SPM #5 PERIODIC SHUT DOWN REPORT

OVERVIEW:

Once in every three years the floating hoses are subjected detailed inspection to review condition of
the hoses and the suitability to re-use the hoses. Any hose that shows any signs of deterioration is
replaced. The ramification of a mid-cycle shut down cannot be overemphasized. The hoses are
flushed out, disconnected from the SPM, towed to the shore side where the inspection regime is
carried out and likewise re-commissioned.

Inspection regime comprises of

• Marine growth removal and cleaning

• Visual inspection for cuts, abrasions, bulges, warning system ect.
• Electrical continuity test
• Hydrostatic test (including elongation check)
• Vacuum test.

MAINTENACE SCHEDULE OF FLOATING HOSE:

HOSE TYPE* FOB MAIN LINE REDUCER TAIL TANKER RAIL

Single / Double 12 Months 36 M then 36 M then 36 M then 12 Months
carcass after annually. after annually. after annually.
(SPM 4&5)

*Double carcass hose is designed so that if the main carcass fails, the secondary carcass contains
the leak and protects the ambient environment. An alarm system alerts the operator when the primary
carcass fails.

The first task is to disconnect the floating hoses from their connections and transfer them to the
testing site, in a SAFE manner, without impacting the environment. The floating hoses are flushed
through with sea water until they are rid of traces of oil, there after they are transferred to the
testing area.
DESCRIPTION OF LAYOUT
The connection between pipe arm piping and tanker manifold consists of two(2) No. 20-Inch hose
strings. The Inboard string is of total length 795 feet, while the Outboard string is of total length 835
feet, due to insertion of one additional 40 foot mainline hose. The Pipeline End Manifold (PLEM) is a
subsea unit from which rise two subsea Hoses (pipe lines of 20”ø and 30”ø) to connect to the Multi-
product Delivery Unit (MPDU) located on the top of the SPM. Each one of these pipes has two
hydraulically operated butterfly vales connected, adjacent to the PLEM. The outlets from the MPDU
are connected to the flexible hosing. All flexible hoses are of flange-ended construction. The first
length of Flexible hose nearest to the SPM is known “FIRST OFF BOUY HOSE” (20”ø x 40’) that is a
“half-floating” Hose of heavier construction electrically continuous to be fitted on J tube of SPM.
This hose is followed by 15 lengths of FLOATING MAIN HOSE (20” ø X 40’) that are “fully-floating”
and electrically continuous, next is 1 length of “fully-floating” REDUCER HOSE (20” ø >16” ø X 40’),
next 3 lengths of “FLOATING TAIL HOSE” (16” ø X40’) electrically discontinuous and finally 1 length of
“TANKER RAIL HOSE” (16”ø X 35’x 1) electrically discontinuous, that gets connected to the Tanker.

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 SPM #5 PERIODIC SHUT DOWN REPORT

FLUSHING OPERATION FOR CRUDE OIL FLOATING HOSES:

A suitable tanker requires to be identified for receiving the flushing slops from the floating hoses.
The floating hoses are flushed with sea water taken from the fire line of the tanker. Standard fire line
connections are 4” in diameter. The Tanker Rail Hoses are connected to the manifold in the tanker,
leading to the SLOP Tanks.

The 4” flexible hose is connected to the PLEM, the 30”ø valves and closed and the 24ø valves are
kept open. The flushing commences at a low pressure and when slops are received on board the
tanker, the pressure is increased to 4 Kg/cm2. Flushing is carried out in 5 sessions each of 30 minute
duration. Samples of the slops are drawn every 30 minutes to monitor the Slops. Once the Slop is
“CLEAN” the Tanker rail hoses are disconnected and flanged and prepared for the towing operation.
Depending on the tidal condition, the flushing hose will have to be disconnected and reconnected.

