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TECHNICAL PRESENTATION

REHABILITATION OF FORCADOS TERMINAL WATER DISPOSAL PIPELINE PRESENTED BY

OIS/GREDOR CONSORTIUM

CONTRACTNO:NG01002625 INTEGRATEDPIPELINESMAINTENANCEANDREPAIRS EXECUTIONPLANFORREHABILITATIONOFFORCADSTERMINAL 36WATERDISPOSALLINE PROJECTEXECUTIONPLAN

NG01002625 Page :8 Rev :0 Date :15Apr,2012

1.0

General Introduction
The 36 x 11.1km Forcados Terminal Water Disposal Pipeline (WDL) was commissioned in 1997 to evacuate produced water from the Forcados Terminal oil processing facilities for disposal offshore. The WDL is made up of two sections viz: 36 x 6km onshore section of Glass Re-enforced Epoxy (GRE) material and 36x5.1km offshore Carbon Steel section. An underwater inspection to assess the condition of the diffusers showed that the 500m diffusers at the offshore section had about 30m severed and completely detached. This requires repair to restore the diffuser as described below.

Pipelay/DerrickBarge

VESSEL DATA SHEET

CHEROKEE

HOOK RADIUS vs. LIFTING CAPACITY & HOOK HEIGHT

Akpevweoghene
Pi p e la y Derrick Barge
MOORING EQUIPMENT
No. of Anchors; Weight Make, type No. of Winches Make, type Wire (length/diameter) (8); 30,000 lb (13,608 kg) Navy, Stockless (4) Double Drum Manitowoc 560 5,000 ft (1,524 m) / 1.75 in

GENERAL
Length (overall) Width Depth Classification Year Built Registry (Flag) Operating Draft (min/max) Tonnage (gross / net) Max Deck Load Free Deck Area (length x width) Moon Pool (yes / no) Accommodations Hospital Beds Transit Speed (econ / max) Helicopter Max Rating Helicopter Refueling capacity Helideck Dimensions 387 ft (117.96 m) 100 ft (30.48 m) 25 ft (7.62 m) USCG, ABS A-1

MAIN CRANE
Derrick Make, Model Type Boom Length Main 1 9 6 9 A u x i l i a r y USA Whip 12 ft (3.66 m) / 17 ft (5.19 m) Capacity 7655 / 2296 Main Revolving Project Specific Main Fixed 100 ft (30.48 m) x 60 ft (18.3 m) Auxiliary n o Whip 174 people 6 AUXILIARY CRANE(s) Towed Make, Model 6,200 lbs Type N/A Boom Length 40 ft (18.16 m) x 40 ft (18.6 m) Capacity Manitowoc Seacrane 600 Revolving 200 ft (60.96 m) 260 ft (79.25 m) 275 ft (83.82 m) 600 s. tons @ 70 ft (544 MT @ 21.34 m) 925 s. tons @ 80 ft (839 MT @ 24.38 m) 150 s. tons @ 100 ft (136 MT @ 30.48 m) 50 s. tons @ 250 ft (45.36 MT @ 76.2 m)

Manitowoc 3900 W Crawler 120 ft (36.59 m) 86 s. tons (78 MT)

MACHINERY
Main Engines No. of Generators Main Power Auxiliary Power No. of Compressors Total Output Water Makers Total Capacity N/A
4N

MISSION EQUIPMENT
Pipelay Method(s) Conventional S-Lay o . of Wo r k S t at ion s ( @ 40 ft ) 7 Pipe Diameter (min/max) 2 in / 48 in Tensioners (make, type) (2) Western Gear Total Capacity (ea/ttl) 160 kips (72,576 kg) / 320 kips (145,152 kg) Reel Capacity (tonnage) N/A Abandon/Rec. Winch Type (make/model) AR Wire (length/diameter) Capacity Davits Rental 4 ,000 ft (1 ,219 m) / 2.5 in 300,000 lb (12,000 kg) N/A

(3) 500 kW (1) 100 kW emergency (3) 125 psi 1,759 cfm (2,988.54 m /h)
3

Sea Recovery 780 USG/h (2,952.3 L/h)

