PIPELINE REPAIR AT

KP 110 – KP 133 KUALA TUNGKAL TO

PANARAN TGI OFFSHORE PIPELINE
18th-June-08
 FEED Handover Meeting Agenda

1. Project Introduction
2. Project Status
3. MTO
4. Procurement & Installation Specifications
5. MR’s
6. TBE/Table of Compliance
7. Procurement Status
8. Discussion and Close out
 Project Introduction

KP 133.5

KP 110.5
 Project Introduction

 Details of Damaged Section (KP110.5 to KP133.5)

• Total of 19 buckles along the damaged section
• Maximum deformation of buckle – 7.59% of OD
• Water depth at damaged section – 35m
 Design Basis of Replacement Pipeline
DESCRIPTION UNIT PARAMETERS
Approximate Length km Approximately 23.0
Pipeline OD mm 711.2 (28”)
Material - Carbon Steel
Line Pipe Specification - API 5L X65, manufactured to DNV OS-F101
Pipeline Wall Thickness mm 15.9 (.625”)
Service - Dry Sales Gas
Pipeline Corrosion Allowance mm 0.0
Internal Coating - 80 micron DFT Epoxy Coating
External Corrosion Coating - 3 Layer PE
External Corrosion Coating Thickness mm 2.1
Concrete Weight Coating Thickness mm 94
Design Pressure Barg 113.8 (1650 psig)
Operating Temperature °C 40.6
Hydrotest Pressure Barg 136.7 (1983 psig)
Maximum Operating Pressure Barg 103.4 (1500 psig)
Product Density Kg/m3 63.0
Pressure Rating of Pipeline Components - ANSI Class 900
 FEED OBJECTIVES

 Engineer a feasible repair method that can be executed by available

installation contractors in the region
 Develop a method based on use of industry proven equipment and
procedures
 Review the method with potential EPCC contractors to get feedback
on their construction risks.
 Develop a method which offers no or minimum stoppage of Gas to
the consumers
 Develop a method which enables restoring the gas flow to the full
design pressure as early as possible
 Conduct risk work shop and identify risks that should be managed
by PMT
 Identify long lead items for procurement so that repair work
can be executed as early as practically possible
Schematic Diagram
 MTO for Zero Downtime Method

Hot Tap Tees

Size Material Quantities
28 x 6” ASTM A 694 F65 2
28 x 16” ASTM A 694 F65 2
28 x 28” ASTM A 694 F65 4
28” 5D Hot Induction Bends
28”, 90ºBends API 5L X65 4+1spare 2 for Test bend and WPQT
Mechanical Connectors
28” ASTM A 694 F65 2
Flanges
6” Pressurizing line ASTM A 694 F65 4+1 Swivel type
16” Branch Line ASTM A 694 F65 2+1 WN Flange
4+1 Swivel flange
8+1 Blind flange
Misalignment flange
28” Pipeline ASTM A 694 F65 4+1 WN Flange
6+1 Swivel flange
10+1 Blind flange
2+1 Misalignment flange
28” Pig Launcher/Receiver ASTM A 694 F65 2 Swivel flange
 MTO for Zero Downtime Method

Testable Gaskets
Size Material Quantities
28” SS 316 Octagonal 4+1 Kamos Gasket
16” SS 316 Octagonal 4+1 Kamos Gasket
Test Kit SS316 2 Kamos
Weldolets
28 x 4 “ ASTM A 694 F65 / WPHY65 2+1 80XS
28 x 2” ASTM A 694 F65 / WPHY65 2+1 80XS
16 x 4” ASTM A 694 F65 / WPHY65 2+1 80XS
16 x 6” ASTM A 694 F65 / WPHY65 2+1 80XS
Barred Tee
28” x 16” ASTM A 694 F65 / WPHY65 2 Reducing Tee
Elbow
16” ASTM A 694 F65 / WPHY65 4 90º
Subsea Ball Valves
2" Body: A350-LF-2 / A352 LCC 2 Full Bore, RTJ x Welded End
4" Ball & Seat: A182-F55 with 4 Full Bore, RTJ x Welded End
WC coating
6” 2 Full Bore, RTJ x Welded End
Seat Spring: Inconel X750
 MTO for Zero Downtime Method

Expanding Gate Valves

Size Material Quantities
16” Body: A350-LF-2 / A352 LCC 2 Reduced Bore, Welded end.
Gate & Seat: A182-F55 with Through conduit Double Block
WC coating and Bleed
28” Seat Spring: Inconel X750 2 Full Bore, Piggable and welded
end
Through conduit Double Block
and Bleed
Subsea Globe Valve
6” Body: A350-LF-2 / A352 LCC 2 RTJ X RTJ
Trim : A182-F55 with WC Welded bonnet
coating
Stem packing : Flexible
Graphite
 Material Specifications