The process described above is conventional procedure where the SPM does not have
Surge Tank

FLUSHING LINE DIAGRAM:

4” line conn.
Tanker end
4” isolation valve
MPDU
12 Inner Hose

Outer Hose SPM

4” isolation valve Ebb Tide

Flood Tide
27m CD + Tide
20” PLEM v/v

4” Flexible Hose

PLEM
SEABED
4” Flushing Connections
30” v/v

30” v/v
4” Flexible Hose

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 SPM #5 PERIODIC SHUT DOWN REPORT
Informatively, surge tanks form an integral part of the discharge system that accommodates
pressure surges. In case of a surge in line pressure, the surge relief valve set at 15Kg/cm2
releases the cargo into the surge tank. An alarm is activated when the surge tank come to
50% capacity and the system shuts down when the level reaches 75% capacity. A Wilden
pump is also provided to transfer oil from the surge tank to the system.

In the case the SPM has surge tanks a different procedure as described below can be
adopted. SPM 5 has surge tanks and hence this procedure was adopted. The fire line of the
tanker that is used for flushing operation is bifurcated into 1½”ø branches. These are
connected to the surge line valves on the deck of the SPM. The interconnecting valve
between the 24”ø subsea hoses (SSH) and the surge tank (Normally Open) are kept shut.
The 20”ø and 30”ø are kept shut. The flushing seawater enters the system and enters the
subsea hoses up to the 20”ø valve. Being heavier than oil, the sea water slowly displaces the
oil in the subsea hoses. Displaced oil enters the MPDU and finally gets back to the tanker
Slop Tanks. Flushing is carried out in 5 sessions each of 30 minute duration. Samples of the slops
are drawn every 30 minutes to monitor the Slops. Once the Slop is “CLEAN” the Tanker rail hoses are
disconnected and flanged and prepared for the towing operation. Quantity of liquid pumped to
tanker should be about 250 KL per string.

Advantages:

Less man power required.

Diving operation not required.

Flushing can be continued without any breaks irrespective of tidal changes.

Time saved about 1.5 days.

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SPM #5 PERIODIC SHUT DOWN REPORT

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 SPM #5 PERIODIC SHUT DOWN REPORT
Once the Flushing operation is completed, the mooring hawser is disconnected and secured on the
DSV deck. To facilitate easy towage to the testing site, the First off Buoy hoses, are secured to
floating jackets. Recall that these hoses are “half-floating” and hence need these buoyancy jackets.
The First off Buoy hoses are disconnected from the SPM “J” pipe

Floating jackets secured on First off Buoy hoses First off Buoy hoses disconnected from SPM J pipe

Towing:

6 ‘’ PP to be secured for both Inner and Outer Hoses.

Remove Winker lights and secure on DSV.

Connect Towing ropes on Tanker rail hose and FOB end.

FOB hose end to be blind flanged, to prevent drift wood passing through the bore during
towing.

Floating Hose strings to be towed under supervision from SPM buoy to LOLO Jetty.

Secure both strings to DSV at LOLO Jetty.

Max. Towing speed not be exceeded by 05 Knots.

Transferring Hoses to DSV deck All Hoses transferred on deck of DSV

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 SPM #5 PERIODIC SHUT DOWN REPORT

Hoses transferred to the Jetty

Lifting, Dismantling & Visual Inspection:

Both Strings FOB and TRH to be pulled and secured on DSV deck.

Floats to be disconnected from FOB.

Dismantling can be started from any end preferably from TRH.

Dismantling should be carried out individual strings.

Each hoses dismantled to be marked with hose number and string(Inner/Outer).

Hoses to be inspected for external damage.

Marine Growth to be cleaned externally for inspection by Scrapper and wire brush.

Hoses to be lifted only by using Spreader Bar.

Do Not Use Wire Ropes For Lifting Hoses.

Do Not Lift By Single Point Or By The Ends.

ON SHORE INSPECTION:

Inspect Floating Hoses both Internally and Externally for any Kinks, Deformation, Cracking,
separation, cut marks, abrasion, corrosion spool piece/Flanges

All repairable parts to be attended before re installation of hoses.

In case of any major defects observed hoses can be rejected.

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 SPM #5 PERIODIC SHUT DOWN REPORT

HYDRO TEST PROCEDURE:

Place the hose on ground level as straight as possible on supports that permit the hose to be
elongated freely.

