BSPL-1530-LCL1-CM-MS-0010 (A1) Method Statement For Sub Sea Tie-In Spool & Bolt Tensioning

Leighton Contractors (India) Pvt. Ltd.
Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat

Project No. I0199
METHOD STATEMENT BSPL-1520-LCL1-CM-
Document No.
MS-0010
SUB SEA TIE-IN AND BOLT Rev. A1
TENSIONING
Page No. Page 2 of 16
INDEX
1 INTRODUCTION ............................................................................................................... 3
1.1 Project Description....................................................................................................................... 3
1.2 Scope............................................................................................................................................ 3
2 SAFETY ............................................................................................................................ 3
3 RESPONSIBILITIES ......................................................................................................... 4
4 PROJECT PERSONEL ..................................................................................................... 4
4.1 Project Manager ........................................................................................................................... 4
4.2 Construction Manager.................................................................................................................. 4
4.3 Lead Engineer .............................................................................................................................. 4
4.4 Project Engineer........................................................................................................................... 4
4.5 HSE Manager............................................................................................................................... 5
4.6 Barge Superintendents ................................................................................................................. 5
4.7 Barge Foremen / Crew ................................................................................................................. 5
4.8 Party Chief Surveyor.................................................................................................................... 5
4.9 Diving Supervisor ........................................................................................................................ 5
4.10 Quality Control Engineer............................................................................................................. 5
5 ABBREVIATIONS............................................................................................................. 6
6 REFERENCE DOCUMENTS ............................................................................................ 6
6.1 Project Specifications................................................................................................................... 6
6.2 Project Drawings.......................................................................................................................... 6
6.3 Project Engineering Reports ........................................................................................................ 6
6.4 Project Inspections and Test Plans............................................................................................... 6
6.5 Project Procedures and Plans ....................................................................................................... 7
7 EQUIPMENT ..................................................................................................................... 7
7.1 Marine Spread.............................................................................................................................. 7
7.2 Measurement Equipments............................................................................................................ 7
7.3 Fabrication Equipments ............................................................................................................... 7
7.4 Hydro Testing Equipments .......................................................................................................... 8
7.5 Installation Equipments ............................................................................................................... 8
8 PROCEDURE.................................................................................................................... 8
8.1 General Description ..................................................................................................................... 8
8.2 Tie-in Spool Measurement using Metrology Measurement System............................................ 9
8.3 Tie-in Spool Fabrication .............................................................................................................. 9
8.4 Tie-In Spool Hydro Testing ....................................................................................................... 10
8.5 Preparation for Tie-in Spool Installation ................................................................................... 10
8.6 Installation of Tie-in Spool ........................................................................................................ 11
8.7 Tie-in Flange Connections......................................................................................................... 11
8.8 Tensioning Procedure ................................................................................................................ 12
9 QUALITY......................................................................................................................... 13
10 APPENDICES ................................................................................................................. 14
10.1 Appendix A – DRAWINGS ...................................................................................................... 14
10.2 Appendix B – Crane Specifications........................................................................................... 15
10.3 Appendix C – Metrology Kit ..................................................................................................... 16
Dec 10 Page 2 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

Leighton Contractors (India) Pvt. Ltd. Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat
Project No. I0199
Document No.
MS-0010
TENSIONING
1 INTRODUCTION
1.1 Project Description
Cairn Energy India Pty. Ltd. (Company) intends to install a Single Point Mooring (SPM) system
and 2 no. x 24” diameter x 6.0 km crude oil pipeline as part of its marine infrastructure for its
Bhogat terminal. The marine pipeline will run from the Land Fall Point (LFP) to the Single Point
Mooring (SPM). The land pipeline will run from LFP to the Bhogat terminal in Gujarat on the
West coast of India. The SPM will be used for loading crude oil onto Aframax / Seawaymax
tankers.
Leighton Contractor (India) Pvt. Ltd. (Contractor) has been awarded as the EPC Contractor for
the marine facilities project. Leighton’s scope of work will be carried out as outlined below:
 Pre Engineering survey of the offshore/onshore fields for obtaining field data for design of
dredging, SPM, PLEM, Pipeline and other accessories etc.
 Detailed Engineering of SPM & PLEM system, Offshore/Onshore Pipelines, Diffuser &
Reject water pipeline system, and accessories including installation engineering for
SPM/PLEM and pipelines.
 Procurement of SPM /PLEM system, complete including piles, chains, subsea hoses,
floating hoses, hawser.
 Procurement of diffuser system, reject water pipeline materials, pipe fittings, valves, as
required.
 Installation of a 2 no. x 24” dia. X 6.0 km of long concrete coated and thermally insulated and
heat traced submarine pipeline from the PLEM to the LFP. Line pipes to be free issued by
CEIL.
 Installation of a SPM & PLEM System (at approx. 28 m water depth) including piling, anchor
chain tensioning and installation, connecting subsea and floating hoses with SPM & PLEM
system.
 Installation of a 2 no. x 24” dia. X 0.6 km shore based pipeline from the LFP to the Battery
Limit Point (BLP).
 Testing and pre-commissioning of the complete system.
 Hook-up of marine pipeline with onshore pipeline at the BLP.
 Installation and pre-commissioning of Diffusers and reject water pipeline.
1.2 Scope
The scope of this document is to provide the required procedure for carrying out the Tie-In
Spool activity related to the Offshore Pipeline Installation works, including;
 Measure, Fabricate, Hydro Test and installation of sub sea Tie-In Spool
 Installation and Tension the stud bolts between the Submarine Pipeline, Tie-In Spool and
PLEM flanges
2 SAFETY
All works shall be undertaken in accordance with this document, contract requirements,
approved Leighton safety procedures and any specific job safety analysis conducted prior to
commencement of work.

