OKPOHO PLATFORM JACKETS (SPLASH ZONE)

CORROSION MITIGATION STRATEGY

TECHNICAL PROPOSAL

Proposal Ref: CAIN-OML119-IA-PRP-0000

February 2017

Suite 4, Jinifa Plaza Annex Tel: +234 909 111 0258

Central Business District Contact: info@cainergy.com
Abuja, Nigeria Web: www.cainergy.com
 Cainergy International Limited

February 27, 2016

The Managing Director

Nigerian Petroleum Development Company Ltd.
62, 64 Sapele
Benin City.
Edo State
Dear Sir,

LETTER OF INTRODUCTION

Cainergy International Limited is a specialized Production Assurance and Asset Management Company
providing bespoke Asset Integrity Management and Asset Life Cycle solutions which encompass Asset
Integrity Audits, Integrity Assurance, Process Safety, Operational Integrity, Maintenance services and training
to diverse clients, particularly in the Oil and Gas and Petrochemical industry.

We wish to express our interest to provide site survey , inspection and implementation for Splash
Zone Integrity Protection Services for NPDC offshore asset for OML 119 OKPOHO oilfield platform
jacket with the direct support of our technical team in Dubai and our local Nigerian and international
patners.

Our area of competence cuts across the various strata of the oil and gas industry from wellheads, oil
extraction, central processing, refineries, distribution, pipelines, etc. upstream and downstream, offshore
and onshore. In conjunction with this, we ensure that all the assets and associated utilities and ancillaries
are available and fit for purpose with zero downtime.

With our strong team of professional engineers and subject matter experts (SMEs) and our local and
international partners, Cainergy is well positioned to deliver exceptional Integrity audit services. by
responding to both production and integrity assurance demands on your assets as well as implementing
integrity solutions for an efficient preventive maintenance strategy to forestall future breakdown.

In addition to our technical know how and experience in other parts of the world, our experience in
delivering exceptional Integrity audit services in the Niger delta region has further equipped us to provide
specialized integrity audits and asset management solutions that are effective and well suited for the
onshore and offshore assets in this region.

Cainergy also provides excellent services in Procurement, Construction and Fabrication, Operations,
Vibration Engineering, and Reliability Engineering.

We look forward to working closely with your esteemed organization and supporting your projects.

Yours Faithfully,
For: Cainergy International Limited

Cainergy International Limited.

Goodness Aula PCQI, NSE, CSWIP, ASQ RC No. 1267527
Chief Operating Officer Incorporated in: Nigeria
Suite 4, Jenifa Plaza Annex, Plot 1014, Samuel
Adenulegun Adesujo Street,
Central Business District, Abuja, Nigeria
info@cainergy.com, www.cainergy.com
 OML 119 – OKPOHO jackets (Splash Zone) Corrosion Risk

TABLE OF CONTENTS

1.0 INTRODUCTION .............................................................................. 2

2.0 OBJECTIVE ................................................................................... 2
3.0 UNDERSTANDING SPLASH ZONE AND ITS CORROSION INTEGRITY ISSUES ......... 5
4.0 SPLASH ZONE PROTECTION AND CORROSION CONTROL STRATEGIES ............. 5

4.1 Splash Zone Protection Overview .............................................................. 5

4.2 Splash Zone Protection Requirements ...................................................... 6

4.3 Coating Systems Requirements ................................................................. 6

4.4 Elastomer Coating Technology (Splashtron)............................................. 6

5.0 PROPOSED CORROSION MITIGATION FOR OKPOHO PLATFORM SPLASH ZONE ..... 8

5.1 Elastomer Coating Advantages .................................................................. 8

5.2 Work Execution and Implementation ....................................................... 8

5.3 Cost Benefit Analysis (CBA) ........................................................................ 9

6.0 TERMS OF REFERENCE ................................................................... 10

6.1 List of Grades and Standards To be Followed......................................... 10

6.2 Standards: .................................................................................................. 11

7.0 CONCLUSION ............................................................................... 12

8.0 REFERENCE – OML 40 AUDIT COMPLETION CERTIFICATE ............................ 13

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 OML 119 – OKPOHO jackets (Splash Zone) Corrosion Mitigtion Strategy

1.0 INTRODUCTION

Cainergy has been founded in Abuja, Nigeria with the aim to provide smart solutions
and services which are focused to production assurance and asset integrity
management for our client’s assets in the energy sector, manufacturing, marine,
renewable energy, power, water and other areas. We cover the upstream sector,
midstream and downstream from offshore operations to onshore fields.