Blind both ends of the hoses with rated flanges.

Fill the Hose with water through one side of the hose and vent air from other end.

When constant stream of water is delivered through the venting side of the flange close the
vent valve.

Apply pressure of 0.7 bar and note the time.

Measure the overall length of the hose assembly L1 (Example: L1 = 12.20 m)

Increase the pressure over a period of 5 Min from 0.7 bar to half the rated pressure of hose.

Hold the pressure for 30 Min, then reduce the pressure over a period of 5 Min to Zero bar.

Raise the Pressure over a period of 5 Min to rated pressure of hose.

Measure Length L2 (Example: L2 = 12.24 m)

Reduce the pressure over a period of 5 Min to Zero Bar.

After an interval of 15 Minutes, raise Pressure to 0.7 Bar.

Measure overall length L3 (example: L3 = 12.20 m).

Reduce the pressure to Zero then Drain the Hose.

Measure L1, L2 and L3 are used to measure Temporary and permanent elongation.

Temporary Elongation: T= {(L2-L1)/L1} X 100.

Permanent Elongation: P= {(L3-L1)/L1} X 100.

Hose Retirement Criteria:

Temporary elongation (T) is > +2% of the Temporary elongation recorded during FAT (Tf)
Permanent elongation (P) is > +2% of the Permanent elongation recorded during FAT (Pf)

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 SPM #5 PERIODIC SHUT DOWN REPORT

VACUUM TEST PROCEDURE:

Vacuum test to be carried out after hydrostatic pressure test and not more than four days.

Blank off both end of the hose with transparent Perspex flange using a rubber gaskets to
obtain seal and also secure with C- Clamp.

Apply a vacuum of at least 510 mmHg and hold for 10 Min.

Use a bright flashlight, or mirror to direct the sunlight, and examine the bore for,

Blisters or bulges- these indicates the separation of lining from carcass.

Bubbles of water appearing around the fitting area, or at any point along the bore, which
indicates cuts and lining separation.

Page 8 of 12
 SPM #5 PERIODIC SHUT DOWN REPORT

HOSE THAT FAILED

DURING VACUUM TEST
Internal implosion
occurred at the location
indicated by the arrow.

Electrical Continuity Test:

Hoses should be either electrically Continuous or Discontinuous. Resistance of hose should

be measured by means of a 500 Volt Megger

Continuous: The conductivity should be checked when the hose is under pressure and
again after the completion of pressure test. The test to be conducted by connecting a
wire to each flange to complete a circuit with a small 4.5 V battery and a 4V,3A lamp or
by using Multi meter.

Discontinuous: The discontinuous test should be carried out before or after the pressure
test when hose is dry. The resistance of the hose should not be less than 25000 ohms.

Assembly:

Each Hose to be lowered on DSV deck as per serial number AS BUILT SHEET.

New gaskets and studs to be used and tightened to the requisite torque

Assembling of Break-away Coupling in between Reducer and Tail hose with proper gasket
and studs (Direction of Flow to be checked prior installing).

Support Buoy is to be fixed for Break Away coupling and FOB.

Assembling of pick-up chains on tanker rail hose.

Assembling of Butterfly Valve, Spool Piece and cam lock on other end of Tanker rail hose.

Tightening of all studs of 150# and 300# series flanges to be done in sequence using a
calibrated torque wrench as per following table.

20” X 150# flange Joints (Main line) 900 Nm

20” X 300# flange Joints ( Fob J tube end) 1100 Nm
16” X 150# flange Joints (Tail, Rail and Break away) 600 Nm.

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 SPM #5 PERIODIC SHUT DOWN REPORT

AS BUILT SHEET FOR REFERENCE

Pressure Testing Of Assembled Floating Hose String, Towing & FOB Connection :

Assembled floating hose strings are to be pressure tested. Pressure test at 15 bars and held
for one hour and observe for any pressure drop.

If any pressure drop noticed, check the tightness of the hose and flange connection.

If the pressure holds for one hour, slowly depressurize the floating hose string and blind end
of the string.