Project No. I0199
Document No.
MS-0010
TENSIONING
3 RESPONSIBILITIES
Project Manager shall be responsible for approval of this procedure.
Project Engineer shall be responsible for preparation of this procedure.
Construction Manager shall be responsible for implementation of this procedure.
Actions may be delegated, but responsibility shall not be delegated.
Use of the word ‘shall’ within this document indicates a mandatory requirement.
Use of the word ‘should’ within this document indicates a preferred requirement.
This procedure shall be followed by all personnel involved in the operations. This procedure may
be adjusted by Project Engineer to suit adverse site conditions subject to LIN Site Construction
Manager and Client approval
Definitions:
Use of the Word ‘shall’ within this document indicates a mandatory requirement.
Use of the word ‘should’ within this document indicates a preferred requirement.
4 PROJECT PERSONEL
This procedure has been reviewed by the Lead Engineer / Construction Manager and approved
by the Project Manager. This procedure will serve as a guideline for the field personnel and is
subject to adjustment to accommodate site conditions subject to approval of the Barge
Superintendent. This procedure shall be followed by all personnel directly involved in this scope
of work.
4.1 Project Manager
The Project Manager will report to top management on all aspects of progress and performance
of the project. The Project Manager shall coordinate and monitor the progress and performance
of the project. The Construction Manager, Lead Engineers, HSE Manager and Quality Manager
will report to Project Manager.
4.2 Construction Manager
The Construction Manager will be responsible for all aspects of the performance and progress of
the construction works of the project and will report directly to the Project Manager. He shall
coordinate and lead the construction works through Construction Superintendents and or
Subcontractors ensuring HSE Policies System and Procedures are fully implemented and all
works are conducted / completed in a safe and efficient manner.
4.3 Lead Engineer
The Lead Engineer reports to Project Manager, works closely with Construction Manager,
Quality Manager and Project Manager. He is the main liaison for all Engineering matters with
Client and responsible for Engineering within the Project. Project Engineers report directly to the
Lead Engineer.
4.4 Project Engineer
He will work closely with Construction Manager for the completion of Project on schedule and
within Engineering scope and specification. He will be responsible for all Engineering
implementation aspects of the WMS. The Project Engineer shall report to the Lead Engineer. He

Project No. I0199
Document No.
MS-0010
TENSIONING
will liaise with the Client Project Team, Third Party Inspection Agency and other authorities with
respect to Project Execution.
4.5 HSE Manager
He will be responsible for the development, communication and implementation of an effective,
strategic health, safety and environment programme. He will make sure that we have, at all
times, the capability and resources to operate safely and with no harm to health, and will make
sure that our Health, Safety and Environment Policy and procedures are implemented properly
at all levels. He will coordinate and monitor activities relating to health, safety and environment
at all working locations, promote safety awareness and device safety training and education for
Project team members and Sub-contractors. He will also liaise with the Environmental Agency
and other local authorities on Environmental and Safety aspects of the project.
4.6 Barge Superintendents
The Barge Superintendent will be responsible for all aspects of Tie-In Spool Fabrication,
Installation and testing and all Lay barge marine activities. The Barge Superintendents report to
the Construction Manager.
4.7 Barge Foremen / Crew
The Barge Foremen and Crew will report to the Barge Superintendent, will be responsible for all
aspects of the safe working of the barge. They will be responsible for the positioning, trim and
mooring of the barge and operate the necessary equipments within all applicable programs,
procedures and in a safe and efficient manner.
4.8 Party Chief Surveyor
The Party Chief Surveyors shall report to the Construction Manager, and work closely with the
Project Engineer and Barge Superintendent. He will be responsible of all the survey activities
and will ensure with the Construction Manager that all the resource and equipment are adequate
for the work. The Party Chief Surveyor will supervise all calibration and installation of
equipments and all survey data is correctly logged and processed.
4.9 Diving Supervisor
The Diving Supervisor, who shall report to Barge Superintendent and work closely with Project
Engineer, shall be responsible for the diving team, diving equipment and consumables related to
diving operation. He shall ensure the diving team understands the task to be carried out as per
agreed Project Diving Activities and Barge Superintendent’s requirements / instructions. He will
ensure all diving works are conducted and completed in a safe and efficient manner.
4.10 Quality Control Engineer
The Quality Control Engineer shall carry out all inspection and testing as related to fabrication,
testing and installation of Tie-In Spool. Ensure that Construction team and Subcontractor team
are fully aware of quality standards, working to approved procedures and inspection records are
produced and signed off in a timely manner. QCE is responsible to identify and close out all Non
Conformance Reports (NCR) issued by LCI, TPI or Client prior to commencement of other
activities.

