HPPS Cleaning Flooding Hydrotest Procedure

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Revision History Revision No.

Date of issue

P01

19/nov/2012

R01

07/dec/2012

Reason for change

Document revised as requested by Saipem, no comments received from rev P01

HPPS Document No: UK-120059-PR-006 Rev R01 Page 2 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

TABLE OF CONTENTS 1.0  PROJECT OVERVIEW ............................................................................................................. 4  1.1  Purpose ....................................................................................................................................... 5  1.2  SPHU Operations ....................................................................................................................... 5  2.0  ABREVIATIONS AND DEFINITIONS ................................................................................... 7  2.1  Definitions .................................................................................................................................. 7  3.0  3.1  3.2  3.3  3.4  3.5 

REFERENCES ......................................................................................................................... 10  Codes and Standards................................................................................................................. 10  SNEPCo Reference Documents ............................................................................................... 10  Contractor Reference Documents............................................................................................. 11  Halliburton Reference Documents ........................................................................................... 12  HPPS Project Organogram ....................................................................................................... 13 

4.0  4.1  4.2  4.3 

HEALTH, SAFETY ENVIRONMENT ................................................................................... 14  General Information ................................................................................................................. 14  Material Handling ..................................................................................................................... 16  Incident Reporting .................................................................................................................... 16 

5.0  PREPARATIONS .................................................................................................................... 21  5.1  Resources Required – HPPS Supply ........................................................................................ 21  5.2  Resources Required – Client Supply ........................................................................................ 25  6.0  6.1  6.2  6.3  6.4  6.5  6.6  6.7  6.8 

OPERATIONAL PROCEDURES ........................................................................................... 26  SPHU Pre-deployment procedure ............................................................................................ 26  Deployment of SPHU to Seabed .............................................................................................. 32  SPHU Pipeline Flooding .......................................................................................................... 37  Contingency Plans .................................................................................................................... 52  SPHU Pipeline Hydrotest ......................................................................................................... 54  Recovery of SPHU to Deck ...................................................................................................... 81  Calculations Spreadsheets/Results ........................................................................................... 85  Valve Status Checksheet .......................................................................................................... 86 

APPENDIX 1 DRAWINGS .............................................................................................................. 89  APPENDIX 2 RISK ASSESSMENTS .............................................................................................. 90  APPENDIX 3 FIELD REPORT FORMS.......................................................................................... 91 

HPPS Document No: UK-120059-PR-006 Rev R01 Page 3 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

1.0

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

PROJECT OVERVIEW

BONGA North West is located in Nigeria OML 118 in approximately 900 to 1200 meters of water to the west and north of the BONGA FPSO. The project scope consists of 6 wells (4 off producers and 2 injectors) tied back to the BONGA MAIN infrastructure, but with subsea infrastructure capacity for 12 subsea wells. Subsea manifolds will be BONGA standard 4-slot manifolds. For the production system, the 10” flowlines 08 / 09 will be extended beyond PM1 and, for the water injection system, the 12” WFL01 will be extended beyond the existing WFTA-01. A topsides scope of work includes the addition of chemical injection systems; subsea controls systems and the tie-in of a dedicated new subsea umbilical. The production lines will be pipe-in-pipe insulated to control wax and prevent hydrate formation. A water-injection flowline will transport treated seawater from the Bonga Main FPSO via the existing Bonga Main water injection system to several subsea injection wells. The flowlines between the existing Bonga Main subsea system and the new Bonga Northwest subsea well manifolds will be: 

10”PIP Production Flowlines,



12” Water Injection Flowline.



Fig 1.0: Bonga Northwest Field Layout HPPS Document No: UK-120059-PR-006 Rev R01 Page 4 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

1.1

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Purpose

The purpose of this document is to describe the pre-commissioning activities to be carried out on the Bonga Production & Water Injection Flowlines systems with respect to preliminary flooding, Cleaning, Gauging & Hydrostatic Testing of the newly installed pipeline and flowline infrastructure as stated below:  4 x Production segment 10.36” OD flowline pipe in pipe  1 x Water injection 12.75” OD flowline The general layout of the flowline system is illustrated in figure 1 above.

1.2

SPHU Operations

The concept of the Subsea Pigging Unit is to perform controlled free-flooding of a pipeline using ambient seawater. The driving force is the differential pressure between the subsea ambient pressure due to static head and the empty pipeline. Once opened to the pipeline, raw seawater is drawn through a three-stage filter (the final filtration is to 50 micron), then through a Venturi Contraction, which doses chemicals from chemical bags mounted on the unit into the flooding stream. The water then passes through a turbine flowmeter, connected to a subsea datalogger mounted on the SPHU, which logs the flowrate and total fluid used to flood the line. The datalogger has a subsea display, displaying all the flooding and testing parameters, which can be monitored by ROV. The final stage is a flow control device which chokes back the flow to the desired pig speed. The desired flowrate is calculated during the engineering phase of the project and the correct size nozzles fitted to the SPHU before deployment. The flowrate through the SPHU is primarily controlled by the flow control system, but there is also an ROV operable ¼ turn valve to isolate the free-flooding system from the pipeline to stop flow through the SPHU to allow valve operations for pig train launching. Once the pressure in the pipeline has equalised with the ambient seabed pressure; free-flooding ceases. This usually occurs between 90% - 95% of fill volume, depending on water depth and pipeline size and geometry. The ROV supplies hydraulic power to drive a centrifugal boost pump to finish the flooding operations.

For hydrotest, a second hydraulic powered pump is used to pressurise the line at agreed flowrates to project specific test pressures; again the test can be monitored by ROV on the datalogger display.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 5 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Fig: 1.1: SPHU Operations Schematic

HPPS Document No: UK-120059-PR-006 Rev R01 Page 6 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

2.0

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

ABREVIATIONS AND DEFINITIONS

The following abbreviations and definitions may be used throughout this document. 2.1 Definitions COMPANY

Shell Nigeria Exploration and Production Company Limited (SNEPCo)

CONTRACTOR

Consortium comprising Saipem Contracting Nigeria Limited (SCNL) as Consortium leader, Saipem sa (SAIPEM), Saipem (Portugal) Comércio Marítimo, Sociedade Unipessoal, Lda. (SPCM) and Allied Dominion Oilfield Shipping Services Limited (ADOSS)

Bar

Bar (incremental or differential value)

Barg

Bar Gauge

COSHH

Control of Substances Hazardous to Health

Dep pt

Depressurisation Point

ENF

Early Notification Form

FPSO

Floating, Production, Storage & Offloading Vessel

GA

General Arrangement

Gal

Gallon (US) = 3.785 litres

GPS

Global Positioning System

HMS

Halliburton Management System

HP

High Pressure

HPPS

Halliburton Pipeline & Process Services

HSE

Health Safety and Environment

IATA

International Air Transport Association HPPS Document No: UK-120059-PR-006 Rev R01

Page 7 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

ICAO

International Civil Aviation Organisation

ID

Internal Diameter

IMO

International Maritime Organisation

JSA

Job Safety Analysis

L

Litre

Ltr/min

Litres Per Minute

LOLER

Lifting Operations & Lifting Equipment Regulations

MSDS

Material Safety Data Sheet

OD

Outside Diameter

PLET

Pipeline End Termination

PLR

Pig Launcher Receiver

PPE

Personal Protective Equipment

PPM

Parts Per Million

PRV

Pressure Relief Valve

Psi

Pounds per square inch (incremental or differential value)

Psig

Pounds per square inch gauge

PTW

Permit to Work

PUWER

Provision & Use of Work Equipment Regulations

P/P

Pressure Pump

RA

Risk Assessment

ROV

Remotely Operated Vehicle HPPS Document No: UK-120059-PR-006 Rev R01

Page 8 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Sub-Contractor

Halliburton Energy Services Nigeria Limited (HESNL)

SPHU

Sub-sea Pigging & Hydrotesting Unit

SWH

Significant Wave Height

TBT

Tool Box talk

HPPS Document No: UK-120059-PR-006 Rev R01 Page 9 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

3.0

REFERENCES

3.1

Codes and Standards

Document No.: Document Title:

No. Designation 1. Code of Federal Regulations 30, Parts 250, subpart J, “Mineral Resources”. 2. Gas Transmission Systems and Distribution Piping Systems – June 2008 3. Design, Construction, operation and Maintenance of Offshore Hydrocarbon Pipelines (Limit State Design) 4. Pressure testing of Liquid Pipelines

3.2

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Document Number 30 CFR 250 ASME B31.8 API 1111

API RP 1110

SNEPCo Reference Documents

No. Designation 1. Bonga Northwest Flowline System Basis and Summary of Design 2. Flowlines Precommissioning Plan (2/2007) 3. Precommissioning of Deepwater pipelines (3/2006) 4. Deepwater Line fill Treatment (2/2006) 5. Hydrostatic Pressure Testing Of Deep Water Pipelines (3/2006) 6. Subsea Hydrostatic Pressure Testing Of Deep Water Pipelines (1/2006)

Document Number BNW-SUB-050100-0005 BNW-SUB-050400-0001 DEP 31.40.50.30 DWP DEP 37.81.42.37-EPP DEP 31.40.40.38-DWP DEP.37.81.42.36-EPP

HPPS Document No: UK-120059-PR-006 Rev R01 Page 10 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

3.3

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Contractor Reference Documents

No. Designation 1. General Precommissioning Plan

2.

3.

4.

5.

6.

7. 8. 9. 10. 11.

12. 13. 14.

Document Number BMIP-BNW-D01938-LA-5507-00003000088549-SAI-000-PCO-PRO-00003-000 Rev C01 Bonga Northwest HSE Plan BMIP-BNW-D01938-HX-5798-00003000088549-SAI-000-HSE-PLA-00003-000 Rev C03 Project QA Audit Procedure BMIP-BNW-D01938-QA-6050-00001000088549-SAI-000-QUA-PRO-00001-000 Rev C01 Documentation Management for Subcontractors BMIP-BNW-D01938-JA-6017-00003000088549-SAI-000-DCO-PRO-00003-000 Rev C02 Quality Specification for Subcontractors – High BMIP-BNW-D01938-QA-7753-00003Criticality 000088549-SAI-000-QUA-PPS-00003-000 Rev C02 Requisition For Supply Of Offshore Flowline BMIP-BNW-D01938-LA-5507-00003-000 Commissioning Services 088549-SAI-FLO-PCO-REQ-00036-000 Rev C01 Flow Assurance Study for Precommissioning BMIP-BNW-D01938-PX-4603-00003-000 Operations 088549-SAI-000-PCS-CAL-00003-000 Rev C01 Specification for BMIP-BNW-D01938-MP-7771-00002-000 Vertical Mechanical Connectors 088549-SAI-FLO-EQP-SPC-00002-000 Rev C03 Tagging, Packing, Marking and Shipping BMIP-BNW-D01938-VA-6042-00002-000 Instructions for Subcontractors 088549-SAI-000-SHP-PRO-00002-000 rev C01 Final Data Book preparation for BMIP-BNW-D01938-JA-6017-00004-000 Subcontractors 088549-SAI-000-DCO-PRO-00004-000 rev C01 Expediting and Correspondence BMIP-BNW-D01938-VA-1780-00002-000 Requirements for 088549-SAI-000-EXP-PRO-00002-000 Rev C01 Subcontractors Document Coding and Numbering BMIP-BNW-D01938-JA-6017-00001-000 Procedure 088549-SAI-000-DCO-PRO-00001-000 Rev C02 Non Conformities Managements for BMIP-BNW-D01938-QA-5733-00033-000 Subcontractors 088549-SAI-000-PIM-PRO-00033-000 Rev C01 Manufacturing Surveillance and Inspection for BMIP-BNW-D01938-QA-5733-00002-000 Subcontractors 088549-SAI-000-PIM-PRO-00002-000 Rev C01

HPPS Document No: UK-120059-PR-006 Rev R01 Page 11 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

3.4

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Halliburton Reference Documents

No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Designation HPPS Quality Plan HPPS Project HSE Plan Hazard Identification & Risk Assessment General Work Site Activities High Pressure Discharge Hose Noise Management Hand Tools (Non-Powered) Portable Tools (Powered) Contractor Review Fall Protection Work station lighting Proper Lifting Technique Communication Plan Project Management Plan Environmental Precautions Work Method Flooding Work Method Hydrotesting Pressure Test System Devices Standards Confirm Equipment Rig Up Standards Eye Protection Environmental Management System Manual Offshore Standard – Submarine Pipeline Systems

Document Number FO-GL-HAL-PPS-008 FO-GL-HAL-PPS-102 BP-GL-BU-HSE-ADM0103 BP-GL-BU-HSE-FSV0201 BP-GL-BU-HSE-FSV0206 BP-GL-BU-HSE-HYG0306 BP-GL-BU-HSE-EQP0402 BP-GL-BU-HSE-EQP0403 BP-GL-BU-HSE-GHS0605 BP-GL-BU-HSE-GHS0604 BP-GL-BU-HSE-GHS0607 BP-GL-BU-HSE-GHS0606 FO-GL-HAL-PPS-110 FO-GL-HAL-PPS-102 WM-GL-HAL-PPS-420 WM-GL-HAL-PPS-434 WM-GL-HAL-PPS-461 ST-GL-HAL-PPS-410 ST-GL-HAL-PPS-301 BS EN 207/208 ISO 9001 DNV-OS-101 (2007)

HPPS Document No: UK-120059-PR-006 Rev R01 Page 12 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

3.5

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

HPPS Project Organogram

HPPS Document No: UK-120059-PR-006 Rev R01 Page 13 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

4.0

HEALTH, SAFETY ENVIRONMENT

4.1

General Information

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

4.1.1

All personnel will attend site safety induction prior to commencing any operations. Toolbox talks shall be performed with all relevant personnel and the appropriate form completed.

4.1.2

All relevant generic RA’s for the job MUST be reviewed, amended if necessary and signed off as reviewed by the HPPS Engineer/supervisor.

4.1.3

Workforce leaders will be identified and will be responsible for raising Work Permits and Isolation Certificates to suit site requirements.

4.1.4

HPPS Senior person on site (Project engineer, Field engineer or Supervisor) will ensure that all requirements of the permit are met before commencing work.

4.1.5

Barriers and warning signs will be erected to cordon off the area of testing or other hazard and no unauthorized personnel allowed within the area. Safety PA announcements will also be made before commencement and after completion of testing operations.

4.1.6

All hoses, fittings and instruments will be of a suitable working pressure, and leak tested to a pressure in excess of the highest system test pressure.

4.1.7

Confirm pressure setting of all Pressure Relief Devices and ensure they operate as required.

4.1.8

Ensure valve status check list filled in, signed off and filed as required. Ensure any additional and any special safety equipment is identified and provided before actual operations commence (e.g. special PPE for handling chemicals, eye wash stations, fire extinguishers, etc).

4.1.9

Should any leaks occur, the system will be depressurized to ambient pressure before rectification work may be allowed.