Our goal and key business objective is to work closely with assets owners by
providing asset integrity management solutions and technical strategies to resolve
their challenges & asset problems.

2.0 OBJECTIVE
The objective of this technical proposal is to outline Cainergy’s approach and strategy
in undertaking the rehabilitation of OML 119 – Okpoho platform splash zone with state of
the art splash protection technology designed to protect your asset across its
lifecycle.
OML 119 asset has two producing fields on the block, Okpoho and Okono which were
discovered by NPDC in 1978 and 1983 respectively. The present status of the Okpoho
platform jacket (splash zone) is in a critical condition, as can be seen from the
picture below (Fig 1). An immediate action to mitigate the corrosion and the risk of
further degradation on the jackets is of paramount importance to avert sudden
uxpected structural collapse and any catastrophic failure.

Fig 1. Okpoho Plaform corroded Jackets (Splash Zone)

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 OML 119 – OKPOHO jackets (Splash Zone) Corrosion Risk

3.0 UNDERSTANDING SPLASH ZONE AND ITS CORROSION INTEGRITY ISSUES

The "splash zone," is the area immediately above and below the mean water level,
which has long been a major concern to both design and corrosion engineers of
offshore installations. Tides cause the water level to rise and fall, alternately wetting
and drying exposed metal surfaces, such as offshore oil and gas platform legs and
risers.

The brackish water and exposure to oxygen is corrosive, and the sea wave action is
constantly eroding the metal members and debris and boats come in contact with the
metal to cause damage. Most common areas affected are typically risers, J-Tubes,
bends, spools, (Vortex Induced Vibration) VIV Suppression Strakes, and pipe field joint.

The metal which is constantly submerged can usually be protected by cathodic means,
but that won’t work in the "splash zone” because the water level is constantly
changing. The areas well above the "splash zone,” which are exposed only to
atmosphere, can be protected with various paints and zinc coatings, but they must be
reapplied when necessary.

4.0 SPLASH ZONE PROTECTION AND CORROSION CONTROL STRATEGIES

4.1 Splash Zone Protection Overview

Protecting the "splash zone” with traditional above and below the "splash zone”
solutions have proven unsatisfactory. Monel jackets welded to the metal surface;
special coatings and sprayed-o paint; and even making the metal components thicker,,
are not effective in the "splash zone.”

The splash zone protection/corrosion control can be maintained by a range of coatings

applied to a substantially dry and well-prepared surface while the immersed areas can
be protected by cathodic protection.

Maintenance of effective corrosion control is more difficult in the splash and inter-tidal
zones.

There are more options for new work such as increasing the thickness of the steel to
give a corrosion allowance, metallic coatings such as flame sprayed aluminum and
various heavy-duty coatings applied before installation.

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 OML 119 – OKPOHO jackets (Splash Zone) Corrosion Risk

4.2 Splash Zone Protection Requirements

The criteria for successful "splash zone” protection consists of the following
requirements:

• Metal surface isolation – metal must be isolated and separated from the
environment such as with materials with properties similar to rubber or
polyurethane
• High electrical resistance – coating should inhibit electrolytic corrosion and resist
electrical current flow
• High impact resistance – protects against and resists buffeting from boats and
floatin debris
• Flexible – won't crack under the distortion of pipe bends or twists
• Bio-fouling resistant– isolate metal from sea life, fungus and scale attack
• Good thermal insulation – important in the case of flow lines
• Guaranteed for life – should last virtually the life of the installation

4.3 Coating Systems Requirements

Successful coating for in-situ applications include the following:

• Allow application above and below water.
• Displace water from the metal substrate.
• Be surface tolerant.
• Fill pits and surface irregularities.
• Resist displacement by water.
• Be water resistant and resist saponification or emulsification.
• Resist microbiological action.
• Resist damage.
• Have long term weather resistance.
• Prevent corrosion or reduce it to a very low level.