Upon satisfactory pressure testing, hoses can be towed back to SPM Buoy as per procedure.

First Off Buoy hoses are to be connected to J pipe with new gaskets.

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 SPM #5 PERIODIC SHUT DOWN REPORT
Pressure Testing Of Assembled FHS and System To PLEM:

Moor the DSV by bow on SPM buoy and keep Tanker rail hose on deck of DSV for pressuring
the FHS strings.

Pressurize both floating hoses strings individually against the PLEM valves up to 15 bar and
hold for one hour.

Open both deck valve and centre chamber valve.

Upon satisfactory completion of pressure test, depressurize the floating hoses strings slowly up to 10
Kg/cm2 and inspect the butterfly valve for any leak. If butterfly valve found satisfactory then release
the pressure slowly. Lower the Tanker rail hose in water.

Deck valves

Chamber valves

SINGLE POINT MOORING BUOY (ELEVATION)

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 SPM #5 PERIODIC SHUT DOWN REPORT

SINGLE POINT MOORING BUOY (PLAN)

RECOMMISSIONING OF SPM

Open both deck valve and central chamber valves.

Close surge valves on deck.

Check High Pressure Unit oil level

Accumulators pressure to be checked.

HPU unit to be pressed up to 320 Bar.

Open 30” Manually operated PLEM Valve.

Open 12” valve to surge tanks for both inner and outer.

Page 12 of 12
Appendix
 ACTIVITY LOG-SHEET
Date Time Activity

7-Apr-15 Preparation for Flushing

1048 Hrs - 1536 Hrs Outer Strings Flushing Carried Out

8-Apr-15
1624 Hrs - 2048 Hrs. Inner Strings Flushing Carried Out

0800 Hrs - 1200 Hrs. FON Floats Installation & PPE Rope Secured.

1000 Hrs -1500 Hrs "J" tube- FOB Hose disconnection

9-Apr-15
1500 Hrs to 1630 Hrs FHS Both Strings Towed To LO-LO Jetty.
Floating Hose Strings Lifting and Disconnection.(total 9 Hoses
1715 Hrs - 2300 Hrs.
Disconnected)
Floating Hose Strings Lifting and Disconnection.(total 4 Hoses
0700 Hrs - 0900 Hrs.
Disconnected)
10-Apr-15
Hydrostatic pressure Test , Vacuum Test, Electrical Continuity &
0930 Hrs - 2000 Hrs.
Discontinuity Test Of All 13 Hoses
0600 - 2000 Hrs Lowering Of Hoses and Connection Of Hoses.
11-Apr-15
1800 hrs -2400 hrs
Hydro Test OF Both Strings
0000 hrs - 0300 hrs

12-Apr-15 0600 hrs - 0800 hrs Towing of both string to the SPM

1100 hrs -1900 hrs FOB Connection and Hydrotest of assembly

0900hrs -1200 hrs SPM pre-commissioning checks

13-Apr-15
1500 Hrs Tanker berthed at SPM
 TEST ACCEPTANCE CERTIFICATE

Company Reliance Date 4/11/2015

Unit SPM - 5 Section

INNER STRING PRESSURE TEST
This is to certify that the Inner floating strings

From First of buoy hose

To Tanker rail hose

Was tested as outlined below.

Type of test Hydrostatic

Location of test unit LO-LO jetty

Maximum pressure recorded during test period 15 Kg/ cm2

Duration of Operation Time Date

From 21:00 Hrs 4/11/2015

To 03:10 Hrs 4/12/2015

Filling of hose strings commenced at 21:00 Hrs 4/11/2015

Filling of hose strings Stopped at 22:45 Hrs 4/11/2015

Hydrostatic Pump Started at 22:45 Hrs 4/11/2015

Vent plug closed at 22:50 Hrs 4/11/2015

Time taken for building up pressure from 0 to 15 kg/cm2 22:45 to 00:01 Hrs

Any Pressure drop noticed from 00:01 Hrs to 02:02 Hrs 0.5 Kg/cm2

Pressure released at 02:05 Hrs

Attained ZERO pressure at 03:10 Hrs

Instrument Details Serial No. Mfg. Calibration date

Pressure Gauge C130766 FGB March 31 2015

Completed & witnessed By

RIL Rep. OSL Rep.

