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36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 1 of 13

36IN +6IN SSL OPERATIONAL TEST PROCEDURE ONBOARD CASTORO II

ILUC, WELDING, PFM TESTS

Welding/FJC/ Welding/FJC/ Welding/FJC/


Re - Issued for IDC GR/OS
Asset Asset Asset

Approved
Rev. Date Description of Revision Prepared Verified Approved
(PIM/PM)
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ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 2 of 13

AMENDMENTS AND REVISIONS

Amendment
Date Page Description Project Director
and revision
X1 19/11/2012 All Issued for IDC GS
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Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 3 of 13

INDEX

AMENDMENTS AND REVISIONS......................................................................................................... 2


INDEX..................................................................................................................................................... 3
1. INTRODUCTION.......................................................................................................................... 4
2. DEFINITIONS............................................................................................................................... 7
2.1 ABBREVIATIONS................................................................................................................... 7
3. REFERENCE RULES, CODES AND STANDARDS....................................................................8
3.1 CODES AND STANDARDS / COMPANY DOCUMENTS.......................................................8
3.2 COMPANY DOCUMENTS...................................................................................................... 8
3.3 CONTRACTOR DOCUMENTS...............................................................................................8
4. SCOPE OF DOCUMENT............................................................................................................. 9
4.1 DLB CASTORO II BARGE SET-UP.......................................................................................9
4.1.1 Preparatory Works in the firing line................................................................................9
4.1.2 36in Pipe Facing Machine (PFM) test.........................................................................10
4.1.3 36in ILUC test.............................................................................................................. 10
4.1.4 Welding Set up and Test.............................................................................................. 11
4.1.5 36in + 6in SSL Firing Line Tests..................................................................................11
5. REPORTING.............................................................................................................................. 12
ATTACHMENT A.................................................................................................................................. 13
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ILUC, WELDING, PFM TESTS Sheet 4 of 13

1. INTRODUCTION

The Wasit GasEoIProgram (WGP) will produce approximately 2,500 MMSCFD of Khuff gas from the Arabiyah and
WoI Hasbah offshore fields to meet increasing IK demand for sales gas. The gas will be produced and transported
through a series of offshore/onshore pipelines to Wasit gas Plant (WGP) onshore facilities.
Arabiyah and Hasbah offshore facilities are being developed by the Northern Area Projects Department/ Offshore
Mega Project Division of Saudi Aramco under the subject Requisitions. The Wasit Projects Department of Saudi
Aramco will develop the WGP onshore facilities.
The primary facilities of Arabiyah and Hasbah Offshore/Onshore Facilities are based on Lump Sum Turn Key
(LSTK) Contract Requisitions to cover the design, procurement, transportation, fabrication and installation of the
Arabiyah and Hasbah offshore platforms, pipelines, submarine cables and Wellhead Hook ups and pre-
commissioning. The primary facilities are listed as follows:

Arabiyah Field Facilities (Offshore And Onshore):


The project work includes the engineering, procurement, fabrication, transportation, installation and wellhead hook
ups of the following facilities (pipeline and cable lengths noted below are approximate):
Arabiyah Offshore facilities:
o Six (6) Decks for new wellhead platforms (jackets built and pre-installed by others)
o One (1) tie-in platform (ARBI TP-1) including; jacket, deck, bridge, flare and bridge support
jackets
o One (1) Intermediate MEG injection platform (ARBI TP-2) including jacket and deck
o One (1) 36OD (5L X-65) offshore internally coated Arabiyah trunk line from beach valve station to
ARBI TP-1 (with a total length of 130-km). The Work including the dredged shore pull trenches
o One (1) 12OD (5L X-65) offshore internally coated MEG injection pipeline from beach valve
station to ARBI TP-2 (Intermediate injection platform) (with a length of 75-km). The Work including
the dredged shore pull trenches
o One (1) 10.75OD (5L X-65) internally coated MEG injection pipeline from ARBI TP-2
(Intermediate injection platform) to the ARBI TP-1 (with a length of 50-km)
o One (1) 6"OD (5L X-65) offshore elemental sulfur solvent injection pipeline from beach valve
station to ARBI TP-2 (Intermediate injection platform) (with a length of 75-km). The Work including
the dredged shore pulls trenches.
o Six (6) internally clad 12OD (5L X65) high pressure gas flow lines from the wellhead platforms to
ARBI TP-1
o One (1) 4 OD flexible and subsea valve skid connecting ARBI TP-2 (Intermediate injection
platform) to 36 OD Arabiyah trunk line
o Six (6) composite submarine cables (15-kV power with an internal fiber optic core) from ARBI TP-
1 to Wellhead platforms (with a total length of 23-km)
o One (1) composite submarine cable (15-kV power with an internal fiber optic core) from shore at
Abu Ali to ARBI TP-2 (Intermediate injection platform) (with a total length of 30.8-km long). Work
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includes a dredged shore approach and onshore cable tie-in at Abu Ali GOSP
o One (1) composite submarine cable (15-kV power with an internal fiber optic core) from ARBI TP-
1 to ARBI TP-2 (Intermediate injection platform) (with a total length of 74-km long)
o Eight (8) ICCP systems for ARBI TP-1
o Two (2) ICCP systems for ARBI TP-2 (Intermediate injection platform)
o Four (4) ICCP systems for each wellhead platforms
o Six (6) Wellhead Hook ups, pre-commissioning and SCADA integration for Arabiyah Wellhead
Platforms