BUNKER CAPACITY
Fuel Fresh Water Potable Water 350,000 USG (1,324,750 L) 1,000,000 USG (3,785,000 L) 138,000 USG (522,330 L)

STINGER
Type Truss (Ballast) Stinger 16; 2 section Articulated (Ballast) Stinger 14 160 ft truss; 120 ft articulated

DYNAMIC POSITIONING
N/A Length (min/max)

COMMUNICATION SYSTEMS
(1) 125 watt SS Band (1) Inmarsat B Celluar Phone (4) Modular VHF

PIPE BURY EQUIPMENT


N/A

DIVING SYSTEM
650 SAT System with HRC

NAVIGATION

HOOK RADIUS vs. LIFTING CAPACITY & HOOK HEIGHT


N/A

Akpevweoghene

CHEROKEE

CHEROKEE

Profile

37

Plan

fenog@fenog.com
Operations Office
142 Air-Port Road, Opposite Bright Hope Junction
Warri. Delta State Nigeria
Rev. 1/08

Head Office
Plot 3 Old Ugbuwangue Link Road,
Off NPA Express Road, Warri Delta State Nigeria.

2. ANCHOR HANDLING AND SUPPLY VESSEL PICTURES AND DETAILS OF FENOGS ANCHOR HANDLING AND SUPPLY VESSEL FORMALLY CALLED: OROGHENE

View of Oroghene Anchor Handling /Supply Vessel in Fenogs Jetty, Warri.

REPAIR OF THE 36 FORCADOS WATER DISPOSAL LINE

REPAIR OF THE 36 FORCADOS WATER DISPOSAL LINE

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REPAIR OF THE 36 FORCADOS WATER DISPOSAL LINE

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REPAIR OF THE 36 FORCADOS WATER DISPOSAL LINE

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REPAIR OF THE 36 FORCADOS WATER DISPOSAL LINE

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Engineering Bathymetric Survey Diffuser inspection E i Engineering i C Calculations l l i and dD Design i A Analysis l i

Deliverables Survey plan Diffuser inspection report detailing condition of coating, anodes, diffuser burial and type of material Design report detailing Calculation report for allowable free spam Lifting plan and Drawings Constructability HSE reports Risk management report Work method statement Approved for construction Drawings

Mobilization and Marine Operations General Site Layout

Mobilization and Marine Operations (continued) 1. Mobilization Gredor yard, Warri will be used to support the marine logistics of this project. All Equipment to assemble at FENOG marine base where the AKPEVWOGHENE Lay y Barge g is located. Materials shall be transported to FENOG marine base where they shall be loaded onto the lay barge The Lay Barge shall be towed from FENOG marine base Warri to Forcados slot by the OROGHENE tugboat The spread shall stop for 1day at the Forcados slot for SPDC A dit as may b Audit be N Necessary. There after spread shall leave the Forcados slot through the Forcados River following the route indicated to the work site. Surveyors shall have marked out the allowable at which the 48 export pipeline can be crossed by the OROGHENE Tugboat and the AKPEVWOGHENE Barge.

Mobilization and Marine Operations (cont)

Mobilization and Marine Operations (cont) 2 Anchoring 2.1

Anchor Mooring System

The APKEVWOGHENE Barge g anchor mooring g system y is shown in the table below

Name of Vessel Length of Overall Breadth Moulded Depth Moulded Max. Draft Bollard Pull Main Engine Positioning (anchor) Winch - Quantity - Type - Capacity Anchor Type yp Wire Size x Length

Akpevwoghene 117.96 m 30.48 m 7.62 m 5.19 m

4 Double Drum -Manitowoc - 560 ton 8 each, , Navy, y, Stockless 44 mm x1524 m

22 2.2

Anchorage Criteria

1. Barge on the same side of the pipeline as anchor

Anchor

Vessel

>=100m P l Pipeline

ANCHORAGE CRITERIA (continued) 1. The pipeline lies between the Barge and the anchor Anchor