 TEST ACCEPTANCE CERTIFICATE
Company Reliance Date 4/11/2015

Unit SPM - 5 Section OUTER STRING

PRESSURE TEST
This is to certify that the Outer floating strings

From First of buoy hose

To Tanker rail hose

Was tested as outlined below.

Type of test Hydrostatic

Location of test unit LO-LO jetty

Maximum pressure recorded during test period 15 Kg/ cm2

Duration of Operation Time Date

From 16:15 Hrs 4/11/2015

To 22:32 Hrs 4/11/2015

Filling of hose strings commenced at 16:15 Hrs 4/11/2015

Filling of hose strings Stopped at 19:30 Hrs 4/11/2015

Hydrostatic Pump Started at 19:30 Hrs 4/11/2015

Vent plug closed at 19:35 Hrs 4/11/2015

Time taken for building up pressure from 0 to 15 kg/cm2 19:30 to 20:30 Hrs

Any Pressure drop noticed from 20:30 Hrs to 21:30 Hrs 0.5 Kg/cm2

Pressure released at 21:35 Hrs

Attained ZERO pressure at 22:32 Hrs

Instrument Details Serial No. Mfg. Calibration date
Pressure Gauge C130760 FGB March 31 2015

Completed & witnessed By

RIL Rep. OSL Rep.

 TEST ACCEPTANCE CERTIFICATE

Company Reliance Date 4/12/2015

Unit SPM - 5 Section INNER STRING SYSTEM PRESSURE

TEST
This is to certify that the Inner floating strings

From Tanker rail hose

To PLEM Valve

Was tested as outlined below.

Type of test Leak Test

Location of test unit SPM - 5

Maximum pressure recorded during test period 15 Kg/ cm2

Duration of Operation Time Date

From 11:50 Hrs 4/12/2015

To 16:20 Hrs 4/12/2015

Filling of hose strings commenced at 11:50 Hrs 4/12/2015

Filling of hose strings Stopped at 12:55 Hrs 4/12/2015

Hydrostatic Pump Started at 12:55 Hrs 4/12/2015

Vent plug closed at 13:00 Hrs 4/12/2015

Time taken for building up pressure from 0 to 15 kg/cm2 12:55 to 14:15Hrs

Any Pressure drop noticed from 14:15 Hrs to 15:15Hrs 0.5 Kg/cm2

Pressure released at 15:17 Hrs

Attained ZERO pressure at 16:20 Hrs

Instrument Details Serial No. Mfg. Calibration date

Pressure Gauge C130766 FGB 30.03.2015

Completed & witnessed By

RIL Rep. OSL Rep.

 TEST ACCEPTANCE CERTIFICATE
Company Reliance Date 4/12/2015

Unit SPM - 5 Section OUTER STRING SYSTEM

PRESSURE TEST
This is to certify that the Outer floating strings

From Tanker rail hose

To PLEM Valve

Was tested as outlined below.

Type of test Leak Test

Location of test unit SPM - 5

Maximum pressure recorded during test period 15 Kg/ cm2

Duration of Operation Time Date

From 16:00 Hrs 4/12/2015

To 19:00 Hrs 4/12/2015

Filling of hose strings commenced at 16:00 Hrs 4/12/2015

Filling of hose strings Stopped at 16:30 Hrs 4/12/2015

Hydrostatic Pump Started at 16:30 Hrs 4/12/2015

Vent plug closed at 16:35 Hrs 4/12/2015

Time taken for building up pressure from 0 to 15 kg/cm2 16:30 to17:15 Hrs

Any Pressure drop noticed from 17:15 Hrs to 18:15 Hrs 0.5 Kg/cm2

Pressure released at 18:15 Hrs

Attained ZERO pressure at 19:00 Hrs

Instrument Details Serial No. Mfg. Calibration date
Pressure Gauge C130760 FGB 30.03.2015

Completed & witnessed By

RIL Rep. OSL Rep.