4.1.10 Valves under pressure should be opened and closed carefully (in a controlled manner). 4.1.11 All hoses should be secured (to a permanent fixture, i.e. structural support and not  a scaffold) at regular intervals to prevent flailing in the event of a failure. 4.1.12 Pressure must not be allowed to exceed maximum test pressure. Where required, fluid will be bled off in measured amounts to keep pressure below maximum test pressure. 4.1.13 Whilst depressurising, discharge fluid will be routed to a safe area with discharge hose secured sufficiently to prevent flailing. 4.1.14 All personnel will wear personal protective clothing (Coveralls, Steel Toe-cap Boots, Hard-hat, Safety Glasses, and Gloves) at all times on the work site. Additional protective clothing will be worn in accordance with details of any hazardous substances being handled.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 14 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

4.1.15 Halliburton diesel driven units can exceed the recommended limit of 85-dB (A) for excessive noise. Personnel in the vicinity of these units shall wear ear protection while the engine in running. 4.1.16 All visitors witnessing the trials will wear PPE required by the Halliburton site (Hard-hat, Safety Glasses, Steel Toe-cap boots, Hi-Vis Vest/Jacket) at all times on the work site.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 15 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

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4.2

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Material Handling

GENERAL INFORMATION Materials in the offshore environment can place operatives in situations that could be harmful to their health and as such any handling of material should be subject to the Risk Assessment process BP-GL-BU-HSEADM0103, in accordance with the requirements of the Control of Substances Hazardous to Health (C.O.S.H.H.) Regulations 1999 (S.I. 1999/437). The C.O.S.H.H. Regulations apply to substances classified as being carcinogenic, very toxic, toxic, harmful, corrosive or irritant under the (Chemicals Hazard Information and Packaging for Supply, CHIP)(Amendment) Regulations 2005 (S.I. 1999/197 as amended). They include substances such as pesticides, biological agents, dust and fumes, etc. Also, in respect of disposal, as a business you have a duty to ensure that any waste you produce is handled safely and within the law. This is your ‘duty of care’.

4.3

Incident Reporting

GENERAL INFORMATION If the work included in this procedure is being performed at the contractor’s facility: The client reporting and investigating procedure will take precedence in the event of an emergency. However any incidents involving injury to Halliburton personnel, damage to equipment, or high potential “Near Misses” will also be reported through Halliburton’s own reporting system, the Global Crisis Management plan. Synopsis of Global Crisis Management Plan EMERGENCY RESPONSE FRAMEWORK Emergencies are classified, under the Halliburton Company Crisis Management plan, in three general levels. Escalation potential must always be included in assessing the appropriate response levels.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 16 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Level 1 Minor Incident

A worksite incident which can be handled by an on-scene HPPS Project engineer/Field engineer, or Senior Supervisor.

Level 2 Serious Incident

A worksite incident, where the on-scene HPPS Project engineer/Field engineer, or Senior Supervisor requires additional assistance from the offsite Incident Management Team for the Halliburton Production Enhancement PSL.

Level 3 Major Incident

A worksite incident where the Halliburton Production Enhancement Incident Management Team requires assistance from the Halliburton Business Unit Management Team.

Escalation to a Higher Level of Incident The decision on whether to escalate the level of the incident to a higher level, in the Halliburton incident reporting system, is taken by the person in charge of the site (HPPS Project engineer/Field engineer, or Senior Supervisor.). As a general guide the next level of response must always be notified of an emergency situation as near to its onset as practicable. If in doubt, always escalate the response to the next level.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 17 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Duties and Responsibilities         

The duties and responsibilities of our onsite personnel, (Project engineer, Field engineer or Supervisor) when involved in any incident or emergency, are outlined below Assess the situation and decide the Response Level. (1, 2 or 3) Determine the extent of injury/damage Report the full circumstances of the incident, as soon as possible, to the HPPS Service coordinator or deputy (during working hours), or HPPS duty engineer (if outside working hours) If a Level 2 incident mobilize the Incident Management Team by contacting +234-805-5097841/+234-803-681-5737 and request that the Management Rep / HSE Manager be contacted. The person answering the phone will request details of the incident Do not talk to anyone else outside the company, except the client, about the incident and in particular do not release any information of any nature whatsoever to the media Complete the Incident early notification form, as soon as possible and within 12 hours of the incident; (see sample of ENF in following page). Subsequently other forms may need to be raised Keep abreast of the situation as it develops, logging information, time, personnel present, decisions made, etc Offer assistance wherever possible

 Be aware of the reactions that any of your actions may have on other personnel or property nearby  Remain calm  In an emergency the time of day does not matter. An immediate response and contact with management is required

HPPS Document No: UK-120059-PR-006 Rev R01 Page 18 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

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Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Halliburton Nigeria Emergency Contact Any incident involving first aid, lost time, leakages, etc. occurring at the job location, operational base or in traffic, needs to be communicated to Halliburton’s Service Supervision/Coordination and to the Emergency Coordinator at the Port Harcourt base. See contact list below: CONTACT NAME

GSM / LAND LINE

COMMENTS

LAGOS Sanjeev Verma Bardon Francois Blessing Onyeike Tony Ezekeke Josephat Edomobi Faith City Hospital Ideal Eagle Clinic Havana Specialist Hospital

01-4610780 08055101463 08055097821 08055097929 08055097906 08055097885 01-2705612, 01-3200189 08034000911,7757077, 01-4705300, 01-834996

Radio Room All BD Security WPS Travels

SOS Clinic Lagos

01-7756080

(Dr Rutvien Raymon)

PORT HARCOURT Uche Samuel Anthony Alozie Henry Oki Vincent Onwo Kanayo Nwaojei Nobsam Hospital Morning Star Clinic Princess Medical Clinic SMI Clinic (SOS) PHC PHC WARRI

084-462160 08055097897 08055097880 08055097867 08036815737 08055097888 080 37960393, 084-230775, 08033130778 084-233349, 08033373663 07034118459, 08034086093, 084-612475 084-612475 053-251739

Radio Room Mgt Team Lead/ER Fin/ER CMT HSE/ER Security / ER

WARRI Albert Ehikhuemhen Kadiri Ahmed Gabriel Eduviere Vertimon Clinic

053-251739 08055097813 08055097888 08055097853 08033882397, 053250042

Regal Clinic Westend Clinic Lily Clinic SMI Clinic (SOS) WRI Gbeye Hospital

08033488830, 08037164639 053250333, 08037078988 08050858766, 08035201186 08022906364, 053255023 08033418580, 08034446362

Dr. Hobeiche Emergency - 08027272727

Radio 148,880 MHz Radio Room WPS-S/Line Radio Room Slick line / ER Security / ER Community

Radio 148,880 MHz Dr Danagogo and Dr Cyril

HPPS Document No: UK-120059-PR-006 Rev R01 Page 19 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

HS & E Incident Early Notification Form Sample below (FO-UK-HES-HSE-002-1 Rev 4)



HPPS Document No: UK-120059-PR-006 Rev R01 Page 20 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

5.0

PREPARATIONS

5.1

Resources Required – HPPS Supply

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Equipment

Item

Description

1. 2. 3.

SPHU Lift Pump Air Driven Pressurising Pumps (DHDA 66) Hydraulic Power Unit Storage Container Test cabin HP Recorders (0-1000 Bar) Air driven Diaphragm/welding Pump Hydraulic Power Unit 2x Flooding Hose in Transport basket Halliburton Standalone dataloggers 10” HP Gauges (0-1000 Bar) SPHU Datalogger system Tool Kit Harnesses and Fall Arrestors 3m lengths of ¾” Air Hose 10k psi crowsfoot 3m length x ¼” HP (10k) pressurisation Hose 20m length x ¼” HP (10k) pressurisation Hose 20m length x ½” HP (10k) pressurisation Hose 40m length x ¾” HP (20k) pressurisation Hose 20m Lengths of ¾” Air Hose 10k psi crowsfoot 20K psi 6 or 10 Way Manifold PRV set at 600 Bar 1/4” NPT Ball Valve SS 15k psi 1/4” BSP Female Tee (Swivel) SS

4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

L (m) 3.25 3.9

B (m) 1.90 2

H (m) 5.74 2.3

W (Tons) 12.0 4.5

0.7

0.6

0.7

0.16

1

1.9 2.8 2.95 0.5 0.57 2.00 0.65 1

3 10.3 10 0.01 0.08 3.6 5.4 0.5

1 1 1 2 2 1 1 2 2 1 2 2

1.85 1.3 3.2 2.4 3.7 2.4 0.35 0.14 0.45 0.35 2.50 1.40 10.35 1.00 1 1 Contained in item 6 Fitted to SPHU Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5

Qty 1 1

2 2 2 2 2 2 1 1 3 3

HPPS Document No: UK-120059-PR-006 Rev R01 Page 21 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.

Document No.: Document Title:

1/4” NPT / BSP Male - male SS 15k psi 1/4” BSP / BSP Male - Male SS 15k psi 1/4” BSP Female (Swivel) SS 15kpsi 1/4” BSP Plug SS 15k psi 1/4” NPT / NPT Male - Male, SS 15k psi 1/2” NPT Ball Valve SS 10k psi 1/2” BSP Female Tee (Swivel) SS 10k psi 1/2” BSP Swivel SS 10k psi 1/2” BSP / BSP Male - Male SS 10k psi 1/2” NPT / BSP Male - male SS 10k psi 1/2” NPT Male - 1/4” BSP Male ss 15k psi 1/2” NPT Male - 1/4” NPT Male ss 15k psi Turbine Flowmeters Set of SPHU spares Set of Electronics Kit Set of DME irons Hydac spin Oil filters Set of compensators

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Fitted to SPHU Contained in item 5 Contained in item 5 Contained in item 5 Contained in item 5 Fitted to SPHU

3 3 3 3 3 3 3 3 3 3 3 3 4 1 1 1 2 2

HPPS Document No: UK-120059-PR-006 Rev R01 Page 22 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Consumables

Item 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Description

Qty

Filter Elements – included within spares kit for test pumps Shell Tellus 46 Hydraulic Fluid (Saipem supply) Spare seal kits for pumps Work gloves (pack) Sticky labels (roll) Junior Hacksaw blades (pack) Safety glasses – clear (pair) Set of Hot stab 2” Female Receptacle Set of Stab tools & seals 6” CNAF Gaskets 8” CNAF Gaskets 3” 300 R35 Flanges R35 Ring Gaskets Stud Bolts c/w Nuts: M30 x 180mm R45 Ring Gaskets Stud Bolts c/w Nuts: 1-1/8” x 1-1/4” Spill Kits Caution tapes (roll) Moffat Stab (Saipem supply) Fluoreceine Dye Norust CR 486 (corrosion inhibitor)

4 209 ltrs 2 1 1 1 4 2 1 1 2 2 2 2 4 2 4 2 2 3 60 ltrs 1128 ltrs

HPPS Document No: UK-120059-PR-006 Rev R01 Page 23 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Project Critical Items

Item 1 2 3 4 5 6 7 8 9 10

Description

Qty

Spare Harben Pump Spare Boost Pump Spare Flooding hose (2 per set in transit box) Spare Test Hoses Spare Complete Datalogging System Spare Complete Flowmeter Package for SPHU Deepstar 3-way Port Connector Seal Kit Fittings Package Set of Compensators Repair Package – Seals/Gaskets (set)

1 1 1 2 1 1 3 1 1 4

Personnel

Item 1 2 3

Discipline

Qty

HPPS Engineer HPPS Supervisor HPPS Operator/Technician

1 2 2

HPPS Document No: UK-120059-PR-006 Rev R01 Page 24 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

5.2

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Resources Required – Saipem Supply

Equipment/Consmables

Item 1 2 3 4 5 6 7 9 10

Description

Qty

2” Moffat Hot Stab crossed over to 2”1502 thread 2” Moffat Hot Stab crossed over to ¾” NPT 2” Moffat Hot Stab Seal Kit Hot Stab seal Replacement Tool 2” Female Receptacle for Testing on Deck Acoustic Signal Detection Equipment 801 pingers Production Pigs (for PFL 13, 14, 15 & 16) Water Injection Pigs (WFL-04)

2 2 24 1 1 2 5 5 2

Services

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Description

Qty

Crane/ Rigging / Scaffolding support Transport to and from site Diesel Lighting Water Supply 2.5m³/min @ 7 bar Air Supply 100 psi @ 400 scfm Electrical Supply 110V 60 Hz single phase Electrical Supply 220-440V 50-60 Hz three phase Standard engine lubricants Disposal Consents Civil & Mechanical works Worksite Inductions Permit to work system Site Medical Response Medical Evacuation Messing, Ablutions and Accommodation

As Req. As Req. As Req. As Req. As Req. As Req. As Req. As Req. As Req. As Req. As Req. As Req. As Req. As Req. As Req. As Req.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 25 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

6.0

OPERATIONAL PROCEDURES

6.1

SPHU Pre-deployment procedure

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.1.1

Prior to deployment of the SPHU, the HPPS engineer/supervisor will introduce the ROV supervisors and operators to the operation and layout of the SPHU.

6.1.2

Particular attention will be paid to valve arrangement & control, instrumentation & control, pressure gauges, DeepStar 3-way connector positioning and operation.

6.1.3

Before operations commence, the HPPS Test Engineer will perform a Tool Box Talk with the HPPS crew, relevant personnel and Saipem Rep on the Technical and safety aspects of the operations, highlighting as a minimum the following topics: Safety – MSDS and COSH assessment on site Incident Reporting Process Review of generic Risk Assessments (job specific RA’s will be developed if required) Operational pressures Equipment layout Duration of operations Rectification of leaks Location of and setting of PRV Communications Frequency of PA Announcements Housekeeping Impact on other activities Any questions

             6.1.4

ROV supervisor and operations shall sign on the TBT, acknowledging their understanding of the SPHU functions.

6.1.5

Raise Permit for Pre-deployment operations. Name

6.1.6

Permit No.

Sign

Date

Temporary barriers will be erected around the worksite. Check communication in the Vicinity of test boundaries, prior to applying any pressure. Name

Sign

Date

HPPS Document No: UK-120059-PR-006 Rev R01 Page 26 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.1.7

During pressurisation, stabilization period, hold period and depressurisation of the given system, no personnel will be allowed in the vicinity. Only essential personnel associated with testing shall be allowed within the immediate vicinity of the test ends.

6.1.8

Before any remedial work on a section or associated connection under pressure is permitted, the pressure will be reduced to ambient.

6.1.9

Ensure hydraulic fluid in the SPHU components is compatible with that used by the ROV – Shell Tellus Oil.

6.1.10 If the unit is to be tested on deck, water will be obtained from the vessel mains to an empty IBC.

Chemical Bag Fill 6.1.11 Raise Permit for chemical bag filling operations. Name

Permit No.

Sign

Date

HSE

6.1.12 Check communications between, Deck foreman and Vessel Bridge. Erect temporary barriers around work sites. Inform of commencement of chemical transfer. Name

Sign

Date

HSE

6.1.13 Rig up clear chemical hoses to chemical bags and insert into the hold at the bottom of the SPHU. 6.1.14 Secure the chemical bags by tying off with rope to the SPHU structure; this will ensure the bags do not slide around during deployment. HSE

Name

Sign

Date

6.1.15 Rig up chemical transfer equipment as per UK-120059-DR-010. Ensure service air supply to diaphragm pump is connected and open to enable pump operation.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 27 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.1.16 Open the following valves on the temporary chemical transfer system.