Project No. I0199
Document No.
MS-0010
TENSIONING
5 ABBREVIATIONS
COMPANY : Cairn Energy India Pty. Ltd. (CEIL)

CONTRACTOR : Leighton Contractors (India) Pvt Ltd. (LCL1)
BES : Bluewater Energy Services
PLEM : Pipeline End Manifold
SPM : Single Point Mooring
LFP : Land Fall Point
AHT : Anchor Handling Tug
6 REFERENCE DOCUMENTS
The latest revision of the following reference documents shall be used in conjunction with this
procedure.
6.1 Project Specifications

Table 6.1 Project Specifications
Document No. Title
BSPL-1500-PENS-SS-SOW-0001 Scope of work for the Marine EPC Contractor
6.2 Project Drawings

Table 6.2 Project Drawings
Document No. Title
BSPL-1500-LCL1-SS-DWG-2018-01 Field Layout
BSPL-1510-LCL1-PL-DWG-2020-01 SPM/PLEM Location Plan
BSPL-1550-LCL1-PL-DWG-2026-01 Offshore Pipeline Tie-in details at SPM location
6.3 Project Engineering Reports

Table 6.3 Project Engineering Reports
Document No. Title

Design Basis Memorandum – Onshore and Offshore
BSPL-1500-LCL1-SS-BD-2001
Pipelines
BSPL-1500-LCL1-PE-REP-2037 Conceptual Design and BDEP Verification Report
6.4 Project Inspections and Test Plans

Table 6.4 Project Inspection and Test Plans
Document No. Title

Project No. I0199
Document No.
MS-0010
TENSIONING
Inspection and Test Plan for Sub Sea Tie-in and Bolt
BSPL-1540-LCL1-QA-ITP-0010
Tensioning
6.5 Project Procedures and Plans

Table 6.5 Project Procedure
Document No. Title

Method Statement for Pipeline Installation – Bottom
BSPL-1520-LCL1-CM-MS-0006
Pull Method
BSPL-1520-LCL1-CM-MS-0008 Method Statement for Field Joint Coating and Repair
Method Statement for Pipeline End Manifold (PLEM)
BSPL-1540-LCL1-CM-MS-0004
Installation
BSPL-1540-LCL1-SH-PRO-8001 Diving Procedure
Pipeline Flooding, Cleaning, Gauging, Hydro testing
BSPL-1520-LCL1-CT-MS-0016
and Leak Test
BSPL-1500-LCL1-CM-PLN-0001 Project Construction Plan
BSPL-1500-LCL1-QA-PLN-0001 Project Quality Plan
BSPL-1500-LCL1-HS-PLN-0001 Project Health and Safety Plan
BSPL-1500-LCL1-HS-PLN-0002 Project Environment Plan
BSPL-1500-LCL1-HS-PLN-0003 Project Emergency Response Plan
7 EQUIPMENT
The major equipment involved in Sub sea tie-in spool Installation & Tensioning are as follows;
7.1 Marine Spread
 Installation Barge (Leighton MYNX) with 400MT Capacity Manitowoc Crawler Crane,
16000 series.
 Anchor Handling Tug Boat – Britoil 57
 Anchor Handling Tug – PW Reliance
 Tow Tug – Maritime Raja
 Material Barge – Maritime Hawk – 250’ Long Barge
 Material Barge – Maritime Dawn – 250’ Long Barge
7.2 Measurement Equipments
 Metrology Unit
 Measurement Unit
7.3 Fabrication Equipments
 Measurement Tools
 Cutting and Grinding Tools
 Welding and NDT Equipments

Project No. I0199
Document No.
MS-0010
TENSIONING
 Coating Equipments and Holiday Detector

