5000-220-V-Vd-stx-00021 - VD of Tandem Offloading & Mooring System - c01

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Gaza FSO
Client
STX Offshore & Shipbuilding Co., Ltd

Aker Pusnes AS
Box 732 - Stoa, Tel.: +47 37 08 73 00

N-4808 Arendal, pusnes@akersolutions.com
NORWAY www.akersolutions.com/pusnes
Client project no. Pusnes project no.
5305-01
Document title
20” Stern Offloading System

Technical Specification
Client doc. no. Pusnes doc. no. Total pages
3400-000-M-ST-PUS-00001 5305-01-PUS-Z-SA-0001 26
Revisions
01 16.10.2013 Updated due to customer’s requirement PEL SAN
00 15.10.2013 Initial issue PEL EE/DAO/OT SAN
Rev. Date Reason for issue Prepared Checked Accepted
Acceptance code Date / Signature ………………………………………………………….
Code 1 Accepted
Code 2 Accepted with comments incorporated
Code 3 Not accepted, revise and resubmit
Code 4 Issued for information
Code 5 Interface information as clouded is accepted and frozen
©2013 Aker Pusnes AS: This document and contents remain the company’s exclusive property; they shall not be copied,
reproduced and/or made available to third parties without the company’s expressed consent.
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Client doc. no. 3400-000-M-ST-PUS-00001

Pusnes doc. no. 5305-01-PUS-Z-SA-0001 Pusnes rev. 01 Aker Pusnes AS
Title Technical Specification
Table of Contents:
Technical Specification ............................................................................................... 1

1 Specifications ................................................................................................... 4
1.1 Purpose of this Document ............................................................................... 4
1.2 Revision History .............................................................................................. 4
1.3 Abbreviations .................................................................................................. 4
2 References ........................................................................................................ 5
2.1 Codes and Standards ..................................................................................... 5
2.2 Ambient Temperatures .................................................................................... 5
2.3 Crude Oil Transfer Pressure............................................................................ 5
2.4 Classification ................................................................................................... 5
2.5 Materials and Corrosion Protection ................................................................. 5
3 General information ......................................................................................... 6
3.1 Piping & Fittings .............................................................................................. 6
3.2 Grease Nipples ............................................................................................... 6
3.3 Lifting / Handling ............................................................................................. 6
3.4 Welding ........................................................................................................... 6
3.5 Maintenance ................................................................................................... 6
3.6 Surface Treatment .......................................................................................... 6
3.7 Inspection and Testing .................................................................................... 7
3.8 Shipment ......................................................................................................... 7
3.9 Documentation ................................................................................................ 7
4 Descriptions...................................................................................................... 7
5 Scope of Supply ............................................................................................... 7
5.1 Interfaces ........................................................................................................ 8
5.1.1 Foundations .................................................................................................... 9
5.1.2 Hydraulic piping............................................................................................... 9
5.1.3 Power supply and electrical wiring .................................................................. 9
5.1.4 Signal and control system ............................................................................... 9
6 Technical Description ...................................................................................... 9
6.1 Hose System................................................................................................... 9
6.1.1 Hose Winch..................................................................................................... 9
6.1.2 Hose Stopper ................................................................................................ 10
6.1.3 Swivelling Loading Manifold 20” .................................................................... 10
6.1.4 Slipway with Rollers ...................................................................................... 11
6.1.5 Chute with Rollers ......................................................................................... 11
6.1.6 Crude Oil Hose ............................................................................................. 12
6.1.7 Inboard Hose Termination Piece (IHTP) ........................................................ 15
6.1.8 16” Outboard Hose Termination Piece (OHTP) ............................................. 15
6.2 Mooring Hawser System ............................................................................... 16
6.2.1 Hawser Winch ............................................................................................... 16
6.2.2 Hawser Winch Foundation ............................................................................ 19
6.2.3 Mooring Hawser ............................................................................................ 19
6.2.4 Control Device for Load Cell ......................................................................... 20
6.2.5 Pneumatic Line Thrower ............................................................................... 20
6.3 Electro-Hydraulic Control System .................................................................. 21
6.3.1 Remote Control Post (RCP H/E) for Hawser Winch ...................................... 21
6.3.2 Remote Control Post (RCP H) for Swivelling Loading Manifold ..................... 22
6.3.3 CCR Control Panel........................................................................................ 22
6.3.4 Aux. & Starter Cabinet w/ PLC ...................................................................... 23
CONFIDENTIAL Page 2 of 26
©2013 Aker Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed consent.
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6.3.5 Valve unit, Accumulator Skid & PLC Cabinet ................................................ 24

6.3.6 Hydraulic Power Unit (HPU) .......................................................................... 25
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1 Specifications
1.1 Purpose of this Document

The objective of this technical specification is to describe the functional, technical, testing and
delivery conditions for the Pusnes equipment package for the stern offloading tandem system
for discharging crude oil from FSO to the shuttle tanker.
1.2 Revision History
Revision: Date Change revision
00 15.10.2013 Initial issue
01 16.10.2013 Updated Ch. 3.2 and Ch. 6.3.4 – 6.3.6
1.3 Abbreviations
FSO - Floating Storage and Offloading
7000 RHHW - Releasable Hawser Handling Winch
RCPH/E - Remote Control Post Hydraulic / Electric
HPU - Hydraulic Power Unit
P & ID - Piping and Instrumentation Diagram
OHTP - Outboard Hose Termination Piece
IHTP - Inboard Hose Termination Piece
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2 References
Below are listed the applicable rules, regulations, specifications, standards, codes and
guidelines which may apply to design, engineering, fabrication, assembly, installation,
operation, maintenance and repair of the equipment to be supplied.
2.1 Codes and Standards
Applicable standards:
• ANSI B 16.5 Flanges in pipe
• ISO 9001 Quality System
• EN 15614-1 Welding procedure test
EN 287 Welders certificate
DNV-OS-C401 Fabrication and Testing of Offshore Structures
• OCIMF Guide to Purchasing, Manufacturing and Testing
Of Loading and Discharge Hoses for Offshore
Moorings (GMPHOM / OCIMF 2009)
2.2 Ambient Temperatures

The "on deck" equipment is designed for an ambient temperature: - 20 to + 50 degrees.
The "below deck" design temperature is +5 to +45 deg. C.
2.3 Crude Oil Transfer Pressure

The specification is based on max. pressure 13 bar and ANSI B 16.5 150 flanges.
2.4 Classification
The applicable offloading components will have DNV certificates
2.5 Materials and Corrosion Protection

Material selection will follow applicable codes, separating piping components and
machinery parts. Recognised deck machinery standards shall be followed.
Materials in nuts and bolts are to be A4 stainless for dimensions M12 and less. Larger
dimensions are to be hot dip galvanised.
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3 General information
3.1 Piping & Fittings

• Hose end flanges and internal piping system comply with ANSI B 16.5, #300.
• Tube materials for dimension below O.D: 34 mm are acid-proof material according to AISI
316 or equivalent.
• Piping materials for dimensions O.D 34 mm and above are to be St.52.4, DIN2445 or
equivalent.
• Counter flanges with pipe size 34 mm and above will be carbon steel.
• All internal piping/tubing is stainless steel, except for HPU where it is carbon steel.
• All tubes are of mm size.
• Standard EO2 tube fitting is used on all stainless piping.
• Flanges are according to SAE 3000/6000.
• Counter fittings and counter flanges are supplied.
3.2 Grease Nipples

All grease nipples (ball type) are stainless steel and according to JIS B1575 with rubber cap.
3.3 Lifting / Handling

Lifting devices for hose maintenance are included in the scope of supply. All
equipment will be equipped with lifting eyes, or will be suitable for connection to
standard lifting equipment.
3.4 Welding
Applicable codes and standards are given in section 2 of this specification.
3.5 Maintenance
Handling philosophy as well as maintenance description and periodicity of the equipment will
be described in the Instruction Manual.
3.6 Surface Treatment
Deck equipment:
Painting and surface preparation according to NORSOK M-501 rev5 System 1, annex A,
table A1.
Below deck equipment:

Painting and surface preparation according to NORSOK M-501 rev5 System 1, annex A,
table A1.
RAL Code: Client to inform.
Starters / Control Cabinets:

Maker’s standard
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El. Deck Console:

AISI 316 stainless steel
3.7 Inspection and Testing

Non-destructive testing will be executed in accordance with our Inspection and Test
Plan (ITP), and according to requirements set by the DNV.
All items will be checked for weight and dimension.

Hoses will be tested in accordance with OCIMF’s “Guide to Manufacturing and Purchasing
Hoses for Offshore Moorings” (GMPHOM 2009)
Notification of hose test and final inspection (of all equipment) will be given three weeks prior
to test date.
3.8 Shipment
All openings will be covered and sealed in order to prevent ingress of dirt and
moisture.
Loose items will be grouped and packed in suitable packing.
3.9 Documentation
Documentation schedules will be according to client requirements.
4 Descriptions
5 Scope of Supply
The table below lists the equipment included in Aker Pusnes scope of supply.
The list shows equipment name, drawing and weight
Section Equipment Drawing Pusnes Weights Remarks

supply
6. Offloading system base
1073220
case, GA
6.1 Hose system
6.1.1 Hose winch 1077027 1 8 500 kg
6.1.2 Hose stopper 1075886 1
6.1.3 Swivelling loading manifold 1073219 1 7 600 kg
21 000 kg Drawings and
6.1.4 Slipway with rollers 1073938 Drawings
rollers
20 000kg Drawings and
6.1.5 Chute with rollers 1073893 Drawings rollers/Guide
Sheave
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Section Equipment Drawing Pusnes Weights Remarks

supply
6.1.6 Crude oil hose 1076146 1 98 000 kg
Inboard Hose Termination 2 100 kg
6.1.8 1077327 1
Piece (IHTP)
16” Outboard hose 380 kg
6.1.9 1077339 1
termination Piece (OHTP)
6.1.10 20” ESD Valve 1077838 1 2 800 kg
6.1.11 P&ID 1075970 Drawing
6.2 Mooring hawser system

6.2.1 Hawser winch 7000 RHHW 1075647 1 11 800 kg
Hawser winch 7000 RHHW
6.2.2 1075723 1 14 600 kg
Foundation
6.2.3 Mooring hawser 1076433 1 2 720 kg
6.2.4 Control device for load cell 1077956 1
6.2.5 Pneumatic Line Thrower 1
Electrohydraulic control
6.3
system
Remote control post
6.3.1 (RCPH/E) For Hawser 1076550 1
2 150 kg
Winch
Remote control post (RCPH)
6.3.2 for Swivelling Loading 1077276 1
2 130 kg
Manifold
6.3.3 CCR Control Panel 1076878 1 5 kg
Auxiliary and Starter cabinet
6.3.4 1076775 1 250 kg
w/ PLC
Valve unit, accumulator skid
6.3.3 1076544 1 750 kg
, PLC Cabinet
6.3.4 Hydraulic Power Unit (HPU) 1076510 1 3 300 kg
Piping Diagram 1076484

Hydraulic System 1077038
Single Line Diagram
Table 5.1 Scope of supply and position of equipment
5.1 Interfaces
The following physical interfaces between the stern offloading system and FSO hull systems
exist:
• Foundations
• Hydraulic piping
• Power supply and electrical wiring
• Signal and Control System
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5.1.1 Foundations
Footprint and foundation forces are shown on the GA drawings where it is applicable.
A complete foundation for the 7000 RHHW Hawser Winch is delivered by Aker Pusnes.
5.1.2 Hydraulic piping

Hydraulic piping is shown on the piping diagram 1076484.
Connection points are shown on the GA drawing for each unit where it is applicable.
5.1.3 Power supply and electrical wiring

Aker Pusnes provides drawings (single line diagram / external connection diagram) showing
the external connections for power supply and control lines.
A cable list is also provided specifying all cables to be used in the system, both Aker Pusnes
and yard supply.
Note that 220V / 50 Hz / 1 ph UPS (Uninterrupted Power Supply) to be provided to the PLC
cabinet. Power consumption of the PLC is 400 Watt.
5.1.4 Signal and control system
6 Technical Description
6.1 Hose System
The primary function of the hose system is to provide a safe 20/16" hose connection
between the FSO and a shuttle tanker.
The system is designed for connection of the loading hose to a hydraulically operated
Swivelling Loading Manifold at the stern of the FSO. The hose will be resting in a
slipway and hose stopper when connected to the swivelling Loading Manifold.
Hose sections can be pulled into the chute for service/hose replacement and
inspection.
Emergency release of the hose is included.
6.1.1 Hose Winch

Drawing no : 1077027
The hose winch is hydraulically operated and has a drum capacity of 140m x 42mm dia
wire rope in two layers.
The winch has two split drums, with tension part width of 350 mm.
The drums have manual declutching and one drum has hydraulic band brake while the
other has a manual band brake.
Capacity:
- Pulling force : 400 kN on first layer
- Braking force : 600 kN, adjustable.
- Operating speed : 0-10 m/min
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6.1.2 Hose Stopper
The hose stopper shall hold and support the inboard hose termination piece in the
offloading position. Guide means for positioning of the hose termination piece is
provided.
The hose termination piece is bolted to the swivelling manifold.
The hose stopper will be bolted to the swivelling loading manifold.
In the hose stopper foundation there are load cells sensing the load in the hose.
(Ex(i)).
Performance
Design load : 800 kN
Load cell : 0 - 400 kN ( +/- 50 kN )
Pull from hose winch : 400 kN.
6.1.3 Swivelling Loading Manifold 20”
A bracket for bolting to the ship's deck foundation is supporting a 20" 90 degrees long
radius pipe bend which shall be connected to the vessel's offloading pipe line in
horizontal direction, and to a swivelling elbow with Inboard Hose Termination Piece.
The elbow contains three 90 degrees long and short radius bends.
The elbow can rotate 190 degrees by means of a remotely controlled hydraulic motor.
The manifold is arranged with a Pusnes 20" release flange and butterfly valve, the
release flange is bolted to the hose flange.
The connection to the FSO crude oil export pipe is through an 20" ESD valve with
metal seals. This valve is normally operated from the central control room system.
Specifications
Valve bore : 20"
Piping size : 20"
Flange dimensions : ANSI B16.5 300 PSI
Emergency release of the hose is performed hydraulically by the quick release flange.
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This can be activated from the CCR Control Panel and from the RCHPH/E installed on
the Hawser Winch.
One 20” Inboard Hose Termination Piece (IHTP) is supplied. The IHTP is fitted
between the hose end flange and the Swivelling Manifold flange.
The QRF is mechanically locked with bolts, and can be released quickly in case of an
emergency.
6.1.4 Slipway with Rollers
The slipway is designed for ±90o misalignment of the vessels during hose deployment
and loading.
The slipway consists of a central section with support rollers, and a bellmouth formed
hose guiding structure.
Scope of slipway is being discussed between yard and Aker Pusnes.
Safe access for maintenance and renewal of the rollers is yard responsibility.
The support rollers have the following dimensions: Length 1000 mm and dia. 375.
6.1.5 Chute with Rollers
A 65 m long chute for servicing hose sections runs along starboard side of the deck.
The chute width is 1450 mm.
The chute is supported by columns to the deck.
The chute itself is an open, welded steel construction supplied by the yard.
Aker PUSNES will provide design drawings for the chute structure.
The weight of the hose is resting on horizontal rollers, supplied by Aker Pusnes.
The rollers will have the following dimensions:

Length : 1000 mm
Diameter : 220 mm
Centre distance : 1000 mm
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6.1.6 Crude Oil Hose
The 20/16" single carcass crude oil loading hose is designed to fishtail behind the FSO,
the hose can partly be retrieved on a roller-based chute in order to perform service and
maintenance. A marine brake away coupling is included in the hose string.
It is to be equipped for operation towards dedicated shuttle tankers.
The hose will be equipped with a butterfly valve on the FSO side and a hose
termination piece with camlock coupling on the hose end as well as a 16” Standard
Double Closure Marine Breakaway Coupling (MBC).
It is recommended that the MBC is installed between the 4th and 5th hose section
counting from the shuttle tanker manifold.
The total length of the hoses in this combination is approximately 360 m.
Aker PUSNES will provide a spreader bar for hose handling.
The hose is manufactured and tested in accordance with the standard GMPHOM 2009
Hose configuration:
Qty Type Description Size Comments
SuperSampson Saflote 20 inch x 35 Elec. Continuous
1 541 F End Reinforced Hose, ft.
fully floating,
Saflote Mainline Hose, 20 inch x 35 Elec. Continuous
2 542 N
Controlled Buoyancy ft.
Saflote Mainline 20 inch x 35 Elec. Continuous
26 542
Floating Hose, ft.
Saflote reducing hose 20/16inch x 35 Elec. Continuous
1 543X feet
Saflote Tail hose 16 inch x 35 Elec. Continuous
1 544x
ft.
Saflote tail hose 16 inch x 35 Elec. Continuous
1 544
ft.
Saflote tail hose 16 inch x 35 Elec. Discontinuous
1 544
ft.
Saflote Barbell Rail 16 inch x 30 Elec. Continuous
1 544x
Hose ft.
Lever Actuated 16 inch
2 BFV519 Butterfly Valve ASME#150
Short Spool Camlock 16 inch
2 CLP519 Coupling ASME#150
Light weight Blind 16 inch
2 BFA519 Flange Type A
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2 GASR519 Rigid IBC Gasket 20 inch ASME#150

60 GASN519 NAF FF Gasket 20 inch ASME#150
Stainless Studbolt c/w
1240 SBN519 2 nuts 1.25”x6.25”
160 SBN519 2 nuts 1”x5.5”
32 SBN519 2 nuts 1”x9.5”
1 PUC519 Pick up chain 26mm 2m
1 SNC519 Snubbing Chain 26mm 35ft
Floating concentric
1 RED519 reducer 20”-16” ASME#150
3 PAL519 OCIMF Steel Pallet
Note: “Red Italic” will be part of the Outboard Hose Termination Piece 3.1.12
Hose Spares
Qty Type Description Size Comments

SuperSampson Saflote End 20 inch x 35 Elec. Continuous
1 541 F Reinforced Hose, fully ft.
floating,
Saflote Mainline Hose, 20 inch x 35 Elec. Continuous
1 542 N
Controlled Buoyancy ft.
Saflote Mainline Floating 20 inch x 35 Elec. Continuous
3 542
Hose, ft.
Saflote tail hose 20 inch x 35 Elec. Continuous
0 544
ft.
Saflote tail hose 20 inch x 35 Elec. Discontinuous
0 544
ft.
Saflote Barbell Rail Hose 20 inch x 30 Elec. Continuous
1 545X
ft.
Lever Actuated Butterfly 16 inch
1 BFV519 Valve ASME#150
Short Spool Camlock 16 inch
1 CLP519 Coupling ASME#150
1 BFA519 Light weight Blind Flange 16 inch Type A
1 GASR519 Rigid IBC Gasket 20 inch ASME#150
Stainless Studbolt c/w 2
620 SBN519 nuts 1.25”x6.25”
80 SBN519 nuts 1”x5.5”
16 SBN519 nuts 1”x9.5”
Note: “Red Italic” will be part of the Outboard Hose Termination Piece 3.1.12
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Storage rack for spare hoses
The spare hoses will be delivered from supplier with OCIMF pallets that can be used as
storage rack.
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6.1.7 Inboard Hose Termination Piece (IHTP)

Emergency release of the hose is performed hydraulically by the quick release flange.
This can be activated both locally from the RCPH/E and from the CCR Control Panel.
One 20” Inboard Hose Termination Piece(IHTP) is supplied. The IHTP is fitted
between the hose end flange and the Swivelling manifold flange .
The QRF is mechanically locked with bolts, and can be released quickly in case of an
emergency.
6.1.8 16” Outboard Hose Termination Piece (OHTP)
Type : OHTP, 16” 150lbs

Drawing no : : 1077339
On the tanker end of the hose, one outboard termination piece (OHTP) is provided. The
OHTP includes as follows:
• One 16” spool piece with camlock coupling
• One 16” butterfly valve is fitted between the spool piece and the rail hose.
• Hang off chain
• Pick up chain
• Pick up rope w. marker buoy
• Bolts, gaskets and nuts
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6.2 Mooring Hawser System
The mooring hawser system is designed for storage, deployment and holding of the
mooring hawser with all ancillaries.
First, a shooting line establishes contact between the two vessels, then the mooring
hawser is pulled over to the crude oil carrier. This is done with the tensioning
messenger paid out to keep low tension in the line while handling the chafing chain on
the crude oil carrier. Finally the crude oil carrier is pulled towards the FSO by means of
the tensioning messenger, and the chain stopper is closed.
Emergency release of the hawser is included.
6.2.1 Hawser Winch

Type : 7000 RHHW
The releasable hawser-handling winch is a combined hawser handling/storage drum

and mooring strongpoint with hawser tension measurement.
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This gives supreme functionality as the hawser and ancillaries can be driven out and
the hawser is permanently locked in a strongpoint in the drum. The hawser is
releasable.
Performance Data:
Drum strongpoint
Design load : 7000 kN Horizontally ± 45º pivoting in drum, and

± 90º in recess fairing. Vertically ± 30º
Release load : 3500 kN
Oil consumption : About. 300 l/min
Hydraulic system : 250 bar
pressure
Max allowable oil : 270 bar (safety valve setting)
pressure
Heave-in and pay-out, first layer

