PIPELINE INSTALLATION PROCEDURE

Doc. Title : FOR 38-INCH DIA. (EXPORT GAS)

PEGAGA TO WYE TIE-IN PIPELINE
Doc. No. : PGPA-MR-PRC-7-405
Rev. No. : C4

Flow Chart 1-0: Pipeline Start-Up Flow Chart

START

1. S3000 MOBILIZATION
2. SURVEY SYSTEM CALIBRATION
3. SET-UP PIPELAY EQUIPMENT
S3000 MOBILIZATION 4. PREPARE PIPELAY MATERIAL
5. FILL-UP FIRING TUNNEL
6. TRANSIT TO FIELD

1. VESSEL SET-UP OUTSIDE 500METERS FROM START

UP LOCATION
S3000 ARRIVE ON SITE 2. DP TRIAL
3. TEMPORARY CROSSING INSTALLATION
4. PREPARE START-UP RIGGING

VESSEL SET-UP AT START-UP ROV PRE-SURVEY ON TARGET BOX PRIOR TO PIPELINE

COORDINATES START-UP

1. PIPELAY INITIATION (DMA INITIATION METHOD) – DWG

NO. PGPA-MR-DWG-7-003
PIPELINE START-UP 2. DMA SOAK TEST AT 125MT
3. ROV TO MONITOR PIPELINE START-UP PROCESS
UNTIL THE PIPELINE TOUCHDOWN

1. DUMMY SPOOL INSTALLATION AT KP 0.155 TO KP

0.235
COMMENCE PIPELAY 2. BUCKLE DETECTOR INSERTION AT JOINT 149
3. INSTALLATION OF ANODES EVERY 10 JOINTS
4. INSTALLATION OF BUCKLE ARRESTOR EVERY 20
JOINTS

1. PREPARE RIGGING FOR LAYDOWN

2. DETERMINE FINAL JOINT FOR LAYDOWN
3. RECOVER BUCKLE DETECTOR
PIPELINE LAYDOWN 4. LAYDOWN PIPELINE WITH A&R
5. DISCONNECT A&R FROM LAYDOWN HEAD
6. ROV TO MONITOR LAYDOWN PROCESS UNTIL A&R
DISCONNECTED FROM LAYDOWN HEAD

MEANWHILE: FREE SPAN SURVEY WILL BE CARRIED OUT UPON COMPLETION OF PIPELAY

END

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 PIPELINE INSTALLATION PROCEDURE
Doc. Title : FOR 38-INCH DIA. (EXPORT GAS)
PEGAGA TO WYE TIE-IN PIPELINE
Doc. No. : PGPA-MR-PRC-7-405
Rev. No. : C4

2.3 Detailed Procedure: Temporary Crossing Support Installation

TASK PLAN: TEMPORARY CROSSING SUPPORT INSTALLATION

Item Description Reference Resp.

Set up S3000 at the clear area outside approx. 500m zone of

proposed laydown location. S3000 to perform DP trial outside
500m zone of proposed laydown location.
Surveyor,
MC,
1 OCM,
and
NOTE: MWS.

1. All and approved related PTW to be in place prior to

start work.

(Meanwhile) Install temporary flange protector at the bottom of

the flange tie-in to allow it to pass through the stinger rollers. PGPA-MR-
2 DWG-7-001
BF
The temporary flange protector shall be tightened using impact
wrench.

Page 25 of 88
 PIPELINE INSTALLATION PROCEDURE
Doc. Title : FOR 38-INCH DIA. (EXPORT GAS)
PEGAGA TO WYE TIE-IN PIPELINE
Doc. No. : PGPA-MR-PRC-7-405
Rev. No. : C4

TASK PLAN: TEMPORARY CROSSING SUPPORT INSTALLATION

Item Description Reference Resp.

Next, set up S3000 at laydown / temporary crossing support

installation location. Surveyor to plot the proposed support
location on the navigation screen.
Riggers to rig up the temporary crossing support.

PGPA-MR-
NOTE: DWG-7-024 -
VESSEL SET-
1. The temporary support platform is installed to protect UP FOR
the existing PL-395 pipeline from the A&R wire during TEMPORARY
SUPPORT Surveyor,
laydown operation. INSTALLATION
ROV,
3 2. Weather Restriction for ROV: & MC, FE
The ROV Supervisor will have the final say on whether PGPA-MR- and OCM
or not to launch/ continue operations. As a guideline, DWG-7-027-
TEMPORARY
ROV shall not be operated when sea states are in
SUPPORT
excess of the limits outlined below: INSTALLATION
SEQUENCE
 Beaufort Scale No.6
 27 Knot wind
 3 meters (9ft) significant wave height
3. Weather Restriction for Temporary Crossing Support
Installation:
Limiting sea-state for installation of temporary crossing
support is Hs 2.0m.