Valve Identification FV01

Description

Fill Valve 1

FV02

Fill Valve 2

CF01

Fill Valve 3 For Chemical Bag 1

PID/Drawing Reference UK-120059-DR010

UK-120059-DR010

Location Temporary chemical transfer system (IBC isolation Valve) Temporary chemical transfer system (Pump Isolation Valve)

UK-120059-DR010

In SPHU

Status

Check

Open

Open

Open

6.1.17 Commence pumping to transfer chemical from the IBC to the chemical bags. 6.1.18 At all times monitor clear hose connected to valve CF01 – just upstream of chemical filter. As soon as chemical is noticed flowing into this valve, shut off the diaphragm pump as depicted below. Valve Identification

Description

FV01

Fill Valve 1

FV02

Fill Valve 2

PID/Drawing Reference UK-120059-DR010 UK-120059-DR010

Location Temporary chemical transfer system (IBC isolation Valve Temporary chemical transfer system (Pump Isolation Valve)

Status

Check

Closed

Closed

6.1.19 Break the hose connection at the fitting on the clear hose link to the chemical bag (suction end) – ensure that a chemical spill mat is placed to absorb any spill, and then cap the fitting and secure hose unto the SPHU. 6.1.20 Flush the temporary chemical transfer system thoroughly with clean water into a waste IBC. 6.1.21 Connect the temporary chemical transfer system to the second chemical storage tank. 6.1.22 Reconnect the hose link to the second chemical bag (suction end) and repeat items 6.1.21 to 6.1.25 this time substituting CF02 for CF01. 6.1.23 Flush the temporary chemical transfer system with clean water and store away hoses and pump in tools container. 6.1.24 Break the hose connection at the fitting on the clear hose link to the chemical bag (suction end) – HPPS Document No: UK-120059-PR-006 Rev R01 Page 28 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

ensure that a chemical spill mat is placed to absorb any spill, and then cap the fitting and secure hose unto the SPHU. 6.1.25 Flush the temporary chemical transfer system with clean water and store away hoses and pump in tools container.

Pre-deployment Checklist 6.1.26 Carry out the following checks on the unit. Refer to doc: FO-GL-HAL-PPS-422 – SPHU PreDeployment Checklist. 

Pump and bleed hydraulic fluid through the Deepstar Stab (3-way port) to ensure it is free of air



Charge hydraulic compensators to 2/3 full



Ensure hydrotest pump crankcase has enough oil



Properly inspect the SPHU, paying special attention to all hydraulic hose/tube connections and fittings, pipework flanges, electrical connections, pump mountings and hydraulic connections as well as filter cage



Check smooth functioning of SPHU valves



Power up the datalogger and function test sensor cables and display lights



Ensure that bolts on dataloggers pod are tight



Check charge on batteries, if needed re-charge them



Inspect the seals on the hydrotest panel hotstabs and if in doubt of their condition replace them

 Inspect seals on the Saipem provided hotstabs and if in doubt of their condition replace them 

Prepare 2 x 40m lengths of hydrotest hose by connecting the 1” hotstab and client supplied 2” Moffat hotstab at either end



Connect the hydrotest lines to the panel via the 1” stabs. Each hose in use will be demarcated with a different colour and the ports on the SPHU hydrotest panel will be similarly marked to identify each system being tested



Fit Coflexip jumper hose with buoyancy modules (at 50m deployment check if configuration is correct)



Assemble Coflexip hose c/w bouyancy modules unto the SPHU Panel Saddles



Replace the straight lift slings with the offset lifting slings used for lifting and deployment of HPPS Document No: UK-120059-PR-006 Rev R01

Page 29 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

the fully assembled SPHU 

Deploy outrigger mats



Fit chemical bags into hold and secure fast with rope (6.1.29 – 6.1.30)



Fill chemical bags with sufficient chemicals for the operation (this operation to be carried out 4-6 hrs before deployment (6.1.31 – 6.1.38)

6.1.27 The following readings of the instrument panel should be recorded in the table below prior to deployment. The data logger will have to be powered up to obtain some of these readings. Instrument Identification V1 C1 C2 P3 T1 P1 P2 H1 T2 HG1 HG2 HG3

Instrument Description Bulk volume – Flood display Chemical volume – Flood display Chemical volume – Flood display Ambient Pressure – Flood display Temperature – Flood display Hydrotest Pressure – Hydro display Ambient Pressure – Hydro display Hydro volume – Hydro display Temperature – Hydro display Hydraulic pressure – Supply Hydraulic pressure – Return Hydraulic pressure – Case

Location

Reading/Status

Check

Data logger Data logger Data logger Data logger Data logger Data logger Data logger Data logger Data logger On Hydrotest Panel On Hydrotest Panel On Hydrotest Panel

6.1.28 Once the readings on the datalogger have been checked and recorded, power down the datalogger.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 30 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.1.29 Confirm the following valve status on the SPHU (ref drawing no. UK-120059-DR-008 in preparation for the deployment operation.

Valve Identification LPV1 HPV1 HPV2 CV01 CV02 DV1 HTV01 HTV02 HTV03 HTV04 HTV05 VV01 N/A N/A

Description Filter Isolation valve Line Isolation valve Booster Pump Isolation valve Chemical Control valve Chemical Control valve Programme Diverter valve Hydrotest Isolation valve 1 Hydrotest Isolation valve 2 Hydrotest Isolation valve 3 Hydrotest Isolation valve 4 Hydrotest Isolation valve 5 Hydrotest Vent valve Boost pump vent: 4 JIC Boost pump drain: 4 JIC

N/A

Chemical fill point

N/A

Chemical fill point

CF01 CF02

Chemical Discharge Valve Chemical Discharge Valve

PID/Drawing Reference UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008

Location

Status

In SPHU On top SPHU

Open ½ Open

On top SPHU

½ Open

On Hydrotest Panel On Hydrotest Panel On Hydrotest Panel On Hydrotest Panel On Hydrotest Panel On Hydrotest Panel On Hydrotest Panel On Hydrotest Panel On Hydrotest Panel

3 Turns Open 3 Turns Open Set on P1 ½ Open ½ Open ½ Open ½ Open ½ Open ½ Open

On Boost pump

Capped

On Boost pump

Capped

On chemical bag On chemical bag On chemical bag On chemical bag

Check

Capped Capped Open Open

HPPS Document No: UK-120059-PR-006 Rev R01 Page 31 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.1.30 Confirm checks have been conducted according to this procedure. Ensure TBTs, TRAs, test charts and reports are signed off.

Name

6.2

HPPS Sign

Saipem Sign

Date

Deployment of SPHU to Seabed

6.2.1

Prior to deployment of the SPHU, the HPPS engineer/supervisor will inform the Saipem Rep. and vessel master of the readiness to deploy.

6.2.2

Before operations commence, the HPPS Test Engineer will perform a Toolbox Talk with the HPPS crew, relevant personnel and Saipem Rep on the technical and safety aspects of operations, highlighting as a minimum the following topics.            

Safety Incident Reporting Review of generic Risk Assessments (job specific RA’s will be developed if required) Operational pressures Equipment layout Duration of operations Emergency actions Communications Frequency of PA Announcements Housekeeping Impact on other activities Any questions

HPPS Document No: UK-120059-PR-006 Rev R01 Page 32 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

6.2.3

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Raise Permit for Deployment operations.

Pipeline

Permit No.

Name

Sign

Date

PFL13 PFL14 PFL15 PFL16 WFL04 6.2.4

Check communication between Vessel bridge, ROV/Dive control and Deck Foreman.

Pipeline

Name

Sign

Date

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 33 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.2.5

The SPHU shall not be deployed in a sea state greater than 2m SWH nor without prior approval of the HPPS project engineer/supervisor.

6.2.6

Only minimum personnel are to be involved in the on-deck lifting and deployment operation.

6.2.7

On attaching the crane hook to the SPHU lifting slings, the slack will be taken up on the sling and shackle lifting assembly and correct orientation established.

6.2.8

The unit houses flexible chemical bags in the bottom hold, for this reason it is important that the unit is carefully lowered through the splash zone.

6.2.9

Once the chemical hold is through the splash zone, the SPHU should be quickly lowered beyond the top of the unit to prevent wave/swell damage to the unit’s internals.

6.2.10 For the remainder of the deployment the SPHU will be deployed at a rate not exceeding 1m/s or as instructed by the HPPS engineer/supervisor. 6.2.11 Once overboard, a flotation check shall be carried out with the SPHU at a depth of 50m. The ROV shall establish that the hose is correctly balanced with the centre latch assembly holding the floating hose in place. 6.2.12 On completion of the flotation check, the SPHU shall be further deployed to a minimum height of 50m, and a maximum of 10m offset from the launching Abandonment PFTA/WFTA. 6.2.13 The SPHU will then be slowly lowered to clear the Abandonment PFTA/WFTA structure, all the time being monitored by the ROV. 6.2.14 Once the Saipem and HPPS engineer/supervisor approve the relative position of the SPHU, the unit shall be safely set down on the Seabed and monitored to establish stability. 6.2.15 If the SPHU is incorrectly positioned, the unit will be raised from the seabed and repositioned in its correct orientation. 6.2.16 When the orientation of the SPHU is correct, the ROV will inspect the Abandonment PFTA/WFTA to establish accessibility of the female stab receptacle. 6.2.17 HPPS engineer shall approve the position of the SPHU relative to the Abandonment PFTA/WFTA female stab receptacle. 6.2.18 HPPS supervisor shall request the ROV to release the crane wire from the master link of the SPHU. 6.2.19 The crane hook shall be offset of the SPHU and recovered to the short mark, so as to prevent collision with the ROV.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 34 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.2.20 HPPS supervisor shall instruct the ROV to power up the datalogger and function both the Flooding and Hydrotest modes. This should be done before the crane hook is fully recovered to surface.

Task

Description

Sign

1

Power up datalogger

2

Hydrotest and Flood modes properly functioning

Date

6.2.21 If the SPHU datalogger is functioning properly, then the crane operator can recover the crane hook to surface., if however in the unlikely event that the SPHU’s datalogger is malfunctioned, the ROV shall reconnect the crane wire to the master link of the SPHU and the unit shall be recovered to surface according to section 6.6.

Task

Description

Sign

1

Crane hook can be recovered fully to surface.

Date

6.2.22 The Coflexip jumper hose retaining clamp located on the hose saddle frame can be opened by pulling the monkey’s fist on the latch. This will allow the Coflexip jumper hose c/w buoyancy modules to float free of the support frame. 6.2.23 The ROV shall remove the dummy stab inserted in the female receptacle on the Abandonment PFTA/WFTA pressure cap and stow away in a safe location. 6.2.24 The ROV will then grab the handle on the jumper hose-handling clamp c/w 3D swivel assembly and client’s hotstab. 6.2.25 The ROV shall manoeuvre the hotstab towards the female receptacle and engage it completely.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 35 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.2.26 ROV to configure the following valves: HPV1, HPV2, CV1, HTV01, HTV02, HTV03, HTV04, HTV05, VV1; in preparation for the flooding operation.

Valve Identification HPV1 HPV2 CV01 CV02 DV1 HTV01

Description Line Isolation valve Booster Pump Isolation valve Chemical Control valve Chemical Control valve Programme Diverter valve Hydrotest Isolation valve 1

PID/Drawing Reference UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008 UK-120059-DR-008

Location

Status

On top SPHU

Closed

On top SPHU

Closed

On Hydrotest Panel On Hydrotest Panel On Hydrotest Panel On Hydrotest Panel

Closed Closed Set on P1 Closed

HTV02

Hydrotest Isolation valve 2

UK-120059-DR-008

On Hydrotest Panel

Closed

Hydrotest Isolation valve 3

UK-120059-DR-008

HTV03

On Hydrotest Panel

Closed

HTV04

Hydrotest Isolation valve 4

UK-120059-DR-008

On Hydrotest Panel

Closed

Hydrotest Isolation valve 5 Hydrotest Vent valve

UK-120059-DR-008

On Hydrotest Panel On Hydrotest Panel

HTV05 VV01

UK-120059-DR-008

Check

Closed Closed

HPPS Document No: UK-120059-PR-006 Rev R01 Page 36 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

6.3 6.3.1

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

SPHU Pipeline Flooding Before operations commence, the HPPS Test Engineer will perform a Toolbox Talk with the HPPS crew and Saipem Rep on the technical and safety aspects of operations, highlighting as a minimum the following topics.              

6.3.2

Document No.: Document Title:

Safety Incident reporting Process Review of generic Risk Assessments (job specific RA’s will be developed if required) Operational pressures Field, equipment and asset layout Duration of operations Rectification of leaks Location of and setting of PRV Emergency shutdown Communications Frequency of PA Announcements Housekeeping Impact on other activities Any questions

Ensure operational permit is valid.

Pipeline

Permit No.

Name

Sign

Date

HSE

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 37 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

6.3.3

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Check communications between HPPS, and ROV Control. Pipeline

Name

Sign

Date

HSE

PFL13 PFL14 PFL15 PFL16 WFL04

6.3.4

The HPPS engineer/supervisor shall be present or in direct contact with ROV control throughout the stages of panel readings/operations to advise and coordinate the ROV-SPHU interface.

6.3.5

If two ROVs are utilized for testing operations, one ROV can be connected to the SPHU via the Deepstar hydraulic stab assembly at all times, while the other ROV will be utilized for valve configuration and hose connection.

6.3.6

The onboard data logging system is activated or deactivated by operating the power on/off switch. This also serves to reset the data logger prior to or following a flooding operation. All data is retained in the logger to be downloaded at a convenient time.

6.3.7

The data logger display backlight is activated by flashing a beam of light on the display light sensor, it deactivates after a couple of minutes.

6.3.8

The following procedure is common to all SPHU flooding operations regardless of the line size.

6.3.9

All pipelines will be flooded from “Abandonment PFTA/WFTA/WFTA to Initiation PFTA/WFTA via the SPHU.

6.3.10 All water entering the pipelines will be filtered to 50 microns and chemically treated with the following chemicals:

Chemical Norust CR 486 Fluoresceine dye

Function Corrosion Inhibitor, Biocide & Oxygen Scavenger Dye

Dosage ppmv/v 1000 50

HPPS Document No: UK-120059-PR-006 Rev R01 Page 38 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.11 Depending on the given pipeline size and depth, the specific flow rate and pig velocity may vary for each pipeline, but are within the threshold stipulated by Saipem. 6.3.12 Information on the expected flow rate and pig velocity for each pipeline to be flooded is given in the calculations spreadsheet in section 6.7. 6.3.13 If the SPU is being monitored during flooding operations, the following operations will be recorded at 15 minute intervals :  Time  Volume of water pumped  Flow rates  Chemical Injection volumes 6.3.14 Before flooding operations commence, ensure that Saipem Valve checklist in the tables for Northwest system contained in section 6.8 shall be reviewed and signed off by all the concerned parties. 6.3.15 During flooding operations, use the following table to cross reference the corresponding valve status checklist (see section 6) for each pipeline. Pipeline PFL13 PFL14 PFL15 PFL16 WFL04

Operation

Procedure Step

Launch Pig

6.3.21

FCG Completion

6.3.51

Launch Pig

6.3.21

FCG Completion

6.3.51

Launch Pig

6.3.21

FCG Completion

6.3.51

Launch Pig

6.3.21

FCG Completion

6.3.51

Launch Pig

6.3.21

FCG Completion

6.3.51

Check

6.3.16 Once the above operation has been completed, Saipem Rep. shall be informed of readiness to continue on to the flooding operations. Name

Saipem Sign

HPPS Sign

Date

HPPS Document No: UK-120059-PR-006 Rev R01 Page 39 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.17 The Saipem Rep. shall give permission for flooding operations to proceed.