Nominal force : 125 kN 1st layer
Launching speed : 40 m/min
Retrieval speed : 40 m/min
Disc brake
Holding capacity : 150 kN (Parking Brake)
Loadcell
Reading range : 0 – 3500 kN
Storage capacity
The winch has capacity to store the complete mooring hawser assembly, including all
messenger line and pick-up rope.
Construction
The winch drum has sufficient strength to hold the design load. The drum can store
the complete hawser with ancillaries.
The drum is split, with one part for storage of the outer chafing chain and thimble, and
one part for storage of hawser and ropes.
A v-shaped groove for the first turn of the messenger line secures the chaffing chain
to the drum in pay-out/heave operations.
The hawser is held in a hydraulically releasable strong-point mechanism pivoting in

the opening in the drum.
The drum is supported on both sides in bearing brackets, which are transferring the
hawser load to the deck structure. A pivot movement in these bearings is allowing the
hawser to orient the drum in the pulling direction.
The drum is driven by one radial piston hydraulic motor with control block via a gear
rim.
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The disc brake is acting on the motor shaft and is spring set and hydraulically
released (fail safe).
Spooling gear
The spooling gear is consisting of a grooved sheave, which can rotate on an axle
parallel with the drum shaft. The freewheeling sheave can also be displaced along
this axle over the drum length. The axle is fixed in hinged arms with pivots near the
hawser bracket shaft - one on each side of the drum.
A separate hydraulic motor drives the spooling gear.
The spooling gear is thus pivoting and is lifted as much as necessary by two hydraulic
cylinders, one for each arm. The profile of the spooling gear sheave can support
hawser, chafing chain, messenger and forerunner.
The pivot movement of the spooling gear is limited by the deck in the lower end and
the horizontal bar of the tubular frame in the top end.
Installation
The hawser-handling winch is positioned on bearing brackets bolted to foundations on
deck. A tubular frame is fitted above the winch. The foundations and the tubular frame
to be fabricated by yard based on construction drawings supplied by Pusnes.
Recommended radius where the hawser can be in contact with the hull sideways and
downwards is 700 mm.
The hawser handling winch drawing includes the half pipe with 500mm radius outside
the hull.
Instrumentation
The mooring tension is monitored by a loadcell installed in the drum. The cable for the
loadcell is connected to a swivel at the drum shaft end in the center of the winch and
routed to a junction box on the bearing bracket.
Hydraulic description
The winch is powered by one radial piston hydraulic motor acting directly on the winch
main wheel. A valve unit controls the motor, which is located on the hydraulic motor.
The hawser handling winch is operated from the RCPH/E.
The valve unit has an automatic brake release valve for the disc brake.
The release mechanism is hydraulically operated. A cylinder is operating an “over

center” mechanism during release. The hawser is released by releasing the complete
hawser connection from a claw. The hawser is released by push button located in the
RCPH/E and CCR.
Hawser connected
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Hawser released
6.2.2 Hawser Winch Foundation

A complete foundation for the Hawser Handling Winch is supplied. The foundation is
approved by class.
6.2.3 Mooring Hawser

The mooring hawser assembly consists of the following elements:
Hawser
One (1) 21” 120 m (after permanent stretch) super-line or double braid nylon hawser
with soft eyes in both ends.
Hawser breaking load (new and dry): About 6 000 kN.
The hawser is protected by an outer thinner nylon braid with polyurethane coating or
polyester covering with proper bonding. The soft eyes are protected only by tubular
polyester cloth.
The hawser is connected directly to the hawser winch.
The hawser is equipped with buoyancy elements.
Pusnes Thimble
A special Pusnes thimble for connection between the hawser and the messenger line
is provided.
Chafing Chain
One (1) length of 9 m 76 mm grade R4 stud link chain is provided.
Messenger Line
One (1) length of 220 m dia. 80 mm (10" circumference) polypropylene floating rope
with one (1) steel thimble in one end, and soft eye in the other end.
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Pick up Rope
One length of 150m ø24mm (3" circumference) polypropylene floating rope is
included.
Handling Lines
Handling lines for easy handling of mooring line onboard the shuttle tanker are
included
6.2.4 Control Device for Load Cell

Drawing no. : 1077956
The load cell control equipment is for adjusting value of hose and hawser tension
displayed on CCR monitor such that it shows correct tension. There are three load
cells, one inside the hawser winch drum to monitor hawser tension and two on the
Hose Stopper to monitor hose tension
The equipment is supplied in one aluminium box.
6.2.5 Pneumatic Line Thrower
Type : PLT Rescue 230 Complete

BASICS:
PLT Rescue 230 is used to make the initial contact with the FPSO/FSO for connection
of the crude oil hose.
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Scope of supply
1 x PLT Launching Unit

1 x Launching Tube Rescue 230
4 x Projectile Rescue 230
1 x Loading Device
1 x Launching Tube 125/150
1 x Projectile PLT 150
1 x Linebox 5mm floating line
1 x CD / User Manual
1 x Tube for Pivot Support
1 x Pivot Support
2 x Air Cylinder for Rescue 230
380V, 50Hz,
1 x Air Filling Compressor 400VAC, 3 Phase
50Hz, 3 Phase
TECHNICAL DATA:
Shooting range: Typical 230m
Line strength: min 2000N
Line thickness: 5 mm
Recoil: Max 5400N
Flight time: approx. 4 sec
6.3 Electro-Hydraulic Control System
The entire offloading system can be operated by one man . This control panels
enables one man operation of the entire offloading system; HPU, hose coupler,
hawser winch, hose winch, and hawser handling winch.
The piping diagram, drawing 1076484 shows how the various components are
connected hydraulically.
The single line diagram, drawing 1077440 shows how the various components are
connected electrically.
6.3.1 Remote Control Post (RCP H/E) for Hawser Winch
Type : RCP H/E

The remote control posts will be in AISI 316, and explosion proof according to class
requirement. The housings, signs and panels will be in AISI 316 as well as the
hydraulic pipes and fittings. Control valves and blocks are carbon steel.
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Hydraulically operated functions:

Hawser Winch
Speed control : Heave-in/pay-out, stepless 0-max.
Spooling gear : Port / stop / starboard, up / stop / down
Electrically operated functions:

Emergency stop HPU
Emergency close ESD Valve
Emergency release Hose
Emergency release Hawser
Open / Close Claw RHHW (for service purposes)
6.3.2 Remote Control Post (RCP H) for Swivelling Loading Manifold
Type : RCP H
The remote control post will be in AISI 316. The housings, signs and panels will be in
AISI 316 as well as the hydraulic pipes and fittings. Control valves and blocks are
carbon steel.
Hydraulically components included:

Necessary control valves and equipment to be included
Hydraulically operated functions:

Swivelling Loading Manifold
Rotation : Operation / Stowed
6.3.3 CCR Control Panel
A CCR Control panel for installation in CCR is provided.

The graphic display together with three emergency push buttons will be delivered.
Components included:
Operator Terminal
3 Mushrooms type push buttons for:
− Emergency Close ESD Valve
− Emergency Release Hose
− Emergency Release Hawser
Mimic diagram for «Offloading line»
Pressure available in acc. Ind.screen OK / Not OK

Permissive to open Crude Oil valve Ind.screen OK / Not OK
Crude oil line valve Ind. screen CLOSED / OPEN
27
Project Gaza FSO

Offloading line Ind. screen READY / NOT READY

Offloading permitted Ind. screen PERMITTED / NOT PERMITTED
Emergency functions (Hardwired):

Emergency close ESD Valve Push button Activate
Emergency release Hawser Push button Activate
Emergency release Hose Push button Activate
HPU Control
Hydr.pump no.1 Ind. screen RUN / STOP
Pressure available Ind. screen Available
HPU level alarm Ind. Screen Low
HPU level alarm Ind. Screen Low / Shutdown
Oil temperature Ind. Screen High
Oil temperature Ind. Screen High / Shutdown
Pressure filter clogged Ind. Screen Alarm
Return filter clogged Ind. Screen Alarm
Common failure alarm Ind. Screen HPU alarm
HPU shutdown alarm Ind. screen HPU alarm
Power available motor 1 Ind.screen Available
Overload motor 1 Ind.screen shutdown
Hawser handling winch

Hawser tension Ind. screen 0 - 3500 kN
Hawser tension alarm Ind. Screen High tension
Swivelling coupler
Hose tension Ind. screen 0 - 400 kN
Hose tension alarm Ind. Screen High tension
Accumulator rack
Locking accu. press. Ind. screen Low
System accu. press. Ind. screen Low
General
PLC failure Ind. Screen Alarm
24V DC failure Ind. Screen Alarm
6.3.4 Aux. & Starter Cabinet w/ PLC
Drawing No. : 1076775
28
Project Gaza FSO

The unit comprises separate steel cabinets for each of the main pump starters, the
first cabinet contains all control and auxiliary functions. The cabinets are mounted
together in one unit to ease the installation work.
The starters are arranged as follows:
Main switch Disconnecting switch

Start method DOL
Running current 160 A for 99 kW motor
Start current 1050 A for 99 kW motor
Push buttons Start, Stop, lamp test and heater on/off
Indication light Power available, heater on, run, overload
Instrument Ampermeter, hour counter
Heater space heater in cabinets
Control voltage 220V/50 Hz/1 ph with internal transformer
The Control Unit is arranged as follows:
Communication Ethernet cable to PLC Cabinet

Main switch Disconnecting switch
Power Consumption 400W
Push buttons Pressure selection 3 steps, lamp test/Reset and heaters
on/off
Indication light Power available, heater on, low level alarms, low low level
alarm, high temp alarm, high high temp alarm,
return filter clogged alarm, pressure selected
Heater space heater in cabinet
Control voltage 220V/50 Hz/1 ph supplied from starter cabinets
Protection class : IP 56
6.3.5 Valve unit, Accumulator Skid & PLC Cabinet
The accumulator provides power back up for fail safe operation of the hawser release.
The Valve unit & accumulator skid is placed under deck.
Accumulator pressure : 250 bar

Capacity : 3 x 50 l
1 x 20 l
Nitrogen charging pressure : 160 Bar
The solenoid valves for hawser handling winch are mounted on this unit.
In addition, the valve unit has valves for draining of the accumulators.
The pressure transmitter on this rack is monitoring the accumulator pressure.
29
Project Gaza FSO

An accumulator N2 filling adapter kit is also provided.
The PLC Cabinet is mounted to this skid, and consists of:

PLC
Interface to field instrumentation
Amplifiers, safety relays and safety barriers.
The Ethernet communication interface to terminal in CCR and aux & starter cabinet
for control and alarm of offloading system
Power supply : AC 220 V UPS (yard supply)

Protection class: IP 56
The PLC power use is 400W
6.3.6 Hydraulic Power Unit (HPU)

Drawing No. : 1076510
Type : 3 x 140 PP
Weight : 3300 Kg
The pump station consists of the following main components:

- Three main pumps.
- Duty, S2-30min
- Three main electric motors, about 99 kW each for the main pumps.
- Running current 160 A
- Start current 1050 A DOL
- One full flow return filter
- One oil cooler
- Two level switches
- One Temperature transmitter
- One safety valve unit
- One filter clogged sensor
- One terminal box
- One pressure control valve
- One oil tank
- Silencers for each pump
Capacity:
Oil delivery : 3 x 195 l/min
Pressure : 250 bar
Pump particulars : 315 bar peak pressure
Power limited to : 99 kW input shaft power each pump.
Sea water flow : 210 l/min, maximum 6,9 bar supply pressure.
The hydraulic system is based on a main ring system of about 250 bar working
pressure. The HPU shall be installed in the hydraulic room, in order to supply the
offloading system.
The hydraulic system has two different pressure steps.
30
Project Gaza FSO

• “work” pressure 250 bar

• “stand-by low” pressure 20-30 bar
Motor:
Protection class : IP 56
Integrated heater : Included
Insulation class : «F» class with temperature rise as «B» class
Cable glands are included in the scope of supply.
Electric motor data:
Type : Squirrel cage induction motor, 4-pole

Quantity pr. HPU : Three (3)
Weight pr. unit : 460 kg
Output pr. el. motor : 99 kW

Revolution : 1500 rpm
Duty : S2-30min
Efficiency : 94,5%
Power factor (cos φ) : 0,86
Running current : 160A
Starting method : D.O.L
Start current : 1050A
Starting time : approx. 0,4 s
Protection : IP 56
Insulation : “F” class with temperature rise class B
Integrated space heater : 2 x 42 W
Ball bearing (DE/NDE) : 6315C3
Thermistor : 3 x PTC 130° C
Electric power supply:
3 x 106 kW 380V/50Hz/3ph starters main pumps
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1510
C
A
Guide roller (Pusnes Supply) A
Platform and ladder for access to hose guide roller

(Yard Supply) Fix plate
1342
C Sliding plate, adjustable height
649
30
Support for Working platform
(Yard Supply)
B B
B
a6 TYP.
a8 TYP. Frame (Yard Supply)

1450
C C
DETAIL C
~30° SCALE 1 : 10
8574
a8 TYP.
10552
Adjustable Bolt
Adjustable Bolt
649 649 649
2501
A
D D
Deck level
6054
Slipway with rollers
Pusnes supply
1480
3308
E Area under the slipway C E
accessible for inspection
1266
A
FSO Hull Structure
B
C 5000* 5000*
SECTION B-B
FSO Hull Structure
Connection shackle for safety

2018 1720 3020 rope under slipway structure
F F
7433
* Maintenance area for rollers replacement SECTION B-B
240
2100
3738
7433
G 135 G
0
230
70
E2 D2
Y
410
C2 X
2070 B2
1450 Z
00 36
13,5
1 YP
R2 T
20 TYP
Sliding plate, adjustable height (Pusnes Supply) A
C
H H
10
B1
2501
Roller (Pusnes Supply)

24
1450
5650
C1
1210
I
15 15 E1 D1 I
10 TYP
7433
15
2825
300
300
24
9048
15 Foundation Forces
29,7
0° 462
13,5
300
1320 1403
46
°
24 2937 4505
J 400 3695 J
0
TYP R210
FSO Hull Structure
TYP Self locking gate

Notes:
Footprint Slipway Foundations to be fully welded to the deck with full penetration
Section A-A Guide Roller to be fully welded with full penetration
All dimensions are suitable for change
FSO Hull Structure Slipway´s frame and structure are Yard Supply
K Reference: K
1607
Surface symbols Tolerances when not specified: Drawing Category: Scale: Weight:
ISO1302.
GA
Machining ISO 2768-mk
Welding Symbols
ISO 2553
Welding ISO 13920 B
Casting ISO 8062 CT13 1:50 26000.8 Kg
3207 2157 Slipway with rollers

Aker Pusnes AS
C 6057
Arendal, Norway
This drawing remains our exclusive property. Type: Group: State: Sheet: Format:
L
Should not be copied, reproduced and/or made
available to third parties without our written consent. Slipway Approved 1 of 1 A1 L
C 28.03.14 Found. forces clarified FTa BGi SAN This is a computer aided drawing and must not be altered manually
B 18.12.13 Design Updated FTa BGi SAN DRG. / Art.No.:
0
Rev. Field
11.03.13 Initial issue.
dd.mm.yy Reason for issue.
EE
Design.
BGi SAN
Checked Approved
1073938.
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MacGregor Pusnes AS
Group Part List Page 1(1)

Date 23.05.2014
Drg/Art.No: 1088504.001 RCPE Component Layout
Type: Group: 0710
Revision Date Description Design Controlled Approved

0 16.01.2014 Initial issue OT TDT OCT
Pos ItemNo No of Description Remarks

010P24.00480 1,00 Junction Box
Drain 010P12.00174 1,00 Drain Plug Eexe Brass
Drain 010P12.00248 1,00 Nut for Drain Gland
S1-S3 010P43.01157 3,00 Cover for Emergency stop
S1-S3 418659.00000 3,00 Washer
S1-S3 010S43.00423 3,00 Contact Element
S1-S4 010S43.03288 4,00 Emergency Stop
S1-S4 010P45.00913 4,00 Resistor module
S4 010S43.03392 1,00 Lockable Ring Em. P. Botton
S5 010S43.03321 1,00 Selector Switch
W4 010P12.00484 1,00 Cable Gland
W4 010S12.54193 1,00 Lock Nut
X24i 010S12.64925 20,00 Terminal 2,5mm2
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MacGregor Pusnes AS

Date 23.05.2014
Drg/Art.No: 1088102.001 PLC Cabinet Component Layout
Type: El.Eq.Cab. Group: 0710


+VA 010P13.00029 2,00 Wall Bracket
+VA 325532.00000 1,00 Sign/Logo
+VA 010P24.00004 2,00 Enclosure
+VA 010P24.00089 1,00 Document Case A4
A1.0.1 010P45.01211 1,00 Compact Flash card
A1.1 010P45.00904 1,00 CompactLogix CPU, 750kB
A1.1 010P45.00625 1,00 Compact I/O, Inputmodule
A1.2 010P45.00625 1,00 Compact I/O, Inputmodule
A1.3 010P45.00812 1,00 Compact I/O, Outputmodule
A1.4 010P45.00905 1,00 Power Supply
A1.5 010P45.00821 1,00 Compact I/O, Analogmodule
A1.6 010P45.00821 1,00 Compact I/O, Analogmodule
A1.7 010P45.00628 1,00 Compact I/O, Terminator
A2 010P45.00945 1,00 Ethernet Switch
A3 010P45.00945 1,00 Ethernet Switch
E1 010S15.47623 1,00 Service Socket
F1 010S16.02626 1,00 Fuse/Circuit Breaker
F11-27 010P16.00124 2,00 Fuse/Circuit Breaker 24VDC, Jumper
F11-27 010P16.00123 1,00 Fuse/Circuit Breaker 24VDC, Copper bar
F11-27 010P16.00122 17,00 Fuse/Circuit Breaker 24VDC
F11-27 010P16.00125 1,00 Fuse/Circuit Breaker 24VDC, End connection
G1 010S66.13042 1,00 Power supply 24VDC 10A
Gl-1 010P12.00253 12,00 Cable Gland
Gl-2 010P12.00252 6,00 Cable Gland
Gl-3 010P12.00452 8,00 Cable Gland
Gl-4 010P12.00484 2,00 Cable Gland
Gln-1 010S12.54191 18,00 Lock Nut
Gln-3 010S12.54192 8,00 Lock Nut
Gln-4 010S12.54193 2,00 Lock Nut
Gln-5 010P12.00453 2,00 Drain Plug
K1-16 010S41.24700 16,00 Relay
K1-16 010S41.24780 16,00 Relay Socket
K20-21 010P41.00253 2,00 Relay
K20-21 010P41.00254 2,00 Relay Base
R1, R2 010P24.00593 2,00 Cabinet heater 230VAC 50W
TS1, TS2 010S24.32736 2,00 Thermostat
U1 010P45.00683 1,00 Ex.i Amplifier
U 1.1 010P12.00408 2,00 Spacer
U 1.1 010P12.00451 1,00 Connector
U10 010P45.01095 1,00 Ex.i Amplifier
U10.1 010P12.00451 1,00 Connector
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MacGregor Pusnes AS

Date 23.05.2014
Drg/Art.No: 1088102.001 PLC Cabinet Component Layout
Type: El.Eq.Cab. Group: 0710


U10.1 010P12.00408 1,00 Spacer
U11 010P45.01095 1,00 Ex.i Amplifier
X0, X3 010S12.64914 60,00 Terminal 2,5mm
X1 010S12.66423 2,00 Terminal 4mm2 w/knife disconnect
X2i 010S12.64915 48,00 Terminal 0,14-2,5 w/knife disconnect
X3 010S12.64953 8,00 Terminal 2,5mm2 w/Diode
z 1081942.001 1,00 Circuit Diagram, Sheet 1
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Additional Spare Parts Gaza FSO Page 1(1)

Date 28.03.2014
Drg/Art.No: SPL-A-5305-01 Spare Part List Additional Spare Parts
Type: Group:

B 29.01.2014 Butterfly valve chg. to Pos.0305, Storage rack add. as 0111 EE BGi SAN
Pos ItemNo No of Description

0100 1076146.001 0,00 Crude Oil Hose
0101 002602.52900 1,00 Crude oil hose FPSO end section
0102 002602.52800 1,00 Crude oil hose Midsection
0103 002602.52700 3,00 Crude oil hose Midsection
0104 002602.53400 1,00 Crude oil hose rail
0105 002495.10100 9,00 Gasket
0106 002495.05000 4,00 Gasket Non Asbestos
0107 002195.29100 370,00 Hexagon nut
0108 002195.29200 40,00 Hexagon nut
0109 002195.28900 185,00 Stud
0110 002195.29000 18,00 Stud
0111 002602.53800 3,00 Storage rack for Crude Oil Hose
0200 1076433.001 0,00 Mooring Hawser
0201 323667.00000 1,00 Chafing Chain
0202 416611.00000 1,00 Special Shackle 2¨
0203 416613.00000 1,00 Shackle Bolt 2¨ *
0204 327441.001 2,00 Mooring Hawser
0205 002392.13800 5,00 Bolt Type Anchor Shackle
0206 002392.09000 1,00 Chain Shackle
0207 002396.04200 10,00 Lace on float element
0300 1077339.001 0,00 16" Outboard Hose Term. Piece
0301 002515.01200 1,00 Short Spool Camlock Coupling
0302 002524.51300 1,00 Blind Flange, Lightweight
0303 002195.29300 18,00 Stud
0304 002195.29200 35,00 Hexagon nut
0305 002613.03700 1,00 Butterfly Valve 16" Wafer
0400 1077327.001 0,00 Inboard Hose Termination Piece
0401 002118.475HD 22,00 Stud
0402 002120.010HD 42,00 Hexagon Nut
67
STX-F1006 GAZA FSO - OL