PGPA-MR-
Deploy ROV to perform survey and take fixes on the existing PL- DWG-7-027-
Surveyor,
395 Pipeline. ROV shall perform survey to ensure the seabed TEMPORARY
4 SUPPORT
ROV, MC
condition on proposed support location is clear from any and OCM
anomaly. INSTALLATION
SEQUENCE

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 PIPELINE INSTALLATION PROCEDURE
Doc. Title : FOR 38-INCH DIA. (EXPORT GAS)
PEGAGA TO WYE TIE-IN PIPELINE
Doc. No. : PGPA-MR-PRC-7-405
Rev. No. : C4

TASK PLAN: TEMPORARY CROSSING SUPPORT INSTALLATION

Item Description Reference Resp.

Move vessel to safe deployment area (approx.100meters away

from target location). Lift up the crossing support using the crane
and lower down to seabed.

PGPA-MR-
DWG-7-027-
Surveyor,
TEMPORARY
5 ROV, MC
NOTE: SUPPORT
INSTALLATION and OCM
1. Stop the crossing support lowering until support is SEQUENCE
approximately 10meters off seabed.
2. ROV to closely monitor the lowering operation and
monitor the position of support by means of USBL
positioning if required.

Next, move the vessel closer toward target location. ROV to

PGPA-MR-
guide the crossing support orientation, while the crane positions
DWG-7-027-
the crossing support to target location. Surveyor,
TEMPORARY
6 SUPPORT
ROV, MC
Temporary crossing support installation coordinates; and OCM
INSTALLATION
Temporary Support 605 253.84 E SEQUENCE
Coordinates 552 867.56 N

Once temporary support platform has been installed, ROV to

take fixes on the crossing support.

PGPA-MR-
DWG-7-027-
Surveyor,
TEMPORARY
7 SUPPORT
ROV, MC
INSTALLATION and OCM
SEQUENCE

Page 27 of 88
 PIPELINE INSTALLATION PROCEDURE
Doc. Title : FOR 38-INCH DIA. (EXPORT GAS)
PEGAGA TO WYE TIE-IN PIPELINE
Doc. No. : PGPA-MR-PRC-7-405
Rev. No. : C4

TASK PLAN: TEMPORARY CROSSING SUPPORT INSTALLATION

Item Description Reference Resp.

PGPA-MR-
DWG-7-027-
TEMPORARY ROV, MC
8 ROV to disconnect the riggings and recover crane to surface. SUPPORT and OCM
INSTALLATION
SEQUENCE

Page 28 of 88
 PIPELINE INSTALLATION PROCEDURE
Doc. Title : FOR 38-INCH DIA. (EXPORT GAS)
PEGAGA TO WYE TIE-IN PIPELINE
Doc. No. : PGPA-MR-PRC-7-405
Rev. No. : C4

2.4 Detailed Procedure: Pipeline Start-up

TASK PLAN: PIPELINE START-UP

Item Description Reference Resp.

Bring alongside to portside side line pipe barge and transfer line MC and
1
pipes to deck during temporary set up. BF

Fill up pipe tunnel with 38-inch line pipes (if the pipe tunnel has
yet to be filled up with line pipes). Insert internal line-up clamp
into the first pipe joint and commence welding until the first joint
reaches station 9.
Stop trolley, x-ray crawler, and reach rod should be inserted
inside the pipes after eight joints have been welded.
Appendix 4
BF and
2 “Line pipe
Sequence”
WF

NOTE:
1. COMPANY representative(s) shall witness the
insertion of stop trolley and x-ray crawler into the
pipeline.

Weld permanent RTJ weld neck flange to the first line pipe joint
(at station 9) and perform NDT on the weldment and apply field
joint coating.
PGPA-MR- BF and
3 Rig up start-up head (pre-welded to a temporary RTJ weld neck DWG-7-013 WF
flange) to WN flange on the first line pipe. Insert oval ring gasket,
temporary stud bolts and tighten the flange using impact wrench
followed by using bolt tensioning tools.

Turn the ball valve on the start-up head to close position.

BF and
4
FE
NOTE:
1. Take photos on start-up head fitting in closed position
i.e. ball valve and bull plug just before entering stinger.

Page 29 of 88
 PIPELINE INSTALLATION PROCEDURE
Doc. Title : FOR 38-INCH DIA. (EXPORT GAS)
PEGAGA TO WYE TIE-IN PIPELINE
Doc. No. : PGPA-MR-PRC-7-405
Rev. No. : C4

TASK PLAN: PIPELINE START-UP

Item Description Reference Resp.