Name

Saipem Sign

HPPS Sign

Date

6.3.18 Saipem Rep. / ROV Control to confirm valve status and ensure that the 2" hotstab (c/w check valve assembly) is engaged in the "J" hook at the Initiation PFTA/WFTA (receiving end).

Valve Identification R1

Description Receiving Cap valve

PID/Drawing Reference N/A

Location Initiation PFTA/WFTA

Status

Open

Check PFL13 PFL14 PFL15 PFL16

6.3.19 Vessel to relocate to Abandonment PFTA/WFTA (Pig launch end) and then instruct ROV control to confirm valve status on launching end.

Valve Identification

L1

Description

Launching Cap Valve

PID/Drawing Reference

N/A

Location

Abandonment PFTA/WFTA

Status

Check PFL13 PFL14 PFL15 PFL16

Closed

WFL04 HPPS Document No: UK-120059-PR-006 Rev R01 Page 40 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.20 Instruct ROV to be in position 3 metres downstream of where the pig has been installed in the

pipeline i.e. at the second weld from the Abandonment PFTA/WFTA. This is so that a confirmation of pig launch is obtained by the acoustic pinger detector. 6.3.21 On approval from the Saipem Rep. and HPPS engineer/supervisor, the designated flooding valve (L1) on the launching Cap will be slowly opened in 30° increments. This will prevent any excessive shock pressure/flow being applied to either the SPHU or the launcher assembly.

Valve Identification

L1

Description

Flooding valve

PID/Drawing Reference

N/A

Location

Initiation PFTA/WFTA

Status

Open

Check PFL13 PFL14 PFL15 PFL16 WFL04

6.3.22 On authorization by the HPPS engineer/supervisor, the ROV will land on the top of the SPHU frame to power up the data logger. 6.3.23 Ensure programme selected on the data logger display indicates flooding operations. If not instruct ROV to switch off data logger, toggle the programme switch to FLOOD and power up the logger again. 6.3.24 All readings displayed on the data logger as well as gauges shall be recorded by the HPPS engineer/supervisor.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 41 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Launch Pig 6.3.25 Instruct the ROV to set the Chemical control valve on the SPHU panel at the required number of turns open from its closed position. This is to allow spiking of chemicals from the onset of Pig launch. Valve Identification

Description

PID/Drawing Reference

Location

Status

Check PFL13

CV01 & CV02

PFL14

Chemical Control valves

UK-120059DR-008

On ROV Display Panel

Closed

PFL15 PFL16 WFL04

6.3.26 On authorization from Saipem Rep., Instruct the ROV to slowly open valve HPV1 enabling the launch of the Pig and the flooding of the flowline with a line volume of treated filtered sea water. Valve Identification

Description

PID/Drawing Reference

Location

Status

Check PFL13 PFL14

HPV1

Line Isolation valve

UK-120059DR-008

PFL15 On top SPHU

Open

PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 42 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.27 ROV to utilize hydrophone and check for signal of acoustic transmitter located in the pig. This signal should be triggered by the water activation mechanism.

Transmitter

Pipeline

Signal Located

PFL13 PFL14 PFL15 PFL16 WFL04

Check

Note: Frequencies of acoustic pingers for any given flowline will be known only after installation into Pig during Pig loading of the PFTA/WFTA s and will be provided prior to mobilisation. This list should be approved of by Saipem.

Free-Flooding 6.3.28 Instruct the ROV to slowly increase or decrease the setting of CV01 & CV02; Chemical Dosing Valves, to regulate the spiking of the filtered Seawater with chemicals. 6.3.29 HPPS engineer/supervisor to advice on dosage level and number of turns, with respect to the given pipeline. 6.3.30 During the flooding operations, the HPPS engineer/supervisor shall monitor the flooding readings on the SPHU’s datalogger and over a 15 minute span record readings in 5 minute intervals, to establish correct bulk water flow and chemical addition. Thereafter, readings will be recorded every 15 minutes. Use record sheet. 6.3.31 From the figures, the correct ppm of chemicals can be established, checked and approved by the client representatives. Concentration levels are to be in accordance to point 6.3.10. 6.3.32 All readings shall be recorded by the HPPS engineer/supervisor on the relevant HPPS form. HPPS Document No: UK-120059-PR-006 Rev R01 Page 43 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.33 The flow of treated filtered seawater will cease when the line is pressure balanced i.e. the pressure behind the pig matches the pressure of compressed air ahead of the pig. This will be indicated by the datalogger pressure value reading depth pressure. 6.3.34 The HPPS engineer/supervisor will check the data logger display pod and note the bulk flow and chemical flow total. From this a ppm of chemicals injected so far can be calculated for the bulk flow and compared to the line volume table for each flowline. 6.3.35 The ROV shall await instructions from the HPPS engineer/supervisor to carry out Boost pump operations.

Boost Pump Flooding 6.3.36 The boost pump is utilized to complete the final stage of flooding after pressure equalization of the pipeline. This is generally in the region of 5%÷10% of the pipeline volume. 6.3.37 The ROV shall use the bucket wrench to close HPV1 and open HPV2 – Boost pump isolation valve. A 90° rotation of the wrench indicates when the valve is in the fully open position (ref drawing: UK120059-DR-009). Valve Identification

Description

PID/Drawing Reference

Location

Status

Check PFL13

HPV1

Line Isolation valve

UK-120059DR-009

PFL14 On top SPHU

Closed

PFL15 PFL16 WFL04 PFL13

HPV2

Line Isolation valve

UK-120059DR-009

PFL14 On top SPHU

Open

PFL15 PFL16 WFL04

6.3.38 The ROV will then proceed to connect the Deepstar hydraulic umbilical male stab c/w hoses (3 off) to the Deepstar female receptacle located on the SPHU. (Ref. drawing UK-120059-DR-009). 6.3.39 Inform ROV control that the SPHU hydraulic system is designed to function with a 100 ltrs/min supply of hydraulic oil at a max pressure of 200 barg.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 44 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.40 The ROV will engage the Deepstar stab by guiding the probe into its mating bush and allowing the spigot on the opposite side of the connector to self-centre in the guide plate. 6.3.41 When centred the ROV should grasp the centre fish tail or T-bar and push down while rotating to start the screw thread. The screw will enter 10mm into the bush before the flange starts to push the male connectors out of their housing and into the receptacles. 6.3.42 The Deepstar connector stab is properly connected when the back plate is flush with the male connector shroud plate. 6.3.43 The HPPS engineer/supervisor shall witness and advise on correct engagement of the Deepstar hydraulic stab assembly. The locking handle should engage in the female receptacle.

Task

Pipeline

Deepstar hydraulic stab assembly properly engaged

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Check

Saipem Check

6.3.44 The ROV shall power up its auxiliary power pack which will in turn engage the boost pump, to complete flooding of the line. 6.3.45 Instruct the ROV to confirm that the Bulk and Chemical flowmeters are both functioning during pumping operations, indicating that the SPHU Boost pump is operating properly. The pressure displayed on the datalogger will indicate the pressure generated by the Boost pump.

Task

Pipeline

Bulk and Chemical flowmeters registering

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Check

Saipem Check

HPPS Document No: UK-120059-PR-006 Rev R01 Page 45 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.46 At start of Boost pumping, the ppm of chemicals injected into the pipeline shall be calculated, monitored and regulated if required. 6.3.47 Throughout operation of the Boost pump, ROV control and HPPS engineer/supervisor will monitor the pressures temperature and flow on the ROV hydraulic pack as well as on the SPHU to ensure the hydraulic system is functioning properly. 6.3.48 Ensure that the volume details for the given pipeline are known and noted, see section 6.7-for calculations. 6.3.49 When 100% of line volume has been pumped behind the Pig, and a pressure increase and/or no flow on the bulk flowmeter display is noticed inform ROV Control to stop hydraulic supply to boost pump. 6.3.50 An additional 2 attempts will be carried out to dead head the boost pump to confirm that the pig has arrived at the Initiation PFTA/WFTA pressure cap.

Pipeline

Name

Sign

Date

HSE

PFL13 PFL14 PFL15 PFL16 WFL04

6.3.51 Instruct ROV to close valve HPV2 – boost pump isolation valve. Valve Identification

HPV2

Description

Line Isolation valve

PID/Drawing Reference

UK-120059DR-009

Location

On top SPHU

Status

Closed

Check PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 46 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.52 All readings shall be monitored by the HPPS engineer/supervisor and recorded on the relevant HPPS form. Total volume pumped and the ppm for the line shall be calculated and recorded (concentration levels should be in accordance with section 6.3.10). 6.3.53 On approval from the Saipem Rep., instruct the ROV to close the inlet port valve (L1) on the Abandonment PFTA/WFTA launching Cap.

Valve Identification

L1

Description

Launching Cap Valve

PID/Drawing Reference

N/A

Location

Abandonment PFTA/WFTA

Status

Check

PFL13 PFL14 Closed PFL15 PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 47 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.54 After completion of flooding operations, the vessel will transit to the Initiation PFTA/WFTA where the ROV will confirm that the acoustic pinger fitted pigs have arrived by detecting the transmitted signal utilizing the ROV mounted hydrophone.

Transmitter

Pipeline

Signal Located

PFL13 PFL14 PFL15 PFL16 WFL04

Check

Note: Frequencies of acoustic pingers for any given flowline will be known only after installation into Pig during Pig loading of the PFTA/WFTA is and will be provided prior to mobilisation. This list should be approved of by Saipem. 6.3.55 If pig receipt is not confirmed, the HPPS engineer/supervisor will decide on a further amount of filtered treated seawater to be pumped into the pipeline. In order to do so, repeat sections (6.2.25 to 6.2.26) to reconnect the SPHU to pipeline (if earlier disconnected) and open launching Cap inlet port valve (L1). Then conduct boost pump flooding according to section (6.3.37 to 6.3.51). HPPS engineer/supervisor will note volumes and pipeline pressures.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 48 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.56 Once Pig receipt is confirmed, and with the Saipem Rep. approval, instruct the ROV to close valve R1 on the Initiation PFTA/WFTA. Valve Identification

Description

PID/Drawing Reference

Location

Status

Check PFL13 PFL14

R1

Receiving Cap Valve

N/A

Initiation PFTA/WFTA

Closed

PFL15 PFL16 WFL04

6.3.57 Contractor shall then remove the Initiation PFTA/WFTA hotstab c/w check valve. 6.3.58 Contractor shall remove the Initiation PFTA/WFTA pressure cap. 6.3.59 Contractor shall install a Pig catcher cage. 6.3.60 The vessel shall then transit to the Abandonment PFTA/WFTA and the ROV will configure the inlet valve L1 on the Abandonment PFTA/WFTA to the Open position.

Valve Identification

L1

Description

Launching Cap Valve

PID/Drawing Reference

N/A

Location

Abandonment PFTA/WFTA

Status

Open

Check PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 49 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.61 The ROV shall then mate the Deepstar hydraulic male hotstab to the female hydraulic hotstab receptacle. 6.3.62 Once the ROV has mated the male and female Deepstar hydraulic hotstab, the boost pump shall be engaged and a client specified volume of water shall be pumped into the system to enable the Pig at the Initiation PFTA/WFTA to be slowly propelled out of the end termination and into the Pig catcher cage. 6.3.63 As soon as the boost pump is engaged, an increase in the pressure displayed on the datalogger should be noticed. The successful removal of the pig shall be indicated by a drop in pressure to ambient subsea pressure on the datalogger display. 6.3.64 The ROV shall then disengage the Deepstar hydraulic hotstab and close the Abandonment PFTA/WFTA Inlet valve, L1.

Valve Identification

L1

Description

Launching Cap Valve

PID/Drawing Reference

N/A

Location

Abandonment PFTA/WFTA

Status

Closed

Check PFL13 PFL14 PFL15 PFL16 WFL04

6.3.65 The vessel will transit to the Initiation PFTA/WFTA and the ROV shall visually confirm that the Pig is now located in the Pig catcher cage. 6.3.66 The Pig catcher cage shall then be disconnected from the Initiation PFTA/WFTA and the cage complete with the Pig recovered to the vessel deck. 6.3.67 Once on deck, the gauge plate mounted on the recovered pig will be retrieved and inspected. 6.3.68 Further operations will not commence without prior approval by all parties, i.e. Total, Saipem and HPPS, of the retrieved gauge plate. 6.3.69 Upon approval of the gauge plate, Saipem shall re-instate the pressure cap unto the Initiation PFTA/WFTA and then conduct a back-seal test in preparation for hydrotest operations.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 50 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.70 Upon satisfactory back-seal test, the ROV shall ensure that the Initiation PFTA/WFTA cap valve R1 is in the closed position, the dummy stab will be re-instated and the 2” hotstab c/w check valve recovered to the vessel deck.

Valve Identification

Description

PID/Drawing Reference

Location

Status

Check PFL13 PFL14

Receiving Cap Valve

R1

N/A

Initiation PFTA/WFTA

Closed

PFL15 PFL16 WFL04

6.3.71 The vessel will then transit to the Abandonment PFTA/WFTA. 6.3.72 At the Abandonment PFTA/WFTA location, instruct the ROV to disengage the 2” Moffat male hot stab from the Abandonment PFTA/WFTA launching Cap, retrieve and reposition the Coflexip jumper hose in its support frame saddle and lock it in position using the retaining clamp.

Task

Pipeline

Return Coflexip hose to panel frame saddle and lock in position.

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Check

Saipem Check

6.3.73 For all pipelines to be flooded, cleaned and gauged, repeat sections 6.2.23 to 6.2.26 for hook-up and sections 6.3.16 to 6.3.69 for flooding operations.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 51 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.3.74 On completion of operation collate and organize all paperwork and present to the Saipem Rep. for acceptance and signature.

Pipeline

Name

Sign

Date

PFL13 PFL14 PFL15 PFL16 WFL04

6.4

Contingency Plans

Stuck PIG Dislodging Procedure – Free Flooding If the pig is believed to be stuck in the pipeline during free flooding operations, the ROV will close the inlet valve L1 on the Abandonment PFTA/WFTA pressure cap, isolating the SPHU. When the differential pressure behind the pig is deemed to have dissipated, the ROV will quickly reopen the inlet valve on the Abandonment PFTA/WFTA introducing seawater at subsea ambient pressure via the SPHU in a bid to shock the pig into moving. If the pig remains stuck repeat this process 3 times. If this process does not produce movement of the pig, check the operational logs and flooding report to ascertain the potential location of the pig in the pipeline. Inform client representative, investigate possible causes of the problem and propose the use of the boost pump. The ROV will then engage the 3-way Hydraulic Deepstar hotstab and supply hydraulic power to drive the Boost pump.