S/N Activities Status Further Actions

1. Line Pipe TGI Specification Done -
2. Flanges, Bolts, Nuts, 29780-00-SU-SPC- Done -
Gaskets and Fittings 001
3. Subsea DBB Expandable 29780-00-SU-SPC- Done -
Gate Valves / Gate Valves 003

4. 5D Induction Bends 29780-00-SU-SPC- Done

004 EPC
5. Subsea Mechanical 29780-00-SU-SPC- Done Contractor to attend all FAT testing for
Connectors & Hot Tap 005 both mechanical connectors and hot tap
Assembly assemblies
EPC Contractor to perform mock testing at
the works followed by full mock up before the
actual installation works
6. Field Welding and NDT 29780-00-SU-SPC- Done EPC Contractor to prepare welding and NDT
002 procedures

7. Installation 29780-00-SU-SPC- Done EPC Contractor to develop installation

007 procedures.
8. Survey and Monitoring 29780-00-SU-SPC- Done -
008
9. Hydrotest, Gauging and 29780-00-SU-SPC- Done EPC to develop site procedures. Final HAZOP
Pigging 009 and HAZID need to be performed.
10. Construction Materials ---- Not Done All non-long lead and construction materials to
be procured by EPC Contractor
 Material Requisitions

S/N Activities Status Further Actions

1. Line Pipe TGI Done -
2. Flanges, Bolts, Nuts, 29780-00-SU-RFQ-0003 Done -
Gaskets and Fittings
3. Subsea DBB Expandable 29780-00-SU-RFQ-0002 Done -
Gate Valves / Ball Valves

4. 5D Induction Bends 29780-00-SU-RFQ-0001 Done -

5. Subsea Mechanical 29780-00-SU-RFQ-0004 Done -

Connectors & Hot Tap
Assembly
 TBE/Table of Complinace

S/N Activities Status Further Actions

1. Line Pipe TGI -- -
2. 5D Induction Bends TGI -- -
3. Flanges, Bolts, Nuts, TGI Done -
Gaskets and Fittings
4. Subsea DBB Expandable TGI Done -
Gate Valves / Ball Valves
5. Subsea Mechanical TGI Done -
Connectors & Hot Tap
Assembly
 Project Status – Procurement

 Steel Plate and Line Pipe Manufacturing Inspection

• AnYang Steel Plate Mill audit – Done
• Line Pipe Manufacture Kick-off meeting and Mill audit – ????

 All non-long lead items & consumables to be supplied by EPC

Contractor and subjected to PMT’s approval – status ????

 Specifications and MRs for Long Lead Items Preparation – Done

• Long lead items are identified in the MTO Report
 Project Status – Procurement

 Procurement Assistance

S/N Activities Status Further Actions

Float MR TBE

1. Flanges, Bolts, Nuts, Done Done -

Gaskets and Fittings
2. Subsea Double Done Done -
Expandable Gate Valves /
Gate Valves
3. 5D Induction Bends - - Specifications and MRs issued to TGI. TGI to
send out for quotations – Status unknown ???
4. Subsea Mechanical Done Done PMT to ensure EPC Contractor attend all FAT
Connectors & Hot Tap testing and perform mock testing before actual
Assembly repair works
 Project Status – Procurement

 Procurement Assistance

S/N Activities Selected Vendor Further Actions

1. Line Pipe PT Bakrie 28” Line Production status to be updated by TGI.
Status of 16” pipe to be informed by TGI ????
2. 5D Induction Bends - - Specifications and MRs issued to TGI. Awaiting
TGI to send out for quotations. TGI to update the
status ????
3. Coating & Anodes BrederoShaw -Batam TGI to update the status ?????

4. Flanges, Bolts, Nuts, Oceanering TGI to update the staus

Gaskets and Fittings
5. Subsea Double BEL Valves -
Expandable Gate Valves /
Globe/Ball Valves
6. Subsea Mechanical OCEANERING PMT to ensure EPC Contractor attend all FAT
Connectors & Hot Tap testing and perform mock testing before actual
Assembly repair works
 Project Status – Procurement

 Balance Procurement Items

S/N Activities
1. Line Pipe Small bore pipes like 6”,4”, 2” etc to be procured by
EPC contractor
2. Small Bore valves ¾” 2 “

3. Flanges, Bolts, Nuts, Small bore and miscellaneous items to be procured

Gaskets and Fittings by EPC contractor
5. Barred Tee To be confirmed by TGI ?????

6. Structurals for Skid To be Procured by EPC contractor

assembly
Discussion and Close Out