Hasdrubal Asset Integrity

Overview

Mounir Ben Salem

5 August 2009
CONTENT

• Asset Integrity Strategy

• Status of Key Asset integrity Documentation
• Status of WSoE
– Pressure vessels inspection plan
– Status of Base line Survey
– SD plan
– Structure inspection plan
– Pipelines Inspection plan
– Business Plan
• List of major AI contracts
• Issues / concerns / challenges

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Asset Integrity Strategy
• Strategy Adopted is Similar to Miskar Asset Strategy
• Compliance with BG standards and guidelines
• Compliance with UK (SCR / PFEER/PSSR) and Tunisian
Regulation
• Identification of Safety Critical Elements through SCR and
PFEER
• Identification of SCE’s performance standards
• Establishing a maintenance and inspection Plan
• Appointment of technical Authority for each SCE’s
• Appointment of ICP for pressure system, pipeline and sub sea
Structure
• Performing maintenance and inspection plan
• Checking compliance with performance standards
• Putting in place correction actions if required
PFEER: Prevention of Fire and Explosion, and Emergency Response Regulations
SCR : Offshore Safety Case Regulations

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Status of Key Asset integrity Documentation

• BG standards requires that key asset integrity documentation

should be ready before start-up
• Project team prepared most of the required documents
• Safety case for Offshore, Onshore have been prepared
• SCE’s and PS identified for all the asset facilities.
• AI strategy, Policy has been updated to include Hasdrubal asset.
• Pressure system, pipeline, structure, integrity management
strategies of Miskar asset will be used
• WSoE have been prepared for all the asset facilities
• Maintenance strategies and procedures are in place
• Maintenance implementation using MAXIMO completed for
platform, plant and Gabes
• Operating philosophies, manuals are in place.

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Status of Key Asset integrity Documentation

• MoC procedure of Miskar asset will be used

• Supporting documents, PID’s, C&E Diagrams, vendor MRB’s…
have been uploaded into Documentum
• Corrosion monitoring requirements identified thought the
corrosion management strategy and it’s appendices
• SIL Assessment reports are in place
• NDT procedure of Miskar Asset to be used

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Status of WSoE

• Seven WSoE have been prepared early in the

construction phase, final issue January 2009
– Plant pressure systems
– Platform Pressure Systems
– Platforms structure (sub sea jacket, air gap and top side
structure)
– Multiphase pipeline
– Export pipeline
– Gabes Terminal pressure systems
– LPG Trucks

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Pressure System Inspection

• Base line survey for PV and PW (External visual + UT check)

– 1st inspection before start-up followed by 2 nd inspection after 2 years
• Internal inspection + NDT’s (MPI/DPE/ Bore scope…)
– According to IP12/13 and Tunisian regulation, first inspection due after 3
years of operation next inspection base on the inspection findings
• Hydro Testing of PV
– According to the Tunisian Decree 5 years for sour service and 10 years for
non sour service
• PSV’s inspection
– Initially after 24 months of service according to IP 12/13

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Status of Base line Survey

• Base line survey launched on April 2009

• Adoption of criticality categorisation due to time/Access limitation
• Inspection of 2”Dia and Above of CS process pipe work as high
priority
• Actual Progress is

• Plant: Vessels 69% Pipe work 30.4%

• Gabes: Vessels 100% Pipe work 52%

• Offshore: Vessels 0% Pipe work 55% (Completed during the

construction phase)

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Pressure Vessels Categorisation

T05: Vessels requiring Hydrotest every 5 years

T10: Vessels requiring Hydrotest every 10 years
201
T0: Vessels not requiring Hydrotest
169
TWV :Vessels requiring Waiver from hydrotest

Number

83
73
54
41 34 46
26
17 15 19
8 7
2 8 7 0 0 0

Sub total T10 T05 T0 TW

Total Plant Platform Gabes Category

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Pressure Vessels Inspection Plan

Vessels thorough Inspection Vessels Hydrotest

Year Plant Platform Gabes Plant Platform Gabes
(Q3) 2012 (ATER 3 YEARS OF
OPERATION ) ALL VESSELS
169 17 15  0 0  0 
HAVE TO BE THOROUHLY
EXAMINATED (IVI)
(Q3) 2015 ALL VESSELS HAVE
TO BE THOROUHLY
EXAMINATED AND VESSELS
169 7 12 34 7 0
WITH CORROSIVE MEDIA
HAVE TO BE HYDROTESTED
(IVI+T5)
(Q3) 2019ALL VESSELS HAVE
TO BE THOROUHLY
169 7 12 112 9 8
EXAMINATED AND
HYDROTESTED (IVI +T5+T10)

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 Initial SD plan

Hasdrubal - SD PLAN
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021

Miskar Asset

Contractual Shut Down 5 Days 5 Days 14 Days 5 Days 5 Days 14 Days 5 Days 5 Days 14 Days 5 Days 5 Days 14 Days 5 Days

Activities

Hasdrubal Asset

IP 12 REQUIREMENTS IVI
Quarter Q4 Q1 Q1 Q3 Q1

TUNISIAN DECREE IVI

Quarter Q4 Q1 Q4 Q1 Q3 Q1

TUNISIAN DECREE HYDROTEST

Hasdrubal Written Scheme of Examination

Q1 Q1 Q1

Contractual Shut Down 14 Days 5 Days 5 Days 14 Days 5 Days 5 Days 14 Days 5 Days 5 Days 14 Days 5 Days 5 Days

key

Internal Visual inspection of All vessels

Hydrotesting of vessels (T5)

Hydrotesting of vessels (T10)

*2012 Production critical year.?