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SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Stuck PIG Dislodging Procedure – Boost Pump Flooding In the event of a pig becoming stuck in the pipeline whilst boost pumping, the ROV will increase its hydraulic supply to the boost pump to increase the flow delivered by the pump. Note that the boost pump deadheads at 10 bar and should not be run for more than 10 minutes at any time when deadheading. Carry out process 3 times in the event the Pig remains stuck. If this process does not produce movement of the pig, then ROV should close the Abandonment PFTA/WFTA inlet port valve L1 on the pressure cap to lock the 10 bar pressure from the boost pump behind the pig. The vessel shall then transit to the Initiation PFTA/WFTA and the ROV will quickly open the Initiation PFTA/WFTA valve R1. Carry out the process 3 times if the Pig is still stuck. If this process does not produce movement of the pig, the vessel will then begin the search for the acoustic signal from the pinger inserted into the Pig. If the option of reversing the flow is available, then the SPHU could be relocated to the Initiation PFTA/WFTA, and set up to introduce filtered seawater, to dislodge the stuck pig(s) and transport to the Abandonment PFTA/WFTA.

Note: Any of these methods requires a MOC (Management of Change) and a Deviation to procedure request should be filled out and submitted to the Project Manager by the HPPS engineer/supervisor.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 53 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

6.5 6.5.1

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

SPHU Pipeline Hydrotest Before operations commence, the HPPS Test Engineer will perform a Toolbox Talk with the HPPS crew, relevant personnel and Saipem Rep on the technical and safety aspects of operations, highlighting as a minimum the following topics: 

Safety



Incident Reporting Process



Review of generic Risk Assessments (job specific RA’s will be developed if required)



Equipment layout



Duration of operations



Rectification of leaks



Location of and setting of PRV



Emergency shutdown



Communications



Frequency of PA Announcements



Housekeeping



Impact on other activities

 Any questions 6.5.2

The hydrotest panel valves do not require a torque tool and shall be opened using the ROV manipulator.

6.5.3

During operations, pipelines can be pressurized simultaneously using the SPHU. Some pipelines may also be pressurized through the standalone Halliburton Datalogger Units; to allow disconnection of the SPHU, once the test hold period has started, and allow the SPHU to be utilized for work on other pipelines.

6.5.4

Pressure relief valves for the hydrotest panel shall be pre-set to 5% of Test pressure over the TP for each set of pipelines. These shall be attached to a “1” hotstab, and mated with one of the receptacles on the panel.

6.5.5

All instrumentation has been calibrated within two months prior to mobilization with the calibration certificate available on site.

6.5.6

Pressure Relief Valves will be calibrated immediately prior to mobilization.

6.5.7

Pressure gauges and recorders will be chosen such that the test pressure falls within 50%-90% of the range of the instrument. HPPS Document No: UK-120059-PR-006 Rev R01

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SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

6.5.8

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Ensure operational permit is valid. Pipeline

Permit No.

Name

Sign

Date

HSE

PFL13 PFL14 PFL15 PFL16 WFL04

6.5.9

Check communication between ROV control and client Rep., prior to applying any pressure. Pipeline

Name

Sign

Date

PFL13 PFL14 PFL15 PFL16 WFL04 6.5.10 Before hydrotesting operations commence, ensure that the Saipem Valve checklist in the tables for Northwest system contained in section 6.7 shall be reviewed and signed off by all the concerned parties.

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SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.11 During Hydrotest operations, use the following table to cross reference the corresponding valve status checklist (see section 6.8) for each pipeline. Pipeline Operation Procedure Step Check PFL13 PFL14 PFL15 PFL16 WFL04

Hydrotest

6.5.44

Completion

6.5.60

Hydrotest

6.5.44

Completion

6.5.60

Hydrotest

6.5.44

Completion

6.5.60

Hydrotest

6.5.44

Completion

6.5.60

Hydrotest

6.5.44

Completion

6.5.60

6.5.12 Ensure correct test hose identification during hook-up to pipeline and testing. RISK

Pipeline

Hose Identification

Name

Sign

Date

PFL13 PFL14 PFL15 PFL16 WFL04 6.5.13 During the pressurising, stabilization period, hold period and depressurising of the pipelines, HPPS engineer/supervisor shall be in direct contact with ROV control. 6.5.14 If two ROVs are utilized for testing operations, one ROV can be connected to the SPHU via the Deepstar hydraulic stab assembly at all times, while the other ROV will be utilized for valve configuration and hose connection.

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SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.15 Instruct the ROV to set the 3-way programme diverter valve DV01 on the hydrotest panel to position P2 (Ref. drawing:UK-120059-DR-009). This will switch the hydraulic flow loop from the Boost pump to the Harben pump.

Valve Identification

Description

PID/Drawing Reference

Location

Status

Check PFL13

DV01

Programme Diverter valve

PFL14 UK-120059DR-009

On Hydrotest Panel

Set on P2

PFL15 PFL16 WFL04

6.5.16 The ROV will then proceed to connect the Deepstar hydraulic umbilical male stab c/w hoses (3 off) to the DeepStar female receptacle located on the SPHU. (Ref. drawing:UK-120059-DR-009). Inform ROV control that the SPHU hydraulic system is designed to function with a 100 ltrs/min supply of hydraulic oil at a max pressure of 200 barg. 6.5.17 The ROV will engage the DeepStar stab by guiding the probe into its mating bush and allowing the spigot on the opposite side of the connector to self-centre in the V-shaped guide plate. 6.5.18 When centred the ROV should grasp the centre fish tail or T-bar and push down while rotating to start the screw thread. The screw will enter 10mm into the bush before the flange starts to push the male connectors out of their housing and into the receptacles. 6.5.19 The DeepStar connector stab is properly connected when the back plate is flush with the male connector shroud plate.

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SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.20 The HPPS engineer/supervisor shall witness and advise on correct engagement of the DeepStar hydraulic stab assembly. The locking handle should engage in the female receptacle.

Task

Pipeline

Deepstar hydraulic stab assembly properly engaged

PFL13 PFL14 PFL15 PFL16

HPPS Check

Saipem Check

WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 58 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.21 Open the panel valves which have got the required hydrotest hose attached to them.

RISK

Pipeline

Hose Identification

Panel Valve No.

Status

Date

PFL13 PFL14 PFL15 PFL16 WFL04

6.5.22 Instruct the ROV to power up the data logger. 6.5.23 Instruct the ROV to activate the data logger backlight by flashing a beam of light on the sensor. Ensure that the data logger is displaying the HYDRO programme. Readings of the displayed parameters shall be taken by the HPPS engineer/supervisor in the daily log.

Task

Pipeline

Hydro programme displayed on datalogger

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Check

6.5.24 Instruct the ROV to charge up the hydraulic supply line to the hydrotest pump by slowly increasing the flow to the pump motor. 6.5.25 This will power up the pump slowly and start pumping filtered seawater through the hydrotest hoses to ensure that they are flushed.

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SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.26 Once a steady stream is seen to exit the hotstab at the end of the hydrotest hoses, shut of hydraulic supply to the hydrotest pump.

Task

Pipeline

Shut off hydraulic supply to hydrotest pump

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Check

6.5.27 Instruct ROV to unreel the 40m ¾” test hose, taking care not to contaminate the hotstab with dirt. 6.5.28 The ROV should connect the hydrotest hose c/w hotstab to the designated inlet port on the Abandonment PFTA/WFTA pressurisation cap.

Task

Pipeline

Connect hydrotest hose c/w hotstab to inlet port on pressurisation cap.

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Check

6.5.29 PRVs are attached to a 1” hotstab, and are installed in a free panel port on the SPHU. This is to ensure safe testing of the hydrotest hose against the closed inlet valves as well as during pipeline pressurisation and hydrotesting operations. 6.5.30 A connection/leak test of the hydrotest hose (datalogger hose) shall be conducted against the closed inlet valve of the launcher at a pressure of 1.1 x max pressure of given pipeline (or 5bar below PRV set pressure) for 15 minutes. Note: If 1.1 x Max pressure is decided upon, make sure to isolate the PRV.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 60 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.31 Ensure that prior to testing, the correct line shall be opened using the corresponding panel isolation valves; HTV01 to HTV04.

RISK

Pipeline

Hose Identification

Panel Valve No.

Status

Date

PFL13 PFL14 PFL15 PFL16 WFL04 6.5.32 Any lines not being tested or connected require their corresponding valves to be closed. 6.5.33 Pressure is to be applied in a controlled manner, utilizing the ROV proportional control or two stage high-low control to drive the pump. Fill out HPPS pressurisation report: FO-GL-HAL-PPS-426.

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SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.34 On attaining test pressure, a 15 minute hold shall be carried out to confirm connection integrity. Pressure shall be monitored on the SPHU data logger display, confirm operation of flowmeter.

Pipeline

Hose Test Hold Pressure

Status

Time

Date

PFL13 PFL14 PFL15 PFL16 WFL04

6.5.35 On a satisfactory hose and stab integrity test, the ROV will discontinue supply of hydraulic fluid to the pump and then vent the lines via the hydrotest panel by opening HTV05 and VV01 – vent valve.

Pipeline

Stop hydraulic supply

Vent to ambient

Time

Date

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 62 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.36 Pressure is to be confirmed at ambient before closing the vent valve VV01 and hydrotest isolation valve HTV05. Valve Identification

Description

PID/Drawing Reference

Location

Status

Check PFL13

HTV05

Hydrotest Isolation valve 5

UK-120059DR-009

PFL14 On Hydrotest Panel

Closed

PFL15 PFL16 WFL04 PFL13

VV01

Hydrotest Vent valve

UK-120059DR-009

PFL14 On Hydrotest Panel

Closed

PFL15 PFL16 WFL04

6.5.37 Confirm function testing completed satisfactorily. Complete function test acceptance sheet. ref: FO-GL-HAL-PPS-604.

Pipeline

Name

Sign

Date

HSE

PFL13 PFL14 PFL15 PFL16 WFL04

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SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.38 ROV shall disconnect the Deepstar Hydraulic stab assembly –if necessary, fly to the Abandonment PFTA/WFTA pressure Cap for the pipeline to be tested, and configure the appropriate valve L1 open, in preparation for pressurisation.

Valve Identification

L1

Description

Launching Cap Valve

PID/Drawing Reference

N/A

Location

Abandonment PFTA/WFTA

Status

Open

Check PFL13 PFL14 PFL15 PFL16 WFL04

6.5.39 The ROV shall return to the SPHU and reconnect the DeepStar hydraulic stab assembly, ready to commence pressurisation of the pipelines.

Task

Pipeline

Reconnect Deepstar hydraulic stab assembly.

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Check

6.5.40 The system is to be strength tested using filtered seawater treated with the following chemicals:

Chemical Norust CR 486 – Corrosion Inhibitor, Biocide and Oxygen Scavenger Fluoresceine Dye

Dosage ppmv/v 1000 50

HPPS Document No: UK-120059-PR-006 Rev R01 Page 64 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.41 Pipeline specification for the given project determines the test pressures and durations. Pipeline Specification As per Northwest system Precommissioning Specification

Required Test Pressure

Test Duration

Saipem Supplied in Northwest system Precommissioning Specification.

Minimum 8 hour hold period

6.5.42 Test Pressures, the table below outlines test pressures for each system, a maximum of 101% of design pressure as stipulated in Northwest system specification.

Project *Minimum *Maximum Test Test Test Pipeline Pressure Pressure Pressure (Barg) (Barg) (Barg) PFL13 PFL14 PFL15 PFL16 WFL04

413 413 413 413 423

413 413 413 413 413

418 418 418 418 428

Allowable Drop in 8 hr hold period 0.2% (Barg) 0.83 0.83 0.83 0.83 0.85

Allowable Drop in 1 hr period 0.2% (Barg)

Average Pressure change /°C (Barg)

PRV Relief Pressure (Barg)

0.104 0.104 0.104 0.104 0.106

3.42 3.42 3.42 3.42 3.37

434 434 434 434 445

*The pressures values displayed on the datalogger will be: Strength Test Pressure (as in table above) plus Subsea Ambient Pressure for the location at the given PFTA/WFTA.

Pressurisation 6.5.43 Inform Saipem Rep. and ROV Control of readiness to commence pressurisation operation. Check radio communications. Pipeline

Name

Sign

Date

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 65 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.44 The hydrotest panel valve for the pipeline to be pressurised shall be in the open position and any unused lines/ports shall be closed. Pipeline

Hose Identification

Panel Valve No.

Status

Date

PFL13 PFL14 PFL15 PFL16 WFL04

6.5.45 The vent valve VV01 and hydrotest panel isolation valve HTV05 shall be closed. Valve Identification

Description

PID/Drawing Reference

Location

Status

Check PFL13

HTV05

Hydrotest Isolation valve 5

UK-120059DR-009

PFL14 On Hydrotest Panel

Closed

PFL15 PFL16 WFL04 PFL13

VV01

Hydrotest Vent valve

UK-120059DR-009

PFL14 On Hydrotest Panel

Closed

PFL15 PFL16 WFL04

6.5.46 Hydraulic flowrate is controllable by ROV hydraulic supply percentage control or 2 stage high-low control.

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SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.47 A pressure reading shall be taken and logged from the SPHU prior to commencement of pressurisation.

Pipeline

Hose Identification

Panel Valve No.

Pressure Reading

Time

Date

PFL13 PFL14 PFL15 PFL16 WFL04

6.5.48 The ROV hydraulic work pack shall be powered up and the hydraulic gauges monitored to confirm correct function. This will activate the SPHU hydrotest pump and pressurisation of the flow line will commence slowly.

Pipeline

Power-up

Supply Pressure

Supply Flow

Return Case Pressure Pressure

Time

Date

PFL13 PFL14 PFL15 PFL16 WFL04

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SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Air Inclusion 6.5.49 Commence pressurising at a rate not exceeding one bar/minute from ambient pressure, until 35% of TP has been reached, with volume of water injected, pressure, temperature and time being logged at 1% of TP intervals. Ref. document - Pipeline Pressurisation Report: FO-GL-HAL-PPS-426. 6.5.50 A 15 minute pause in pressurisation shall be allowed for leak checks to be conducted on the system, and an air inclusion report to be filled out. Ref. document - Pipeline Air Inclusion Report: FO-GLHAL-PPS-428. The assessed air content shall not exceed 0.2% of the calculated total volume of the pipeline under test.

Pressurisation (Compliant with DNV-OS-101) 6.5.51 Continue pressurising at a rate not exceeding 1 bar/minute, until 80% of TP has been reached, with volume of water injected, pressure, temperature and time being logged at 5% of TP intervals. Ref. document - Pipeline Pressurisation Report: FO-GL-HAL-PPS-426. 6.5.52 At 80% of pressure, the hydraulic supply to the pump shall be reduced to allow a pressurisation rate of 0.69 bar/min with volume of water injected, pressure, temperature and time being logged. 6.5.53 The pressure is then increased without stopping at a rate of 0.69 bar/min (10 psi/min) with injected volumes, rates & pressures recorded. 6.5.54 After a one hour hold, water shall then be released to lower the pressure to 50% of the specified test pressure. 6.5.55 Once the pressure has reached the specified level, the flow line shall be repressurised as mentioned above. 6.5.56 On reaching test pressure isolate the system at the hydrotest panel. 6.5.57 Confirm test pressure has been achieved. Pipeline

Name

Sign

Date

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 68 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Stabilisation 6.5.58 On completion of pressurisation, a period of stabilisation will commence. There is no minimum or maximum period of stabilisation. 6.5.59 During the stabilisation period, readings of time, pressure and temperature are to be logged every 15 minutes and a pressure / temperature versus time graph is to be plotted to help assess when stabilisation is complete. Ref. document - Pipeline Test Report: FO-GL-HAL-PPS-427. 6.5.60 Should the pressure drop below the minimum test pressure at any time during the stabilisation period, it is to be re-pressurised and the stabilisation period extended. 6.5.61 During the stabilisation period, thorough leak checks are to be carried out by ROV on all flanges and connections at regular intervals. 6.5.62 Stabilisation of the line will be considered to be complete when pressure variations could be reconcilable to temperature change (i.e test water temperature stabilization occurance).See table in section 6.5.43 for values). 6.5.63 Confirm stabilisation has been achieved.