Client
Aker Pusnes AS
Box 732 - Stoa, Tel.: +47 37 08 73 00

3400-000-A-PT-PUS-00001 5305-01-PUS-H-KA-0001
Document title
HYDRAULIC INSTALLATION 8104

3400-000-A-PT-PUS-00001 5305-01-PUS-H-KA-0001
29
Revisions
00 06.09.2013 Initial issue MMH
Code 1 Accepted

68
Project STX F1006 GAZA FSO-OL
Client doc. no. 3400-000-A-PT-PUS-00001

Pusnes doc. no. 5305-01-PUS-H-KA-0001 Pusnes rev. 00 Aker Pusnes AS
Title HYDRAULIC INSTALLATION 8104
Table of Contents:
INSTALLATION PROCEDURE- HYDRAULIC 8104 ................................................. 1

1 Hydraulic installation 8104 .............................................................................. 3
1.1 Instructions for pipe installations (Instr. 8101) ................................................. 4
1.1.1 Generally about the pipe installation and flushing............................................ 5
1.1.2 Select pipes for hydraulic system. ................................................................... 6
1.1.3 Determine the lay-out of the pipe lines ............................................................ 7
1.1.4 Make pipes to correct shape ........................................................................... 9
1.1.5 Prepare pipes for connection......................................................................... 10
1.1.6 Grind and sandblast the pipe piece ............................................................... 11
1.1.7 Clean the pipes ............................................................................................. 11
1.1.8 Protect pipe against contamination................................................................ 13
1.1.9 Install the pipes ............................................................................................. 14
1.1.10 Connect the pipes ......................................................................................... 17
1.1.11 Check the pipe system .................................................................................. 19
1.1.12 Flush the pipe system ................................................................................... 19
1.1.13 Check the cleanliness of the pipe system/Pusnes' approval .......................... 19
1.1.14 Pressure testing ............................................................................................ 20
1.1.15 Starting up..................................................................................................... 20
1.2 Instructions for flushing of pipe system (Instr. 8102) ...................................... 21
1.2.1 Flushing the pipe system (general notes) ...................................................... 21
1.2.2 Recommended flushing procedure ................................................................ 21
1.2.3 Specifications/recommendations ................................................................... 22
1.3 Instruction for starting up systems (Instr. 8103) ............................................. 27
1.3.1 General notes ............................................................................................... 27
1.3.2 Hydraulic oil recommended types ................................................................. 27
1.3.3 Procedure: .................................................................................................... 28
1.3.4 Sketches ....................................................................................................... 29
69

1 Hydraulic installation 8104

Note!
The "Instructions/recommendations for installation and starting up
PUSNES HYDRAULIC SYSTEMS" is enclosed as a guideline and reference
for future repair and maintenance of the hydraulic system.
70

1.1 Instructions for pipe installations (Instr. 8101)
Important
This instruction should be read by designers and pipe fitters before

installation of hydraulic pipes onboard the vessel. This is extremely
important in order to achieve trouble free operation of the hydraulic
equipment when the complete system is started up.
Please observe that if the hydraulic pipe installation is not in

accordance with these instructions, the guarantee will not come into
effect!
For normal periods of guarantee see "Pusnes conditions for supply of deck
machinery", Rev. D.
Do not hesitate to contact Pusnes in questions concerning installation of

the hydraulic system.
71

1.1.1 Generally about the pipe installation and flushing
The following are instructions for planning, making and mounting

hydraulic pipe installations for connection with Pusnes hydraulic
equipment. The pipe installation should be carried out in same
succession as described. For each operation are also mentioned
recommended or not approved production methods, materials etc.
It is of greatest importance that the installation of the hydraulic pipes is

carried out according to the following instructions. Especially the
cleaning of pipes must be paid the greatest attention, as cleanliness is
the main requirement for trouble-free operation of any hydraulic system.
Please note that when starting up the complete system, any impurities
will have to pass through pumps, motors, valves etc. and possibly cause
damage to these parts. Therefore it is most important that the complete
pipe system is thoroughly cleaned before starting up.
The pipe system is the section where most of the impurities can enter
the circuit. The rough particles cause deep scratches while the minute
ones work like grinding paste causing a rapid wear and tear of pumps,
valves etc. Also, the impurities can jam hydraulic valves and put the
system out of function.
In order to assure that the impurities in the system are reduced to an

acceptable level, the pipe system will have to be flushed properly.
Generally we recommend that flushing is done with separate flushing
pumps and with special flushing filters (see instructions/
recommendations).
The hydraulic systems built by Pusnes are normally equipped with

filters, which mainly are meant for removing particles being generated in
the system during operation. These filters should normally not be used
for flushing, however, if by any reason it should be required to use the
working pumps for flushing; this will have to be carried out strictly in
accordance with special instructions given separately on request.
72

1.1.2 Select pipes for hydraulic system.
The correct type and size of pipes should be selected according to

Pusnes requirements and as required by the classification society.
Quality, Material
Pressure lines
Quality: Seamless steel precision tubes, cold drawn or cold rolled, DIN
2391-C, NBK. Phosphated and oil impregnated.
Material: St. 35,4, DIN 1629/4 or better.
Return lines, 0 - 10 bar:
Quality: We recommend steel tubes similar to the pressure lines, or

according to DIN 2448.
Material: St. 35, DIN 1629/3 or better.

Note!
For pipes with outside diameter less than 18 mm we recommend
acid resistant material.
Not approved: Copper pipes are not recommended.

Galvanized pipes and accessories must not be used.
Dimensions
Pipe dimensions should be as recommended certified in Pusnes

drawings of the pipe system. If the pipe line should be extremely long,
Pusnes should always be contacted in case special modification should
be required. Install flexible rubber hoses where indicated.
The wall thickness must comply with the rules of the classification
society. Note inside and outside additions for corrosion, the latter
depending on mounting arrangements.
73

1.1.3 Determine the lay-out of the pipe lines
The pipe lines should be well arranged and easy to survey. It is also
important that the various components of the system are of easy access
for checking and adjusting, or removal for repair. See also chapters
"Connect the pipe" and "Check the pipe system" for fastening of pipes
and pipe connections.
Expansion compensation
In a hydraulic system the temperature can vary considerably. Under
certain conditions the temperature in the pipes varies from –30oC at
stand still in the winter to +80°C in service at summer time. This gives a
110oC possible temperature difference, which again means a length
variation for steel tubes of about 1,2 mm per meter.
The pipe lengths and temperature differences must be given special

attention when installing the pipes. If, for example, pipes are to be fitted
between two fixed points there have to be flexible parts somewhere to
take care of the length variations.
Noise damping
To keep the noise level at a minimum the below instructions should be
followed:
• All pipe connections to the power pack/pump station must be

made by flexible rubber hoses, length 0,5 m to 1,0 m.
All components should be mounted to solid foundations that cause a

minimum of vibrations.
• Make sure the pipe lines are fastened to well stiffened deck
plating, bulkheads etc.
• The use of bulkhead penetrations and pipe bends(elbows)
should be kept at a minimum.
• In accommodation areas; use pipe clips and bulkhead
penetrations with noise dampers.
Recommended arrangements
The pipe line should be laid up the shortest way between the power
pack and the consumer (winch). The pipes should be well protected from
external forces by mounting them below deck, in pipe tracks etc. where
possible.
Make sure the distance between the pipes is sufficient for easy access
of couplings. Bends and couplings should be kept at a minimum to
prevent unnecessary pressure drops.
74

The illustrations beneath show correct pipe fitting by use of length compensators.
Figure 1
75

1.1.4 Make pipes to correct shape
It is important that the tubes are made to correct length and shape in
order to avoid statical forces and leaks caused by inaccurate pipe
pieces being forced into position assembled.
By assembling it should be possible to connect the pipes and

components without bending and twisting.
Methods of cutting
For cutting tubes, cross cut saws are recommended. Small size pipes
with outside diameter less than 25 mm may also be cut by pipe cutters.
After cutting, clean off the burrs. This should also be done when flanges
are to be welded to the pipe.

Note!
Pipe must not be cut by flame cutting or any other method which will heat
the pipe.
Pipe bending
The steel tubes should be bent without heating. It is important to use the
correct bending device for the actual pipe diameter. In order to maintain
strength and to prevent unnecessary pressure drop, the cross section of
the pipe must remain circular after bending.
The bend radius should be as large as practically possible. Minimum

bend radius guidance is following:
Up to 18 mm dia. - 3 x pipe dia.
20 mm dia. and over - 4 x pipe dia.
Check that the pipe is open and free from impurities before bending.

Note!
Do not use sand or heat when bending.
76

1.1.5 Prepare pipes for connection

All welding of flanges to the pipes must be done before the pipes are
cleaned and mounted. No welding must be done where mechanical
cleaning is not possible.
Threads for threaded connections should also be made before the pipe
is cleaned. After cutting threads, clean off the burrs.
High and low pressure lines with outside dia. 25 mm or more must be
connected by welding flanges. Use solid flanges designed for high
pressure lines and with required number of bolt holes. The flanges
should comply with the rules of the classification society.
Check that one of the flanges for each connection is equipped with
groove for O-ring or other satisfactory sealing.
Welding of flanges
Before welding check that all burrs from cutting of the pipes are
removed. When welding the flange to the pipe make sure the weld
penetrates completely.
Checking of accuracy
Make sure the flanges are welded at the correct angle to the pipe. The
flanges of two adjacent pipes must be absolutely parallel when
connected. Adjust if necessary.
Figure 2
77

1.1.6 Grind and sandblast the pipe piece
Slag, burrs and other contamination from welding and cutting should be
mechanically removed. Special attention should be paid to the inside of
the pipe. Outside slag and corrosion should be removed by
sandblasting.
Required grinding
Edges of pipe ends should be well grinded when pipes are connected by
threaded connections or compression type couplings.
Grind the inside of the pipe where welded.

Note!
Check also that there are no welds where grinding is not accessible.
Figure 3
1.1.7 Clean the pipes
The complete pipe piece should be thoroughly cleaned before mounting.
No pipe must be mounted unless they have been treated by the
cleaning methods described below.
78

Methods of cleaning
1. All pipes must be degreased.
• Clean mechanically the pipe from visual impurities.
• Then wash the inside of the pipe with white spirit,
trichloroethylene or some other solvent.
• Blow the pipe dry by using dry, filtered, compressed air or
nitrogen.
Pipes not fitted with welding flanges should be inspected for

corrosion. Pull a nap-free piece of clothing through the pipe (twist
must not be used). If no corrosion is observed inside, the pipe may
be mounted without being acid washed. Blow through the pipe with
compressed air before mounting.
2. Pipes which have been exposed to heat (welding of flanges) and

pipes with sign of corrosion must also be chemically cleaned (acid
washed). See recommended methods.

Note!
Note that all pipes must be degreased before acid washing.
Chemical cleaning
The pipes should be acid washed and then neutralized, or they should
be washed in combined cleaning/neutralizing chemicals.
1. Combined cleaning/neutralizing chemicals

There are chemicals on the market, which are cleaning (acid
washing) and neutralizing with water. Usually on the basis of
phosphoric acid. Degreasing before the acid washing is required in
this case too. Working period is about 2 - 4 hours dependent on the
acid density, the degree of pollution and the temperature.
Check the result and repeat the treatment if necessary.
2. Acid washing
Acid bath
1 part 35 % hydrochloric acid
3 parts of water

Warning!!!
Hydrochloric acid to be poured into the water; never the opposite way.
The part to be cleaned should stay in the bath for 6 - 8 hours dependent
on temperature and the amount of impurities. By temperature above 20°
C the bath period can be reduced. If the solution is filled into the tube, it
must be completely filled. Check that no air is left inside.
79

Neutralization
The hydrochloric acid solution to be removed.
The tube to be scoured well with water.
Neutralizing liquid:
1 part anhydrous sodium carbonate
1 part of water
All the sodium carbonate must be dissolved in the water (to be fully
agitated).
Hot water accelerates the dissolving. The part should stay in the bath for
6 hours. As the sodium carbonate crystallizes at low temperatures, the
bath should be kept at 18-20O C.
Scour the part well with water

Check that the result is satisfactory, repeat process if necessary.

Note!
Ensure that the pipes are completely dry.
Impregnate the pipes immediately after cleaning.
1.1.8 Protect pipe against contamination

Immediately after cleaning, the inside of the pipe must be impregnated
because it is strongly disposed to corrosion, especially after being acid
washed. Make sure no foreign particles can enter the cleaned pipe.
The external part of the pipes should be coated with primer, especially if
the pipes are to be stored before installation.
Impregnation against corrosion

The inside of the pipes should be completely covered with an
impregnation fluid which will protect the pipes against corrosion in the
time from cleaning until the system is filled with hydraulic oil.
The actual quality of the impregnation fluid depends on the time the
pipes are expected to be stored. Choose an impregnation fluid which
covers the pipe inside well, gives required protection and does not flow
towards the bottom of pipe when stored.

Note!
Make sure the impregnation fluid will not harm the hydraulic oil when the
system is taken into use. Check with the suppliers of impregnation and
hydraulic oil.
Plugging of pipes
80

When the pipes are impregnated, the pipe ends should be properly
closed against contamination. This is important as impurities, which
enter the tube, will stick to the impregnation fluid.
Use plastic plugs to close the pipes. The plugs should remain inserted in
the pipe ends at all time during storage, transport etc. They should not
be removed until the pipe is being mounted.
Figure 4
1.1.9 Install the pipes

Mounting devices for the hydraulic pipe system should be spaced adequately and
have sufficient strength to absorb static and dynamic influences on pipes (Weight of
pipe line and components fitted to them, as well as the ships motion in the sea).

Note!
One should notice that a pipe coupling is a pipe assembling device and
not suitable as support for components.
Fastening of pipes
Some recommendations for fastening of pipes:
• A pipe clip must have sufficient mechanical strength to keep the
pipe in place.
• It must not prevent the pipe from expanding (axial load)
• A pipe clip should be made from a wear resistant material in
order to minimise wear and tear by axial movement.
• It should be made from corrosion resistant material or protected
against corrosion.
• The pipe clip should also be made from a noise damping
material. Where extra noise damping is required
(accommodation areas) use pipe clips with built-in noise
dampers.
• Several pipes in a common pipe clip should have the possibility
to be removed one by one.
81

There are no fixed rules for calculating the distance between the pipe clips.
Recommended distance:
Recommended spacing for clamps (acc. Max. tightening torque in Nm.
To ASTM 121.1.4)
Pipe O.D. Spacing Material Poly- Polyamide Aluminium
in mm in (m) properties propylene PA AL
Series PP
6-12,7 0,9 Standard M 6 8 10 12
15,9-22,2 1,2 Gr 1 M 6 5 6 -
25,4 1,5 Double Gr 2-4 M 8 12 12 -
31,8-38,1 2,1 Gr 5 8 8 -
48,3 2,7 3S M 10 12 20 30
60,3 3 4S M 10 12 20 30
73 3,4 Heavy 5S M 10 15 25 35
88,9 3,7 6S M 12 30 40 55
101,6 4 7S M 16 45 55 120
114,3 4,3 8S M 20 90 180 280
141,3 4,9 9S M 24 150 300 350
168,3 5,2 10 S M 30 250 500 700
219,1 5,8 11 S M 30 350 600 850
273 6,7 12 S M 30 350 600 850
323,9 7
355,6 7,6
406,4 8,2
457,2 8,5
508 9,1
558,8 9,8
Plastic clips are recommended

Available on the market in most of the actual
dimensions.
Reducing the transfer of noise and vibrations.
Allows for axial movement.
Figure 5
82

Special arrangement of clips supported by vibration dampers. To be used when noise

reduction is very important.
Figure 6
Figure 7
Figure 8
Not recommended! Flat steel clips with lead lining

The lead lining is compressed by the
pulsations of the pipe and is getting loose.
Wear and tear of pipes and clips, as well as
transfer of noise and vibrations are
considerable.
Figure 9
83

Bulkhead penetrations
Standard bulkhead penetrations can be used.

Note!
Note that the bulkhead penetration is a fixed point in respect of
expansion.
In accommodation areas bulkhead penetrations with noise dampers

should be used.
Rubber compressed in a steel casing

eventually vulcanized.
Necessary when noise damping is very

important.
Figure 10
The weight of the pipe must not act as an extra load on the noise
damping bulkhead penetration. Check that the pipe line is well
supported on each side of the bulkhead.
1.1.10 Connect the pipes

Before connecting the pipes, check that all parts are properly prepared
and cleaned as described in the foregoing chapters.
Bonded seal/o-ring should be covered with grease when fitted. This

helps keeping them in position in the groove of the flange when the
pipes are being mounted.

Note!
Do not forget to remove the plastic plugs!
84

Couplings
Only couplings approved by the classification society may be used.
No pipe must be connected by welding only; scale and slag from the
welding is impossible to remove.
Figure 11
One of the following coupling types should be used dependent on pipe size
and pressure:
1. Flange connection
All high and low pressure lines with outside diameter 25 mm or more
must be connected by welding flanges. See also chapter "Prepare pipes
for connection" for welding of flanges. For sealing of the flange
connections use bonded seal/o-ring mounted in a groove in one of the
flanges. Size and finish of the grooves should be in accordance with the
recommendations from the sealing makers.
Drain lines may be connected by couplings designed for low pressure

lines (e.g. flanges for steam lines).
2. Compression type couplings

Follow the instructions given by the various makers. Check that the
precision steel tubes have the required tolerances for use of this type of
coupling.
85

3 Threaded connections
Generally only to use when the two coupling types above are not
suitable.
Properly sealing must be assured, e.g. by means of O-rings, bonded

seals, hardening sealing liquids (Lactite) etc. Follow the makers'
instructions.

Note!
Hemp and Teflon tape is not recommended.
Accuracy of work
• Check that pipe lines are not exposed to external load by being
forced into position when connected.
• Check that coupling flanges are absolutely parallel and that

connection bolts are evenly tightened.
• Check that compression couplings are properly tightened.
1.1.11 Check the pipe system

The complete pipe system should be thoroughly checked for cleanliness
and leakage. Normally flushing of the system will be necessary.
1.1.12 Flush the pipe system

Pusnes recommendations for flushing and cleanliness approval
(acceptance figures) are given separately (see instr. 8102).
1.1.13 Check the cleanliness of the pipe system/Pusnes' approval

The installation should be checked and approved by Pusnes'
representative before starting up. Pusnes' representative is entitled to
order parts of the pipe system dismantled for inspection.
If not satisfactory, the complete system may be ordered flushed once

more, or dismantled for proper cleaning.

Note!
The life time of the components are closely connected to the cleanliness
of the system when starting up, and maintenance on board later on.
86

1.1.14 Pressure testing

Pressure testing of the pipe system is the responsibility of the yard.
Pressure testing should preferably be carried out with a special pump
before connecting Pusnes equipment to the pipe system.
Testing pressure should be in accordance with the requirements of

classification society. The calculation of test pressure should be based
on max. working pressures specified for the actual hydraulic system.
If, by any reason, pressure testing should need to be carried out after
connecting Pusnes' equipment, this should be done as a part of the
starting up procedure. In such case Pusnes' representative should be
present for careful evaluation of method and precautions against
damages.
 Warning!
Protect Pusnes' equipment from abnormal pressure!
Extensive damage can occur!
1.1.15 Starting up
Starting up must be carried out in accordance with

instructions/recommendations given separately
See instr. 8103.

Pusnes' representative should preferably be present.
87

1.2 Instructions for flushing of pipe system (Instr. 8102)

1.2.1 Flushing the pipe system (general notes)
In the instruction/recommendations for hydraulic pipe-installations we
have given information which is considered as important for ensuring an
acceptable pipe installation.
A system which is properly cleaned and free from particles will

safeguard the components and ensure the best possible operation of
the equipment, as well as long lifetime.

Note!
Read this instruction carefully!
1.2.2 Recommended flushing procedure

1. Check that all connections on the lines are free from leakage.
This may be done by applying compressed air (recommended pressure

6 kg/cm2) and test the connections with soap water. If no bubbles are
observed, the lines are acceptable and the flushing can be prepared.
2. Provide necessary equipment (separate flushing station, filters as

recommended, and hoses).
3. Connect the hoses for by-passing the equipment as indicated in the

sketch.
4. Make sure that the filter, placed in the return line of the system is
suitable.
5. Fill up the pipe system with suitable flushing oil.
6. Close the valves for leak oil pipe (on deck) and start the flushing
through P- and T lines.
7. Check that the flushing is acceptable according to recommendations

in chapter "Specification/Recommendation", paragraph "Main criteria
for proper flushing”.

Note!
Check all lines carefully !!
8. Run the pump about 20 - 30 min. and check the filter. Clean or
change the filter according to which type (paper or gauze) is
used. Repeat the flushing until the filter seems to be completely
free from particles.
88

Open valves for leak oil pipe (on deck). Close the valve for T-pipe
and start the flushing through P and L lines. Repeat the flushing until
the filter seems to be free from particles.
9. Check that the cleanliness of the system is acceptable according to

NAS 1638 class 7, or ISO 4406 class 16/13. Oil sample to be taken
from the system before the filter. Follow instructions.
10.If special flushing oil is used, or if by any reason the oil is not
acceptable, drain the complete system and fill oil of correct quality
through filling filters (5 microns is recommended)
11.Disconnect flushing station and hoses above deck.
12.Connect the permanent pump stations and hydraulic equipment to

the lines.
13.Follow the instructions for starting up hydraulic systems (see instr.

