METHODOLOGY

SECTIONAL REPLACEMENT OF 8” CARGOLINE

AT
SHELL BACOLOD

A. Setting of Marker Buoy for Pipe spool location

 Prepare and secure all the necessary permits.

 Check site preparation for safety issues.
 With the use of an accredited Light Boat (Bangka) for offshore transport.
 Navigation and location of pipe spool to be repaired will be done with the
aid of Hydro graphic survey report or by On-site verification.
 Upon location of pipe spools, temporary marking buoys and reference line
(using plastic drums with tensioned nylon rope) will be provided on the
damage pipe spool section.

B. Drum Boat Preparation/Fabrication

 Fabrication of Drum boat will be done on Racahe wharf and will be

constructed as per approved drawings for assembly.
 Materials and other consumables will be provided by the contractor in the
fabrication.
 Check dimensions in fabrication by the use of client approved isometric
drawing.

C. Removal and Hauling of Pipe Spools

 Check and make sure that all PPE, tools and equipment to be used are all
in good working condition.
 Prepare and secure all the necessary permits.
 Check site preparation for safety issues.
 All lifting equipment shall bear load testing certificate.
 Removal of petrolatum tape on flange connections of damage spool.
 Cleaning of flanges with the aid of steel brush.
  Unbolting and loosening of flange bolts and nuts prior to removal.
 After removal of bolts, install the lift bag on each end and mid length with
the use of lifting straps (1-5 Tonnes).
 Gradually inflate the lift bag for hoisting of the spool to be placed into the
drum boat platform for hauling to onshore fabrication shop.
 Lifting of the spool from the drum boat to onshore fabrication shop will
initiated by the use of Boom Truck.
 Repeat the above procedure for another spool to be repaired.

D. Welding/Fabrication of New Spools

 Check and make sure that all PPE, tools and equipment to be used are all
in good working condition.
 Ensure all materials for fabrication are within the required specification
(Material and Mill certificates) accordingly (approved PSPC/Contractor
Inspection and Test Plan).
 Check all materials and consumable items are acceptable and in good
condition for use needed for spool fabrication.
 Approved drawings with dimensions are reviewed and understood.
 Check spool, flange and welding machine equipment preparation, all
spools fit-up must be shop fabricated.
 All welding works will be performed by a certified welder accredited by
PSPC, bearing an approved Welding Procedure Specification.
 Company authorized Certified Quality Control personnel to carry out
visual inspection of each weld joint.
 Prior to welding works, double check the alignment of the pipes to be
connected.
 Third party inspector will perform NDT to ensure quality assurance.
 Dye Penetrant Testing (DPT) will be carried out on new spool joints to
check welder’s workmanship (3rd party).
 Conduct hydro testing on all shop fabricated spools at fabrication shop
prior to installation in accordance with ASTM E1003 Standard Test
Method for Hydro Leak Testing.
 Clearing and House Keeping.

E. Repair of damaged spools by Installing/Welding of Sleeve Pipes

 Check and make sure that all PPE, tools and equipment to be used are all
in good working condition.
 Prepare and secure all the necessary permits.
 Approved drawings with dimensions are reviewed.
 Check site preparation to enhance field works.
  Ensure all materials are within the required specification (Material and
Mill certificates) accordingly (approved PSPC/Contractor Inspection and
Test Plan)
 All welding works will be performed by a certified welder accredited by
PSPC, bearing an approved Welding Procedure Specification.
 Company authorized Certified Quality Control personnel to carry out
visual inspection of each weld joint.
 Prepare and clean the spool’s joint prior to installation of sleeve pipe.
 Install and fit the sleeve pipe in accordance with the approved plan and
specification.
 Full weld the installed sleeve pipe performed by qualified contractor pipe
welders.
 Third party inspector will perform NDT to ensure quality assurance.
 Dye Penetrant Testing (DPT) will be carried out on repaired sleeve pipe
welds to check weld quality (3rd party).
 Once the welding and testing is done, install petrolatum tape and cover the
entire portion of sleeve pipes with approximate 100mm overlap at both
ends.