4.4 Elastomer Coating Technology (Splashtron)

Splashtron is high density elastomer coating for splash zone protection. it features
excellent resistance to weathering , fungus , marine life and most oils. The coating is
uniformly bonded to the metal surface which is exposed in the splash zone in
thicknesses of 1/4", 1/2", 3/4", and 1". It can resist impact damage, features exceptional
weatherability, requires no routine maintenance, has excellent insulating properties
(thermal and electrical) and can be used at temperatures from -45°F to 200°F.
Most common applications of Splashtron include platform structural members (legs and
diagonals), conventional risers, pipelines pulled through J-tubes, conductors and the

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 OML 119 – OKPOHO jackets (Splash Zone) Corrosion Risk

lining of riser clamps. The coating elastomer provides complete protection against the
erosive action of abrasive-laden seawater, the harsh attack of ozone and ultraviolet
rays, incidental impact from boats and floating debris and the effect of sea life which
builds upon all offshore installations.

Some pictures below show how the Splashtron coating is applied to the splash zone of a
typical platform.

Platform Splashzone Area Badly Corroded Splashtron applied to the splash zone of a platform

© Cainergy 2017 Technical Proposal 7

 OML 119 – OKPOHO jackets (Splash Zone) Corrosion Risk

5.0 PROPOSED CORROSION MITIGATION OF OKPOHO PLATFORM SPLASH ZONE

Cainergy and its JV partner (Nicnoc Nigeria Ltd) are in a position to offer a
complete rehabilitation service and corrosion control solution for the Okpoho
platform splash zone to forestall further corrosion an degradation on the platform
jackets.

In order to perform and implement an effective integrity solution, Cainergy propose

to undertake a site survey and physical examination to assess the extent of the
corrosion damage of the platform jackets/splash zone, and also to review the
‘structural drawing’ of the platform in order to allow for the calculation of the total
surface area.
The corrosion control ELASTOMER COATING (SPLASHTRON) will be applied to the
platform jacket 1.5m below the identified water level while the upper section will
be coated with marine base paints up to the upper deck of the platform.

5.1 Elastomer Coating Advantages

The greatest benefits of this type of coating when applied for the Okpoho platform
are the following;
• Extended life for the jacket legs
• Reduced cost of maintenance and inspection for sub-surface anodes
• Reduced formation of barnacles, marine growth and corrosion on the jackets.

5.2 Work Execution and Implementation

Cainergy with its JV Partner, Nicnoc will undertake to carry out the total rehabilitation
of the badly corroded splash zone of the Okpoho platform, and implement
completion of the works within a fixed time frame of one month, using the following
deployment of equipment and materials.
• Scaffolding – Erection of scaffolds on the entire work area within the splash
zone area to allow for the movement of personnel and equipments
• Hydro blasting Equipment – The total surface area of the splash zone will be
hydro blasted to bare metal using hydro blasting equipment with a capacity of
10,000 psi
• Anti-corrosion / Marine paints - Application of three coats of anticorrosion
marine paints ie (International / Sigma brand )on the splash zone jackets to the
entire upper deck of the platform
• Elastomer Coating (Splashtron) – Application of splash zone material on the
entire area 1.5m below the identified water level

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 OML 119 – OKPOHO jackets (Splash Zone) Corrosion Risk

5.3 Cost Benefit Analysis (CBA)

The rehabilitation of Okpoho splash zone area will in no doubt help in extending the
design life of the platform and restoring its integrity. With the application of
ELASTOMER COATING (SPLASHTRON) which comes with a life span validity period of
over 8 years, Cainergy and its joint partner Nicnoc, are in no doubt confident that
further maintenance on the area applied with the marine coated paints will be at least
six years interval. This in turn will reduce the periodic maintenance cost on the
rehabilitation of the entire splash zone.

This type of coating technology will also help to protect the entire area from the
surrounding salt water corrosion, deformation of the existing structure (pitting due to
corrosion) and reduce the anode de-gradation of the subsea anode protection.

As part of this proposal and offered service, Cainergy would also like to recommend
a survey of the subsea anode protection of the jacket legs. This gives a 100%
protection of the jacket legs from the platform to the seabed of the jacket legs.