7.4 Hydro Testing Equipments
 Filling Pump / Barge Fire Pump
 Pressurization Pump
 Filling and Pressurization Hoses
 Blind Flanges and tapings for Hydro Testing
 Pressure Gauges
 Fittings
 Digital Temp. Meter
 Gauge Meter
7.5 Installation Equipments
 Rigging Equipments
 Webbing Slings
 Chain Pulley Block
 Buoyancy aids with fixing kit
 Bolt Tightening Equipment / Bolt Tensioner with Hydraulic Power Pack
 Diving Equipment
 Hydraulic Jack
 Flange Puller / Jacking Plate
 Flange Catchers
 Merlin Spikes (Long and Short)
 Long Draw Bolts for flange pulling (drawing)
 Sand Bags
 High Pressure Impact Wrench / Hydraulic Torque Wrench
 Survey Equipments – Transponders & Gyro
 Diving Spread
 Air Lifting Pipe
 Compressor
 High Pressure Air Hoses
 Skillet (Flange Holder)
8 PROCEDURE
8.1 General Description
Following the PLEM and Submarine pipeline installation, the tie-in spool piece shall be
fabricated to connect the submarine pipeline and the PLEM Pipe System. The following is an
outline of the tie-in spool installation plan;
 A number of the sections of the spool will be ready welded together prior to taking any
measurements. (Refer drawing BSPL-1520-LCL1-SS-DWG-2023 – Crude Oil (CO) Pipeline
approach & Tie-in details at PLEM).
 Prior to removal of Pig launchers from the pipeline the flooding valves shall be open so as to
equalize the pressure in the pipeline. As the Pig launchers are disconnected from the pipeline
end, there may be some eddy flow in and out of the pipeline to achieve equilibrium and caution
is to be taken by the diver(s) not to stand in front of the pipeline inlet while the flange is being
opened.

Project No. I0199
Document No.
MS-0010
TENSIONING
 Air lifting should be carried out if required, surrounding the Sledge to ensure the bolts are clear
from mud and diver have sufficient clear space to remove stud bolts and Pig launchers.
 Perform under water cutting and removal of the Pulling head for tie-in spools installation.
 Metrology measurements for both the tie-in spools shall be done one after the other.
 The distance and angles between the two fixed flanges of the PLEM and Pipeline shall be
accurately measured utilizing metrology units. The measurements obtained shall be analyzed
for consistency.
 The spool piece shall be fabricated on the work barge or onshore jetty/yard with NDT completed
on the field welds. Gauging and hydro test shall be completed prior to field joint coating.
 The divers shall swim the spool installation area to ensure that there are no obstructions. Also
diver shall note if there are any high spots that could impact on the spool setting down on the
seabed.
 The spool piece shall then be lowered into position, the bolts inserted and tensioned.
8.2 Tie-in Spool Measurement using Metrology Measurement System

 An accurate dimension in the X, Y, and Z planes is essential so that the spool piece can be
fabricated correctly and thus result in a good fit. For this a taught wire (stain steel wire)
metrology measurement system will be used. This system measures the horizontal, vertical and
aligned distance between the flanges and consists of two plates, one of each is attached to each
flange.
 Divers shall install the first unit on the PLEM flange and the second on the pipeline section. The
measuring wire will then be drawn out from the first unit to the second unit with horizontal and
vertical angles scales loosened for movement.
 Divers shall tighten the wire at the required end using the crank on the metrology unit. Once the
wire is tighten the diver shall read off the horizontal and vertical angles at both ends and
measure the length of the tighten cable.
 Multiple readings will be taken at each end of the metrology unit to give readings in both faces.
 Upon completion of the measurement process, a dive shall be utilized to install flange catchers
at PLEM flange side in preparation for the Tie-In Spool installation.
 With a range of result taken, average measurement will then be calculated. From these
measurements a 3D model will be produced in Auto Cad from which the X, Y and Z offset will be
calculated with the spool. In addition checks will be done using simple geometry.
 As-built drawings for the tie-in spools shall be prepared.
8.3 Tie-in Spool Fabrication

 All Bends shall be properly marked the 12 O’ Clock position to ensure the bends are correctly
orientated prior to weld out.
 The Tie-in spool pieces shall be partly fabricated, prior to tie-in spool measurements. The pre-
fabricated spool pieces shall be cut back as per the final dimensions obtained.
 With the final angles and distances calculated and confirmed between the two flanges ends are
confirmed, a RTJ flange template to simulate PLEM flange will be mounted on the deck of a flat
top barge and fixed in position. The other end of RTJ Flange template to simulate pipeline flange
position should be established temporarily by mathematical method and upon temporary fixing
on deck. The Metrological System shall be used on deck to confirm accurately the position of
the 2nd flange template against the first flange template. Adjustment should be carried out to
ensure that both templates are exactly positioned as per the measurement angles and distance

Project No. I0199
Document No.
MS-0010
TENSIONING
obtained. Once the confirmation made, the metrological system shall be removed from the
flange template and both of the flange template should be connected with the pre-fabricated
spool flange sections with bolts and nuts. The other pre-fabricated spool pieces shall then be
installed between the two fixed ends and final welding shall be carried out as per approved WPS
and follow by NDT process on completion of each weld joint.
 The Tie-In Spool shall be cleaned internally then gauging shall be carried through out Tie-In
Spool to ensure the Spool Piece is PIG able. Basic 12mm thick aluminum gauge plate shall be
inserted into the spool via one end and riggers shall pull the plate through the total length of the
spool.
 Upon completion of Gauging and Spool Hydro testing as explained below section 7.4, all weld
joints shall be applied with Field Joint Coating and Holiday Inspection shall be carried out.
8.4 Tie-In Spool Hydro Testing