V Vessel l

>=200m

Pipeline

ANCHORIAGE PLAN L barge Lay b will ill b be supported t db by anchor h h handling dli tugs t Lay barge will be moored by 8(eight) Navy, Stockless anchors with (1.75) ) O.D. cable in 1524 meter lengths. g 44mm ( The length of the mooring lines is based on catenary theory to have sufficient length of mooring line lying on seabed under expected mooring loads While moving barge, the tugs will be responsible for the placement and relocation of the barge anchors The anchor handling tugs will use their winch to set and retrieve the barge anchors Every Anchor position shall be established by the On-Board Survey team To prevent damage to the pipeline where it is crossed by anchor lines damage prevention (D.P) buoys will be installed to prevent contact between anchor wire and the pipeline

ANCHORAGE CRITERIA (continued)

Damage Prevention

D. P. Buoy Pendant Wire

Position of D. P. Buoy to be checked by Diver every 12 hours of operation

Anchor

ANCHORAGE CRITERIA (continued) Catenary Tables

ANCHORAGE CRITERIA (continued) Typycal Anchor Layout Existing Pipeline

Existing Pipeline D. P. Buoy

LIFTING 1. Items to be Lifted

Above figure is a typical representation of the WDL showing the damaged Diffuser. While the severed section is to be salvaged the main section is to be repaired

LIFTING (continued) 2. Lifting Methods For th F the M Main i S Section ti th the Ab Abandonment/Recovery d t/R (A/R) (A/R). Winch on the Lay barge shall be used g g of the Severed Section Davits on the For the Salvaging Barge shall be utilized

LIFTING (continued) 3. Preparation for Lifting Th following The f ll i h has been b accomplished li h d Pre Repair Survey Initial I iti l I Inspection ti h has b been carried i d out t and d repair i scope fully established p and type yp of debris is known Extent of deposition

And the following g are available on Site Design Reports and AFC Drawings p Diving g and Survey y Spreads p Complete Air bags, Lifting and Rigging Tools Spreader Bars of up to 15m Span

LIFTING (continued) 4. Step I : Diving Activities

D bi R Debris Removal l Debris deposited on and around the Diffuser shall be removed by y Water Jetting g Divers will use Air at high Pressure to Air-Lift and hence fluidize debris around and beneath the diffuser . The entire length of the Diffuser will be covered covered. Water currents at the Sea Bed will carry the fluidized debris away thereby freeing the Diffuser. The Boat MV DELTA SKY will support this activity

Installation of Lifting Apparatus Lifting Slings and Shackles Air Bags (Main Diffuser Section only)

LIFTING (continued) 4. 4 Step I : Diving Activities


15m 30m

Severed Section of Diffuser D d End E d of f Damaged Diffuser


20m 20m 20m

10 T Ton Ai Air Bag

Lifting Sling

LIFTING (continued) 5. Step II : Lifting

Determine D t i allowable ll bl f free span of f the th 36 diameter di t pipe i b by engineering calculation. Previous computation for similar size of pipe at 50barg established the allowable free span at between 55m to 60m. 60m For this presentation 20m is used Controlling Factor is the minimum allowable radius of Concrete coating determined for previous test as equal to 800m To work within this range previous practice shows that for water depth of about 10m the horizontal distance to touch down is about 110m from the barge stern and a bending radius more than 800m

LIFTING (continued) 5. Step II : Lifting

bending be applied in thi this lifti lifting AA b di radius di of f 1000m or more shall h ll b li d i Based on Engineering computations to be done before the actual g the horizontal distance to achieve this will be determined. lifting 10ton Air Bags shall be installed at 20m intervals over the entire length of the diffuser in order to achieve this. Determine the minimum distance between the end of the the diffuser and the barge stern (Minimum X). From previous analysis the minimum X for 36 diameter pipe was found to be 58m.

LIFTING (continued) 5. Step II : Lifting

Pipeline

Position the lay barge along the pipeline route with stern towards the end of the diffuser. Pre-ballast the stinger. Pass lifting cable around the end of the diffuser and attach to a marker buoy.