8103).
1.2.3 Specifications/recommendations
Main criteria for proper flushing
A flushing procedure should be adapted to the practical condition. Certain main

criteria shall, however, be fulfilled to obtain sufficient results.
The reservoir of a portable pump station shall be cleaned to the level required of the
system.
The system is filled through a filter. Air should not be brought into the system when
filling. If necessary, top the system and bleed.
With Reynolds number larger than 3000 there will be a turbulent flow. Having this
condition the fluid wipes the surfaces with high energy and tears off the contaminants.
To prevent more contaminants to be wiped off during working operation the Reynolds
number by flushing has to be at least 25% higher than the maximum achievable
Reynolds number when the system is in operation.
The Reynolds number may be calculated as follows:
where
21220 ⋅ Q
Re =
υ ⋅d
 is flow in l/min
υ is viscosity in mm 2/s (centistokes)
d is internal tube diameter in mm
89

It is often difficult to obtain a Reynolds number large enough. The following methods
are recommended to increase the Reynolds number:
Increase the fluid flow, q. This may be both unpractical and expensive as it requires a
larger flushing pump and larger power unit.
Reduction of viscosity, υ. In most cases this is the best way to achieve the required
Re .The reduction may be obtained by increasing the temperature, thus lowering the
viscosity, or by using a flushing fluid with lower viscosity.
If a special flushing fluid is used, it shall be compatible with the system oil, which is to
be used in operation. The only general recommendation is to use the same type of
fluid, possibly with a lower viscosity.
The use of vibration, high frequency sound, changing flow directions or gas injections
would contribute to a faster removal of particles. This is, however, a supplement and
not an alternative to the right Reynolds number.
To ensure transportation of the contaminants from the system to the filters, it is very
important – in all parts of the system - to have both turbulent flow and a velocity of
minimum 1 m/s of the flushing fluid.
Filters and the separation of solid particles
The filters used for flushing are quite decisive for two essential conditions. The filters
decide the final cleanliness level which can be expected, and how fast this level can
be reached.
The choice of an optimal filtration ratio is important. When using filters with a too poor
filtration ratio, situations may arise where the specified cleanliness is not achieved or
is achieved after an unnecessarily long flushing time.
The flushing filters should be provided with alarm or visual indicator.
Sizing of external flushing filters
It is generally good economy to use large flushing filters. The smallest flushing filter
which should be accepted has a pressure drop through a clean element of 5 % of the
opening pressure of the bypass valve or the indicator setting , calculated at the
relevant flushing viscosity.
Selection of filtration performance
Filtration performance is measured according to ISO 4572.

ISO 4572 defines Beta ratio (filtration ratio) as the relationship between the number
of particles greater than a given size upstream of the filter, and the number of
particles greater than the same size downstream of the filter. If there are 20 times as
many particles greater than 5µm in the oil upstream of the filter compared to
downstream of the filter, the Beta ratio for 5 µm equals 20. This may be presented
as; β5 = 20.
90

Filters with β5 - values, considerably higher than 1, should be used. Recommended

minimum value is:
-Until filters seem to be free from particles, β5 ≥ 20
-Thereafter, until satisfactory cleanliness level is reached β5 > 75
External flushing filters
It is recommended to use external filters during flushing. The system filters normally
are selected with a certain dirt capacity to keep the system on a recommended
cleanliness level. It is not economical to use system filters as flushing filters. The
selected flushing filtration ratio very often deviates from that of the system filters of
the system.
Minimum flushing time

The flushing time depends on the system capacity and its complexity.

Even if samples from the system indicate that the specified cleanliness
level is reached after a short time, the flushing shall continue for a total of
at least three hours at turbulent flow.

The probability of removing particles sticking hard to the tube walls therefore
increases.
Verification of cleanliness level
The obtained cleanliness level shall be documented before a flushing operation may
be considered as finalised. Use particle counting or comparison membrane.
Particle counting
The use of an automatic particle counter is the fastest method for particle counting in
a flushing fluid sample. See ISO 4402 for calibration.
Particles may alternatively be separated on a membrane filter and counted by using

a microscope. See ISO 5884.
When required cleanliness level is specified according to ISO 4406 , it is sufficient to

count particles larger than 5 and 15 µm.
91

Comparison membrane
The equipment for microscopic particle counting may also be used by applying
comparison membrane. The procedure is the same except for the counting. Instead
of counting particles, the relevant test membrane is compared to a reference
membrane by using a microscope. For a trained operator it is easy to ascertain that
the sample is equal to or better than the reference. The reference membrane should
be made for the relevant type of system, and it shall represent the cleanliness level
required.

Note!
The membranes shall be compared using a microscope only. Dye pigment
and other substances, which create colour nuances, may give completely
misleading results. Samples should be verified by counting of particles.
Verification of turbulence
In cold environment the flushing of pipe systems may suffer from loss of heat. To
verify that the Reynolds number is larger than 3000, the temperature shall be
checked at the estimated coldest spot of the system. The flushing is only real when
the lowest temperature gives a Reynolds number larger than 3000. See data for the
viscosity and temperature of the relevant flushing fluid.
Especially cold environments

Under especially cold conditions, the pipe system etc. should be insulated to keep
the temperature above the necessary minimum level.
92

Special recommendations
Max. flushing pressure must not exceed the "design pressure" for the actual pipes.
Temperature of flushing oil should not exceed +70o C
Nomogram for oil velocity
Figure 12
93

1.3 Instruction for starting up systems (Instr. 8103)

1.3.1 General notes
• We recommend to install filters with filtration ratio β 5 > 75 during

the starting up period.
• Ensure that starting up procedures and instruction books for all units
are available
• Follow these procedures strictly
1.3.2 Hydraulic oil recommended types

For detailed information on the selection of hydraulic fluids and application
conditions please see our data sheet: Pusnes document: PS 1954
In general, we recommend a mineral based hydraulic oil with viscosity index

above 140 and viscosity class according to ISO VG 46.
Viscosity limits:
For critical operating conditions the following values apply:
υ min = 25 cSt
for short periods with a max. permissible leakage oil temp. of 80oC
υ max= 1000 cSt
for short periods when starting from cold.
In order to simplify selection, different viscosity grades have been created. The
identifying codes relate to average viscosity in cSt at 40oC. Viscosity grades
(VG) 22 to 100 are in most common use.
VG 22 A: for arctic conditions or for extremely long pipelines
VG 32 W: for winter conditions in areas as Central Europe and North Sea
VG 46 S: for summer conditions in areas like Central Europe and the

Mediterranean
VG 68 T: for tropical conditions or for areas with high temperature
VG 100 U: for excessive high temperatures
Hydraulic oil with a higher viscosity index (VI ≥140) and multi-grade engine oils
are particularly suitable for larger temperature ranges.
The temp switch on the hydraulic power unit has to be set in accordance to the
oil quality. The high temp level have to be set at a temperature corresponding
to an oil viscosity of 25 cSt, and the shut down temperature corresponding to
94

an oil viscosity of 20 cSt.
Mixing of oil viscosity is possible. Please consult Maritime Pusnes engineering

department.
Mixing of oil types is not recommended.

Note!
Selection of viscosity grade is made on the basis of starting viscosity with
ambient temperature (consider pour point where necessary) and optimum
operating viscosity according to system and operating data (collective
load).
1.3.3 Procedure:
1. Start up pump station/power pack (see instruction books!)
2. Connect to the pipe system
3. Air bleed properly the complete system
4. Check all units and adjust the pressures as described in instruction

books and "Valve adjustments"
5. Function test all units

Note!
"VALVE ADJUSTMENTS" is normally attached to the equipment when

despatched from Pusnes. A copy is also normally inserted in the
instruction books. Extra copies may be ordered from Pusnes.
95

1.3.4 Sketches
= By- passing/interconnection for flushing
Pump motor system
Figure 13
Ring main system
Figure 14
96
STX F1006 Gaza FSO - OL

Client
STX Offshore & Shipbuilding,

CO. LTD
Aker Pusnes AS
Box 732 - Stoa, Tel.: +47 37 08 73 00

5305-01
Document title
Cable List
Client doc. No. Pusnes doc. No. Total pages
3400-000-E-EP-PUS-00001 5305-01-PUS-E-LA-0001 10
Revisions
02 03.03.2014 Updated with customer comments OT TDT OCT
01 09.01.2014 Updated OT TDT OCT
00 18.10.2013 Initial issue OT AnM OCT
Code 1 Accepted
97
Project STX F1006 Gaza FSO - OL
Client doc. no. 3400-000-E-EP-PUS-00001
Pusnes doc. no. 5305-01-PUS-E-LA-0001 Pusnes rev. 02 Aker Pusnes AS
Title Cable List
Table of Contents:
Cable List ................................................................................................................... 1

1 Specifications.................................................................................................... 3
1.1 Purpose of this Document................................................................................ 3
1.2 Revision History............................................................................................... 3
1.3 Abbreviations ................................................................................................... 3
2 Cable List ........................................................................................................... 4
3 Comments to Cable List ................................................................................. 10
3.1 Rev.01 ........................................................................................................... 10
3.2 Rev.02 ........................................................................................................... 10
98
Title Cable List
1 Specifications

The purpose of document is to list up the cables to be used for correct selection of
cable glands. Yard to specify cable type, dimension and diameter for yard supplied
and installed cables. Pusnes to specify voltage level and number of cores needed.
01 09.01.2014 Se detailed description for changes in chapter 2.1

Updated with customer cable information for all yard
02 03.03.2014
supplied cables
1.3 Abbreviations
YS Yard supply
YI Yard installation
APS Aker Pusnes supply
API Aker Pusnes Installation
99
Title Cable List
2 Cable List
Cable Cable
No. of
Cable Voltage STX Cable Dim. diameter Supplied
Cores Cable Type From To Remarks
No. Level Circuit No. (max OD) By
Needed
(mm²) (mm)
Fused : 10A
200-003-
W1 2 220VAC RFOU, black 1x2x2.5 14.1 Supply 220VAC PLC Cabinet YS/YI Rev.02
PG
(M25)
220-101- Rev.02
W2 2 24VDC BFOU, grey 1x2x1.0 11.7 CER PLC Cabinet YS/YI
CC (M25)
220-101- Rev.02
W3 2 24VDC BFOU, grey 2x2x1.0 15.5 PLC Cabinet CER YS/YI
CA (M25)
(E)RFOU(C), 220-401- Rev.01 Rev.02

W4 16 Exi
SB
10x2x1.0 22.4 PLC Cabinet RCPH/E YS/YI
(M40)
Blue
W5 Removed in Rev.01
(E)RFOU(i), 220-402- Junction box for hose Rev.02

W7 8 Exi 4x2x1.0 17.5 PLC Cabinet YS/YI
Blue SB tension (M32)
2x2 Junction box for

W7.1 4 Exi BFOU(i), blue 14,5±0,8 Load cell A Hose tension APS/API
x0,75 hose tension

W7.2 4 Exi BFOU(i), blue 14,5±0,8 Load cell B Hose tension APS/API
x0,75 hose tension
W8 2 Exi
(E)RFOU(i), 1x2x1.0 10.9 PLC Cabinet Crude oil transmitter YS/YI
Rev.01 Rev.02
Blue 220-404- (M20)
100
Title Cable List
2 Cable List
Cable Cable
No. of
Needed
(mm²) (mm)
SB
W9.1 Removed in Rev.01
W9.1.1 Removed in Rev.01
W10 4 Exi
(E)BFOU(C), 220-101-
2x2x1.0 15.8 PLC Cabinet
Junction box for ESD
YS/YI
Rev.02
Blue CA Valve (M25)
Proximity switch is
Junction box for Proximity switch for ESD
W10.1 2 Exi APS/API located inside
ESD Valve valve open
junction box
Proximity switch is
Junction box for Proximity switch for ESD
W10.2 2 Exi APS/API located inside
ESD Valve valve closed
junction box
RFOU(C), 220-203- Rev.01 Rev.02

W13 12 24VDC 7x2x1.0 19.0 PLC Cabinet Panel in CCR YS/YI
Grey CK (M32)
RFOU(C), 220-204- Rev.01 Rev.02

W14 4 24VDC 2x2x1.0 14.8 PLC Cabinet Panel in CCR YS/YI
Grey CK (M25)
LC connectors
W15 Ethernet Optic fibre 220-012-TF 4-core 16.1 PLC Cabinet Panel in CCR YS/YI Rev.02
(M25)
101
Title Cable List
2 Cable List
Cable Cable
No. of
Needed
(mm²) (mm)
comm
LC connectors
Ethernet AUX Control panel for
W16 Optic fibre 220-011-TF 4-core 16.1 PLC Cabinet YS/YI Rev.02
comm HPU
(M25)
RFOU(C), 220-001- AUX Control panel for
W17 4 24VDC 2x2x1.0 14.8 PLC Cabinet YS/YI (M25)
Grey CC HPU
BFOU(C), 220-101- Rev.01 Rev.02

W19 8 24VDC 7x2x1.0 20.7 PLC Cabinet CER YS/YI
Grey CK (M32)
W20 4 Exi
(E)RFOU(i), 220-403-
2x2x1.0 15.5 PLC Cabinet
Junction box for hawser
YS/YI
Rev.01 Rev.02
Blue SB tension (M25)

W20.1 4 Exi BFOU(i), blue 14,5±0,8 Swivel on RHHW APS/API Rev.01
x0,75 hawser tension
2x2 Load cell for Hawser

W20.1.1 4 Exi BFOU(i), blue 14,5±0,8 Swivel on RHHW APS/API Rev.01
x0,75 tension
PT211 Accumulator Rev.01

W31 2 24VDC Lif9YH-11YH 2x0,75 5,7 PLC Cabinet APS /API
pressure (M16)
Rev.01
W32 2 24VDC Lif9YH-11YH 2x0,75 5,7 PLC Cabinet HY205, Acc valve APS /API
(M16)
102
Title Cable List
2 Cable List
Cable Cable
No. of
Needed
(mm²) (mm)
Rev.01
W33 2 24VDC Lif9YH-11YH 2x0,75 5,7 PLC Cabinet HY225, Open ESD valve APS /API
(M16)
HY216, Quick Release Rev.01
flange (QRF) valve (M16)
PT217 Accumulator Rev.01

pressure, Hawser release (M16)
HY235, Release Hawser Rev.01

valve (M16)
HY201A, Open Claw Rev.01

RHHW valve (M16)
HY201B, Close Claw Rev.01

RHHW valve (M16)
RFOU(C), 220-201- Rev.01 Rev.02

W120 12 24VDC 7x2x1.0 19.0 Aux.Cabinet HPU Junction box HPU YS/YI
Grey CK (M32)
Solenoid valve: Standby

W120.1 2 24VDC MPRXCX 2 x 1,5 9,5±1,0 Junction box HPU APS/API Rev.01
low pressure
RFOU(C), 220-202- Rev.01 Rev.02

W121 12 24VDC 7x2x1.0 19.0 HPU Aux.Cabinet Junction box HPU YS/YI
Grey CK (M32)
103
Title Cable List
2 Cable List
Cable Cable
No. of
Needed
(mm²) (mm)
W121.1 2 24VDC MPRXCX 2 x 1,5 9,5±1,0 Aux.Cabinet HPU Oil level switch low APS/API Rev.01
W121.2 2 24VDC MPRXCX 2 x 1,5 9,5±1,0 Aux.Cabinet HPU Oil level switch low low APS/API Rev.01
Oil temperature
W121.3 2 24VDC MPRXCX 2 x 1,5 9,5±1,0 Aux.Cabinet HPU APS/API Rev.01
transmitter
Return filter clogged

W121.5 2 24VDC MPRXCX 2 x 1,5 9,5±1,0 Aux.Cabinet HPU APS/API Rev.01
Pressure switch
220-001- Rev.01 Rev.02

W123 3 380VAC RFOU, Black 1x3x150 51,2 Supply 380V Starter Cabinet 1 YS/YI
PB (M63+)
220-009- Rev.01 Rev.02

W123.1 3 380VAC RFOU, Black 1x3x95 42.9 Starter Cabinet 1 Motor hydr.pump.no1 YS/YI
PB (M63)
Rev.01 Rev.02
220-011-
W123.2 2 PTC RFOU, Black 1x2x2.5 14.1 Starter Cabinet 1 Motor hydr.pump.no1 YS/YI Thermistor
PB
(M25)
Rev.01 Rev.02
220-010-
W123.3 2 220VAC RFOU, Black 1x2x2.5 14.1 Starter Cabinet 1 Motor hydr.pump.no1 YS/YI Motor heater
PB
(M25)
220-005- Rev.01 Rev.02
W124 3 380VAC RFOU, Black 1x3x150 51,2 Supply 380V Starter hydr.pump.no2 YS/YI
PB (M63+)
104
Title Cable List
2 Cable List
Cable Cable
No. of
Needed
(mm²) (mm)
220-012- Starter Rev.01 Rev.02

W124.1 3 380VAC RFOU, Black 1x3x95 42.9 Motor hydr.pump.no2 YS/YI
PB hydr.pump.no2 (M63)
Rev.01 Rev.02
220-014- Starter
W124.2 2 PTC RFOU, Black 1x2x2.5 14.1 Motor hydr.pump.no2 YS/YI Thermistor
PB hydr.pump.no2
(M25)
Rev.01 Rev.02
220-013- Starter
W124.3 2 220VAC RFOU, Black 1x2x2.5 14.1 Motor hydr.pump.no2 YS/YI Motor heater
PB hydr.pump.no2
(M25)
220-007- Rev.01 Rev.02
W125 3 380VAC RFOU, Black 1x3x150 51,2 Supply 380V Starter hydr.pump.no3 YS/YI
PB (M63+)
220-015- Starter Rev.01 Rev.02

W125.1 3 380VAC RFOU, Black 1x3x95 42.9 Motor hydr.pump.no3 YS/YI
PB hydr.pump.no2 (M63)
Rev.01 Rev.02
220-017- Starter
W125.2 2 PTC RFOU, Black 1x2x2.5 14.1 Motor hydr.pump.no3 YS/YI Thermistor
PB hydr.pump.no2
(M25)
Rev.01 Rev.02
220-016- Starter
W125.3 2 220VAC RFOU, Black 1x2x2.5 14.1 Motor hydr.pump.no3 YS/YI Motor heater
PB hydr.pump.no2
(M25)
105
Title Cable List
3 Comments to Cable List

3.1 Rev.01
W4 W4, W5 and W6 are combined in W4, W4 is changed from 2 to 16 cores
W5 W4, W5 and W6 are combined in W4, W5 is deleted
W6 W4, W5 and W6 are combined in W4, W6 is deleted
W8 W8 is added
W9 W9 is renamed to W20
W13 No of cores needed are changed from 2 to 12
W18 W18 is deleted
W19 W19 is added
W30 – W38 JB on valve unit skid is removed and the cable numbers for W30 to W38 are re-arranged
W120 – W123 All Cables for the HPU starter, are changed from W20-W23 to W120-W123
3.2 Rev.02
Updated with customer cable information for all yard supplied cables
106
Project:
OLS STX Gaza FSO
20” Stern Offloading System
Client:
STX Offshore and Shipbuilding Co.,Ltd

Aker Pusnes AS
Postbox 732 Tel.: +47 37 08 73 00
Stoa 4808 Arendal Fax: +47 37 08 65 50
Norway
Client project no.:

Pusnes project no.: 5305-01
Document title:
Quality Plan (QP) with Inspection and Test Plan (ITP)
Client document no.: Pusnes document no.: 5305-01-PUS-Q-TA-001

3400-000-Q-QB-PUS-00001_rev.A01
Revision history:
2 24.03.1014 Reissued for Quality Assurance PEL TD OSk PEL

1 21.01.2014 Reissued for Quality Assurance PEL TD OSk PEL
0 19.09.2013 Issued for Quality Assurance PEL SAN OSk PEL
Rev. Rev. Reason for issue Prepared Checked Q.A. Project
Code Date by by Check approval
Access: Retention: Retention Code:

Open 5 years For information
Internal 10 years For internal use
Confidential Product life Include in MRB
Strictly Confidential Include in Users Manual
Doc. ref.: PS0004.01301, rev. 11, 20.09.2010

Page 1 of 14
107
Project No.: 5305-01 ITP No.: 493 Rev. No: 2
Aker Pusnes AS Quality Plan with Inspection and Test Plan (ITP) Rev. Date: 24.03.2014
Table of Content
1 CHANGES TO PREVIOUS REVISIONS...............................................................................2

2 GENERAL QUALITY PLAN (QP) .........................................................................................3
3 GENERAL DESCRIPTION OF ITP FORM..........................................................................4
4 DEFINITION OF ACTIVITY / REQUIREMENT LIST IN ITP.........................................5
5 QUALITY ACTIVITIES (ITP) ................................................................................................8
6 NOTES TO ITP........................................................................................................................13
7 APPENDIX A - MATERIAL SPECIFICATIONS FOR DNV............................................14
1 CHANGES TO PREVIOUS REVISIONS
Rev. ID Description of change

00 NA NA (First issue)
01 NA Added notes for Hawser Winch, item 11
02 NA Removed activity 11 for item 7. Updated activities for item 1 - 5, 7 - 12, 15 – 16, 18,
21.
Added more notes.
Doc. ref.: PS0004.01301, rev. 11, 20.09.2010 Page 2 of 14

108
2 GENERAL QUALITY PLAN (QP)
No Item / Requirement Description / Reference*)

.
1 Structure of this QP Based on NS-ISO 10005 and our own QA-system
2 Objective of this QP Setting out the specific quality practice relevant to this
project
3 Scope of this QP Scope of contract.
4 Management responsibility Quality Assurance Manual (QAM0000.00000E)
5 Contract review PS0003.00100
6 Resources Identify resource requirements and provide adequate
competence and capacity for the project.
7 Process description Pusnes Project Execution Model (PEM)
8 Design control PS0004.01500
9 Document and data control PS0004.00400
10 Purchasing Supply Management process
11 Control of customer-supplied product PS0005.00900
12 Product identification and traceability PS0005.01000
13 Process control PS0004.01300 and PS0004.02200
14 Control at suppliers PS0004.02500
15 Inspection and testing PS0004.01301, PS0004.02100, PS0004.02500
16 Control of nonconforming product PS0100.02700 and PS0005.00800
17 Corrective and preventive actions PS0100.02700 and PS0100.02800
18 Handling, storage and packaging PS0005.00900
19 Control of quality records PS0004.02100
20 Quality audits PS0800.00200
21 Training PS0100.02200
22 Servicing PS0600.05200
23 Critical activities / components for PS0004.01100
delivery time
24 Correspondence PS0004.00700
25 Documentation See contract and each procedure
26
27
Order of Precedence: Comments:
Statutory regulations.
Class. rules.
Contract.
Applicable codes and standards.
*) All PS-Nos. are with ref. to our ISO 9001:2008 certified QA-system, which is the basis of all QP’s, but not
enclosed.