F. Repair of Cement Coated Pipes of New/Old Spools

 Ensure all materials are within the required specification (Material and
Mill certificates) accordingly (approved PSPC/Contractor Inspection and
Test Plan).
 Surface preparation of damaged concrete coated pipe surface and pipe-to-
flange surface must be done prior to repair.
 Remove all loose cement coating material on the pipe area by using
scraper or other means (Care must be observed to prevent unnecessary
damage to the adjacent coatings).
 Epoxy coating, Type V cement and wire mesh materials are to be used.
 Apply epoxy coating materials to the pipe area or its circumference from
pipe cut back up to the end portion of the flange then wait until dry.
 Install reinforcement wire mesh 1”x1” (gauge #14) with the fabricated clip
(G.I. wire #16) to the pipe body.
 Sectional wire mesh will be wrapped to the damaged concrete coated pipe
surface to be repaired prior to plastering of Type V cement.
 The prepared area for repair must be wetted with cement slurry (cement
water mix) to provide good bonding between surface of the pipe and new
mortar mixture.
 Cement coating must be done by means of patching by hand or trowel
using newly mixed mortar with little water just enough to moisten the
mixture and smoothened by cement slurry.
 Finished coating must be one and the same in appearance and thickness.
 Curing time (up to 2 to 3 days) before any movement of the pipe.
  Concrete samples will be taken from repaired pipes for testing
(Compressive Testing) to assure Concrete coating design is achieved
(5000psi).

G. Hydrostatic Testing/Leak Testing and Purging

 Identify the test pressure to be used, as determined by a required approved

pressure.
 Identify the type of pipe system to be tested.
 Examine all weld seam connections to ensure no visible leaks.
 Determine the pressure rating to ensure for the maximum test pressure.
 Secure a blind flange suitable for the system’s rated pressure on two sides
of the pipe end.
 Ensure that the equipment (hydro test pump) to be used is capable to test
at a given maximum pressure, check that all pipe fittings, test pressure
gauges and its connection are installed properly.
 Fill the piping system with water and apply first a preliminary test
pressure of 25 psig, or directed by the client.
 While holding the pressure, all remaining air from the piping system will
remove while continue filling of water as necessary to maintain initial fill
pressure. This pressure held for a minimum of 10 minutes to allow for the
location of any leaks.
 If leaks area detected or any time during the test, release the pressure and
take appropriate action to correct the source of leak.
 Remove pressure and verify that all air bleed ports are appropriately
secured.
 Apply the hydrostatic test pressure of 25psig until the maximum test
pressure is reached, hold the pressure and inspect the pipes for leaks
before adding more pressure.
Note: The test pressures is 1.5x (times) the design pressure.
 Establish that the required test pressure has been achieved.
 Hold the required pressure for 10-20 minutes or provided by client
specifications.
 Obtain confirmation of a successful test by the PSPC representative after
the required time period.
 Remove the pressure, with caution to avoid escaping water and debris if
any, ensure that water will be release safely before disposal.
 Prepare the photograph of pressures gauges value before and after the test.
 Assist in water purging of the pipeline prior to commissioning (after
installation).
 H. Installation of New Spools and Reinstallation of Repaired Spools

 Check and make sure that all PPE, tools and equipment to be used are all
in good working condition.
 Prepare and secure all the necessary permits.
 Check site preparation for safety issues.
 All lifting equipment shall bear load testing certificate.
 Inspection and preparation of seabed prior to pipe laying.
 Provide temporary marking buoys and reference line (tensioned nylon
rope) on the pipe section.
 Attached the three (3) cables of A-frame into both ends & mid portion of
the spool then attached lift bags on both end of the pipe.
 Deflating lift bags gradually while lowering down the spool to its
designated location.
 Repeat above procedure for lowering the spool.
 Remove the blind flange prior to bolt and nut installation to reinstall the
flanges of the spool.
 Prior to bolt tightening, check the 12, 3, 6 and 9oclock position of the
flanges for the spool alignment.
 Wrapping of flange-to-flange connection by petrolatum/Densyl tape.
 Clearing and House Keeping.

I. Quality Assurance

 Ensure all Quality control supporting documents are on file likewise duly
signed by the Client’s representative.
 Approved Inspection and Test Plan are followed.
 Pictographs of every undertaking shall be available on file for Client’s
reference.
 Ensure certified third-party inspectors/Client’s representatives are being
utilized.
 Issuances of Project file/documents reflecting therein the following:
methodology, Safety concern, Quality assurance, progress, as built plans
and permits for client’s reference.
 Submission of original copies duly signed (by Client, Client
Representative and Contractor) and completed quality records for turn-
over.

Prepared by:rav

SUBSEA SERVICES INC.