 Tie-in spool pre-installation hydro testing shall be carried out as per method below.
 The Tie-in spool shall be Hydro tested at test pressure of 56bar for duration of 8 hours. The
hydro testing of tie-in spool will be done prior to any field joint coating work and NDT clearance
shall be obtained prior to the Hydro testing. All Hydro testing gears such pressure gauges,
digital temperature gauges shall have valid certificates and available on barge.
 The tie-in spool will be pressurized with treated sea water at a rate of not greater than
2.0bar/min up to 80% of the test pressure. On achieving this pressure, pressurization shall be
stopped.
 Visual inspection of any potential leakage shall be performed and the pressure shall be
stabilized for 30 minutes.
 After stabilization at 80% of test pressure period has been successfully completed, the full
pressurization (100% test pressure) shall be resumed at a rate of 1bar/min maximum.
 After completion of the pressurization to full test pressure, the pressurization will be stopped and
the tie-in spool isolated. The hydro test pressure shall be maintained for a period of 8 hours.
 Upon completion and acceptance of the hydro test hold period, the tie-in spool will be
depressurized in a controlled manner at a rate not exceeding 2.0 Bar/min.
 Hydro test records and certificate to be generated and signed of by all relevant parties.
8.5 Preparation for Tie-in Spool Installation

 During Tie-in spool fabrication on barge deck, a series of guides at both sides of the spool shall
be fixed to the barge deck so that when the spool is lifted to determine if the rigging is correct
the spool cannot swing out of position.
 A trial lift height of 1 to 2 feet from deck shall be done before the spool installation to confirm
correct rigging configuration. Adjustment on the rigging and the point of lifting shall be carried
out immediately if necessary.
 The series of the guides facing the lifting crane shall be removed upon achieving best result
from the trial lift of the spool.
 Lifting slings and the arrangement for handling the completed tie-in spool are as per drawing.
Where the lifting slings are to be attached directly to the steel pipe, a webbing sling shall be
used around the pipe to protect the pipe coatings and at other places steel straps shall be used.
 Polypropylene tag lines (ropes) are to be attached to the ends of pipe to control the spool
movements during lifting from the barge.

Project No. I0199
Document No.
MS-0010
TENSIONING
 Buoyancy units should be attached to the spool and secured so that they can be used by the
divers should they be needed. The position of the buoyancy units on Spool Piece shall be
numbered clearly on the concrete weight coating surface with paint for Diver’s easy
identification.
 All bolts holes on both swivel flanges on the Spool piece shall be numbered clearly for Diver’s
easy identification while the process of bolts and nuts installation and tightening/tensioning.
 Prepare gasket spacers and long stud bolts and nuts for flange connections.
8.6 Installation of Tie-in Spool

 After the completion of preparation/rigging for tie-in spool installation the work barge crane shall
lift the spool for installation. Handling of the vertical and the horizontal bends shall be done with
additional care and therefore the temporary knee braces are required keeping the bends in
position during lifting and lowering of the Spool Piece. During the installation operation care
must be taken that the radius of the crane boom is always within safe working load for that
radius. The envisaged maximum weight of the tie-in spool piece including the rigging gear and
the lifting hook is approximately 63 MT. All appropriated rigging gear should be checked, made
ready for the installation and all valid Test Certificates are available on board. Safe Working
Load and the Factor of Safety rating of all lifting gears such the shackles and the lifting wire rope
slings are mentioned in Drawing No. BSPL-1520-LCL!-PE-DWG-0183. The Flexible Concrete
Mattress shall be placed before and after Installation of Tie-In spool, Drawing No. BSPL-1520-
LCL1-SS-DWG-2023-01 (C1) Crude Oil (CO) Pipeline Approach & Tie-IN Details at Pipeline
End Manifold (PLEM) & BSPL-1520-LCL1-SS-DWG-2023-02 (C1) Crude Oil (CO) Pipeline
Approach & Tie-IN Details at Pipeline End Manifold (PLEM) shall be referred for details.
 As the spool is lifted the material barge shall be pulled away by a tug.
 Lower the spool into the water, flood and continue to lower to the Tie-in location.
 Divers shall be in position to monitor each end of spool and to guide the lowering of the spool in
a safe and efficient manner.
 Great care must be taken as the spool is lowered, to ensure that a high impact landing does not
take place. The divers shall observe which flanges are lower (preferably the pipeline end) and
then guide the Tie-In Spool flange to the pipeline flange.
 Move the mating flanges (Pipeline and Tie-In Spool) as close as possible so that the mating
flange of the PLEM and Tie-In spool can be aligned.
 The diver shall swim the line and ensure that the spool is positioned properly on the seabed. It
may also be necessary to give support to the spool piece by placing sand bags especially
around the bends, if not adequately supported by the seabed.
 Divers shall check and re-confirm the PLEM and Pipeline flange condition to ensure they are
aligned and no damages taken place.
 Once the spool is properly and safely placed which means the spool flange is resting on the pre-
installed flange catcher on the PLEM flange and additional flange catchers shall be inserted if
required at both side of the spool flanges to prevent the flange from miss align upon removal of
the lifting sling.
 Once everything is in order, the guide slings and lifting slings shall be detached from the crane.
8.7 Tie-in Flange Connections

 Divers shall confirmed the overall measurements of both side flanges of spool with pipeline and
PLEM flanges respectively that are the X, Y and Z planes. Tape measurement shall be used to
take the exact measurement.