The long term benefits of this exercise are immense and will assist in safeguarding
the integrity of the entire structure for future production. The entire exercise would in
no way disrupt the production from this platform as the work would be carried out
while the plant is running live. It is worth noting that the ‘elastomer Splashtron
coating’ shall not be limited to the jacket legs alone, but also for the well caissons.

A cost benefit can be given of this exercise when the client agrees for a proper survey
to be carried out and the commercial implication involved is submitted for review.
The survey in conjunction with the as built drawings of the plant with special
emphasis on the jackets and caisson would assist us in
• Producing a proper work execution plan
• JHA - job hazard analysis
• Entire surface area to be coated, thereby letting us give a cost per square meter
of the entire job, which can be multiplied by the total area to be covered.
• The best form of developing a SIMOPS ( simultaneous operation schedule) for
the whole operations.

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 OML 119 – OKPOHO jackets (Splash Zone) Corrosion Risk

6.0 TERMS OF REFERENCE

6.1 List of Grades and Standards To be Followed

Grades Definition.:-

Rust Grade C:
Steel surface completely covered with rust but with little or slight pitting under normal
vision.

Rust Grade D:
Steel surface completely covered with rust on which general pitting is visible under
normal vision.

3.2 Blast Standards

The standard illustrates grade C and D surfaces prepared by hydro blasting to two
different degrees of cleanliness. These are designated HB2 and HB2 ½ and are
comparable to Sa2 and Sa2 ½ described in the ISO 8501-1:1988 surface preparation
standard and to SSPC-SP6 and SSPC-SP10 of the Steel Structures Painting Council
surface preparation standards. The definitions are:

HB2 Thorough Hydro blast Cleaning

When viewed without magnification the surface shall be free from visible oil, grease,
dirt, paint coatings and foreign matter and from most of the rust. Any remaining
contamination and staining shall be firmly adherent

HB2 ½ Very Thorough Hydro blast Cleaning

When viewed without magnification the surface shall be free from visible oil, grease,
dirt, loose rust, paint coatings and foreign matter except for staining. A brown-black
discoloration of ferric oxide may remain as a tightly adherent thin film on corroded
and pitted steel.

3.3 Degrees of Flash Rusting

The standard illustrates three grades of flash rusting. Light flash rusting, designated L,
moderate flash rusting, designated M, and heavy flash rusting, designated H.
The definitions are:

L: Light Flash Rusting

When viewed without magnification small quantities of light tan-brown rust will
partially discolor the original metallic surface. The discoloration may be evenly
distributed, or in patches, but it will be tightly adherent and will not be heavy enough
to easily mark objects brushed against it.

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 OML 119 – OKPOHO jackets (Splash Zone) Corrosion Risk

M: Moderate Flash Rusting

When viewed without magnification small quantities of light tan-brown rust will
obscure the original metallic surface. This layer may be evenly distributed or patchy in
appearance but it will be heavy enough to mark objects brushed against it.

H: Heavy Flash Rusting

When viewed without magnification a heavy layer of dark tan-brown rust will
completely obscure the original metallic surface. This layer of rust will be loosely
adherent and will easily mark objects brushed against it

6.2 Standards:

ISO 8501-1 : 1988 Surface Preparation

SSPC VIS – 1 – 89 Surface Preparation

D870 – 15 Standard practice for testing water resistance of coating using

water immersion

D6675 – 01(2015) Salt accelerated outdoor cosmetic corrosion testing

D 4288 – 05 (2012) Standard practice for qualification of coating application of

coating to steel

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 OML 119 – OKPOHO jackets (Splash Zone) Corrosion Risk

7.0 CONCLUSION

The importance of maintaining integrity of an asset and its structural components

such as the ‘splash zone’ is part of a good industry practice and also prevents

material failure which can be catastophic in worst cases.

Cainergy's expertise in integrity and production assurance is to maintain asset

value, integrity and quality by taking the approach of ‘prevention’ rather than a
cure, and avoiding downtime but preserving uptime.

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 OML 119 – OKPOHO jackets (Splash Zone) Corrosion Risk

8.0 REFERENCE – OML 40 AUDIT COMPLETION CERTIFICATE

A completion certificate is attached in this proposal too demonstrate what we have

achieved and executed last year for OML 40 asset to the satisfaction of our Client.

© Cainergy 2017 Technical Proposal 13