109
3 GENERAL DESCRIPTION OF ITP FORM
The information shown in the ITP form is explained in the following with arrow indications to the various
form fields:
3
1
6
1. Item No., description and drawing No. of either a complete product, a group (collection of parts into one
defined unit) or a single component (part).
2. All changes made in this revision are marked by rings.
3. Abbreviations/identifications of intervention parties.
4. Symbols for intervention/inspection/documentation points used in plan. (See “Mark” below.)
5. Activity identification numbers/Inspection activities/reference procedures/accept criterions.
6. Showing which party is responsible for what intervention/inspection/documentation, related to a
specific activity.
Note! For “W” (= Witness point), and “H” (= Hold point), the following procedure applies:
 “Hold point”: Point, beyond which an activity must not proceed without the approval of designated
(intervention) parties.
 “Witness point”: Activity to be notified to and witnessed by intervention parties. But activity is
carried out even if any of the parties do not appear.
 Notification of witness shall be done 10 working days in advance, if not other specified in
chapter 6, notes to ITP sheet.

110
4 DEFINITION OF ACTIVITY / REQUIREMENT LIST IN ITP
INSPECTION ACTIVITIES / DOCUMENTATION REQUIREMENTS
1. N.A
2. Certificate of compliance from classification society.

A certificate which verifies that the particular product complies with the given specification and
applicable rules and regulations. To be issued by the involved Classification Society (or other third
party agreed upon).
3. Letter of conformity from subsupplier.

A document issued by a sub supplier, conforming that the complete product unit supplied, complies
with the contract/specification.
4. N.A.
5. MRB from subsupplier.

A Manufacturing Record Book containing all relevant data related to the production of the product /
component.
6. Material certificate.
Material certificates according to drawings and group parts lists.
7. Traceability.
Where traceability is a specified requirement, individual products / components or batches shall have
a unique identification, which shall be recorded and location shall be traceable. Products such as
standard el-motors, el-cabinets, control consoles, hydraulic pumps, planetary gear units, load cells
etc. will be traceable just as complete units. Location of materials shall be traceable, but standard
bolts, nuts, retaining rings, o-rings, etc. will not be traceable.
8. N.A.
9. N.A.
10. N.A.
11. WPAR = Welding Procedure Approval Record.

Where specified, a welding procedure approval test has to be carried out for the particular material /
geometry combination.
12.WPS = Welding Procedure Specification.

Where specified, a WPS has to be made prior to production start.
13.WQ = Welders Qualification (certificate).

Where specified, the welder shall hold a certificate verifying his / her capability regarding the
particular type of welding.
14. N.A.
15. NDTQ = NDT Inspector Qualification (certificate).
16. VT = Visual Testing.

Standard and extent to be specified.

111
17. RT = Radiografic Testing.
18. UT = Ultrasonic Testing.
19. MT = Magnetic Particle Testing.
20. PT = Penetrant Testing.
21. N.A.
22. Heat treatment (stress relieving).

Depending on combination of geometry complexity, material and material thickness, post weld heat
treatment (PWHT) may be necessary.
23. N. A.
24. Dimension control

Examination to be carried out if specified in ITP.
25. N.A.
26. Pressure / leakage control.

Examination to be carried out if specified in ITP.
27. N.A.
28. Surface Treatment – Blast cleaning.

Plate constructions and castings to be blast cleaned according to specification.
The fulfilment of this activity shall be recorded on the check-list.
29. Surface Treatment - Painting.

The product / components shall be painted according to specification.
The fulfilment of this activity shall be recorded on the check list.
30. N.A.
31. Identification, Serial No., name plate.

All units that have been given a Serial No., shall have a name plate containing type of product
and the Serial No.
If more than one equal unit number added (example 217732-1, 217732-2 etc…),the location
of the hard stamping shall be identified in the documentation.
All units without serial numbers, shall be hard stamped with drawing number in PO (usually
GA drawing number).
All identification Nos., material certification Nos., production Nos. etc. shall be recorded
and linked to the unique unit No. at the unit.
32. Weighing.
All units more than 1 tons, to be weighed in accordance to EN-ISO 19901-5. The weight shall be
logged in the weight certificate.

112
33. Final control / Despatching.

Before despatching, all non-conformities found during inspections or tests, shall be rectified and
approved.
No products shall be despatched until all activities specified in ITP and / or documented procedures
have been satisfactorily completed, and all associated data and documentation is available and
authorised.
34. FAT (Factory Acceptance Test)

A test for a complete unit or a part of it, in accordance to Pusnes procedures or specific project
procedures. Notification of FAT shall be done 10 working days in advance, if not other specified in
chapter 6, notes to ITP sheet.
35. Function test.

A test to verify function without loads and power, other than necessary for idling, signals etc.
36. Preservation and packing.

The equipment is to be preserved, packed and marked according to the specification.
Packing list shall be made.
37. N.A.
38. N.A.
39. User Manual / Instruction Manual

Describing the properties, the capacities, the use and the maintenance of the product.
40. See separate ITP

When specified, a separate ITP for a unit, group or component is issued.
41. Subsupplier’s Quality Plan.

When specified, a Quality Plan is issued by subsupplier.

113
5 QUALITY ACTIVITIES (ITP) INTERVENTION / RESPONSE

Inspection and Test Plan PARTIES ***):
No.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
1
2
3
4
5
6
7
8
9
SS = Sub-supplier
DNV APPR.
DNV APPR
DNV APPR
DNV APPR
criteria
Table 3 -1
Table 3 -1
Table 3 -1
Table 3 -1
Table 3 -1
Acc.
Pusnes = Aker Pusnes
Class society: 3P = Third party/ Class. Society
CU = Customer (Purchaser)
5305-01-PUS-Z-KA-01
5305-01-PUS-Z-KA-01
procedure *)
NS –EN 15614-1
NS –EN 15614-1
DNV-OS-C401 Cat II
DNV-OS-C401 Cat II
DNV-OS-C401 Cat II
DNV-OS-C401 Cat II
DNV-OS-C401 Cat II
DNV Reference
Certificate of compliance from class. soc. PS0004.01700

PS0004.01900
PS0004.01900
PS0005.01000
PS0004.02100
PS0004.02500
PS0004.02100
PS0004.02100
PS0004.02000
INTERVENTION SYMBOLS:
NS-EN 287
NS-EN 473
Drawings
NS 2131
R = Review of doc/drwg/certif.
/ = Inspection w/o paper report
Notes:
X = Inspection w/report or certif.
WPS - Welding Procedure Specification

WQ - Welder's Qualification (certificate)
WPAR - Welding Proc. Approval Record
Letter of conformity from subsupplier
Identification, Serial no., Name Plate

NDTQ - NDT Inspector Qualification
*) PSxxxx.xxxxx: These are basic W = Witness point
Process / Inspection
Surface Treatment/Blast cleaning

procedures from our ISO-9001
User manual/Instruction manual

FAT – Factory Acceptance Test
S = Spot-check witnessing
MT - Magnetic Particle Testing

Certified QA-system
Surface treatment - Painting

H = Hold point
Final Control / Despatching

RT - Radiographic Testing
Pressure/Leakage Control
Preservation and packing

activity
Subsupplier quality plan

UT - Ultrasonic Testing
PT - Penetrant Testing
**) Changes are marked with
MRB from subsupplier
"circles/ovals" or red font
VT - Visual Testing
Dimension Control
Material certificate
Function testing
Heat treatment
***) Sub-supplier is responsible to
Traceabillity
give notice / effect in due time. Comments
Weighing
Item Item Drawing
no.: description no.:
SS X X X X X X X X X X X X X X X X X X X / X
Pusnes W X Secondary Structure
Hose Winch 1077027.001
1 3P X X
CU / /
SS X X X X X X X X X X X X X X X X X X X X / X
Pusnes W X Primary Structure
Hose Stopper 1075886.001
2 3P X H H H H H H X X W
CU / /
SS X X X X X X X X X X X X X X X X X X X X X / X
Swivelling Pusnes W X Primary Structure
Loading 1073219.001
3 3P X H H H H H H X X W See Note
Manifold 20”
CU / /
SS
Slipway with Pusnes X Drawing only
Rollers, 1073938.002
4 Yard supply 3P Secondary Structure
CU See Note
SS X X X X X X X X X X X X X X X X X / X
Slipway with Pusnes X
Rollers, 1073938.001 Bottom plate and Rollers only
5 3P X X Secondary Structure
Pusnes supply
CU / /

114
5 QUALITY ACTIVITIES (ITP) INTERVENTION / RESPONSE

Inspection and Test Plan PARTIES ***):
No.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
1
2
3
4
5
6
7
8
9
SS = Sub-supplier
DNV APPR.
DNV APPR
DNV APPR
DNV APPR
criteria
Table 3 -1
Table 3 -1
Table 3 -1
Table 3 -1
Table 3 -1
Acc.
Class society: 3P = Third party/ Class. Society
5305-01-PUS-Z-KA-01
5305-01-PUS-Z-KA-01
procedure *)
NS –EN 15614-1
NS –EN 15614-1
DNV-OS-C401 Cat II
DNV-OS-C401 Cat II
DNV-OS-C401 Cat II
DNV-OS-C401 Cat II
DNV-OS-C401 Cat II
Reference
DNV

PS0004.01900
PS0004.01900
PS0005.01000
PS0004.02100
PS0004.02500
PS0004.02100
PS0004.02100
PS0004.02000
NS-EN 287
NS-EN 473
Drawings
NS 2131
Notes:
WPS - Welding Procedure Specification

WQ - Welder's Qualification (certificate)
WPAR - Welding Proc. Approval Record
Letter of conformity from subsupplier

NDTQ - NDT Inspector Qualification
*) PSxxxx.xxxxx: These are basic W = Witness point
Process / Inspection

User manual/Instruction manual

FAT – Factory Acceptance Test
MT - Magnetic Particle Testing

Certified QA-system

H = Hold point
Final Control / Despatching

RT - Radiographic Testing
Pressure/Leakage Control
Preservation and packing

activity

UT - Ultrasonic Testing
PT - Penetrant Testing
MRB from subsupplier
VT - Visual Testing
Dimension Control
Function testing
Heat treatment
Traceabillity
give notice / effect in due time. Comments
Weighing
Item Item Drawing
no.: description no.:
SS
Chute with Pusnes X
6 Drawing only
Rollers, 1073893.002
3P
Yard supply
CU Secondary Structure
SS X X X X X X X X X X X X X X X X X / X
Chute with Pusnes X
7 Rollers, 1073893.001 Rollers, Brackets and Guide
3P X X Sheave only
Pusnes supply
CU / / Secondary Structure
SS X X X X X X X X X X X X X X X / X
8 Crude Oil Pusnes To be in accordance with
1076146.001
Hose 3P X W GMPHOM 2009
CU See Note
SS X X X X X X X X X X X X X X X X X X X X X / X
9 Pusnes W W Primary Structure
IHTP 1077327.001
3P X X
CU / /
SS X X X X X X X X X X X X X X X X X X X / X
10 Pusnes Primary Structure
OHTP 1077339.001
3P X X See Note
CU / /

15
14
13
12
11
Notes:
Item Item
Hawser
Remote
Mooring
RCPH/E
no.: description
Foundation
for Loadcell
Control Post
7000 RHHW
7000 RHHW
Control device
Hawser Winch
Hawser Winch
Certified QA-system
DNV
no.:
Aker Pusnes AS

Class society:
Drawing

*) PSxxxx.xxxxx: These are basic
give notice / effect in due time.
1076560.001
1077956.001
1076433.001
1075723.001
1075647.001
Inspection and Test Plan
Process / Inspection Reference Acc. No.
3P
3P
3P
3P
3P
SS
SS
SS
SS
SS
CU
CU
CU
CU
CU
activity procedure *) criteria
Pusnes
Pusnes
Pusnes
Pusnes
Pusnes
1
X
X
X
2
Letter of conformity from subsupplier PS0004.01900
X
X
X
X
X
3
Project No.: 5305-01
4
MRB from subsupplier PS0004.01900
X
X
X
X
X
5
X
X
X
X
X
6
Traceabillity PS0005.01000
X
X
X
7
8
9
10
WPAR - Welding Proc. Approval Record NS –EN 15614-1 DNV APPR
X
X
11
WPS - Welding Procedure Specification NS –EN 15614-1 DNV APPR. 12
5
ITP No.:
WQ - Welder's Qualification (certificate) NS-EN 287 DNV APPR
X X
X X
H H H
H H H
13
14
NDTQ - NDT Inspector Qualification NS-EN 473 DNV APPR
X
X
15
DNV-OS-C401 Cat II
/
VT - Visual Testing Table 3 -1 16
Quality Plan with Inspection and Test Plan (ITP)
493
RT - Radiographic Testing DNV-OS-C401 Cat II Table 3 -1

X X
X X
17
UT - Ultrasonic Testing DNV-OS-C401 Cat II Table 3 -1 18
DNV-OS-C401 Cat II
X X
X X
MT - Magnetic Particle Testing Table 3 -1

H H H
H H H
19
DNV-OS-C401 Cat II
X
X
PT - Penetrant Testing Table 3 -1 20

21
Doc. ref.: PS0004.01301, rev. 11, 20.09.2010

Heat treatment
Rev. No:
22
Rev. Date:
/ 23
X
Dimension Control Drawings
X
X
24
25
Pressure/Leakage Control PS0004.02100
X
26
2
27
QUALITY ACTIVITIES (ITP)
5305-01-PUS-Z-KA-01
/
/
/
/

X
X
X
X
X
28
24.03.2014
5305-01-PUS-Z-KA-01
/
/
/
/
X Surface treatment - Painting

X
X
X
X
29
30
X
X
Identification, Serial no., Name Plate 31

Weighing NS 2131
X
X X
X X
32
/
Final Control / Despatching PS0004.02500

X
X
X
X
33
/
X
X
FAT – Factory Acceptance Test PS0004.02100

X
X
34
Function testing PS0004.02100 35
/
/
/
/
/
Preservation and packing 36

37
38
User manual/Instruction manual PS0004.02000 39
40
X
X

R
R
41
42
PARTIES ***):
H = Hold point
W = Witness point
SS = Sub-supplier
Page 10 of 14
See Note
See Notes
Comments
Primary Structure
Primary Structure
Secondary Structure
115
INTERVENTION / RESPONSE
3P = Third party/ Class. Society

20
19
18
17
16
Notes:
Item Item
PLC
RCPH
Cabinet
Remote
Hydraulic
no.: description
Skid, PLC
Pneumatic
Valve Unit,
Power Unit
Cabinet with
Control Post
Accumulator
Line Thrower
Aux & Starter
Certified QA-system
DNV
no.:
Aker Pusnes AS

Class society:
Drawing

1076510.001
1076544.001
1076775.001
1077276.001
3P
3P
3P
3P
3P
SS
SS
SS
SS
SS
CU
CU
CU
CU
CU
Pusnes
Pusnes
Pusnes
Pusnes
Pusnes
1
Certificate of compliance from class. soc. PS0004.01700 2
X
X
X
X
X
3
4
X
X
X
X
5
X
X
X
6
X
7
8
9
10
WPAR - Welding Proc. Approval Record NS –EN 15614-1 DNV APPR 11
5
ITP No.:
WQ - Welder's Qualification (certificate) NS-EN 287 DNV APPR
X X
X X
13
14
NDTQ - NDT Inspector Qualification NS-EN 473 DNV APPR 15
DNV-OS-C401 Cat II
/
/
/

493
RT - Radiographic Testing DNV-OS-C401 Cat II Table 3 -1
X X
17
MT - Magnetic Particle Testing DNV-OS-C401 Cat II Table 3 -1
X
19
PT - Penetrant Testing DNV-OS-C401 Cat II Table 3 -1 20
21
Doc. ref.: PS0004.01301, rev. 11, 20.09.2010

Heat treatment
Rev. No:
22
Rev. Date:
23
X
X
Dimension Control Drawings

X
24
25
X
Pressure/Leakage Control PS0004.02100

X
X
26
2
27
5305-01-PUS-Z-KA-01
/
/
/
/

X
X
X
X
28
24.03.2014
5305-01-PUS-Z-KA-01
/
/
/
/
/

X
X
X
X
29
30
X
X
31
Weighing NS 2131
X X
X X
32
/
/
/

X
33
X
X
X
X
X
W
W
W
34
/
/
/

37
38
X

40
X
Subsupplier quality plan 41

42
PARTIES ***):
H = Hold point
W = Witness point
SS = Sub-supplier
Page 11 of 14
See Note
See Note
Comments
Secondary Structure
Secondary Structure
116

22
21
Notes:
Item Item
Panel
no.: description
ESD Valve
CCR Control
Certified QA-system
DNV
no.:
Aker Pusnes AS

Class society:
Drawing

1076878.001
1077833.001
3P
3P
SS
SS
CU
CU
Pusnes
Pusnes
1
X
2
X
X
3
4
X
5
X
6
X
7
8
9
10
WPAR - Welding Proc. Approval Record NS –EN 15614-1 DNV APPR 11
5
ITP No.:
WQ - Welder's Qualification (certificate) NS-EN 287 DNV APPR 13

14
NDTQ - NDT Inspector Qualification NS-EN 473 DNV APPR 15
/ DNV-OS-C401 Cat II
/

493
RT - Radiographic Testing DNV-OS-C401 Cat II Table 3 -1 17

MT - Magnetic Particle Testing DNV-OS-C401 Cat II Table 3 -1 19
PT - Penetrant Testing DNV-OS-C401 Cat II Table 3 -1 20
21
Doc. ref.: PS0004.01301, rev. 11, 20.09.2010

Heat treatment
Rev. No:
22
Rev. Date:
23
/
/
Dimension Control Drawings 24

25
Pressure/Leakage Control PS0004.02100 26
2
27
5305-01-PUS-Z-KA-01
/
X

X
28
24.03.2014
5305-01-PUS-Z-KA-01
/
/

X
X
29
30
Identification, Serial no., Name Plate 31
Weighing NS 2131
X X
32
/

X
33
X

X
X
34
/
/

37
38
40
X
Subsupplier quality plan 41

42
PARTIES ***):
H = Hold point
W = Witness point
SS = Sub-supplier
Page 12 of 14
See Note
Comments
117

118
Project No 4016-04 QIP No.: 489 Rev. No: 2
6 NOTES TO ITP
Item
Activity No.: Description:
No.:
General material requirements for primary structure: DNV-OS-B101.

All 6
See appendix A
All 24 Dimensions ref GA drawings
3 17 Crude Oil Pipe shall have 100% RT
All All
Design Temperature is -20 °C to +50 °C
17,18,
34
22 The Control System and Starter cabinets will be tested during FAT
Materials specification for DNV as listed in appendix A must be adhered to.

4,6
Yard responsible for manufacturing.
8 6,11  20 Applicable only for hose nipples
Verify that bracket fits during FAT of Hawser Winch as well as for Hose
14 34
Stopper
18 6-7 3.2 certificate for accumulator bottles
All All areas under lifting points shall be subject to 100% ultrasonic inspection
before welding on the attachment to ensure area is free from subsurface
laminations, followed by UT inspection to verify weld quality. Acceptance
criteria S1
3 & 21 For swivelling loading manifold and ESD valve, internals coming into
contact with crude oil shall be painted.
swivelling loading manifold : Norsok M-501, system 7, annex A, table A7
ESD valve : TK-226
Control of structural welds according to DNV-OS-C401 cat.II Structural
11 16 -19 welds are defined as : Bearing Bracket, Barrel, Release mechanism.
Remaining parts are secondary structure
All 28 - 29 When inspection by third party / Customer is mentioned in ITP we need to
give them notice 3 weeks in advance. This means we need this
information 4 weeks before equipment is ready for paint inspection.