Arabiyah Onshore facilities:


o One (1) 36OD (5L X-65) onshore trunk lines for Arabiyah from shoreline to Wasit Gas Plant
(WGP) including installation of valves station on the beach, scraping receiving facilities at WGP
(with a total length of 60-km)
o One (1) 12OD (5L X-65) MEG onshore pipeline from shoreline to Wasit Gas Plant (WGP)
including installation of valves station on the beach, scraping receiving facilities at WGP (with a
total length of 30-km)
o DCS at Manifa CCR
o One (1) 6"OD (5L X-65) elemental sulfur solvent onshore pipeline from shoreline to Wasit Gas
Plant (WGP) including installation of valves station on the beach, scraping receiving facilities at
WGP (with a total length of 30-km)"

Hasbah Field Development (Offshore and Onshore):


The project work includes the engineering, procurement, fabrication, transportation, installation and wellhead hook
ups of the following facilities (pipeline and cable lengths noted below are approximate):

Hasbah Offshore facilities:


o Seven (7) Decks for new wellhead platforms (jackets built and pre-installed by others)
o One (1) tie-in platform (HSBH TP-1) including; jacket, deck, bridge, flare and bridge support
jackets
o One (1) 36OD (5L X-65) offshore internally coated Hasbah trunk line from beach valve station to
HSBH TP-1 (with a total length of 131-km). The Work including the dredged shore pull trenches.
o One (1) 10.75OD (5L X-65) internally coated MEG injection pipeline from ARBI TP-2
(Intermediate injection platform) to the HSBH TP-1 (with a length of 50-km)
o Seven (7) internally clad 12OD (5L X65) high pressure gas flow lines from the wellhead platforms
to HSBH TP-1.
o One (1) 4"<1> (5L X-65) elemental sulfur solvent injection pipeline from ARB I TP-2 (Intermediate
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ILUC, WELDING, PFM TESTS Sheet 6 of 13

injection platform) to the HSBH TP- 1 (with a length of 50-km)"


o One (1) 4 OD flexible and subsea valve skid connecting IIP to 36 OD Hasbah trunk line.
o Seven (7) umbilicals (15-kV power with an internal fiber optic core and tubes for elemental sulfur
solvent injection) from HSBH TP-1 to Wellhead platforms (with a total length about 21-km).
o One (1) composite submarine cable (15-kV power with an internal fiber optic core) from MRJN
GOSP-2 to HSBH TP-1 (with a total length of 50.9-km long).
o Eight (8) ICCP systems for HSBH TP-1
o Four (4) ICCP systems for each wellhead platforms
o Seven (7) Wellhead Hook ups, pre-commissioning and SCADA integration for Hasbah Wellhead
Platforms

Hasbah Onshore facilities:


o One (1) 36OD (5L X-65) onshore trunk lines for Hasbah from shoreline to Wasit Gas Plant
(WGP) including installation of valves station on the beach, scraping receiving facilities at WGP
(with a total length of 60-km)
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ILUC, WELDING, PFM TESTS Sheet 7 of 13