Project No. I0199
Document No.
MS-0010
TENSIONING
 Preferably the flange connection at PLEM side shall be worked first prior to working on the
Pipeline side.
 Analysis and planning shall be carried out based on the measurement obtained from the divers.
 Once the PLEM side flange is temporary secured with flange catchers, merlins spikes and long
draw bolts, diver and equipment will transfer to pipeline side flanges.
 Re-measurement should be taken on the Pipeline section if required between both pipeline and
spool flanges to ensure the current condition that is after temporary connection carried out at
PLEM side.
 Both Pipeline flange and spool flange shall be aligned with flange catchers and merlins spikes.
 As required, flange puller (come along), hydraulic jacks and jacking plates, buoyancy units shall
be used to align both flanges.
 Once both flanges properly aligned and if required long temporary draw bolts shall be inserted to
draw both flanges together mechanically.
 Once the appropriate gap achieved then the temporary bolts and marlin spikes if any shall be
removed at top section from 3 to 9 O’ clock to insert the RTJ Gasket and Skillet should be used
to hold the gasket.
 Upon installation of RTJ gasket, permanent bolts and nuts shall be inserted at the top section
and temporary long draw bolts at bottom section if any shall be replaced by permanent bolts and
nuts one by one.
 Stud bolts are assembled with alternative tails protruding from opposite side of the flange for the
100% or 50% Bolt Tensioning Procedure.
 Bolts shall be tightened using impact wrench and at a same time diver shall ensure that the RTJ
gasket seats correctly into the groove of both flanges.
 If required bolt tensioner shall be used to draw both flanges till appropriate gap achieved around
the circumference of the flanges.
 Once the appropriate gap achieved the bolt tensioner shall be installed to flange bolts as per
Bolt Tightening Procedure and tensioner supplier recommendation.
 Section 7.8 shall be referred for details on tensioning procedure.
 Operate the bolt tensioners to the specified pressure for the flange and as recommended by bolt
tensioner supplier in question to achieve the correct stud bolt tension. The tension details of the
bolts shall be submitted later for reference.
 Upon completion of the stud tensioning operation, dismantle and remove the tensioning
equipment.
 The same operation shall be carried out for the PLEM end and spool flange connection.
 When all flange-tensioning operations are complete, remove all installation aids including
redundant sand bags ensuring Tie-In Spool is adequately supported.
 Diving inspection shall be done along 20m pipeline, Tie-In Spool and PLEM to confirm no free
spans and all installation aids have been removed.
8.8 Tensioning Procedure

 The Bolt Tensioner is a hydraulic tool, which is used for tensioning the stud bolts of the flanges.
The basic principle of bolt tensioning is that the required load is induced into the bolt by
stretching it along its axis by means of an external power source. The load that is induced is
retained by rotating the nut while the load is applied until the nut is sitting on the face of the
flange.
 To utilize a Hydraulic Bolt Tensioner, an extra long bolt is specified and both accompanying nuts
shall be pre-drilled for use with Tommy bars during tightening.

Project No. I0199
Document No.
MS-0010
TENSIONING
 Tensioning of the stud bolts is carried out by positioning the tensioner over each bolt. Tension is
retained by the reaction nut and pressure is monitored by a gauge on the Hydraulic Power Pack.
 High pressure flexible hoses are utilized to link the tensioning tools together, forming a complete
hydraulic manifold. The manifold is linked via an umbilical to the work barge, where the hydraulic
pump and other related equipments are set up. Pressure generated by hydraulic pump and
delivered thru the umbilical simultaneously tensions all of the bolts in one smooth operation.
 The bolt extension is retained by the diver by simply turning the nut with a Tommy bar. Once the
pressure is released from the system, it leaves a fully compressed joint with each and every bolt
tensioned to the predetermined load.
 Divers performing bolt tightening shall be conversant with the operation of the system.
 Stud Bolts shall be tensioned as per the required load
9 QUALITY
All the works involved in the Sub Sea Tie-in and Bolt Tensioning and related supporting
operations shall be carried out as per BSPL-1540-LCL1-QA-ITP-0010 - Inspection and Test
Plan for Sub Sea Tie-in and Bolt Tensioning.