119
7 APPENDIX A - MATERIAL SPECIFICATIONS FOR DNV

This appendix lists the material specification. Yield limit for material listed on the production drawings shall always be followed.
This appendix only specifies the testing temperature and impact values.
This appendix is valid for design temperature: - 20°C to +50°C

These tables are based on:
DNV-OS-C101 Sec. 4 table D2 and D3 for test temperature and plate thickness.
DNV –OS-B101 Ch.2 Sec. 1 table C5 for charpy values
Design temperature shall be defined in the QIP (Quality Inspection Plan) for each project.
All secondary structure is defined as structural welds and shall be tested according to DNV-OS-C401 cat 3.
All primary structure is defined as structural welds and shall be tested according to DNV-OS-C401 cat 2.
PRIMARY STRUCTURE
Material Thickness Impact Test Temp: Sharpy Test Requirements: Recomended Comments:
(Longitudinal) Materials:
T  15 mm 0°C 355 N/mm2  34J NV A36
15 < T  30 mm -20°C 355 N/mm2  34J NV D36
30 < T  50 mm -40°C 355 N/mm2  34J NV E36
50 < T  60 mm -40°C 355 N/mm2  41J NV E36
60 < T  70 mm -40°C 355 N/mm2  41J NV E36
70 < T  150 mm -40°C 355 N/mm2  50J NV E36
T  20 mm 0°C 690 N/mm2  69J NV A690

20 < T  40 mm -20°C 690 N/mm2  69J NV D690
40 < T  80 mm -40°C 690 N/mm2  69J NV E690
80 < T  150 mm -40°C 690 N/mm2  69J NV E690
Forging 0°C 32J

Forged X4CrNiMo16-5 Acc. To EN10088 32J QT900 shall be used
Castings, non welded 0°C Average 32J No single value less
than 70% of average
SECONDARY STRUCTURE
Material Thickness Impact Test Temp: Sharpy Test Requirements: Recomended Comments:
(Longitudinal) Materials:
T  30 mm 0°C 355 N/mm2  34J NV A36
30 < T  50 mm -20°C 355 N/mm2  34J NV D36
50 < T  60 mm -20°C 355 N/mm2  41J NV D36
60 < T  70 mm -40°C 355 N/mm2  41J NV E36
70 < T  150 mm -40°C 355 N/mm2  50J NV E36
T  40 mm 0°C 690 N/mm2  69J NV A690

40 < T  80 mm -20°C 690 N/mm2  69J NV D690
80 < T  150 mm -40°C 690 N/mm2  69J NV E690
Forging 0°C 32J 25CrNiMo4V

36CrNiMo6V
42CrMo4V
Forged X4CrNiMo16-5 Acc. To EN10088 32J QT900 shall be used
Castings, non welded 0°C Average 32J No single value less
than 70% of average
Round bars to be welded shall follow the same requirement as stated for plates, diameter equals plate thickness for both primary
structure and secondary structure, else requirement as forged material
If casting is welded it shall follow the same requirements as stated for plates.
Doc. ref.: PS0004.01301, rev. 11, 20.09.2010

Page 14 of 14
120

Client
Aker Pusnes AS
Box 732 - Stoa, Tel.: +47 37 08 73 00

5305-01
Document title
LIFTING, HANDLING AND PRESERVATION PROCEDURE

3400-000-M-PT-PUS-00011 5305-01-PUS-Z-KA-0003
17
Client Tag no. Pusnes product serial no.
Revisions
00 23.05.2014 Initial Issue EE DAO/OT/BGi/PEL SAN
Code 1 Accepted

121
Client doc. no. 3400-000-M-PT-PUS-00011
Pusnes doc. no. 5305-01-PUS-Z-KA-0003 Pusnes rev. 00 Aker Pusnes AS
Title LIFTING, HANDLING AND PRESERVATION PROCEDURE
Table of Contents:
LIFTING, HANDLING AND PRESERVATION PROCEDURE ....................................... 1

1 General................................................................................................................. 3
1.1 Purpose of this Document ................................................................................ 3
1.2 Revision History ................................................................................................ 3
1.3 Reference Documents ...................................................................................... 3
2 HSE (Health Safety Environment) ..................................................................... 4
3 Hose System ....................................................................................................... 4
3.1 Hose Handling Winch ....................................................................................... 4
3.2 Inboard Hose Termination Piece (IHTP) ........................................................... 6
3.3 Swivelling Loading Manifold with IHTP ............................................................. 6
3.4 Hose Stopper .................................................................................................... 7
3.5 Slipway and Lifting Plate with Rollers ............................................................... 8
3.6 Chute with Rollers ............................................................................................. 9
3.7 Outboard Hose Termination Piece (OHTP) ...................................................... 9
3.8 ESD Valve with Actuator and Pressure Transmitter ....................................... 10
3.9 Crude Oil Hose and Marine Breakaway Coupling (MBC) ............................... 10
4 Mooring Hawser System .................................................................................. 11
4.1 Releasable Hawser Handling Winch (7000 RHHW) ....................................... 11
4.2 Foundation 7000 RHHW ................................................................................. 12
4.3 Mooring Hawser .............................................................................................. 13
5 Electro Hydraulic Control System ................................................................... 13
5.1 Remote Control Post (RCPH/E) ..................................................................... 13
5.2 Remote Control Post (RCPH) ......................................................................... 14
5.3 Aux & Starter Cabinets w/PLC ........................................................................ 14
5.4 CCR Control Panel ......................................................................................... 15
5.5 Valve Unit & Accumulator Skid ....................................................................... 15
5.6 Hydraulic Power Unit (HPU) ........................................................................... 16
Page 2 of 17
122
1 General
The purpose of this instruction is to describe the handling of all the components in
the Pusnes equipment package for the offloading system for GAZA FSO. This
includes how equipment should be lifted, how to secure it for transportation and how
to preserve it before installation.
The equipment must be placed on wooden or steel pallets that are strong enough to
handle the weight of the components. The components must be fixed to the pallets
with straps and the width of the pallets must not exceed 2400 mm. Make sure that all
moving parts are secured to their respective pallet.
CAUTION!
Only trained personnel should carry out lifting of these units and only by
using certified equipment.
Improper lifting and handling can cause serious or fatal injury to

personnel and substantial property damage.
00 23.05.2014 Initial Issue
01
1.3 Reference Documents

Reference documents will be given in each chapter.
Page 3 of 17
123
2 HSE (Health Safety Environment)

The primary concern when carrying out the operations described in this document, is
to ensure that the work is carried out in such a way that the preparations, checks and
tasks are done without injury or equipment damage. To help achieve this, everyone
participating is strongly urged to have at all times his or her minds focused on their
own and colleagues' personal safety.
During these processes some situations are naturally hazardous, because of:
• Operating cranes with hanging cargo.
• Clamping hazards around many parts such as: straps, chains,
hydraulic cylinders and clutches.
• Rotating shafts, wheels and gears.
We recommend that each participant:

• Wear protective footwear.
• Wear safety glasses.
• Wear a helmet.
The general rule is:

Stay clear (a safe distance) from hanging cargo and moving parts.
3 Hose System
3.1 Hose Handling Winch
Drawing. No. 1077027
Weight ~ 8500kg
3.1.1 Lifting and Handling
Lifting straps around shaft
Page 4 of 17
124
3.1.2 Transportation
The hose handling winch is to be secured with straps during transportation.
The gear case must be drained of oil.
3.1.3 Preservation
All components must be cleaned on all exposed surfaces. All machined surfaces are
to be corrosion protected (tectylene). All bearings and grease nipples must be filled
with grease. The hose handling winch must be covered to avoid sparks from welding
and grinding as well as dust from sandblasting. It is important that all counter
fittings/flanges are blinded with heat shrinkable end caps to avoid pollution of the
system. The hose handling winch must be stored indoor or covered with watertight
tarpaulin. The gear case must be drained of oil.
Page 5 of 17
125
3.2 Inboard Hose Termination Piece (IHTP)

1079926
Weight ~ 2100 kg
The IHTP shall be mounted on to the swivelling loading manifold and be transported
and preserved together with this. See Ch. 3.3.
3.3 Swivelling Loading Manifold with IHTP

Drawing. No. 1073219 Swivelling Loading Manifold
10778364
1077327 IHTP
1079926
Weight 7600 kg

The Swivelling Loading Manifold with IHTP shall be strapped around the 20” pipe on
each side of Gear Case. In addition, two secondary soft slings around the pipe right
behind the QRF, and from the foundation frame. See figure below.
WARNING
Do not use lifting lugs on gear case to lift the complete unit, this is only for
removal of gearcase cover!
Soft Sling around Pipe on each side of Gear

case
Secondary Soft slings to support

during lifting
Lifting Lugs for Transportation
The swivelling manifold with IHTP shall be transported on the frame that was used
for test. The frame is equipped with lifting lugs, see picture above.
Page 6 of 17
126
3.3.2 Preservation
The swivelling loading manifold shall be stored protected from welding and grinding
as well as dust from sandblasting. Grease nipples must be filled with grease. All
counter flanges/fittings must be blinded with heat shrinkable end caps to avoid
pollution of the system. IHTP and Cargo pipe end of swivelling loading manifold must
be blinded with wood blind flanges.
3.4 Hose Stopper

1088437
Weight 3000 kg

The hose stopper shall be lifted by shackles connected to the points shown on
picture below.
Lifting Points, two on each side
The hose stopper to be secured with straps during transportation.
3.4.3 Preservation
The hose stopper shall be stored protected from welding and grinding as well as dust
from sandblasting. All counter flanges/fittings must be blinded with heat shrinkable
end caps to avoid pollution of the system. All machined surfaces are to be corrosion
protected (tectylene).
Page 7 of 17
127
3.5 Slipway and Lifting Plate with Rollers

Drawing. No. 1073938.001
1080582.001, 002
Weight Slipway w. rollers: 9200 kg
Lifting plate w. rollers: 1400 kg
Lifting points
Slipway view from inside
The slipway, with rollers and shafts mounted, shall be shackled and lifted by the
lifting lugs shown on picture above. 1¼” -12 tonnes. Safe working load (SWL)
shackles shall be used.
Lifting plate
The lifting plate with rollers and shafts shall be lifted separately from slipway.
Page 8 of 17
128
The slipway and lifting plate shall be transported with rollers and shafts mounted and
must be secured by straps.
3.5.3 Preservation
The slipway and lifting plate shall be stored protected from welding and grinding as
well as dust from sandblasting. Machined surfaces (threaded holes) shall be
protected against corrosion.
3.6 Chute with Rollers

1080477.001, .002, .003
Weight Min. 419 kg
Max. 540 kg
3.6.1 Lifting, Handling

The chute sections shall be lifted, handled and transported with the rollers and shafts
mounted.
3.6.2 Preservation
The chute sections shall be stored protected from welding and grinding as well as
dust from sandblasting.
3.7 Outboard Hose Termination Piece (OHTP)

292958.10200
Weight ~ 380kg

The OHTP should be lifted in the lifting ring lugs or in a basket.
The OHTP to be secured with straps during transportation. A wood blind flange shall
be bolted to the butterfly valve.
3.7.3 Preservation
The OHTP shall be stored protected from welding and grinding as well as dust from
sandblasting.
Page 9 of 17
129
3.8 ESD Valve with Actuator and Pressure Transmitter

Weight ~ 380kg
3.8.1 Lifting, Handling

The ESD-valve shall be lifted using soft straps in the 4 lifting lugs.
The ESD-valve to be secured with straps during transportation.
3.8.3 Preservation
The ESD-valve shall be stored protected from welding and grinding as well as dust
from sandblasting. Grease nipples must be filled with grease. All counter
flanges/fittings must be blinded with heat shrinkable end caps to avoid pollution of the
system and to protect the gasket surface. The ESD-valve must be stored indoor or
covered with a watertight tarpaulin.
3.9 Crude Oil Hose and Marine Breakaway Coupling (MBC)

Drawing. No. 1076146 Crude Oil Hose
1077219
Weight 20” hoses: Min. 2810 kg, Max. 3350 kg
16” hoses: Min. 1990 kg, Max. 2510 kg
In order to perform a safe installation operation, the following steps must be followed:
• The hoses must NOT be lifted with fork-lift trucks.
• The lifting beam for the crude oil hose is to be used for the lifting of each hose
section.
• Use extra wide lifting straps. Make sure the straps lie flat around the body of
the hose. Use three straps to lift a hose section.
• Avoid lifting / handling the hose in a way that can cause damages. Minimum
bend radius for the crude oil hose is 3,0m (6 times the inner diameter).
Bending beyond this will seriously damage the hose structure.
Make sure the chains, straps, shackles and hooks are in good condition and properly
fastened.
MBC to be lifted with soft slings or in a basket.
Page 10 of 17
130
Lifting Beam
Extra wide lifting strop
SAFETY NOTE
Only trained personnel, using certified equipment should carry out lifting of
units. Improper lifting and handling can cause serious or fatal injuries and
substantial equipment damage.
The hose sections are usually transported on manufacturers steel pallets. The hoses
must be secured individually to the pallet by strapping. There are normally two hose
sections side by side on each pallet. If desirable the hoses can also be transported
in open top containers or specially packed in wooden cases. In any case possible
sharp edges or loose objects that can damage the hoses during transport must be
removed. Never move the hoses by dragging them across the ground.
MBC to be secured by straps during transportation.
3.9.3 Preservation
The crude oil hose shall be stored protected from welding and grinding as well as
dust from sandblasting. Shall also be protected from sunlight. Ends of the hose
sections and MBC must be covered by wood plates. Drill 3 or 4 -1” holes in plates for
the hose sections to allow circulation of air.
4 Mooring Hawser System
4.1 Releasable Hawser Handling Winch (7000 RHHW)

Weight ~ 118000 kg

The winch shall be lifted by slings around the drum.
Make sure that the bearing brackets are properly secured to the drum by straps to
avoid sliding off the shaft, or rotating. The spooling gear must also be secured to the
drum with straps. The winch must not be lifted in the lifting lugs on the bearing
brackets, as these are only for lifting them separately.
Page 11 of 17
131
Transportation of the winch/bearing brackets and spooling gear
The winch shall be transported with the spooling gear and bearing brackets mounted
and placed on the temporary foundation blocks.
Bearing brackets must be secured against sliding off the drums shaft by strapping
them to the drum. The spooling gear must be properly secured to the transport winch
foundation. Drum shall be rotated so that the releasing mechanism is hanging
downwards and be secured in this position, see figure on next page.
Transportation of the Hawser Winch
4.1.3 Preservation
All components must be cleaned on all exposed surfaces. All machined surfaces are
to be corrosion protected (tectylene). All bearings and grease nipples must be filled
with grease. The hawser winch must be covered to avoid sparks from welding and
grinding as well as dust from sandblasting. It is important that all counter
fittings/flanges are blinded with heat shrinkable end caps to avoid pollution of the
system. The hawser winch must be stored indoor or covered with watertight
tarpaulin.
4.2 Foundation 7000 RHHW

Weight ~ 14600 kg

At the delivery, the foundation for each winch is split in the following parts:
• Foundation 1 Weight: approx. 4700 kg.
• Foundation 2 Weight: approx. 4700 kg.
• Foundation Pipe Weight: approx. 1100 kg.
• Half Pipe Weight: approx. 1100 kg.
• Platforms 7000RHHW Tot.Weight: approx. 760 kg.
Page 12 of 17
132
The winch foundation 1 & 2 shall be lifted by 4 slings – one in each lifting lug.
Min. angle between lifting strap and foundation is 60 deg.
The foundation pipe and half pipe is to be lifted with straps.
The winch foundation to be secured with straps during transportation
4.2.3 Preservation
The crude oil hose shall be stored protected from welding and grinding as well as
dust from sandblasting. All machined surfaces are to be corrosion protected
(tectylene)
4.3 Mooring Hawser

395775.10200
Weight ~ 2720 kg

The mooring rope and ancillaries shall be lifted with straps or in a basket.
The mooring hawser and ancillaries shall be secured with straps.
4.3.3 Preservation
The mooring hawser shall be stored protected from welding and grinding as well as
dust from sandblasting. Must also be protected against sunlight.
5 Electro Hydraulic Control System
5.1 Remote Control Post (RCPH/E)

Weight ~ 150kg

The RCPH/E should be lifted with two soft round slings around the steel case with
cover.
The RCPH/E should be packed in wooden frame, and must be properly secured by
straps during transportation.
Page 13 of 17
133
5.1.3 Preservation
All hydraulic thread openings are to be provided with metal plugs or threaded plastic
plugs. All components must be cleaned on all exposed surfaces. It is important that
all counter fittings/flanges are blinded with heat shrinkable end caps to avoid pollution
of the system. The RCPH/E must be stored indoors, or covered with watertight
tarpaulin. Make sure the RCPH/E is not stored in areas close to welding,
sandblasting, grinding or painting.
5.2 Remote Control Post (RCPH)

Weight ~ 130kg

The RCPH should be lifted with two soft round slings around the steel case with
cover.
The RCPH/E should be packed in wooden frame, and must be properly secured by
straps during transportation.
5.2.3 Preservation
All hydraulic thread openings are to be provided with metal plugs or threaded plastic
plugs. All components must be cleaned on all exposed surfaces. It is important that
all counter fittings/flanges are blinded with heat shrinkable end caps to avoid pollution
of the system. The RCPH must be stored indoors, or covered with watertight
tarpaulin. Make sure the RCPH is not stored in areas close to welding, sandblasting,
grinding or painting.
5.3 Aux & Starter Cabinets w/PLC

Weight ~ 250kg

The starter cabinets should be lifted with two slings, one in each lifting eyebolt on top.
The starter cabinets should be packed in a wooden frame and must be properly
secured by straps during transportation.
5.3.3 Preservation
Cabinets shall be enclosed with plastic and packed in wooden boxes to be protected
from mechanical damage. Make sure the equipment is not stored in areas close to
welding, sandblasting, grinding, or painting. The cabinets shall be stored indoor.
Page 14 of 17
134
5.4 CCR Control Panel

Weight ~ 5kg

CCR control panel shall be lifted carefully by hand.
The CCR shall be transported in a box.
5.4.3 Preservation
The CCR control panel must be stored indoors. Make sure the equipment is not
stored in areas close to welding, sandblasting, grinding, or painting.
5.5 Valve Unit & Accumulator Skid

Weight ~ 750 kg

The valve unit, accumulator skid must be lifted from the lugs on the top of the frame.
The valve unit, accumulator skid should be packed in wooden frame, and must be
properly secured by slings during transportation. Make sure that the accumulators
are drained.
5.5.3 Preservation
All hydraulic thread openings to be provided with metal plugs or threaded plastic
plugs. All components must be cleaned on all exposed surfaces. The valve unit,
accumulator skid must be stored indoors, or covered with watertight tarpaulin. Make
sure the equipment is not stored in areas close to welding, sandblasting, grinding, or
painting.
Page 15 of 17
135
5.6 Hydraulic Power Unit (HPU)

Weight ~ 3300 kg

For lifting application insert shackles in the pad-eyes on top of the HPU lifting frame,
see below. If wire is used for lifting, make sure to protect the HPU painting by rubber
liner or similar.
NOTE
In general the HPU is not designed for lifting by forklift after the wooden case is
removed. However it is possible to do this if the forks of the lift can get underneath the
HPU frame (Only to be lifted by the frame). If this kind of lifting should take place, it will
be a high-risk operation that could lead to overturn of the HPU, and will not be
recommended by Aker Pusnes AS.
CAUTION
The HPU shall only be lifted without hydraulic oil in it.
Min. angle: 60 deg.
Lifting points on HPU for installation
Page 16 of 17
136
Actual HPU might differ from the illustration shown above. Refer to general
arrangement drawing of HPU (1076510) for the specific HPU.
The HPU shall be transported in the wooden case and thoroughly secured.
5.6.3 Preservation
All hydraulic thread openings to be provided with metal plugs, and all counter
flanges/fittings to be fitted with heat shrinkable end caps to prevent pollution of the
hydraulic system. All components must be cleaned on all exposed surfaces. The
HPU must be stored indoors, or covered with watertight tarpaulin. Make sure the
HPU is not stored in areas close to welding, sandblasting, grinding, or painting.
Page 17 of 17
137

Client
STX OFFSHORE &

SHIPBUILDING CO., LTD.
Aker Pusnes AS
Box 732 - Stoa, Tel.: +47 37 08 73 00

5305-01
Document title
INSTALLATION PROCEDURE
3400-000-M-PT-PUS-00010 5305-01-PUS-R-KA-0006
24
Revisions
01 09.09.2014 Internal Updates EE DAO/OT/PEL SAN