Install temporary flange protector at the bottom of the flange tie-

in to allow it to pass through the stinger rollers. PGPA-MR-
5 DWG-7-001
BF
The temporary flange protector shall be tightened using impact
wrench.

Setup vessel for DMA installation and pipeline start-up: PGPA-MR- MC, BF
DWG-7-003 Survey
Option 1 and FE
S3000 set up at DMAs target location and self-deploy DMAs
anchors at target location. Perform soak test and finalize DMA
wire using start-up head/A&R wire.
Option 2
S3000 set up at start-up location. AHT deploy DMAs at target
location. Perform soak test and finalize DMA wire using start-up
head/A&R.

NOTE:
1. MWS shall be present during the whole start-up
activity.
2. In the event of anchor drag, AHT to relocate the DMA
to new location.
3. If A&R wire to be used for DMA start-up option, step
#4 to #7 shall be done after the completion of
finalization sacrificial length of DMA wire.
4. Perform ROV survey on start-up target box.

Page 30 of 88
 PIPELINE INSTALLATION PROCEDURE
Doc. Title : FOR 38-INCH DIA. (EXPORT GAS)
PEGAGA TO WYE TIE-IN PIPELINE
Doc. No. : PGPA-MR-PRC-7-405
Rev. No. : C4

TASK PLAN: PIPELINE START-UP

Item Description Reference Resp.

Option 1 DWG. PGPA- BF, ROV,

MR-DWG-7- MC,
 Deploy ROV and survey seabed condition. ROV to 005-01 to 02 Survey &
remove any debris at target location. FE
 Spool in DMA wire into cable spooler.
 Set and prepare DMA rigging on deck.
 Connect end of DMA wire to anchors and rigging
(including piggy back cable and anchor)
 Deploy DMAs at target location and S3000 lay away
towards start-up location while paying out DMA wire.
 FE & Survey to finalize vessel start-up position.

6.1 NOTE:
1. Vessel start-up position to take account cable gain,
start-up head length, etc.
2. MWS to witness the activities the soak test activity.

 Prepare rigging for DMA soak test using vessel A&R wire
/ pipeline start-up head.
 Perform soak test at 1.25 of maximum start-up tension
(Soak test tension = 100 x 1.25 = 125MT). Hold duration
shall be minimum 30 minutes. MWS shall witness the
activities.
 Reposition vessel if require to final position, apply
maximum start-up tension on DMA rigging and finalize
DMA wire length and to mark the cut point on the wire
 Next, the wire will be slacked till zero tension on the wire
and perform the cut on excess wire and install spelter
socket.

Page 31 of 88
 PIPELINE INSTALLATION PROCEDURE
Doc. Title : FOR 38-INCH DIA. (EXPORT GAS)
PEGAGA TO WYE TIE-IN PIPELINE
Doc. No. : PGPA-MR-PRC-7-405
Rev. No. : C4

TASK PLAN: PIPELINE START-UP

Item Description Reference Resp.

Option 2 DWG. PGPA-

MR-DWG-7-
 Spool in anchor pennant wire and DMA wire (including 005-01 to 02 BF, ROV,
piggy back wire) into AHT’s drums. MC,
Survey &
 Transfer all rigging and prepare on AHT deck. FE

 AHT proceed towards target location whilst S3000 setup

at start-up location. Vessel final position to be advice by
field engineer and surveyor onboard
 Deploy DMAs at target location.
 AHT proceed to S3000 location while paying out DMA
wire.
 Transfer end of DMA from AHT to S3000
 Prepare rigging for DMA soak test using vessel A&R wire
/ pipeline start-up head.
 FE & Survey to finalize vessel start-up position.

6.2

NOTE:
1. Vessel start-up position to take account cable gain,
start-up head length, etc.
2. MWS to witness the activities the soak test activity.

 Perform soak test at 1.25 of maximum start-up tension

(Soak test tension = 100 x 1.25 = 125MT). Hold duration
shall be minimum 30 minutes.
 Reposition vessel if require to final position, apply
maximum start-up tension on DMA rigging and finalize
DMA wire length and to mark the cut point on the wire
 Next, the wire will be slacked till zero tension on the wire
and perform the cut on excess wire and install spelter
socket.

BF,
7 Finalize sacrificial length upon DMA holding test completion. Survey &
FE

Page 32 of 88
 PIPELINE INSTALLATION PROCEDURE
Doc. Title : FOR 38-INCH DIA. (EXPORT GAS)
PEGAGA TO WYE TIE-IN PIPELINE
Doc. No. : PGPA-MR-PRC-7-405
Rev. No. : C4

TASK PLAN: PIPELINE START-UP

Item Description Reference Resp.