Project No. I0199
Document No.
MS-0010
TENSIONING
10 APPENDICES
10.1 Appendix A – DRAWINGS
Drawing No. Title
Crude Oil (CO) Pipeline Approach & Tie-IN Details
BSPL-1520-LCL1-SS-DWG-2023-01
At Pipeline End Manifold (PLEM)
Crude Oil (CO) Pipeline Approach & Tie-IN Details
BSPL-1520-LCL1-SS-DWG-2023-02
At Pipeline End Manifold (PLEM)
BSPL-1520-LCL1-SS-DWG-0183-01 Tie – In Spool Installation Methodology
BSPL-1520-LCL1-SS-DWG-0183-02 Tie – In Spool Installation Methodology

Project No. I0199
Document No.
MS-0010
TENSIONING
10.2 Appendix B – Crane Specifications

Project No. I0199
Document No.
MS-0010
TENSIONING
10.3 Appendix C – Metrology Kit

Metrology Set
MET700
Flexible and cost-effective solutions . . .
Slave unit - no winch

Master unit - with winch
X Large easy to read scales with large measuring angles

X Easy lock protractor settings - big brass wing nuts
X Serviceable - precision machined and bolted assembly
X Master unit 13kg in air & 10.5kg in water
X Slave unit 12kg in air & 8.5kg in water
X Dry / water lubricated bushed pivot bearings
X 100m x 2mm stainless steel wire
X Suitable for Flange face or Pipe saddle mounting
MECHANICAL HANDLING UNDER WATER

. . . extend the capabilities of your business
ALL OCEANS ENGINEERING Ltd.
FIRST ANGLE PROJECTION
LOCKING
WING NUTS
TYPICAL SETUP BETWEEN PIPE FLANGES NOTES

1. 100M X 2mm ST ST WIRE SUPPLIED AS STANDARD
OTHER OPTIONS AVAILABLE ON REQUEST
2. ALL BEARINGS LOW FRICTION NO LUBE DESIGN
3. WEIGHT OF MASTER UNIT IN AIR = 13.O KG

WEIGHT OF MASTER UNIT IN WATER = 10.5 KG
4. WEIGHT OF SLAVE UNIT IN AIR =12.0 KG

WEIGHT OF SLAVE UNIT IN WATER = 8.5 KG
5. MET SET SHOWN INTERFACED TO PIPE FLANGES.

THEY CAN ALSO BE SADDLE MOUNTED BEHIND
FLANGES.
6. ALL OCEANS CAN DESIGN & SUPPLY MOUNTING

BRACKETS GIVEN ALL RELEVANT FLANGE AND
PIPE DETAILS.
MASTER UNIT
SLAVE UNIT
ALL OCEANS
DRG. TITLE MATERIAL
METROLOGY SET xxxx
WEIGHT
ENGINEERING LTD xx KG
WEB SITE: ALLOCEANS.CO.UK
B UPDATED CA 23/10/06 PROJECT JOB No. SHEET
TYREBAGGER WORKS, CLINTERTY, KINELLAR, ABERDEEN AB2 0TT xxx 1251 1 OF 2
A FIRST ISSUE EB 11/99 All Oceans Engineering Ltd. owns the copyright to this document.
DRG. No. REV
It is supplied for a purpose and must not be used for other purposes CLIENT
REV DESCRIPTION BY DATE CHECK DATE APPVD DATE or copied without All Oceans written permission. AOE DR1251/00/01 B
HORIZONTAL NOTES
PROTRACTOR FIRST ANGLE PROJECTION
0-180 1. * HOLE IS IN LINE WITH ARM IN 2 PLANES
2. 159mm & 40mm STAND OFF APPLICABLE

TO MASTER AND SLAVE UNIT
=
560
=
494
WINCH RACHET
38 19mm A/F
WINCH DRIVE
246 crs
38
A
560
*SEE NOTES
212 crs
159 centre
VERTICAL PROTRACTOR
150 150
40 centres
38
38
VIEW ON "A" SHOWING POSITION OF