00 27.02.14 Issued for approval EE DAO/OT SAN
Code 1 Accepted
138
Pusnes doc. no. 5305-01-PUS-R-KA-0006 Pusnes rev. 00 Aker Pusnes AS
Title INSTALLATION PROCEDURE
Table of Contents:
1 General ..................................................................................................... 3
1.3 Reference Documents..................................................................................... 4
1.4 Descriptions .................................................................................................... 4
3 Hose System ............................................................................................ 6
3.1 Hose Handling Winch ...................................................................................... 6
3.2 Inboard Hose Termination Piece (IHTP) .......................................................... 6
3.3 Swivelling Loading Manifold and Hose Stopper ............................................... 7
3.4 Slipway with Rollers ........................................................................................ 9
3.5 Chute with Rollers ......................................................................................... 10
3.6 Outboard Hose Termination Piece (OHTP) ................................................... 10
3.7 ESD Valve with Actuator and Pressure Transmitter....................................... 10
3.8 Crude Oil Hose to Hose Stopper ................................................................... 11
3.8.1 Assembling of Crude Oil Hose incl. OHTP and Marine Breakaway Coupling
(MBC) 11
3.8.2 Leakage Test of Crude Oil Hose ................................................................... 11
3.8.3 Connecting Crude Oil Hose to Vessel’s Hose Stopper .................................. 11
4 Mooring Hawser System ....................................................................... 19
4.1 Foundation 7000 RHHW ............................................................................... 19
4.2 Releasable Hawser Handling Winch (7000 RHHW) ...................................... 19
4.2.1 Erection of Winch .......................................................................................... 19
4.3 Spooling Gear and Load Cell ........................................................................ 21
4.4 Hydraulic Piping ............................................................................................ 21
4.5 Electric Wiring ............................................................................................... 21
4.6 Mooring Hawser ............................................................................................ 21
5 Electro Hydraulic Control System........................................................ 23
5.1 Remote Control Post (RCPH/E) .................................................................... 23
5.2 Remote Control Post (RCPH)........................................................................ 23
5.3 Aux & Starter Cabinets w/PLC ...................................................................... 23
5.4 CCR Control Panel ........................................................................................ 23
5.5 Valve Unit & Accumulator Skid ...................................................................... 23
5.6 Hydraulic Power Unit (HPU) .......................................................................... 24
6 Electrical Wiring .................................................................................... 24
Page 2 of 24
139
1 General

The purpose of this procedure is to describe the installation of the Pusnes equipment
package for the offloading system for the Gaza FSO.
Relevant Procedures and Drawings

The Lifting, Transportation and Preservation Procedure must be available and
followed when installing the components.
During the planning and installation period it is important to study the Certified
(Working) Drawings carefully and comply with the installation tolerances,
requirements and methods given.
In most cases all necessary information for installation of the equipment is given in
these drawings. They give information regarding welding sizes, bolt size, hydraulic
and electric connections etc.
The piping diagram shows the complete hydraulic system. Electric wiring diagrams
are provided in order to enable yard to connect the necessary cables etc.
See drawing 309636 (Appendix 1) for installation of end stoppers.
General Requirements
All openings between the equipment and hull structure (or foundation) where
corrosion attack is possible must be sealed properly.
Where equipment is welded to the hull structure, the structure should keep a top level
tolerance of ± 2,0 mm in all directions. Check by means of a piano string or similar.
Check that bore picture is within ± 1,5 mm.
NOTE:
When welding equipment to hull structure the equipment shall be protected properly
against heat and sparks, make sure that the ground cable for the welding apparatus
is located so that the current is not passing through the Pusnes equipment. This can
seriously damage bearings and electric equipment.
Welding on Pusnes components (pipe supports, cable trays etc.), shall not be
performed without consulting Pusnes
Page 3 of 24
140
01 09.09.2014 Internal Updates

Specific reference documents will be given in each chapter.
Document Number
General Deck Arrangement – 1073220

Pusnes Reel Offloading
System
Assembly Procedure - Quick 5305-01-PUS-R-KA-0010

Release Flange Range 20”
and smaller.
Hose Replacement Procedure 5305-01-PUS-Z-KA-0006
Lifting, Handling and 5305-01-PUS-Z-KA-0003

Preservation Procedure
1.4 Descriptions
The stern offloading system is designed for transfer of the stabilized crude oil from
the FSO to a dedicated shuttle tanker.
The main items for the Stern Offloading System are:

Hose System
Mooring Hawser System
Electro Hydraulic Control System
Page 4 of 24
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2 HSE (Health Safety Environment)

The primary concern when carrying out the operations described in this document, is
to ensure that the work is carried out in such a way that the preparations, checks and
tasks are done without injury or equipment damage. To help achieve this, everyone
participating is strongly urged to have at all times his or her minds focused on their
own and colleagues' personal safety.
During these processes some situations are naturally hazardous, because of:
Operating cranes with hanging cargo.
Clamping hazards around many parts such as: straps, chains,
hydraulic cylinders and clutches.
Rotating shafts, wheels and gears.
We recommend that each participant:

Wear protective footwear.
Wear safety glasses.
Wear a helmet.
The general rule is:

Stay clear (a safe distance) from hanging cargo and moving parts.
Page 5 of 24
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3 Hose System
3.1 Hose Handling Winch
Weight ~ 8500kg
WARNING
See separate “Lifting, Transportation and Preservation Procedure”.
It is very important that the winch is secured with straps as described in this
separate procedure.
1. Position the winch correctly on the foundation and tighten the foundation bolts
slightly.
2. Be sure that the main shaft is resting properly in the bearing.
3. Adjustment is done by the adjustment screws in the foundation. Tolerance on

clearance is ± 0,1mm.
4. Place the brake support in accordance with the foundation and check that the
brake fits properly around the brake drum and check that the link to the
foundation has the correct orientation (See dwg.292711 & dwg.292864)
NOTE:
Please note that the foundation for brakes, are 30 mm lower than the winch
foundation.
5. Check that the foundation bolts slips easily through all bolt holes.
6. The winch can now be set with casting compound or steel liners, and foundation
bolts tightened to specified torque on dwg.1077027.
7. Fit necessary end stoppers.
3.2 Inboard Hose Termination Piece (IHTP)

1079926
Weight ~ 1400 kg
The IHTP is installed first time onto the Swivelling Loading Manifold by manufacturer.
For mounting after maintenance or emergency release, see dwg.1079926 and
5305-01-PUS-R-KA-0010 “Assembly Procedure - Quick release Flange Range 20
and smaller”.
Page 6 of 24
143
3.3 Swivelling Loading Manifold and Hose Stopper

Drawing. No. 1073219 Swivelling Loading Manifold, GA
1078364 Swivelling Loading Manifold, Group
Drawing
1075886 Hose Stopper, GA
1088437 Hose Stopper, Group Drawing
Weight ~ 8450kg
1. The swivelling loading manifold and hose stopper shall be installed to the yard-
supplied foundations as shown on dwg. 1073220. Each shall be placed in relation
to each other according to foundation plans on dwg.1073219 and dwg.1075886.
M20 Bolts to fasten

Swivelling Loading
Manifold to Hose Stopper
Figure 1
2. Check that the hole-pattern on both foundations are within tolerances of +/-
1,5mm.
3. Place the two items on their foundation resting on the adjustments screws.
4. Align swivelling loading manifold to the hose stopper with the adjustments
screws. Make sure that the foundation bolts slip easily through the bolt holes.
Mount some of the foundation bolts with low torque so that the manifold can
be rotated down to the hose stopper.
5. Check that the 10- M20 bolts can be fitted to align the swivelling loading manifold
to hose stopper. (Pos. 214 on dwg. 1078364, see Figure 1)
Page 7 of 24
144
6. Tight the M20 bolts so that the items are aligned properly.
7. Check again that foundation bolts on swivelling loading manifold’s foundation slip
easily through the holes. Keys to be mounted and tightened before casting work.
8. The swivelling loading manifold and the hose stopper are now ready for casting
compound or steel chock liners.
NOTE:
The thickness of the liner compounds shall be in accordance with manufacturer

recommendation.
9. Tighten the foundation bolts according to values given in dwg. 1073219 and
1075886.
Page 8 of 24
145
3.4 Slipway with Rollers

Drawing. No. 1073938, 1080582, 1088418
Weight ~ 26000.8kg
Transverse Pipe
Guide Roller
Working Platform
Slipway Sidewalls
Slipway Bottomplate
With Rollers
Figure 2
1. The yard-supplied parts of slipway shall be aligned and tack-welded to hull
structure according to dwg. 1073938. It is recommended that the
working platform and transverse pipe are installed after mounting of bottom plate.
2. The bottom plate shall be placed and tack-welded between side plates
before the structure is fully welded to deck.
3. The welding can now be completed, and working platform, (Dwg.1088418)

transverse pipe and guide roller can be mounted.
Welding of transverse pipe and guide roller: Full penetration acc. to
dwg. 1073938.
Page 9 of 24
146

1080477
Weight ~ 20880kg
The chute with rollers is delivered in sections with rollers and shafts mounted, see
dwg.1080447. The chute sections shall be tack-welded to the yard-supplied
foundations according to dwg.1073893.
Check that chute sections are aligned so that the roller shafts can be easily
dismantled before welding work is completed.
3.6 Outboard Hose Termination Piece (OHTP)

292958
Weight ~ 380kg
The OHTP shall be mounted to the end of crude oil hose according to dwg. 1077339
and 292958. For tightening and correct torque of bolts, see crude oil
hose dwg. 1077219.
3.7 ESD Valve with Actuator and Pressure Transmitter

293354
Weight ~ 380kg
The ESD valve is bolted onto the crude oil pipe line near the swivelling loading
manifold. The pressure transmitter must be against the swivelling loading manifold
side.
Mount gaskets pos 201 on Gr.dwg 293354
NOTE:
Remove SILICA GEL desiccant packages that have been put inside the ESD valve,
before mounting the valve. Valve must be clean on the inside to avoid damage on
ball.
Page 10 of 24
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3.8 Crude Oil Hose to Hose Stopper

Drawing. No. 1076146 Crude Oil Hose
1077219 Crude Oil Hose
1089043 Hose Ropes
1075886 Hose Stopper
1088437 Hose Stopper Final assembly
292958 OHTP
Weight ~ 98000 kg
3.8.1 Assembling of Crude Oil Hose incl. OHTP and Marine Breakaway Coupling
(MBC)
The crude oil hose with OHTP, MBC and blind flange shall be mounted
according to dwg. 1077219 and 292958.
3.8.2 Leakage Test of Crude Oil Hose

When all items are mounted, a leakage test shall be performed.
Hose shall be filled with water and air drained out.
Connect pressure test hose and manometer to (Not Pusnes supply) the
blind flange, and set on 5 bar pressure and hold for 10 minutes.
3.8.3 Connecting Crude Oil Hose to Vessel’s Hose Stopper
CAUTION!
Keep safe distance away from ropes/wires that are under tension.
Keep clear of the Swivelling Loading Manifold’s operating area.
The inboard hose termination piece (IHTP) shall be mounted to the swivelling loading
manifold before starting of retrieval of hose.
Hose to be drained of all water before start of mounting.
Page 11 of 24
148
Pre-laid auxiliary rope
Wire from drum with hydraulic

brake
Opening in Slipway to
hose fastening-point
Figure 3
1. Connect the shackles and hose ropes (pos. 3, 4 & 5) on crude oil hose end
section as shown on figure 3. (Ref. dwg. 1089043)
2. Lead the rope (pos.6) through hose stopper from the chute’s end area and up to
the working platform.
3. Lead the wire from the hose handling winch’s drum with hydraulic brake, (pos.1)
through the hose stopper.
Lead it further via the guide roller on top of the slipway, and connect it to the blind
flange on crude oil hose end section. (See Figure 3)
Page 12 of 24
149
Figure 4
4. Start to pull in the hose, make sure that it enters slipway smoothly.
Pull in the hose up to abt. 500 mm below working platform. (See Figure 4)
Connect rope pos.4 to rope pos.6.
Connect rope pos.5 to the auxiliary rope that hangs from the working platform
and into the hole in slipway.
5. Pull ropes (pos.3 and pos.5) into the opening in slipway by means of
the auxiliary rope.
Connect rope (pos.3) to the hose securing point inside slipway. (See figure 5)
Page 13 of 24
150
Hose securing point

inside slipway
Figure 5
6. Pull in ropes (pos.6 and pos.4) manually. It is now necessary to tighten these
ropes as much as possible, and tie the end around one of the chute rollers, to
control the hose from bending/tilting, until the winch-wire (pos.2) from the manual
drum has been connected.
7. Lower down hose wire (pos.1) so that the weight of hose is almost carried by
rope (pos.3 - figure 5).
8. Connect the hose rope (pos.6) to the hose winch wire from the drum with manual
brake, (pos.2 -figure 6). The hose wire (pos.2) shall have a minimum of slack
when it is connected to the rope (pos.6).
When the hose winch wire (pos.2) starts pulling, the other hose winch wire
(pos.1) will automatically be slackened.
Therefore, make sure that hose weight is secured by hose securing-rope (pos.3).
Page 14 of 24
151
Figure 6
9. When the hose is being pulled onto the slipway, loosen rope (pos.3) from the
hose securing point. In order to get the hose end in position in hose stopper, it
may be necessary to use a 2,5 tonnes chain hoist to control the stiffness in hose.
10. At the inner end of the slipway, right behind the hose stopper, the horizontal
rollers can be adjusted vertically by means of the four bolts shown in sketch
below. Use the adjusting bolts to get the hose in position.
Adjusting screws
Page 15 of 24
152
Upper Hose Securing

Beam
Lower Hose Securing

Beam
Figure 7
11. When the hose is positioned in the hose stopper as shown in Figure 7, it must be
pulled forward so that the hose securing upper- and lower- beams can engage
behind the hose flange -top and bottom (dwg.1078941 pos.103, 104, 204, 205,
207). The 4-5 bolts on top and bottom of hose flange must be removed before the
beams can be engaged.
Page 16 of 24
153
Securing Bolts and Nuts

(Hinged on opposite side)
Securing Bolts and Nuts

(On both sides)
Figure 8, shown from Port side
12. Lock the securing beams by using the bolts and threaded pins shown on Figure 8
to secure the hose.
13. Check and make sure that the hose flange is properly supported by the securing
beams, and that the bolts shown on Figure 8 are mounted and tightened.
Hose Securing Beams

Engaged
Figure 9
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154
14. When hose is supported and secured as shown in Figures 8 & 9, the wire from
the hose winch can be slacked and released.
15. Remove the wire from the hose winch, and dismount the blind flange
(Weight blind flange: 140kgs).
16. The swivelling loading manifold can now be rotated into position in the hose
stopper, and the swivelling flange on the IHTP can be mounted to the hose
flange. Remove bolts, washers and nuts (pos. 214, 215, 216 on 1078364) before
coupling.
Remember to fit gasket between IHTP and hose flange (pos.208 on
dwg.1077219).
See dwg.1077219 for tightening order and torque for IHTP to crude oil hose.
Swivelling Loading
Manifold with Inboard
Hose Termination Piece
with Swivelling Flange
and Bolts
Swivelling Manifold bolted to

Hose Stopper
Figure 10
17. Check that the gaskets/rubber plates (pos.101 on dwg. 1088437) are properly
fitted and mounted to the bolts, nuts and washers (pos. 214, 215, 216 dwg.
1078364). Tighten torque acc. to dwg. 1078364. Hose securing beams to be
removed from hose flange.
18. Connect the hydraulic hose from the quick release flange to the hose stopper.
(dwg. 1079926 and 1088437)
Fill the QRF with glycol and perform leakage test, See Separate procedure:
5305-01-PUS-R-KA-0010 Assembly Procedure - Quick Release Flange - Range
20" And Smaller, Ch. 2.2
Page 18 of 24
155
4 Mooring Hawser System

4.1 Foundation 7000 RHHW
Weight ~146000 kg
1. The foundation shall be lined up and welded to deck according to drawing

1075723.
2. The end stoppers and wedges are provided by the fabricator of the foundation,
including available parts. The foundation is now ready for mounting and erection
of the 7000 RHHW.
4.2 Releasable Hawser Handling Winch (7000 RHHW)

Weight ~118000 kg
4.2.1 Erection of Winch
1. Place the winch on the foundation (ref. Lifting, Handling and Preservation
Procedure)
2. Align the winch with the aid of adjusting the bolts in the bearing brackets while it
is hanging in the crane. Ensure that there is an axial clearance of 3-6 mm
between the composite thrust ring and the drum structure. This clearance must
be achieved on both sides of the drum. Also, a clearance of approximately 25 mm
between the foundations and the bearing brackets is necessary for casting of
compound liner or steel chock liners. The thickness of compound liners must be
per installation operator’s recommendation.
Axial clearance between drum and Max. 6mm each side

bearing brackets: Min. 3mm each side
3. To ensure that the drum shaft is resting fully in the lower half of the bearing,
a long feeler gauge shall be inserted the full length of the bearing, on both sides.
Bearing clearances to be as follows:
Bearing Clearance
0
12 O’Clock position: 1,3mm -0,3
3 and 9 O’clock
0,6mm ± 0,1
position:
6 O’clock position: 0 mm
4. When items 2 & 3 are achieved, the holes in the foundation can be clearly
marked. The winch is then removed from the foundation and the holes drilled.
Page 19 of 24
156
5. Place the winch on the foundation again and fit the foundation bolts. Ensure that
the bolts fit nicely through the holes in the bearing brackets.
6. Realign the winch according to items 2 & 3. Install the wedges between the
bearing brackets and the end stoppers on the foundation. The whole length of the
wedges shall have contact to the bearing brackets. Use blue paint fitting in order
to achieve this.
7. The winch is now ready to be set with casting compound or steel chock liners.
Recheck steps 2 & 3.
8. Tighten the foundations bolts to the torque 3000Nm.
9. When all is completed check the following:
Axial Clearance
Minimum 3 mm and maximum 6 mm clearance between thrust ring and bearing
bracket on both sides. Clearance shall be identical at all 4 positions.
7000 RHHW axial clearance
Bearing Clearance
Top clearance 1,3 mm, side clearance 0,6 mm both sides and 0 mm in bottom.
Clearance shall be even for the complete length of the bearing.
Port side: Starboard side:
7000 RHHW bearing clearance
Page 20 of 24
157
NOTE:
The thickness of the liner compounds shall be in accordance with manufacturer
recommendation.
NOTE:
All hydraulic connections shall be made after the compound is properly hardened and
the foundation bolts tightened to the specified torque.
The pipes must never create any force to the hydraulic unit. That may affect the
alignment of the gear wheel and pinion in the gear case.
4.3 Spooling Gear and Load Cell

The spooling gear and load cell are already installed to the winch.
4.4 Hydraulic Piping

Connect the hydraulic piping in accordance with the piping diagram and
dwg.1075647.
4.5 Electric Wiring

Connect the electric wires in accordance with the external connection diagrams (dwg
1083175 -1083179).
4.6 Mooring Hawser

395775.10200
Weight ~ 2720 kg
1. Assemble the complete mooring hawser on a barge or on the quay side

according to dwg.1076433 & 395775.
2. Turn the drum to position with releasing claws vertical downwards. Remove
securing pins (pos.117 & pos.119 dwg.194050) from the release mechanism and
open the claw. Fit the thimble to the soft eye of the hawser.
Use two small wire slings to lift the thimble in position with the claws by using a
chain jack (or crane) from top of and through the drum barrel. Close the claws
and remove the wire slings. Fit the securing pins (pos.117 & pos.119
dwg.194050).
3. When the mooring hawser is securely connected to the hawser winch, set the
winch in heave mode. Use the spooling gear to assist the installation of the ropes.
Spool the hawser in the main compartment. The chafing chain shall be stored in a
separate compartment. If extra back tension is needed, this can be achieved by
squeezing the mooring hawser with the spooling gear against the pipe above the
foundation, see sketch and picture below.
Page 21 of 24
158
Chafing Chain part
Hawser- and
Pick-Up Rope part Messenger-
Line part
Use the spooling gear to guide the pick-up rope. First fill up the chafing chain
compartment and then the main compartment.
Finally the messenger line is spooled on to the main compartment.
Page 22 of 24
159
5 Electro Hydraulic Control System

5.1 Remote Control Post (RCPH/E)
Weight ~ 150kg
The remote control post shall be placed on the port side working platform on the
hawser winch, and be welded to the place shown on dwg.1075723, with a5 fillet
weld.
5.2 Remote Control Post (RCPH)

Weight ~ 130kg
The remote control post shall be placed on deck near by the swivelling loading
manifold and hose stopper, so that a good overview can be achieved.
To be welded to deck with a5 fillet weld.
5.3 Aux & Starter Cabinets w/PLC

Weight ~ 250kg
The cabinet shall be installed below deck in safe area. Bolt it to the deck with 4 x
M12 bolts. Please note the free space of min. 1000mm from all corners for service
purposes.
5.4 CCR Control Panel

Weight ~ 5kg
The panel shall be installed in central control room in safe area. Please note the free
space of min. 600mm in front of the CCR control panel for service purposes.
5.5 Valve Unit & Accumulator Skid

Weight ~ 750 kg
The valve unit skid to be bolted to deck with 6 M20 bolts.
Page 23 of 24
160
5.6 Hydraulic Power Unit (HPU)

Weight ~ 3300 kg
The HPU is assembled on a skid. This skid shall be bolted to a frame or deck (yard
supply) with 12 M20 bolts. Please note the free spaces around the HPU for service
purposes.
Connect the wiring in accordance with the external connection diagrams.