8 Connect DMA wire to pipeline start-up head. BF

9 Lower down stinger into water, deploy ROV into water to monitor BF and
start-up activity. Resume welding and push line pipes until start- WF
up head slightly protrudes the stinger end.

10 Bring the stinger end to the start-up elevation. Move S3000 Section 2.4 OCM,
ahead to pick up slack on start-up rigging until minimum start-up BF, FE
tension is registered on the tension machine. Commence and ROV
pipelaying. Supv.

Continue with pipeline start-up. Change stinger elevation and

pipeline tension according engineering analysis.

11 The ROV takes fixes on start-up head, flange tie-in connection ROV
and all field joints from the start-up head until the 5 pipeline field Supv.
joints touchdown on seabed. and FE

12 The recovery of both DMAs and wire will utilize either AHT, or OCM
S3000, subject to condition at site.

2.5 Extracts from Engineering Analysis

Refer to Appendix 1 for extract of engineering analysis for DMA pipeline start-up.

Page 33 of 88
 PIPELINE INSTALLATION PROCEDURE
Doc. Title : FOR 38-INCH DIA. (EXPORT GAS)
PEGAGA TO WYE TIE-IN PIPELINE
Doc. No. : PGPA-MR-PRC-7-405
Rev. No. : C4

3.10 Dummy Spool Installation

There is one (1) SSIV to be installation in the 38” pipeline. Dummy spool will be installed
instead of SSIV during pipelay. Upon completion of pipe lay, the DP DSV shall return to
the dummy spool location and replace it with the SSIV.

Table 3-4: SSIV Dummy Spool Location

Water Depth
Location / Point Easting (m) Northing (m)
(m)

KP 0.155
601 754.25 554 926.28 107
Dummy Spool Start (TIP-SSIV-1)

KP 0.235
601 810.58 554 869.95 107
Dummy Spool End (TIP-SSIV-2)

EQUIPMENT AND TOOLS: DUMMY SPOOL

Item Description Qty Unit Remarks

Stud bolt, Size: 3-1/2” x 1100mm Length, 8UN, Grade

1 B7, Blacken Type. C/W 2nos Heavy Hexagonal Nuts, 40 Nos For flange tie-in
size to suit 3-1/2" Studbolt, Grade 2H, Blacken Type

2 Gasket, ring type joint (RTJ) with soft iron material 2 No For flange tie-in

3 Impact wrench 1 No To tighten studbolts

Impact Wrench Socket, Heavy Duty Size: 5-3/8in Af

4 1 No To tighten studbolts
with 1in Square Drive

5 Flogging spanner heavy duty size: 5-3/8in AF 2 No For flange tie-in

6 Temporary half shell flange protector 2 No

Stud bolt, Size: M30 x 300mm Length, 8UN, Grade For temporary flange
7 16 No
B7, Blacken Type. C/W 2nos Hexagonal Nuts protector

8 Impact Wrench Socket, Heavy Duty Size: 50mm AF 1 No For temporary flange
with 1in Square Drive protector

9 Flogging spanner heavy duty size: 50mm AF 2 No For flange tie-in

Page 52 of 88
 PIPELINE INSTALLATION PROCEDURE
Doc. Title : FOR 38-INCH DIA. (EXPORT GAS)
PEGAGA TO WYE TIE-IN PIPELINE
Doc. No. : PGPA-MR-PRC-7-405
Rev. No. : C4

TASK PLAN: DUMMY SPOOL INSTALLATION

Item Description Reference Resp.

FE,
At designated KP0.155 or Joint no. 13 during pipelay, weld 38” PGPA-MR- Survey,
1 DWG-7-026
WN RTJ flange to running pipeline. BF &
MWS

As a meanwhile activity during installation, the dummy spool shall

be fabricated on board S3000. The dummy length will be
fabricated based on PGPA-PL-DWG-1-014-01 – SSIV Tie-in
Spool General Arrangement which includes pup piece joint if
needed.

WF &
PGPA-PL-
2 DWG-1-014
NDT
Supv.

Bolt tension the dummy spool 38” WN RTJ flange to the 38” WN PGPA-MR-
3 DWG-7-026
WF & BF
RTJ flange at the running pipeline or joint no. 13.

Move the barge ahead and continue welding dummy joint until
KP0.235 or Joint No. 18. Bring another joint to station 1 and weld
another new 38” WN RTJ flange to the pipeline.
Next, bolt tension the newly welded 38” WN RTJ flange the other
end of dummy spool 38” WN RTJ flange at station 1. PGPA-MR-
DWG-7-023
4 & WF & BF
PGPA-MR-
DWG-7-026

NOTE:
1. All flanges area will be protected using flange
protector.

PGPA-MR-
5 Subsequently, normal pipeline installation will continue. DWG-7-026
WF & BF

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