Pipeline

Name

Sign

Date

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 69 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Removal of the SPHU if using the Standalone Datalogger 6.5.64 If the Halliburton subsea data logging unit only is to be used to collect data during pressurisation, and the SPHU is to be deployed elsewhere to operate, then instruct the ROV to configure valves on the manifold on the datalogger as below.

Hydrotest Hose

SPHU

ROV Hotstab Female Receptacle

Inlet

DL1 +

θ

DL2

Vent DPY

p DL6

DL5 DPY

DL3 DL4

Outlet

Subsea Datalogger ROV Hotstab To Pipeline FLET

Fig: 6.0: Subsea Datalogger (c/w SPHU Interface) HPPS Document No: UK-120059-PR-006 Rev R01 Page 70 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Valve Identification

Description

Document No.: Document Title:

PID/Drawing Reference

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Location

Status

DL1 & DL2

SPHU Double Isolation

Fig 6.3

On subsea datalogger manifold

Closed

DL3 & DL4

Pipeline Double Isolation

Fig 6.3

On subsea datalogger manifold

Open

DL5 & DL6

Vent Double Isolation

Fig 6.3

On subsea datalogger manifold

Closed

Check PFL13 PFL14 PFL15 PFL16 WFL04 PFL13 PFL14 PFL15 PFL16 WFL04 PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 71 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.65 Instruct the ROV to slowly open HTV05 and VV01 on the SPHU ROV Panel and de-pressurise the hose between the SPHU and the datalogger to ambient. Valve Identification

Description

PID/Drawing Reference

Location

Status

Check PFL13

Hydrotest Isolation valve 5

HTV05

UK-120059DR-009

PFL14 On Hydrotest Panel

Open

PFL15 PFL16 WFL04 PFL13

VV01

UK-120059DR-009

Hydrotest Vent valve

PFL14 On Hydrotest Panel

Open

PFL15 PFL16 WFL04

Task

Pipeline

Pressure shown on logger at subsea ambient.

PFL13 PFL14 PFL15 PFL16 WFL04

Ambient Pressure

HPPS sign

HPPS Document No: UK-120059-PR-006 Rev R01 Page 72 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.66 Once at ambient, instruct the ROV to close HTV05 and VV01. Valve Identification

Description

PID/Drawing Reference

Location

Status

Check PFL13

Hydrotest Isolation valve 5

HTV05

UK-120059DR-009

PFL14 On Hydrotest Panel

Closed

PFL15 PFL16 WFL04 PFL13

VV01

UK-120059DR-009

Hydrotest Vent valve

PFL14 On Hydrotest Panel

Closed

PFL15 PFL16 WFL04

6.5.67 The ROV is to monitor the pressure in the hose between the SPHU and the datalogger for 15 minutes to ensure that there is no pressure build-up and that the double block valves on the datalogger are not passing.

Task

Pipeline

Monitor for pressure build up in hose b/w SPHU and standalone datalogger – 15min duration.

PFL13 PFL14 PFL15 PFL16 WFL04

Pressure build up

HPPS sign

HPPS Document No: UK-120059-PR-006 Rev R01 Page 73 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.68 Once the valves on the datalogger have been proven to not be passing, instruct the ROV to open HTV05 and VV01 on the SPHU ROV Panel and disconnect the SPHU from the Standalone Datalogger (Please refer to section on recovery of SPHU). Valve Identification

Description

PID/Drawing Reference

Location

Status

Check PFL13 PFL14

Hydrotest Isolation valve 5

HTV05

UK-120059DR-009

On Hydrotest Panel

Open

PFL15 PFL16 WFL04 PFL13 PFL14

VV01

Hydrotest Vent valve

UK-120059DR-009

On Hydrotest Panel

Open

PFL15 PFL16 WFL04

6.5.69 Upon disconnection of the SPHU the ROV will install a dummy stab to act as a block and debris cap at the manifold inlet port.

Task

Disconnect SPHU from standalone datalogger. Task Install debris plug at standalone datalogger manifold female receptacle.

Pipeline

HPPS sign

PFL13 PFL14 PFL15 PFL16 WFL04 Pipeline PFL13 PFL14 PFL15 PFL16 WFL04

HPPS sign

HPPS Document No: UK-120059-PR-006 Rev R01 Page 74 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Test Hold Period 6.5.70 On completion of a satisfactory stabilisation period and with the consent of the Saipem Rep. the test hold period can now commence. 6.5.71 If monitoring the test during the specified 8 hour hold period, readings of time, pressure and temperature are to be logged every 15 minutes within a test report. A pressure / temperature versus time plot is to be kept up to date during the hold period. Ref. document - Pipeline Test Report: FOGL-HAL-PPS-427.

Acceptance Criteria

6.5.72 Confirm test hold period is in accordance with specification.

Pipeline

Name

Sign

Date

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 75 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.5.73 The pressure test is to be considered acceptable if the work has been performed in strict accordance with this procedure (and approved variations, if applicable) and any loss of pressure during the test hold period can be attributed to temperature change. 6.5.74 If the pressure rises above the maximum specified limit, due to changes in temperature, water will be bled from the system. Any water removed or injected will be quantified. 6.5.75 If pressure variances are to be taken into account, refer to calculations section for calculations and allowable values. 6.5.76 Once the test has been accepted an Acceptance Certificate is to be completed. Ref. document Pipeline Acceptance Certificate: FO-GL-HAL-PPS-429.

Acceptance Criteria (Compliant with DNV-OS-101) 6.5.77 The Test shall be considered acceptable if the test pressure is maintained with no loss of internal pressure for the final 4 hours of the hold period. 6.5.78 During the first 4 hours of the hold period, correlation of any internal pressure losses to a corresponding temperature change shall be made for the test to be judged acceptable. 6.5.79 Examination of the visible sections of the pressurized system should reveal no leaks. 6.5.80 Should a drop in pressure occur during the test period that cannot be attributed to changes in the temperatures, the test duration shall be extended. 6.5.81 Additional testing and repressurisation of the line shall be performed until test acceptance criteria are achieved. 6.5.82 If the test pressure falls below the minimum test pressure, the pressure shall be increased to the minimum test pressure and maintained for the required hold period. 6.5.83 At no time shall the maximum allowable test pressure in this specification be exceeded.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 76 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Depressurisation 6.5.84 Ensure that all parties involved have accepted the test hold period and signed off the test acceptance certificate before depressurisation of any pipeline.

Pipeline

Name

Sign

Date

PFL13 PFL14 PFL15 PFL16 WFL04 6.5.85 When the acceptance criteria have been met and agreed by Saipem, commence depressurisation at no more than 3.44 bar/min (50 psi/min). 6.5.86 Before any pipeline can be depressurised it should be connected to either the SPHU and depressurised subsea via the SPHU vent valve, or Halliburton Subsea Datalogging Unit. 6.5.87 The hydrotest hose should be connected to the launching cap inlet port valve. 6.5.88 Depressurisation shall be carried out via the hydrotest isolation valve connecting the panel to the pipeline, HTV05 and Vent valve VV01.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 77 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Valve Identification

Document No.: Document Title:

PID/Drawing Reference

Description

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Location

Status

Check PFL13

HTV05

Hydrotest Isolation valve 5

UK-120059DR-009

PFL14 On Hydrotest Panel

Open

PFL15 PFL16 WFL04 PFL13

VV01

UK-120059DR-009

Hydrotest Vent valve

PFL14 On Hydrotest Panel

Open

PFL15 PFL16 WFL04

6.5.89 OR 6.5.90 If depressurisation is to be carried out through the Standalone Datalogger, then instruct the ROV to slowly open DL2, DL1, DL5 and DL6.

ROV Hotstab Female Receptacle

Inlet

DL1 +

θ

DL2

Vent DPY

p DL6

DL5 DPY

DL3 DL4

Outlet

Subsea Datalogger ROV Hotstab To Pipeline FLET

Fig 6.1: Standalone Datalogger (configured for system depressurization) HPPS Document No: UK-120059-PR-006 Rev R01 Page 78 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Valve Identification

Description

Document No.: Document Title:

PID/Drawing Reference

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Location

Status

DL1 & DL2

SPHU Double Isolation

Fig 6.4

On subsea datalogger manifold

Open

DL3 & DL4

Pipeline Double Isolation

Fig 6.4

On subsea datalogger manifold

Open

DL5 & DL6

Vent Double Isolation

Fig 6.4

On subsea datalogger manifold

Open

Check PFL13 PFL14 PFL15 PFL16 WFL04 PFL13 PFL14 PFL15 PFL16 WFL04 PFL13 PFL14 PFL15 PFL16 WFL04

6.5.91 On reaching subsea ambient pressure, instruct the ROV to close the valve L1 on the Abandonment PFTA/WFTA pressure cap.

Task

Pipeline

Pressure shown on logger at subsea ambient.

PFL13 PFL14 PFL15 PFL16 WFL04

Ambient Pressure

HPPS sign

HPPS Document No: UK-120059-PR-006 Rev R01 Page 79 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Valve Identification

L1

Description

Launching Cap Valve

Document No.: Document Title:

PID/Drawing Reference

N/A

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Location

Abandonment PFTA/WFTA

Status

Check

PFL13 PFL14 Closed PFL15 PFL16 WFL04

6.5.92 On reaching ambient pressure, all pressure and temperature charts, plots, calculations and test records are to be signed off by the HPPS Test Engineer and Saipem representatives. 6.5.93 Section (6.5.80 to 5.5.87) shall be repeated for all pipelines to be depressurized. 6.5.94 Whenever the SPHU or Standalone Datalogger is recovered to deck, data for all performed operations shall be downloaded from the data logger onto a laptop by the HPPS engineer/supervisor. 6.5.95 On completion of operation collate paperwork, charts and present to client for acceptance and signature. 6.5.96 Ensure that all paperwork has been completed.

Pipeline

Name

Sign

Date

PFL13 PFL14 PFL15 PFL16 WFL04

HPPS Document No: UK-120059-PR-006 Rev R01 Page 80 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

6.6

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Recovery of SPHU to Deck

6.6.1

This work method comprises steps to be taken when recovering the SPHU to deck as well as prior to conducting a wet transit.

6.6.2

Before operations commence, the HPPS Test Engineer will perform a Toolbox Talk with the HPPS crew and Saipem Rep on the technical and safety aspects of operations, highlighting as a minimum the following topics:

6.6.3



Safety



Incident Reporting Process



Review of generic Risk Assessments (job specific RA’s will be developed if required



Operational pressures



Equipment layout



Duration of operations



Rectification of leaks



Communications



Housekeeping



Impact on other activities



Any questions

Raise Permit for recovery operations.

Name

HSE

6.6.4

Sign

Date

Check communications between ROV Control, Deck foreman and Vessel Bridge. Erect temporary barriers around work sites.

Name

Sign

Date

HSE

HPPS Document No: UK-120059-PR-006 Rev R01 Page 81 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.6.5

Once the pipeline(s) have been depressurised and pressure is confirmed to be at subsea ambient the ROV shall close all the valves on the Abandonment PFTA/WFTA and disconnect the stab and hose assembly.

6.6.6

The hose and stab assembly shall be returned and secured onto the SPHU ready for recovery.

6.6.7

Valves located on the SPHU shall be configured according to the table below. This shall ensure no pressure is trapped in the system during recovery.

Valve Identification LPV1 HPV1 HPV2

Description Filter Isolation valve Line Isolation valve Booster Pump Isolation valve

PID/Drawing Reference UK-120059DR-008 UK-120059DR-008 UK-120059DR-008 UK-120059DR-008

Location

Status

In SPHU

Open

On top SPHU

Open

On top SPHU

Open

Programme Diverter valve Hydrotest Isolation valve 1

UK-120059DR-008 UK-120059DR-008

On Hydrotest Panel On Hydrotest Panel

3 Turns Open 3 Turns Open Set on P1 ½ Open

HTV02

Hydrotest Isolation valve 2

UK-120059DR-008

On Hydrotest Panel

½ Open

HTV03

Hydrotest Isolation valve 3

UK-120059DR-008

On Hydrotest Panel

½ Open

HTV04

Hydrotest Isolation valve 4

UK-120059DR-008

On Hydrotest Panel

½ Open

HTV05

Hydrotest Isolation valve 5

UK-120059DR-008

On Hydrotest Panel

VV01

Hydrotest Vent valve

½ Open 3 Turns Open

CV01

Chemical Control valve

CV02

Chemical Control valve

DV1 HTV01

UK-120059DR-008

UK-120059DR-008

On Hydrotest Panel On Hydrotest Panel

On Hydrotest Panel

Check

HPPS Document No: UK-120059-PR-006 Rev R01 Page 82 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

6.6.8

The ROV shall inspect the SPHU and ensure that the Coflexip jumper hose is secured and slings are not twisted / snagged prior to connection to the vessel’s crane / winch hook. The HPPS engineer/supervisor shall confirm the unit is ready for recovery.

6.6.9

Lower the crane/winch hook to 5 metres from the seabed using ROV to guide.

6.6.10 ROV to connect hook to master link of the SPHU bridle, paying particular attention to avoid snagging the SPHU framework or panel. 6.6.11 Once the SPHU’s lifting bridle is attached to the hook, the ROV will monitor the unit as it is lifted clear of the seabed. 6.6.12 The SPHU will be recovered to deck following the agreed upon recovery procedure. 6.6.13 Only minimum number of HPPS personnel to be involved with crane lifting. If not required standby at safe distance. 6.6.14 If the SPHU is recovered to deck at any time, the mud mats will be washed down to remove any seabed mud.

Task

Pipeline

Whenever the SPHU is recovered to deck, the unit will be washed down to remove seabed mud.

PFL13 PFL14 PFL15 PFL16 WFL04

Date

Time

HPPS sign

HPPS Document No: UK-120059-PR-006 Rev R01 Page 83 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Recovery of the Standalone Datalogger 6.6.15 If the Standalone Datalogger is to be recovered to deck, ensure that all valves on the manifold, are open before recovery.

Housekeeping / De-mob 6.6.16 The following steps may be carried out prior to any prolonged dry store of the SPHU or demob/backload. HPPS engineer/supervisor has discretion over appropriate actions. Ref. document – Backload check sheet : FO-GL-HAL-PPS-501. 6.6.17 Following approval of Saipem to demob, the SPHU will be prepared for backload. 6.6.18 Remove all electronics and data loggers, flush with fresh water and secure in transit case. 6.6.19 Drain all water / chemical pipework and flush with fresh water. Ensure all valves are half open during and after flushing activities. 6.6.20 Mud mats should be washed down to remove any seabed mud. 6.6.21 Remove hydrotest panel, clean and flush with water. 6.6.22 Uncouple Coflexip hose from SPHU and remove buoyancy modules, flush with fresh water and store in transit boxes. 6.6.23 Flush all used hydrotest hoses with fresh water and store in container. 6.6.24 Empty, flush and store chemical bags in SPHU chemical hold. 6.6.25 Tidy up all SPHU equipment and secure in container for transit. 6.6.26 Lower the crane/winch hook to 5 metres from the seabed using ROV to guide.