2. DEFINITIONS

1.1 ABBREVIATIONS

AUT Automatic Ultrasonic Testing


CRTS Sub-Contractor for Internal Field Joint Coating
ID Inside Diameter of the Pipe
IFJC Internal Field Join Coating
ILUC Internal Line Up Clamp
NDT Non-Destructive Testing
OD Outside Diameter of the Pipe
PFM Pipe Facing Machine
PQT Pre Qualification test
SOW Scope of Work
UT Ultrasonic Testing
WCO Welding Co-coordinator
WE Welding Engineer
WPS Welding Procedure Specification
WT Wall Thickness
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2. REFERENCE RULES, CODES AND STANDARDS

2.1 CODES AND STANDARDS / COMPANY DOCUMENTS

N/A

2.2 COMPANY DOCUMENTS

Ref Document Number Title

CONTRACTOR Documents

Fabrication, transportation and installation of offshore pipelines, submarine composite


power cables, umbilical system, impressed current cathodic protection (iccp) anodes
/1/ PE-GIP026 sledge /cables

Scope of work - hips case with IIP Base Case

/2/ DE-119954 Procedure For Fabrication And Installation Of Submarine Pipelines

2.3 CONTRACTOR DOCUMENTS

Ref Document Number Title

CONTRACTOR Documents

/3/ 45-ZA-E-I77657 Project Welding Summary For Sealines Installation By Castoro II

/4/ 45-ZA-E-I77661 AUT Procedure For Carbon Steel Sealines

/5/ 45-ZA-E-I77665 Manual UT Procedure For Carbon Steel Sealines (Including "Piggy Back")

/6/ 45-ZB-A-I80229 Castoro II Work Station Layout 36in HSBH T/L & 6in Piggyback Solvent Sulphur Line

/7/ 44-ZB-A-I76726 Castoro II 6 Piggyback Sulphur Solvent Line Support Rollers Layout - As Built

5.2 Ton Metallic Buoyancy Tanks For Shorepull Installation Details 36" HSBH TL + 6in
/8/ 45-ZB-A-I80026
Sulphur Solvent Line

/9/ 45-ZB-A-I80373 36" HSBH Trunkline + 6" Sulphur Solvent Line Piggyback Saddle Arrangement
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ILUC, WELDING, PFM TESTS Sheet 9 of 13

3. SCOPE OF DOCUMENT

This document describes an operational procedure that will be implemented onboard DLB Castoro II during
performance of 36in ILUC and PFM in-house tests with internal protections. The aim of tests is to prevent any
damages of internal coating FBE of 36in ARB/HSBH pipelines during offshore installation, with below objectives,

- 36in ILUC test with internal coating protectors


- 36in PFM Test with internal coating protectors
- Welding Station No 1 using SWSe Monotorch
- Welding Station No 2 using SWSe Monotorch / Dual Torch
- Pre heating with 36in coils
- Plasma Modules tests
- 36in + 6in SSL Firing line fitting tests
Results will be reported in a separate report that will summarise findings that are expected to be positive, i.e. no
damages to internal coating occurs using properly fitted above pipelaying equipment.
This document needs to be read in conjunction with referenced documents.

3.1 DLB CASTORO II BARGE SET-UP

3.1.1 Preparatory Works in the firing line

Set-up of 1st welding station


- Supply of welding consumables (welding gases, wires, electrodes,)
- Supply of welding equipment
- Welders mobilisation
- WPS TL-3.
Supply of necessary pipelaying equipment (as per particular task)
- Set-up of36in ILUC AZ342303 / AZ342304 fitted with MTM set-up & copper shoes (ID 850mm)
- Set up of SWSe welding bands
- Set-up of 36in PFM AZ 552539 as per WPS
- Set up of 36in heating coils clamps & generator
- Piggy back clamp and strapping tools
Supply of No.4 internally FBE coated 36in / 31.8mm Line pipe X65
Set-up of tensioners as per 36in / 31.8 mm
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36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 10 of 13

Set-up of firing line supports as per shorepull configuration.


Visual Check and set up of the piggy back firing line supports and rollers.