THE FIVE MOUNTING HOLES 11
ALL OCEANS
DRG. TITLE MATERIAL
METROLOGY SET xxxx
WEIGHT
ENGINEERING LTD xx KG
WEB SITE: ALLOCEANS.CO.UK
B UPDATED CA 23/10/06 PROJECT JOB No. SHEET
TYREBAGGER WORKS, CLINTERTY, KINELLAR, ABERDEEN AB2 0TT xxx 1251 2 OF 2
A FIRST ISSUE EB NOV 99 All Oceans Engineering Ltd. owns the copyright to this document.
DRG. No. REV
It is supplied for a purpose and must not be used for other purposes CLIENT
REV DESCRIPTION BY DATE CHECK DATE APPVD DATE or copied without All Oceans written permission. AOE DR1251/00/01 B
TAUT WIRE METROLOGY UNITS
APPLICATION – Used for determining the relative geometry of two points. The resultant geometric measurements are typically applied to the design and fabrication of a joining pipe spool
required to make a connection between separate pipe ends. The Jigs are custom designed for diver operation underwater and as such are precision engineered to be simple to operate and
easy to repair and service.
OPERATION 7. Tighten the wing nuts on the Master unit enough to allow fine hand adjustment of the
1. Deploy the Master unit (with winch) to one pipe end and the Slave unit (no winch) to the arm
other pipe end 8. Move the arm, normally only slightly downward is required, so that the wire can be seen
2. Set the horizontal protractor (0-180) plate level on both units using a suitable spirit level or felt to exit the plastic arm guide through the centre of the hole. This will mean that the
before rigidly securing them to their pipe ends, alternatively set the other scale vertical wire is aligned through the arm to give the correct angular reading
3. Determine the position of each unit relative to a datum for the pipe end 9. Fully tighten both wing nuts on each unit
4. Disengage the winch ratchet and run wire to the Slave unit. Clip the wire to the ring on the 10. Secure a marker to the wire at the end of the master unit arm and against the plastic
end of the Slave unit pivot arm guide block. Double check the set-up. Record the 4 protractor scale readings
5. Slightly loosen the protractor wing nuts on the Master and Slave units 11. Double check and record the offset measurements relative to a datum of each unit’s
6. Set the winch ratchet to hold tension, wind in slack wire, torque to the required tension attachment. Double check the security of the marker on the wire
and record 12. De-rig and recover the units
NOTE - Normal supply is 2mm x 100m stainless steel wire, which fills the drum. Breaking NOTE - The offsets for both Master and Slave units are normally as follows; 40mm arm pivot
strength +/-230kg. For +/- 85kg tension; Torque should not exceed 20Nm with the drum full, to vertical protractor plate pivot and 119mm vertical protractor plate pivot to back mounting
reducing to 4Nm with the drum empty surface
DISCLAIMER - The operator is responsible for bracket design and mounting to whatever target the units are to be used on. The operator is responsible for measuring and confirming all off-
sets from their chosen datum to the protractor pivots. The operator is responsible for the interpretation of all measurements and their application in any designs and or fabrications. ALL
OCEANS shall in no way be held liable for any consequential loses, injuries or incidents, howsoever caused, as a result of the use or misuse of the units, or use or misuse of the
measurements determined by the units. No other instructions, other than these, are provided by ALL OCEANS for the Taut Wire Metrology Units

BSPL-1530-LCL1-CM-MS-0010 (A1) Method Statement For Sub Sea Tie-In Spool & Bolt Tensioning

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BSPL-1530-LCL1-CM-MS-0010 (A1) Method Statement For Sub Sea Tie-In Spool & Bolt Tensioning

Uploaded by

Copyright:

Available Formats

Leighton Contractors (India) Pvt. Ltd.

Mangala Development Pipeline Project-EPC for Marine Facilities At Bhogat

Dec 10 Page 2 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

Dec 10 Page 3 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

Dec 10 Page 4 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

Dec 10 Page 5 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

COMPANY : Cairn Energy India Pty. Ltd. (CEIL)

6.1 Project Specifications

BSPL-1500-PENS-SS-SOW-0001 Scope of work for the Marine EPC Contractor

6.2 Project Drawings

BSPL-1500-LCL1-SS-DWG-2018-01 Field Layout

BSPL-1510-LCL1-PL-DWG-2020-01 SPM/PLEM Location Plan

BSPL-1550-LCL1-PL-DWG-2026-01 Offshore Pipeline Tie-in details at SPM location

6.3 Project Engineering Reports

Document No. Title

6.4 Project Inspections and Test Plans

Dec 10 Page 6 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

6.5 Project Procedures and Plans

Document No. Title

Dec 10 Page 7 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

 Coating Equipments and Holiday Detector

Dec 10 Page 8 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

8.2 Tie-in Spool Measurement using Metrology Measurement System

8.3 Tie-in Spool Fabrication

Dec 10 Page 9 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

8.4 Tie-In Spool Hydro Testing

8.5 Preparation for Tie-in Spool Installation

Dec 10 Page 10 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

8.6 Installation of Tie-in Spool

8.7 Tie-in Flange Connections

Dec 10 Page 11 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

8.8 Tensioning Procedure

Dec 10 Page 12 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

Dec 10 Page 13 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

Dec 10 Page 14 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

10.2 Appendix B – Crane Specifications

Dec 10 Page 15 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

10.3 Appendix C – Metrology Kit

Dec 10 Page 16 of 16 BSPL-1520-LCL1-CM-MS-0010 (A1)

Flexible and cost-effective solutions . . .

Slave unit - no winch

X Large easy to read scales with large measuring angles

MECHANICAL HANDLING UNDER WATER

TYPICAL SETUP BETWEEN PIPE FLANGES NOTES

2. ALL BEARINGS LOW FRICTION NO LUBE DESIGN

3. WEIGHT OF MASTER UNIT IN AIR = 13.O KG

4. WEIGHT OF SLAVE UNIT IN AIR =12.0 KG

5. MET SET SHOWN INTERFACED TO PIPE FLANGES.

6. ALL OCEANS CAN DESIGN & SUPPLY MOUNTING

2. 159mm & 40mm STAND OFF APPLICABLE

VIEW ON "A" SHOWING POSITION OF

You might also like