrangements

Done

EPC Contractor to update based on final arrangement proposed and approved by PMT / TGI

EPC Contractor to perform HAZOP and HAZID based on the final arrangement and make necessary adjustments 3. Valve Skid Details Done EPC Contractor to include details of installation aids and prepare fabrication drawings.

Discussion and Close Out