LIFTING (continued) 5. Step II : Lifting

Lifting Head

Determine the minimum distance between the end of the diffuser and the barge stern (Minimum X) X ). From previous analysis the minimum X for 36 diameter pipe was found to be 58m. Position lay barge so that the A/R / head is no closer than a minimum X meters from stern of the barge.

LIFTING (continued) 5. Step II : Lifting

Lifting Head Using tug thread cable tied to the pipe through the stinger and pipe ramp, attach end to the A/R winch drum. Inflate airbags beginning with the one farthest from and end with the one nearest to the lay barge.

LIFTING (continued) 5. Step II : Lifting

Lifting Head

Maintain barge position and reel in wire until the Lay Tension is reached.

LIFTING (continued) 5. Step II : Lifting


Direction of Movement of Barge

Lifting Head

Slowly move barge towards the diffuser end position and g the tension. As this is done the diffuser end rises maintaining gradually.

LIFTING (continued) 5. Step II : Lifting


Direction of Movement of Barge

Lifting Head

Continue moving the barge towards the diffuser so that the end moves up the stinger, past the ramp and through the tensioners. Transfer tension from the A/R winch to the tensioners. Detach the pull cable from the end of lifted diffuser. Prepare for cutting and welding.

WELDING
Welding Procedure Specification (WPS) to be qualified for use on this scope of work Welders to be qualified based on the Qualified WPS WPS to be b Developed D l d and d Qualified Q lifi d at the h time i of fW Work kE Execution i Shielded Metal Arc Welding (SMAW) Process shall used for all Welding Works Hot Cutting shall be adopted for Pipe cutting and bevelling Joint Alignment shall be with both Internal and External Line-Up Clamps Joints to be processed one at a time as against the usual multi multi-stage stage practice during a typical pipe laying activity Details of Welding and NDE can be found in Appendix A to Section 6.5 of the Work Execution Plan Quality of Welds Welds shall undergo 100% Radiographic Inspection Other Tests to be at the request of SPDC

JOINT COATING Joints shall be coated in and out as per the original WDL design External Coating shall consist of the appropriate Anti-Corrosion followed by Concrete Coating Internally Surface of the Pipe shall be lined with 10mm thick concrete coating Internal coating shall require the worker going into the pipe with on a trolley and lighting. Ventilation of the inside of the pipe shall also be necessary. Generally procedures for working in confined spaces shall be adopted in order to safely execute the internal coating work

LAUNCHING (LOWERING) Lowering is the direct opposite of lifting. lifting The following steps are involved Sling the flanged end with the A/R cable Gradually transfer Tension from the Tensioners to the A/R Winch Gradually Move the Lay barge away from the diffuser until it is inside water Deploy divers to detach Air Air-Bags Bags randomly making sure that the line is not unduly stressed Remove the A/R cable

LAUNCHING (LOWERING) Lowering is the direct opposite of lifting. lifting The following steps are involved Sling the flanged end with the A/R cable Gradually transfer Tension from the Tensioners to the A/R Winch Gradually Move the Lay barge away from the diffuser until it is inside water Deploy divers to detach Air Air-Bags Bags randomly making sure that the line is not unduly stressed Remove the A/R cable

Special Note A piece shall be welded to the flanged exit of the diffuser to provide a bevel for relatively smooth passage across the rollers

LAUNCHING (LOWERING)

Typical Diffuser Launch

LAUNCHING (LOWERING)

Flange

Transition Piece

Diffuser Pipe

Diffuser Flange Construction for Launching

DIFFUSER PORT OPENING

WDL Port Plug Non Metallic. Requires a Key to open

Diffuser Port Plug Key to be fabricated

SCOOPING OF TOPSOIL) This will be done by scooping the specially marked area with a grab bucket dredge using the deck crane of the lay barge. Effluent soil shall be deposited a specially prepared barge and disposed onshore at an SPDC designated location

CATHODIC PROTECTION SYSTEM REPAIR When required sacrificial Anodes shall be installed by Divers.

REINSTATEMENT Sand for deposition shall be imported from other areas on barges and shall be placed using the deck crane and a grab bucket dredge Concrete Mats shall be placed using the deck crane and spreader bars.