HPPS Document No: UK-120059-PR-006 Rev R01 Page 84 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

6.7

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Calculations Spreadsheets/Results

HPPS Document No: UK-120059-PR-006 Rev R01 Page 85 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

Date produced:

11-Nov-12

Customer

Saipem

Location

Bonga Northwest

Pipeline Description:

Production Flowline 13 (PFL 13) API-5L-X65 OD:263.1mm Wt:20.64mm x 3.243km

Pipeline Length (km) Internal Diameter (m) Total Vol. (imp. gals) Volume per ft (gals) Total Volume (ft³)

3.24 0.222 2.76E+04 2.59 4.43E+03

km m I.gal gal ft³

Outside Diameter (m) Pipeline Lay Total Volume (m³) Vol. per metre (m³) Vol. per metre (ft³)

PIGGING PARAMETERS

0.263 m Unrestrained 125.3 m³ 0.039 m³ 1.36 ft³

Fill fluid : Water Salinity :

Pigging Speed (m/s)

0.50

Friction Factor 0.018703922 Pressure Drop At Pigging Speed

Pig Differential Pump Rate (m³/min) Head Loss (metres) Reynolds Number 5.3 psi =

3.5 % Bar

1.16 3.48 85782 0.37

bar

Chemical Additive Injection Rates Chemical Ihibitor Tracer dye

1 2 3 4

PRESSURE TEST PARAMETERS Volume to pressurise pipeline : Corresponding Inlet (0-bar) Volume : Volume change per bar at test pressure : Temp ºC 0.7 1.4 2.1 2.8 3.3 4.0 4.0

p.p.m. 1000.0 50.0

Injection Rate (litres/min) 1.159 0.058

Test press. Temp. 2.510 m³ 2.555 m³ 5.74 litres

Compressibility Coeff Expan. (bar)¯¹ (deg C)¯¹ 4.16E-05 1.83E-04 4.14E-05 1.87E-04 4.13E-05 1.91E-04 4.11E-05 1.94E-04 4.10E-05 1.98E-04 4.09E-05 2.01E-04 4.07E-05 2.04E-04 (Test) 4.07E-05 2.04E-04 Average pressure change per degree C (bar): Fraction of external pressure added internally:

413.0 bar g 4.0 'C

Pressure change bar/ºC 3.16 3.25 3.34 3.43 3.52 3.58 3.67 3.67 3.42 0.128

Date produced:

11-Nov-12

Customer

Saipem

Location

Bonga Northwest

Pipeline Description:

Production Flowline 14 (PFL 14) API-5L-X65 OD:263.1mm Wt:20.6mm x 3.165km

Pipeline Length (km) Internal Diameter (m) Total Vol. (imp. gals) Volume per ft (gals) Total Volume (ft³)

3.17 0.222 2.69E+04 2.59 4.32E+03

km m I.gal gal ft³

Outside Diameter (m) Pipeline Lay Total Volume (m³) Vol. per metre (m³) Vol. per metre (ft³)

PIGGING PARAMETERS

0.263 m Unrestrained 122.4 m³ 0.039 m³ 1.37 ft³

Fill fluid : Water Salinity :

Pigging Speed (m/s)

0.50

Friction Factor 0.018702562 Pressure Drop At Pigging Speed

Pig Differential Pump Rate (m³/min) Head Loss (metres) Reynolds Number 5.2 psi =

3.5 % Bar

1.16 3.40 85813 0.36

bar

Chemical Additive Injection Rates Chemical Ihibitor Tracer dye

1 2 3 4

PRESSURE TEST PARAMETERS Volume to pressurise pipeline : Corresponding Inlet (0-bar) Volume : Volume change per bar at test pressure : Temp ºC 0.7 1.4 2.1 2.8 3.3 4.0 4.0

p.p.m. 1000.0 50.0

Injection Rate (litres/min) 1.160 0.058

Test press. Temp. 2.452 m³ 2.496 m³ 5.60 litres

Compressibility Coeff Expan. (bar)¯¹ (deg C)¯¹ 4.16E-05 1.83E-04 4.14E-05 1.87E-04 4.13E-05 1.91E-04 4.11E-05 1.94E-04 4.10E-05 1.98E-04 4.09E-05 2.01E-04 4.07E-05 2.04E-04 (Test) 4.07E-05 2.04E-04 Average pressure change per degree C (bar): Fraction of external pressure added internally:

413.0 bar g 4.0 'C

Pressure change bar/ºC 3.15 3.24 3.33 3.42 3.51 3.58 3.67 3.67 3.42 0.128

Date produced:

11-Nov-12

Customer

Saipem

Location

Bonga Northwest

Pipeline Description:

Production Flowline 15 (PFL 15) API-5L-X65 OD:263.1mm Wt:20.6mm x 3.182km

Pipeline Length (km) Internal Diameter (m) Total Vol. (imp. gals) Volume per ft (gals) Total Volume (ft³)

3.18 0.222 2.71E+04 2.59 4.35E+03

km m I.gal gal ft³

Outside Diameter (m) Pipeline Lay Total Volume (m³) Vol. per metre (m³) Vol. per metre (ft³)

PIGGING PARAMETERS

0.263 m Unrestrained 123.1 m³ 0.039 m³ 1.37 ft³

Fill fluid : Water Salinity :

Pigging Speed (m/s)

0.50

Friction Factor 0.018702562 Pressure Drop At Pigging Speed

Pig Differential Pump Rate (m³/min) Head Loss (metres) Reynolds Number 5.2 psi =

3.5 % Bar

1.16 3.42 85813 0.36

bar

Chemical Additive Injection Rates Chemical Ihibitor Tracer dye

1 2 3 4

PRESSURE TEST PARAMETERS Volume to pressurise pipeline : Corresponding Inlet (0-bar) Volume : Volume change per bar at test pressure : Temp ºC 0.7 1.4 2.1 2.8 3.3 4.0 4.0

p.p.m. 1000.0 50.0

Injection Rate (litres/min) 1.160 0.058

Test press. Temp. 2.465 m³ 2.509 m³ 5.63 litres

Compressibility Coeff Expan. (bar)¯¹ (deg C)¯¹ 4.16E-05 1.83E-04 4.14E-05 1.87E-04 4.13E-05 1.91E-04 4.11E-05 1.94E-04 4.10E-05 1.98E-04 4.09E-05 2.01E-04 4.07E-05 2.04E-04 (Test) 4.07E-05 2.04E-04 Average pressure change per degree C (bar): Fraction of external pressure added internally:

413.0 bar g 4.0 'C

Pressure change bar/ºC 3.15 3.24 3.33 3.42 3.51 3.58 3.67 3.67 3.42 0.128

Date produced:

11-Nov-12

Customer

Saipem

Location

Bonga Northwest

Pipeline Description:

Production Flowline 16 (PFL 16) API-5L-X65 OD:263.1mm Wt:20.6mm x 3.216km

Pipeline Length (km) Internal Diameter (m) Total Vol. (imp. gals) Volume per ft (gals) Total Volume (ft³)

3.22 0.222 2.74E+04 2.59 4.39E+03

km m I.gal gal ft³

Outside Diameter (m) Pipeline Lay Total Volume (m³) Vol. per metre (m³) Vol. per metre (ft³)

PIGGING PARAMETERS

0.263 m Unrestrained 124.4 m³ 0.039 m³ 1.37 ft³

Fill fluid : Water Salinity :

Pigging Speed (m/s)

0.50

Friction Factor 0.018702562 Pressure Drop At Pigging Speed

Pig Differential Pump Rate (m³/min) Head Loss (metres) Reynolds Number 5.2 psi =

3.5 % Bar

1.16 3.45 85813 0.36

bar

Chemical Additive Injection Rates Chemical Ihibitor Tracer dye

1 2 3 4

PRESSURE TEST PARAMETERS Volume to pressurise pipeline : Corresponding Inlet (0-bar) Volume : Volume change per bar at test pressure : Temp ºC 0.7 1.4 2.1 2.8 3.3 4.0 4.0

p.p.m. 1000.0 50.0

Injection Rate (litres/min) 1.160 0.058

Test press. Temp. 2.491 m³ 2.536 m³ 5.70 litres

Compressibility Coeff Expan. (bar)¯¹ (deg C)¯¹ 4.16E-05 1.83E-04 4.14E-05 1.87E-04 4.13E-05 1.91E-04 4.11E-05 1.94E-04 4.10E-05 1.98E-04 4.09E-05 2.01E-04 4.07E-05 2.04E-04 (Test) 4.07E-05 2.04E-04 Average pressure change per degree C (bar): Fraction of external pressure added internally:

413.0 bar g 4.0 'C

Pressure change bar/ºC 3.15 3.24 3.33 3.42 3.51 3.58 3.67 3.67 3.42 0.128

Date produced:

11-Nov-12

Customer

Saipem

Location

Bonga Northwest

Pipeline Description:

Water Injection Flowline 04 (WFL 04) API-5L-X65 OD:323.9mm Wt:20.6mm x 4.108km

Pipeline Length (km) Internal Diameter (m) Total Vol. (imp. gals) Volume per ft (gals) Total Volume (ft³)

4.11 0.283 5.67E+04 4.21 9.11E+03

km m I.gal gal ft³

Outside Diameter (m) Pipeline Lay Total Volume (m³) Vol. per metre (m³) Vol. per metre (ft³)

PIGGING PARAMETERS

0.324 m Unrestrained 257.9 m³ 0.063 m³ 2.22 ft³

Fill fluid : Water Salinity :

Pigging Speed (m/s)

0.50

Friction Factor 0.017826732 Pressure Drop At Pigging Speed

Pig Differential Pump Rate (m³/min) Head Loss (metres) Reynolds Number 5.0 psi =

3.5 % Bar

1.88 3.30 109326 0.35

bar

Chemical Additive Injection Rates Chemical Ihibitor Tracer dye

1 2 3 4

PRESSURE TEST PARAMETERS Volume to pressurise pipeline : Corresponding Inlet (0-bar) Volume : Volume change per bar at test pressure : Temp ºC 0.7 1.4 2.1 2.8 3.3 4.0 4.0

p.p.m. 1000.0 50.0

Injection Rate (litres/min) 1.883 0.094

Test press. Temp. 5.430 m³ 5.530 m³ 12.12 litres

Compressibility Coeff Expan. (bar)¯¹ (deg C)¯¹ 4.14E-05 1.85E-04 4.13E-05 1.89E-04 4.11E-05 1.93E-04 4.10E-05 1.96E-04 4.09E-05 2.00E-04 4.08E-05 2.03E-04 4.06E-05 2.06E-04 (Test) 4.06E-05 2.06E-04 Average pressure change per degree C (bar): Fraction of external pressure added internally:

423.0 bar g 4.0 'C

Pressure change bar/ºC 3.12 3.21 3.29 3.38 3.47 3.53 3.61 3.61 3.37 0.154

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

6.8

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Valve Status Checksheet

Production Flowlines valve status for FCG/Hydrotest/Handover

Note: All valves are ROV operable

HPPS Document No: UK-120059-PR-006 Rev R01 Page 86 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Water Injection Flowlines valve status for FCG/Hydrotest/Handover

Note: All valves are ROV operable

Flowline Characteristics

Production Flowline Characteristics

HPPS Document No: UK-120059-PR-006 Rev R01 Page 87 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

Water Injection Flowline Characteristics

HPPS Document No: UK-120059-PR-006 Rev R01 Page 88 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

APPENDIX 1 DRAWINGS Title

Drawing Number

Sheets

Revision

Bonga Northwest Field Layout

Fig 1.0

1

0

SPHU Operations Schematic

Fig 1.1

1

0

Subsea Datalogger (c/w SPHU Interface)

Fig 6.0

1

0

Subsea Datalogger (configured for system depressurisation) SPHU Equipment Setup without ROV Interface SPHU Equipment Setup with ROV Interface

Fig 6.1

1

0

1

0

1

0

1

0

Chemical Transfer Equipment set up

UK-120059-DR-008 UK-120059-DR-009 UK-120059-DR-010

HPPS Document No: UK-120059-PR-006 Rev R01 Page 89 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

CV-01 CV-02 DV-1 HTV-01 PRV HTV-02 3/4" HOSE CONNECTION HTV-03 3/4" HOSE CONNECTION HTV-04

VV-01

HTV-05

SPHU

DEEPSTAR FEMALE RECEPTACLE FILTER

HARBEN P/P HB-1

FILTER LPV-01

HPV-01 OUTLET

INLET CHEMICAL FILL POINTS HPV-02 CHEMICAL BAG

CHEMICAL BAG

BOOST P/P CF-01

FILTERS

CF-02

HALLIBURTON 0 12-11-12

FIRST ISSUE

R.M

C.E.

NTS

DRAWING SIZE

A3

SPHU EQUIPMENT SETUP WITHOUT ROV INTERFACE UK-120059-DR-008

CV-01 CV-02 DV-1 HTV-01 PRV HTV-02 3/4" HOSE CONNECTION HTV-03 3/4" HOSE CONNECTION

ROV INTERFACE

HTV-04 SUPPLY

RETURN

CASE

VV-01

HTV-05

FLOWMETER

HPU

HYDRAULIC BUNDLE

SPHU

DEEPSTAR FEMALE RECEPTACLE FILTER

HARBEN P/P HB-1

FILTER LPV-01

HPV-01 OUTLET

INLET CHEMICAL FILL POINTS HPV-02 CHEMICAL BAG

CHEMICAL BAG

BOOST P/P CF-01

FILTERS

CF-02

HALLIBURTON 0 12-11-12

FIRST ISSUE

R.M

C.E.

NTS

DRAWING SIZE

A3

SPHU EQUIPMENT SETUP WITH ROV INTERFACE UK-120059-DR-009

SPHU

FILTERS

CF-01 / CF-02

CHEMICAL BAG

1/2" PVC CLEAR HOSE CROSSOVER FITTING

AIR SUPPLY 7 BAR @ 200scfm

1/2" B.S.P. HOSE

I.B.C. TANK

FV-01 IBC TK. ISOLATION V/V

DIAPHRAGM PUMP

FV-02 PUMP ISOLATION V/V

HALLIBURTON 0 12-11-12

FIRST ISSUE

R.M

CHEMICAL TRANSFER EQUIPMENT SETUP

C.E.

NTS

DRAWING SIZE

A3

UK-120059-DR-010

SNEPCO-BMIP-BNW and Saipem Consortium – led by SCNL. D01938 - Fabrication of Flowlines & provision of Subsea Installation Services

Document No.: Document Title:

BMIP-BNW-D01938-LA- Rev. R01 6180-00129-000 HPPS FLOWLINE PRECOMMISSIONING – PRODUCTION & WI FLOWLINES CLEANING, FLOODING, PIGGING, GAUGING AND HYDROTESTING PROCEDURE

APPENDIX 2 RISK ASSESSMENTS Title PPS Manual Handling Communication Environment PPS Rig-Up-Equipment PPS Rig-Down Equipment & Backload PPS Hydrotesting Working At Height Flooding

Document Number RA-GL-HAL-PPS-444 RA-GL-HAL-PPS-405 RA-GL-HAL-PPS-406 RA-GL-HAL-PPS-407 RA-GL-HAL-PPS-408 RA-GL-HAL-PPS-403 RA-GL-HAL-PPS-445 RA-GL-HAL-PPS-402

HPPS Document No: UK-120059-PR-006 Rev R01 Page 90 of 91 Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written permission from Shell Nigeria Exploration and Production Company Ltd.