*Avoid STEG high demand and Ramadan Period

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Offshore Structure Inspection Plan

Inspection Due Date Type of Inspection

(Month/Year)
Intermediate Survey Major Survey

July/ 2011 X
July/ 2013 X
July/ 2014 X
July/ 2018 X
July/ 2017 X
July/ 2023 X

• Major Survey: Detailed visual inspection and wall thickness of the topside and
Remote Operated Vehicle (ROV) of the subsea structure
• Intermediate Survey: Detailed visual inspection of the topside of the structure

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Multiphase Pipeline inspection program
Year
Area Covered: Details of examinations to be carried out

Within 6 months
Pipeline Internal Inspection ILI In-Line Inspection of operation
2010

ROV survey. (Complete Pipeline Survey including riser, CP Within 2 years of

Subsea Section of Pipeline potential surveys at anode locations & UT checks of pipeline operation
spools and free span localisation) 2011

The landfall section of the pipeline between the termination point

Within 2 years of
of the ROV survey to the high tide mark on the beach will also
Landfall Section operation
need to be surveyed. This work will need to be carried out from a
2011
smaller vessel probably employing a team of air divers using GPS,

 CIPPS from insulation joint in plant running to whole length of

Onshore Pipeline external
condition
Within 2 years of
pipeline to the high water mark
operation
2011
 DCVG from insulation joint in plant to the high water mark

CIPPS :Close Interval Polarised Potential Survey

ROV: Remote Operated Vehicle
DCVG : Direct Current Voltage Gradient Survey

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Export Pipeline inspection program
Year
Area Covered: Details of examinations to be carried out

Within 2
CIPPS on buried pipeline from insulation joint
years of
Export Pipeline within Hasdrubal and the STEG site at Ben
operation
Sahloun.
2011

Within 2
DCVG on buried pipeline from insulation joint to years of
Export Pipeline
boundary fence within Hasdrubal plant. operation
2011
Within 6
months of
Export Pipeline In line inspection
operation
2010

• CIPPS :Close Interval Polarised Potential Survey

• DCVG : Direct Current Voltage Gradient Survey

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Business Plan

• Business Plan

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Corrosion monitoring Requirements

• Platform
– Platform top side are not equipped with corrosion monitoring
systems, process pipe work and vessels are mainly corrosion
resistant material to Hasdrubal conditions (316L, DSS and alloy 625
Clad)
• Pipeline
– Corrosion coupons and probes are erected in the terminal inlet
facility to monitor the pipeline corrosion.
– Daily download of the probes data is required in the start up period in
order to monitor the performance of the corrosion inhibitor. Any
corrosion rate more than 0.1mm/year have to be reported.
– Loss weight Coupons are to be retrieved and analysed initially every
3months
– Bio-probe assembly to be retrieved and tested every 2months
– Iron count on weekly basis
– Pipeline Pigging is required on weekly basis until the corrosion rate
and the effectiveness of the inhibitor has been demonstrated

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Corrosion monitoring Requirements

• Plant
– Probes and coupons are installed where corrosion is likely to
take place (mainly due to process upset)
– Weekly download of probes data is required in the start up
period. Any corrosion rate more than 0.1mm/year have to be
reported
– Loss weight Coupons are to be retrieved initially every
3months
– Bio-probe assembly to be retrieved and tested every 2months
• Gabes
– Gabes site is not equipped with corrosion monitoring systems,
Butane and Propane considered non corrosive media

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List of major AI contracts

• Contracts required immediately

– ICP contract : Secured for 2009
– Corrosion monitoring system CTB form prepared waiting CTB
and ETAP approval
– Intelligent pigging of 18” multiphase pipeline scope of work
prepared and sent for comments
– NDT services and pressure vessels certification (Miskar
asset?).
– Consultancy services (GL frame work)
• Future contracts
– ROV /UT Divers for sub sea structure and pipeline spools
– CIPPS/DCVG Pipelines

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Issues / Concerns / Challenges

• Pipeline inspection
– CRA section of the pipeline
– Wall thickness of spools using divers( high cost /Access/Periodicity)
– Performance of the Corrosion Inhibitor (in presence of high CO2
content 4%)
• Base line inspection
– Scope will not be completed before start up
– Completion after start up
• Shut downs
– Synergy with Miskar asset
– Limitation of the number of day due to contractual agreements to
undertake the scope of work and specially in 2019
– High number of hydrotest waivers to be requested (26 identified)

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THANK YOU

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