Activity ID

Activity Description

Orig Dur

Early Start

Early Finish 28 4

JUN 11 18 25 2

JUL 9 16 23 30 6

AUG 13 20 27 3

2012 SEP 10 17 24 1

OCT 8 15 22 29 5

NOV 12 19 26 3

DEC JAN 10 17 24 31 7 14 21 28 4

FEB 11 18 25 4

2013 MAR 11 18 25 1

APR MAY 15 22 29 6 13 20 27

REHAB OF FORCADOS TERMINAL WATER DISPOSAL LINE


Subtotal 235 01JUN12 21JAN13

Milestones
WDL0001 WDL0002 WDL0003 WDL0004 Effective Date Engineering Completed Akpevwoghene Barge on Site Pipeline Repair Completed 0 01JUN12 0 0 0 17SEP12 30SEP12 29DEC12 Equipment Premob Inspection Expatriate Personnel Mobilization Documentation Community Engagement Effective Date Engineering Completed Akpevwoghene Barge on Site Pipeline Repair Completed

Contract Mobilization
WDL00101 WDL00102 WDL00103 WDL00104 Equipment Premob Inspection Expatriate Personnel Mobilization Documentation Community Engagement 30 01JUN12 60 01JUN12 30 01JUL12 30 15JUN12 30JUN12 30JUL12 30JUL12 14JUL12

Engineering
WDL00201 WDL00202 WDL00203 WDL00204 Survey Diffuser Inspection Design and Construction Drawings Design Report / Work Method Statement 21 21JUN12 14 02JUL12 38 17JUL12 30 19AUG12 11JUL12 15JUL12 23AUG12 17SEP12 Materials Procurement Blind Flange Preparation Survey Diffuser Inspection Design and Construction Drawings Design Report / Work Method Statement

Procurement
WDL00301 WDL00302 Materials Procurement Blind Flange Preparation 21 17JUN12 7 08JUL12 07JUL12 14JUL12

On - Site Mobilization
WDL00401 WDL00402 Akpevwoghene Barge Tow Anchorage 14 17SEP12 3 01OCT12 30SEP12 03OCT12 Akpevwoghene Barge Tow Anchorage

WDL Repair Works


Preparation
WDL005011 WDL005012 WDL005021 WDL005022 WDL005023 WDL005024 WDL005025 WDL005026 WDL005036 WDL00503 WDL00504 Diffuser Inspection Clear Diffuser Surface and Prepare for Lifting Salvage Severed Diffuser Portion Pipeline Lifting Cut out Dammaged Point, Fit and Weld WN Flange Internal Concrete lining Install Blind Flange and Lower Pipeline Open Diffuser Ports Repair Cathodic Protection Diffuser Reinstatement Post WDL Repair Survey 4 04OCT12 7 07OCT12 18 14OCT12 6 29OCT12 14 31OCT12 7 14NOV12 2 22NOV12 7 17NOV12 14 24NOV12 17 06DEC12 7 23DEC12 07OCT12 13OCT12 31OCT12 03NOV12 13NOV12 20NOV12 23NOV12 23NOV12 07DEC12 22DEC12 29DEC12 Diffuser Inspection Clear Diffuser Surface and Prepare for Lifting Salvage Severed Diffuser Portion Pipeline Lifting Cut out Dammaged Point, Fit and Weld WN Flange Internal Concrete lining Install Blind Flange and Lower Pipeline Open Diffuser Ports Repair Cathodic Protection Diffuser Reinstatement Post WDL Repair Survey

Diffuser Repair

Diffuser Reinstatement

Demobilization
WDL0060 Demobilization 10 29DEC12 07JAN13 Demobilization

Project Close - Out


WDL00701 WDL00702 As-Built Drawings Close Out Report 21 29DEC12 21 01JAN13 18JAN13 21JAN13 As-Built Drawings Close Out Report

Project Start Project Finish Data Date Run Date Primavera Systems, Inc.

01JUN12 01JUN12 26APR12

Early Bar Progress Bar Critical Activity

WDLR
OIS/GREDOR CONSORTIUM REHAB OF FORCADOS TERMINAL WDL Preliminary Execution Schedule

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