Connect piping according to piping diagram, drw.1076484 and hydraulic power unit,
dwg. 1076510.
6 Electrical Wiring
All electrical wirings are shown in the External Connection Diagrams dwg 1083175 -
1083179.
The cables to be terminated as shown and loop tested by yard.
It is important that no cabinets are powered up before an Pusnes service
engineer is present.
All signal cables must be placed away from cables carrying heavy pulsed
current, antennas, and ground cables for radio station.
Use blue coloured cables for intrinsically safety circuits.
All earth bars in cabinets to be terminated to external earth boss.
Sealing of cables, from floor mounted cabinets with bottom cable entry is yard
responsibility.
Page 24 of 24
161

Client
Aker Pusnes AS
Box 732 - Stoa, Tel.: +47 37 08 73 00

5305-01
Document title
HOSE REPLACEMENT PROCEDURE

3400-000-A-PG-PUS-00003 5305-01-PUS-Z-KA-0006
9
Revisions
00 26.05.2014 Initial Issue EE PEL/BGi SAN
Code 1 Accepted

162
Client doc. no. 3400-000-A-PG-PUS-00003
Title HOSE REPLACEMENT PROCEDURE
Table of Contents:
1 General ..................................................................................................... 3
1.2 Precautions ..................................................................................................... 3
1.4 Reference Documents..................................................................................... 3
1.5 Abbreviations .................................................................................................. 3
1.6 Descriptions .................................................................................................... 4
1.7 Tools ............................................................................................................... 4
2 Replacement of Crude Oil Hose Sections ............................................. 4
3 Pulling the Crude Oil Hose into the Sea ................................................ 9
Page 2 of 9
163
1 General

The purpose of this procedure is to describe how to replace Crude Oil Hose sections
of the Pusnes equipment package for the offloading system for the Gaza FSO.
1.2 Precautions
WARNING
Crude Oil Hose must be connected to hose winch if not secured to hose stopper
01
Nr. Dwg. / Doc.no. Title/Description

1.
1073220.001 Offloading System, General Arrangement
2.
3.
1075886.001 Hose Stopper
4.
1088437.001 Hose Stopper Group dwg, Final Assembly
5.
1073219.001 Swivelling Loading Manifold 20”
6.
1077327.001 Inboard Hose Termination Piece
7.
1079926.001 Inboard Hose Termination Piece Group dwg.
8.
1077219.001 Crude Oil Hose Group dwg.
9.
5305-01-PUS-Z-KA-0006 Installation Procedure
1.5 Abbreviations
IHTP - Inboard Hose Termination Piece
QRF - Quick Release Flange
MBC – Marine Breakaway Coupling
Page 3 of 9
164
1.6 Descriptions
The stern offloading system is designed for transfer of the stabilized crude oil from
the FSO to a dedicated shuttle tanker.
The main items for the Stern Offloading System are:

Mooring System
Hose Handling System
Electro Hydraulic Control System
1.7 Tools
To loosen and fasten bolts and nuts on the hose flanges, hydraulically torque wrench
shall be used.
2 Replacement of Crude Oil Hose Sections
CAUTION:
Crew must take precaution around high-tension wires and the hanging crude
oil hose with heavy load while performing these operations.
Upper Hose securing beam
Crude Oil Hose bolted to IHTP
Lower Hose Securing Beam

Figure 1
Page 4 of 9
165
1. Loosen and remove 4 bolts on the top sector and 4 bolts on the bottom
sector of hose flange. See Figures 1 and 2.
Bolts to be removed from hose flange

before engaging hose securing beams
Figure 2
2. Engage the upper –and lower hose securing beam, and make sure that
they both are secured behind the hose flange as shown in Figure 3 and 4.
Securing bolts and nuts

(hinged on opposite side)
Securing bolts and nuts

(on both sides)
Hydraulic snap-on coupling to

be disconnected from QRF
Figure 3
Page 5 of 9
166
3. Loosen and remove the rest of bolts that are connecting IHTP to the hose
flange, and the bolts that are connecting Swivelling Manifold to Hose
Stopper. Disconnect the hydraulic connection from the QRF (Figure 3)
4. Rotate the swivelling loading manifold up, and secure it in upper position.
5. Mount the blind flange (pos. 100 on dwg.1077219) and connect wire from
hose winch drum with manual brake to it. See Figure 4.
Hose securing beams

secured
Connect hose winch wire to

the blind flange
Figure 4
6. Tighten wire so that the load is carried by the hose winch. Remove the
hose securing beams.
7. The hose can now be pulled into the chute, see Figure 5.
Figure 5
Page 6 of 9
167
8. Pull in the hose until the forward end section can be reached from the
vessels deck crane.
Front Hose Securing Beam,

upper
Front Hose Securing Beam,

lower
Figure 6
9. Engage the hose securing beams that are placed in front of the hose
stopper. These shall be secured behind the nearest flange connection on
the hose string. Some bolts in top and bottom sector of flange must be
removed, see figure 2. The front hose securing beams fits both 20” –and
16” flanges.
The hose securing beams shall be horizontal to ensure full contact to
flanges.
See figure 6.
WARNING
Do not disconnect hose winch wire from Crude Oil Hose before it is
properly secured in the Hose Stopper (See Figure 6)
10. When the crude oil hose is supported by the front hose securing beams
on the hose stopper, the forward accessible hose section can be
dismounted from the hose string.
11. Disconnect the blind flange and wire from the hose winch, and lift hose
section with the vessel’s deck crane with the spreader lifting bar.
(pos. 214 on dwg.1077219) see figure 7
Page 7 of 9
168
Figure 7
12. Mount blind flange and hose wire on to next hose section. Pull so that
load can be taken from the hose stopper securing beams, (figure 7) and
disengage them.
IMPORTANT
Be sure that hose winch wire is connected to hose string before
disengaging the Hose Stoppers securing beams.
13. Pull the hose until next section is accessible for deck crane.
Repeat point 9 –12.
When the MBC is entering the vessel, it must not remain in the slipway, it
must be pulled into the chute.
If the MBC shall be dismantled from the hose string, it must be strapped
by soft slings, and secured to the vessels crane.
Page 8 of 9
169
3 Pulling the Crude Oil Hose into the Sea
1. Use a soft sling around the hose flange connection. Connect the wire
from hose winch with drum with hydraulic brake, as shown in Figure 8.
Make sure that wire from drum with manual brake is connected to the
blind flange and hose in forward end.
Start pulling, and at the same time control the forward winch connection
by adjusting the manual brake.
Pull carefully until next flange is accessible, and connect wire from drum
with hydraulic brake to this.
WARNING
Never disconnect hose winch from forward end of the hose when the
hose is pulled into the sea.
Figure 8
2. To connect the crude oil hose to the hose stopper and swivelling loading
manifold, see Installation Procedure Doc.no. 5305-01-PUS-Z-KA-0006
Ch. 3.8.
Page 9 of 9
170
New Quick Release Flange

Client
MacGregor Pusnes AS
Box 732 - Stoa, Tel.: +47 37 08 73 00

N-4808 Arendal, pusnes@macgregor.com
NORWAY www.macgregor.com
2572-2-0026
Document title
ASSEMBLY PROCEDURE - QUICK RELEASE FLANGE -

RANGE 20" AND SMALLER
2572-2-0026-PUS-R-KA-0001
14
Revisions
02 28.04.2014 Updated JJ BGi SAN

01 06.02.2014 Product Description Added MMH SAN
00 04.02.2014 Issued for Construction JJ BGi SAN
Code 1 Accepted
©2014MacGregor Pusnes AS: This document and contents remain the company’s exclusive property; they shall not be
copied, reproduced and/or made available to third parties without the company’s expressed consent.
171
Project New Quick Release Flange
Client doc. no.
Pusnes doc. no. 2572-2-0026-PUS-R-KA-0001 Pusnes rev. 01 MacGregor Pusnes AS
ASSEMBLY PROCEDURE - QUICK RELEASE FLANGE - RANGE 20" AND
Title SMALLER
Table of Contents:
1 General ..................................................................................................... 3
1.1 Purpose of this Document ................................................................................ 3
1.2 Product Description .......................................................................................... 3
1.3 Reference Documents ...................................................................................... 3
1.4 Abbreviations .................................................................................................... 3
2 QRF Assembly ......................................................................................... 4
2.1 Assembly Procedure ......................................................................................... 5
2.2 Leakage Test .................................................................................................. 13
Page 2 of 14
©2014 MacGregor Pusnes AS: not to be copied, reproduced and/or made available to third parties without the company’s expressed
consent.
172
Client doc. no.
Title SMALLER
1 General

The following procedure provides a safe method for assembling the QRF. Deviations
from this procedure may damage the equipment or damage the integrity of the
equipment. Equipment that is not assembled according to this procedure must be
considered unfit for service. Such equipment may only enter into service after
carefully inspection by qualified personnel. Damage to the breakable bolts may not
be apparent.
Include signed document in MRB.
1.2 Product Description
Product Description/Model Quick Release Flange 20” and smaller
Pusnes Project No:
Pusnes Serial No:
ID Document Name Document ID Revision
1 QRF 20” 1074560
1.4 Abbreviations
Abbr. Name Abbr. Name
QRF Quick Release Flange
Page 3 of 14
consent.
173
Client doc. no.
Title SMALLER
2 QRF Assembly
The following procedure provides a safe method for assembling the QRF. Deviations
from this procedure may damage the equipment or damage the integrity of the
equipment. Equipment that is not assembled according to this procedure must be
considered unfit for service. Such equipment may only enter into service after
carefully inspection by qualified personnel.
The QRF is de-assembling by performing the assembly procedure in reverse order.
See separate section on lifting and handling of the QRF
All pos. no. refers to assembly drawing.

Assembly drawing must be used together with this procedure to mount the QRF.
Read complete procedure before starting assembly of the QRF.
All references to grease refer to use of Klüber Staburags NBU 12 K unless otherwise
specified.
Also see notes on the assembly drawing 1074560 regarding the application of
Terostat MS 939 FR.
Page 4 of 14
consent.
174
Client doc. no.
Title SMALLER
2.1 Assembly Procedure
1. Place the female flange

(pos.101) horizontally on a sturdy
support. Clean all unpainted
surfaces with a cleaning agent
such as a brake cleaner.
2. Apply a thin layer of grease to

the vertical walls of the glycol
channel (black arrows). The
threaded holes which
accommodate the bolts (pos.101
– red arrow), are not to be
covered with grease.

the inside of the holes
accommodating the breakable
bolts (pos 111 – blue arrow).
4. Clean the bolts (pos.108) and

threaded hole in female flange
with cleaner Loctite 7063. Apply
activator Loctite 7240 (or 7649)
and locking agent Loctite 243 to
the threaded bolt (pos 108 –
purple arrow). Mount all bolts
(pos 108).
5. After mounting all the bolts into

the female flange, apply grease
to the exposed threads of each
bolt (pos. 108 - Red arrow).
6. Clean the Breakable bolts

(pos.111) and apply a thin layer
of grease to them. Place
breakable bolts with the longest
threaded part into the female
flange as indicated to the right
(blue arrow).
Page 5 of 14
consent.
175
Client doc. no.
Title SMALLER
7. Apply grease to the three large

diameter O-rings (pos.209,
pos.201 and pos.202) and place
them as indicated by the red
arrows. It is particularly important
the gasket with the largest
diameter (pos.202) lay against
the channel wall or as close to
the wall as possible.
8. Apply grease to O-ring (pos.200)

and mount on Sleeve (pos.105)
as indicated by the red arrow.
Apply grease to the threaded part
of the sleeve. Repeat for all the
sleeves.
9. Place the male flange (pos.100)

horizontally on a sturdy support
close to the female flange
(pos.101). Have available a
crane which will be used to
mount the male flange onto the
female flange. Clean all
machined surfaces on the male
flange with a cleaning agent.
10. Use Special Tool 1 (pos.113) to

screw the sleeve (pos.105) into
the male flanges. There shall not
be paint between sleeve and
male flange.
11. Finally apply grease to the O-ring
(pos.205) and mount it onto the
sleeve as indicated by the red
arrow.
Page 6 of 14
consent.
176
Client doc. no.
Title SMALLER
12. Use a crane to lift up the male

flange (pos.100). Clean all
machined surfaces with a brake
cleaner.

the vertical walls of the glycol
channel (red arrows). Apply a
thin layer of grease to the inside
of the holes accommodating the
breakable bolts (pos. 111 – blue
arrow).
14. Inspect to verify that there is no

grease on the horizontal surfaces
of the male and female flange
(pos. 100 and 101).
15. Have two co-workers assist when

mounting the two flanges
together. The male flange may
have to be rotated to allow all
bolts and breakable bolts to
enter. WARNING! DO NOT
APPLY ANY BENDING FORCE
ONTO THE BREAKABLE
BOLT. THIS WILL DAMAGE
THE BOLT. IF THIS HAPPENS
REPLACE ALL BOLTS.
16. When the two flanges (pos.100

and pos.101) are assembled a
uniform gap should be observed
along the circumference of the
flanges (red arrow). Also none of
the Breakable Bolts (pos.111)
should be stuck at this time. If
these two requirements are not
met, the male flange must be
lifted off and the problem solved
before the assembling of the
QRF can continue.
Page 7 of 14
consent.
177
Client doc. no.
Title SMALLER
17. Clean the Piston (pos.102) with a

cleaning agent. Apply grease to
the O-ring (pos.207) and mount
into the track in the Piston
marked with red arrow. Carefully
mount the Teflon ring (pos.207)
marked with blue arrow on the
top of the O-ring. Gently push the
ring into the track to help it regain
its form.
18. Use one of the sleeves (pos.105)

on the male flange (pos.100) as
tool to help the Teflon ring
(pos.207) regain its shape by
carefully entering the Piston into
the sleeve and retracting it again.
Inspect the Teflon ring for
damage.
19. Apply grease to the Guide Band

marked with blue arrow
(pos.106). Mount the Guide Band
with the largest chamfer as
shown on detail in the assembly
drawing (The largest chamfer
facing down and inwards).
20. Apply grease to the sealing

gasket marked with red arrow
(pos. 204) and mount it.
Page 8 of 14
consent.
178
Client doc. no.
Title SMALLER
21. Clean and apply a layer of

grease to all surfaces of the Split-
nut (pos.107).
22. Assemble the Split-nut and insert

two of Spacer 1 (pos.109) and
two of Spacer 2 (pos. 110) as
indicated. Important that there is
grease on all surfaces of the split
nut before placing the spacers.
23. Mount O-ring (pos.206) as

indicated to hold the assembly
together.

the female hexagon part of the
piston (pos.107) and mount the
assembled split-nut (pos.107,
pos.109, pos.110 and pos. 206)
into the hexagon of the Piston.
25. Once this is done, use a thin flat

head screw driver to push the
spacers (pos.109 and 110 – blue
arrows) up against the walls of
the hexagon.
Page 9 of 14
consent.
179
Client doc. no.
Title SMALLER
26. Carefully enter the Piston

(pos.102) into the sleeve
(pos.105). Push down and rotate
the Piston by hand/tool until the
threads of the split-nut mates
with the threads of the bolt.
27. Notice if the torque required

when rotating the piston changes
cyclically during rotation. This
may be an indication that the
segments of the split-nut are not
aligned. (If so, disassemble and
restart). Rotate until the piston
stops at its bottom rest. Hit the
piston several times with a
rubber club.
28. Use the guide ring (pos.104) to

check that the piston and the
guide ring will be flush when the
ring is mounted. If not flush,
disassemble and restart. Us a
blunt end tool to carefully push
the guide band (pos.106) to the
bottom.
29. Clean the Guide Ring (pos.104 –

blue arrow) with cleaner Loctite
7063. Apply activator Loctite
7240 (or 7649) and locking agent
Loctite 243 to the threads on the
Guide Ring and screw it into the
Sleeve (pos.105). Verify that the
O-ring (pos.205) is situated well
within its groove.
30. Use Special tool 1 (pos.113 – red

arrow) to properly fasten the
Guide Ring.
Page 10 of 14
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180
Client doc. no.
Title SMALLER
31. Use a torque wrench to torque up

the pistons in a sequential
pattern as indicated in the next
illustration. First torque all pistons
up to 150 [Nm] according to the
sequence, then 600 [Nm] and
finally 1000 [Nm].
32. The numbers from 1 to 12

indicate the order in which the
pistons are to be torqued up.
When the pistons are torqued up,
all breakable bolts (pos.111)
should be free to move. If not,
determine the cause and fix the
problem before continuing.
33. Use a hexagon tool (blue arrow)

to screw in three Shear Pins
(pos.103 – red arrow) into each
Guide Ring (pos.104). The use of
excessive force may harm the
integrity of the Shear Pins. If the
Shear Pins will not enter,
carefully release the torque of
only one piston at a time, hit the
piston with a rubber club to drive
it down and torque it up to 1000
[Nm] again.
34. Use a hexagon tool (blue arrow)

to screw the plug (pos.203 - red
arrow) into the piston (pos.102).
Page 11 of 14
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181
Client doc. no.
Title SMALLER
35. Apply grease to the seat and

sides of the hole accommodating
the nut (pos.112). Use Special
Tool (pos. 114 - blue arrow)
together with a flat head screw
driver to screw the Locking Nut
(pos.112 – red arrow) on to the
Breakable bolt. Only apply hand
force, no additional tools are to
be used.
36. Measure the control distance

(note 7&8) in the assembly
drawing. Hoist up the QRF and
secure it properly. Use the same
procedure as above to fasten the
Locking Nuts on the lower side of
the QRF.
37. Insert male stud (pos.210) in the

male flange (pos.100) as
indicated by the red arrow to the
right.
Page 12 of 14
consent.
182
Client doc. no.
Title SMALLER
2.2 Leakage Test
38. Connect a hand pump with

reservoir and gage to the male
stud. Unscrew the plugs (pos.203
– red arrow) and pump glycol into
the system.
39. When the air is vented out of
each release mechanism, tighten
the plug. When all plugs are
tightened, pump the pressure up
to 5 [bar] and wait for 10 min. If
no leakage is detected
disconnect the equipment, drain
the QRF for glycol.
40. Seal the male stud with a
shrinkable cap (pos.212). Record
the result of the leakage test in
the field below.
41. When the leakage test is

completed, clean well and fill the
space between the Piston
(pos.102) and Guide Ring
(pos.104), denoted by the red
arrow with Terostat MS 939 FR.
Apply a thick layer and wipe off
the residual with a cloth soaked
in a cleaning agent.
42. When de-assembling the QRF,

carefully remove as much as
practicable of the Terostat MS
939 FR.
Page 13 of 14
consent.
183
Client doc. no.
Title SMALLER
43. Clean well and apply Terostat

MS 939 FR to the space between
the male and female flanges
(blue arrow). The Terostat MS
939 FR must be applied between
the first and second layer of
paint. Allow the Terostat MS 939
FR to dry for 24 hrs. before
applying second layer of paint.
44. Clean well and fill the space

surrounding the nuts (pos.112 –
red arrow) on the upper and
lower side of the QRF with
Terostat MS 939 FR. Wipe off
the residual Terostat MS 939 FR
with a cloth soaked in a cleaning
agent. Apply layer of paint to
cover the Terostat MS 939 FR.
Result of leakage test It is hereby confirmed that the QRF has
been assembled according to this
Date of test:
assembly procedure.
Test responsible:
Date:
Result of test (pass/fail):
Company:
Comments:
Assembly responsible:
Include signed document in MRB.
Page 14 of 14
consent.

5000-220-V-Vd-stx-00021 - VD of Tandem Offloading & Mooring System - c01

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5

STX Offshore & Shipbuilding Co., Ltd

Box 732 - Stoa, Tel.: +47 37 08 73 00

Client project no. Pusnes project no.

20” Stern Offloading System

01 16.10.2013 Updated due to customer’s requirement PEL SAN

00 15.10.2013 Initial issue PEL EE/DAO/OT SAN

Rev. Date Reason for issue Prepared Checked Accepted

Acceptance code Date / Signature ………………………………………………………….

Client doc. no. 3400-000-M-ST-PUS-00001

Technical Specification ............................................................................................... 1

Client doc. no. 3400-000-M-ST-PUS-00001

6.3.5 Valve unit, Accumulator Skid & PLC Cabinet ................................................ 24

Client doc. no. 3400-000-M-ST-PUS-00001

1.1 Purpose of this Document

1.2 Revision History

Revision: Date Change revision

00 15.10.2013 Initial issue

01 16.10.2013 Updated Ch. 3.2 and Ch. 6.3.4 – 6.3.6

FSO - Floating Storage and Offloading

7000 RHHW - Releasable Hawser Handling Winch

RCPH/E - Remote Control Post Hydraulic / Electric

HPU - Hydraulic Power Unit

P & ID - Piping and Instrumentation Diagram

OHTP - Outboard Hose Termination Piece

IHTP - Inboard Hose Termination Piece

Client doc. no. 3400-000-M-ST-PUS-00001

2.1 Codes and Standards

2.2 Ambient Temperatures

2.3 Crude Oil Transfer Pressure

2.5 Materials and Corrosion Protection

Client doc. no. 3400-000-M-ST-PUS-00001

3.1 Piping & Fittings

3.2 Grease Nipples

3.3 Lifting / Handling

3.6 Surface Treatment

Below deck equipment:

RAL Code: Client to inform.

Starters / Control Cabinets:

Client doc. no. 3400-000-M-ST-PUS-00001

El. Deck Console:

3.7 Inspection and Testing

All items will be checked for weight and dimension.

Section Equipment Drawing Pusnes Weights Remarks

Client doc. no. 3400-000-M-ST-PUS-00001

Section Equipment Drawing Pusnes Weights Remarks

6.2 Mooring hawser system

Piping Diagram 1076484

Table 5.1 Scope of supply and position of equipment

Client doc. no. 3400-000-M-ST-PUS-00001

5.1.2 Hydraulic piping

5.1.3 Power supply and electrical wiring

5.1.4 Signal and control system

Emergency release of the hose is included.

6.1.1 Hose Winch

Client doc. no. 3400-000-M-ST-PUS-00001

6.1.2 Hose Stopper

The hose termination piece is bolted to the swivelling manifold.

The hose stopper will be bolted to the swivelling loading manifold.

Load cell : 0 - 400 kN ( +/- 50 kN )

Pull from hose winch : 400 kN.

6.1.3 Swivelling Loading Manifold 20”

Client doc. no. 3400-000-M-ST-PUS-00001