3.1.2 36in Pipe Facing Machine (PFM) test

36in PFM operations will be performed to demonstrate no damages occur during activities where equipment is in
contact with the internal FBE coated surface. For such test following procedure shall be followed,
Each line pipe is taken from Castoro II deck storage area and lowered onto longitudinal conveyor
Pipe joints transfer to beadstall
Pipe ends bevelling as per WPS TL-3, by using PFM AZ XXXXX with internal protectors
Once the bevelling is completed, coating thickness gauge and holiday detector will verify the integrity of
the internal coating at contact locations between PFM and pipe joints
Same operation shall be executed for other two joints (both ends) to be welded.
At the end of the activity, an internal report by Castoro II QA/QC department shall be issued to register the main
data of the operation and obtained results.

3.1.3 36in ILUC test

36in ILUC tests will demonstrate that no damages occur during activities where equipment is in contact with the
internal FBE coated surface. The test shall include a verification during ILUC running, coupling and expansion.
For such tests following procedure shall be followed,
Two line pipes are bevelled and preheated before root & hot welding pass performance
The 36in ILUC is inserted in position
Once the welding is completed, ILUC operator shall run the ILUC forward & aft several times over the
weld
ILUC to be removed from the pipe string
Pipe string cutting at field joint in two pieces for coating thickness gauging and Porosity inspection.
As a minimum, of internal FBE will be executed from pipe edge up to 2000mm inside line pipe
Same operation shall be executed twice in different pipe ends.
At the end of the activity, an internal report by Castoro II QA/QC department shall be issued compiling the main
data of the operation and obtained results.

3.1.4 Welding Set up and Test

Pre-heating (mandatory heating coils) as per WPS TL-3 (target preheating temperature: 140 degrees)
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ILUC, WELDING, PFM TESTS Sheet 11 of 13

Joint transfer to 1st welding station by transversal conveyor


Line-up (using the ILUC with protections and copper shoes)
Welding of the root and hot pass in 1st WS ONLY as per WPS TL-3
ILUC removal
Optional: Completing the welding as per WPS TL-3 (TBC)
Above steps will be repeated until last single joint is welded.
Once string is prepared, trial test will take place as described in reference /3/.

3.1.5 36in + 6in SSL Firing Line Tests

36in +6in SSL shall be ensemble such as to establish the interaction between both pipelines at the several
working stations. This test will confirm the possible interference among both lines and will demonstrate clear
passage over all piggy back rollers. The test for the 36in+6in piggy back installation arrangement shall confirm the
following:
Interference among both pipelines is as per project installation method.
Clear passage for 6in over all piggy back rollers is feasible.
No clash exists for Buoyancy Tank passage.
Installation arrangement as per drawing 45-ZB-A-I80026 is feasible.

For such tests following procedure shall be followed,


Piggy back Firing line is inspected and prepared to allow 6in passage.
4 No 36in pipe string (plus the head) is prepared (2.0in cwc)
8 No x 6in pipe joints are also prepared for welding, as per welding procedure.
Piggy back Firing line is checked and prepared to allow 6in SSL passes.
1no x 6in anode is bolted on the first pipe of the string to verify passage.
With the both pipe strings prepared, simulation of the 36in welding process shall take place by setting up
the 36in welding bands and using a SWS head. Clear passage of welding machines is to be achieved in
the welding stations.
Simulation of the AUT machines located at the assigned welding station shall take place
Piggy back saddles installation using the flat bars and metallic straps at the assigned work station.
Separation used for piggy back saddles as per project specification (case 1: 4070mm, case 2:
7100/5100mm)
Buoyancy tank is installed at the proposed station. Strapping and saddle is used as per installation
drawings.
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ILUC, WELDING, PFM TESTS Sheet 12 of 13

At the end of the activity, an internal report by Castoro II QA/QC department shall be issued compiling the main
data of the operation and obtained results, i.e. to identify the clear distance between the top of buoyancy tank and
the firing line frames or any structural obstruction .

4. REPORTING

After the completion of the tests, an internal report shall be issued by Castoro II QA/QC. Photos are
complementary to the report.
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36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 13 of 13

ATTACHMENT A

Piggy back saddle installation procedure

Piggy Back
Installation Procedure(DRAFT-TRELLEBORG).pdf