RISK ASSESSMENT Title:

HALLIBURTON MANAGEMENT SYSTEM

PPS MANUAL HANDLING REGION: Europe West Africa OWNER: Iain Shepherd

APPROVED BY: Gordon Macnab

DOCUMENT NUMBER: FUNCTION/PSL: Pipeline & Process Services REVISION BY: Richard Voisey

RA-UK-HAL-PPS-444 REV. DATE: th 12 march 2010

REV. NO: 0

PAGE: 1 of 4

RISK ANALYSIS MATRIX Potential Consequences Hazard Severity Category

Probability Rating A Frequent

B Reasonably Probable

C Occasional

D Remote

E Extremely Improbable

F Impossible

Potentially harms or adversely affects the general public and has the potential for widespread public concern of Halliburton operations. Can have serious economic liability on the operation.

1

1

1

2

3

3

$200,000 to $1,000,000

Potentially harms or adversely affects trained employees and the environment. Requires specialised expertise or resources for correction.

1

1

2

3

3

3

Minor Injury or Illness

>$10,000 to $200,000

Presents limited harm to the environment and requires general expertise and resources for correction

2

2

3

3

3

3

No Injury or Illness

$1,000,000

2

Critical

Severe Injury or illness

3

Marginal

4

Negligible

Environmental (Any incident that…)

PROBABILITY RATING JOB INFORMATION AND SUPERVISORY COMPLIANCE SIGNATURE CLIENT

JOB DETAILS

LOCATION

SUPERVISOR / ENGINEER RESPONSIBLE FOR REVIEWING THE RISK ASSESSMENT WITH HIS CREW NAME (PRINT)

SIGNATURE

JOB POSITION

DATE

NOTE : The remainder of the HPPS crew should sign the Pipeline or Process Toolbox Talk Checklist FO-UK-HAL-PPS-401/402 to acknowledge that they been involved the risk assessment review of the job.

RISK ASSESSMENT CARRIED OUT BY:

G.Howard DATE: 20/08/09

APPROVED: G. Macnab

DATE: 22/08/09

LEVEL DESCRIPTION A. FREQUENT: Likely to occur repeatedly during activity/operation. B. REASONABLY PROBABLE: Likely to occur several times. C. OCCASIONAL: Likely to occur sometime. D. REMOTE: Not likely but possible. E. EXTREMELY IMPROBABLE: Probability of occurrence cannot be distinguished from zero.

RISK PRIORITY CODE (RPC) CODE ACTION REQUIRED 1.

HIGH RISK: Imperative to suppress risk to lower level. 2. MEDIUM RISK: Operations may be require waiver endorsed by management. 3. OPERATION PERMISSABLE: Note: Risk priority code of less than 3 is NOT ACCEPTABLE for hazards that target personnel

RISK ASSESSMENT Title:

HALLIBURTON MANAGEMENT SYSTEM

MANUAL HANDLING REGION: Europe West Africa OWNER: Iain Shepherd

APPROVED BY: Gordon Macnab

DOCUMENT NUMBER: FUNCTION/PSL: Pipeline & Process Services REVISION BY: Richard Voisey

INITIAL RISK

Remarks ALL PERSONNEL HAVE THE AUTHORITY AND RESPONSIBILITY TO STOP A JOB IF THEY ARE CONCERNED ABOUT THE SAFETY OF THE

T A R G E T

OPERATION.

S E V E R I T Y

R P C

TASK

HAZARD

HAZARD EFFECT

• Bodily injury

P

III

B

2

Manual handling

• Slippery or uneven ground • Improper use of lift equip. or component failure (i.e. slings) • Insufficient Training • Moving equipment/loads • Poor communication • Weather / poor visibility

• Equipment damage

E

III

B

2

Pinch Points

Pulling /Pushing

TARGETS:

• • • •

Hammers Equipment moves Truck Tool Boxes Discharge line/Pump

• Moving Hoses • Uncentered Lifts

• Bodily injury

P – PEOPLE

RISK ASSESSMENT CARRIED OUT BY:

• Bodily injury

R. Voisey & J. Page

P

P

E – EQUIPMENT DATE: 12/03/2010

III

III

B

B

REV. NO: 0

PAGE: 2 of 4

RESIDUAL RISK

RISK REDUCTION CONTROL MEASURES Note 1:

P R O B A B I L I T Y

RA-UK-HAL-PPS-444 REV. DATE: 12th August 09

Personnel need to be aware of, & take precautions against, the following hazards which may be applicable to all steps of the task. Manual Handling / Slips & Trips / Pinch Points

Note 2:

Personnel need to wear the appropriate PPE for the task at all times

Note 3:

All relevant permits to be in place prior to an operation commencing.

Note 4:

Where applicable hold a Toolbox Talk and produce a Lift Plan.

• • • • • •

Use proper lifting techniques or equipment Obtain assistance as required Appropriate training, authorized personnel only Be aware of shifting load Clear area of personnel not required Communicate instructions clearly to all involved and during job (radios, hand signals) • Use designated banksman Use Taglines

S E V E R I T Y

P R O B A B I L I T Y

III

C

3

III

C

3

R P C

2

• • • • • • • •

PPE Proper Body Position Create a Safe Work Area Use Appropriate Tools for the job Use Tools Properly UtiliseTag Lines Inspect Tools on a regular basis Don't rush lifting operations

III

C

3

2

• • • • •

Proper Techniques Refuse Unsafe Work Use More People where possible Balance the loads Use Tag/Securing lines

III

C

3

ENV – ENVIRONMENTAL APPROVED: G. Macnab

DATE: 15/03/2010

DT – DOWNTIME

M – MATERIALS

A C C E P T A B L E

RISK ASSESSMENT Title:

HALLIBURTON MANAGEMENT SYSTEM

MANUAL HANDLING REGION: Europe West Africa OWNER: Iain Shepherd

APPROVED BY: Gordon Macnab

DOCUMENT NUMBER: FUNCTION/PSL: Pipeline & Process Services REVISION BY: Richard Voisey

INITIAL RISK

Remarks ALL PERSONNEL HAVE THE AUTHORITY AND RESPONSIBILITY TO STOP A JOB IF THEY ARE CONCERNED ABOUT THE SAFETY OF THE

T A R G E T

OPERATION.

TASK

Congested Area

Lighting

Improper spotting of equipment / materials

TARGETS:

HAZARD

• • • • • •

HAZARD EFFECT

Poor Rig Up/Down Space Constraints Multi Site Traffic Vehicular People

• None • Little

• • • •

S E V E R I T Y

REV. NO: 0

PAGE: 3 of 4

RESIDUAL RISK

RISK REDUCTION CONTROL MEASURES Note 1:

P R O B A B I L I T Y

RA-UK-HAL-PPS-444 REV. DATE: 12th August 09

R P C

• Bodily injury

P

III

B

2

• Equipment damage

E

III

B

2

• Bodily injury

P

III

B

2

Personnel need to be aware of, & take precautions against, the following hazards which may be applicable to all steps of the task. Manual Handling / Slips & Trips / Pinch Points

Note 2:

Personnel need to wear the appropriate PPE for the task at all times

Note 3:

All relevant permits to be in place prior to an operation commencing.

Note 4:

Where applicable hold a Toolbox Talk and produce a Lift Plan.

• Plans/Schedules for the FPSO PTW system • Signage/Awareness • Effective Communication Remove all unnecessary equipment from area

S E V E R I T Y

P R O B A B I L I T Y

III

C

3

III

C

3

III

C

3

R P C

• Provide Light in the right places

Poor weather conditions Human error Poor communication Poor visibility

• Equipment damage

E

III

B

2

III

C

3

• Bodily injury

P

III

B

2

II

D

3

• Equipment damage

E

III

B

2

II

D

3

• Environmental

E N V

II

C

2

II

D

3

P – PEOPLE

RISK ASSESSMENT CARRIED OUT BY:

R. Voisey & J. Page

E – EQUIPMENT DATE: 12/03/2010

• Where possible plan laydown of equipment prior to lifting ops being undertaken, walk around equipment to determine hazards. • Discuss spotting of equipment in ToolboxTalk

ENV – ENVIRONMENTAL APPROVED: G. Macnab

DATE: 15/03/2010

DT – DOWNTIME

M – MATERIALS

A C C E P T A B L E

RISK ASSESSMENT Title:

HALLIBURTON MANAGEMENT SYSTEM

MANUAL HANDLING REGION: Europe West Africa OWNER: Iain Shepherd

APPROVED BY: Gordon Macnab

DOCUMENT NUMBER: FUNCTION/PSL: Pipeline & Process Services REVISION BY: Richard Voisey

INITIAL RISK

Remarks ALL PERSONNEL HAVE THE AUTHORITY AND RESPONSIBILITY TO STOP A JOB IF THEY ARE CONCERNED ABOUT THE SAFETY OF THE

T A R G E T

OPERATION.

TASK

HAZARD

HAZARD EFFECT

Contact of hot/cold surfaces

• Running of pumps • Elevated temperatures

• Bodily injury

Flying objects Projectiles

• Tools • Foreign objects (i.e. metal shards) Dropped objects

• Bodily injury

Hand tools

• Improper handling of tools

Heat stress

• Over exertion/fatigue

TARGETS:

P – PEOPLE

RISK ASSESSMENT CARRIED OUT BY:

R. Voisey & J. Page

S E V E R I T Y

REV. NO: 0

PAGE: 4 of 4

RESIDUAL RISK

RISK REDUCTION CONTROL MEASURES Note 1:

P R O B A B I L I T Y

RA-UK-HAL-PPS-444 REV. DATE: 12th August 09

R P C

Personnel need to be aware of, & take precautions against, the following hazards which may be applicable to all steps of the task. Manual Handling / Slips & Trips / Pinch Points

Note 2:

Personnel need to wear the appropriate PPE for the task at all times

Note 3:

All relevant permits to be in place prior to an operation commencing.

Note 4:

Where applicable hold a Toolbox Talk and produce a Lift Plan.

S E V E R I T Y

P R O B A B I L I T Y

III

C

3

II

D

3

II

D

3

R P C

P

III

B

2

P

II

C

2

E

II

C

2

• Bodily injury

P

III

B

2

• Protect exposed skin (i.e. gloves) • Use tools appropriate to the job • Job specific training

III

C

3

• Bodily injury

P

III

B

2

• Provide sufficient fluids/Breaks as needed

III

C

3

E – EQUIPMENT DATE: 12/03/2010

• Protect exposed skin (e.g.. gloves, coveralls)

• Watch line of fire • Ensure face & eye protection is worn

ENV – ENVIRONMENTAL APPROVED: G. Macnab

DATE: 15/03/2010

DT – DOWNTIME

M – MATERIALS

A C C E P T A B L E

Title:

HALLIBURTON MANAGEMENT SYSTEM

PIPELINE – COMMUNICATION REGION: Global OWNER: B&C HMS Coordinator

APPROVED BY: Steve Arrington

DOCUMENT NUMBER:

FUNCTION/PSL: Pipeline & Process Services REVISION BY: Malcolm MacMillan

RA-GL-HAL-PPS-405 REV. DATE: 01.SEPT.2011

REV. NO: 1.0

PAGE: 1 of 3

RISK ANALYSIS MATRIX Potential Consequences Hazard Severity Category

Personal Illness/ Injury Fatal or permanent disabling injury or illness Severe Injury or illness

Descriptive Word

1

Catastrophic

2

Critical

3

Marginal

Minor Injury or Illness

4

Negligible

No Injury or Illness

Probability Rating

Equipment Loss(s)

Environmental (Any incident that…)

A Frequent

B Reasonably Probable

> $1,000,000

Potentially harms or adversely affects the general public and has the potential for widespread public concern of Halliburton operations. Can have serious economic liability on the operation.

1

1

1

2

3

3

Potentially harms or adversely affects trained employees and the environment. Requires specialised expertise or resources for correction.

1

1

2

3

3

3

Presents limited harm to the environment and requires general expertise and resources for correction

2

2

3

3

3

3

Presents limited harm to the environment and requires minor corrective actions (CPI).

3

3

3

3

3

3

$200,000 to $1,000,000 >$10,000 to $200,000 $1,000,00 0

Potentially harms or adversely affects the general public and has the potential for widespread public concern of Halliburton operations. Can have serious economic liability on the operation.

1

1

1

2

3

3

Potentially harms or adversely affects trained employees and the environment. Requires specialised expertise or resources for correction.

1

1

2

3

3

3

Presents limited harm to the environment and requires general expertise and resources for correction

2

2

3

3

3

3

Presents limited harm to the environment and requires minor corrective actions (CPI).

3

3

3

3

3

3

$200,000 to $1,000,000 >$10,000 to $200,000 $1,000,000

Potentially harms or adversely affects the general public and has the potential for widespread public concern of Halliburton operations. Can have serious economic liability on the operation.

1

1

1

2

3

3

Potentially harms or adversely affects trained employees and the environment. Requires specialised expertise or resources for correction.

1

1

2

3

3

3

Presents limited harm to the environment and requires general expertise and resources for correction

2

2

3

3

3

3

Presents limited harm to the environment and requires minor corrective actions (CPI).

3

3

3

3

3

3

$200,000 to $1,000,000 >$10,000 to $200,000 $1,000,000

Potentially harms or adversely affects the general public and has the potential for widespread public concern of Halliburton operations. Can have serious economic liability on the operation.

1

1

1

2

3

3

Potentially harms or adversely affects trained employees and the environment. Requires specialised expertise or resources for correction.

1

1

2

3

3

3

Presents limited harm to the environment and requires general expertise and resources for correction

2

2

3

3

3

3

Presents limited harm to the environment and requires minor corrective actions (CPI).

3

3

3

3

3

3

$200,000 to $1,000,000 >$10,000 to $200,000 $1,000,000

II

Critical

Severe Injury or illness

III

Marginal

IV

Negligible

Probability Rating A Frequent

B Reasonably Probable

C Occasional

D Remote

E Extremely Improbable

F Impossible

Potentially harms or adversely affects the general public and has the potential for widespread public concern of Halliburton operations. Can have serious economic liability on the operation.

1

1

1

2

3

3

$200,000 to $1,000,000

Potentially harms or adversely affects trained employees and the environment. Requires specialised expertise or resources for correction.

1

1

2

3

3

3

Minor Injury or Illness

>$10,000 to $200,000

Presents limited harm to the environment and requires general expertise and resources for correction

2

2

3

3

3

3

No Injury or Illness

$1,000,00 0

Potentially harms or adversely affects the general public and has the potential for widespread public concern of Halliburton operations. Can have serious economic liability on the operation.

1

1

1

2

3

3

Potentially harms or adversely affects trained employees and the environment. Requires specialised expertise or resources for correction.

1

1

2

3

3

3

Presents limited harm to the environment and requires general expertise and resources for correction

2

2

3

3

3

3

Presents limited harm to the environment and requires minor corrective actions (CPI).

3

3

3

3

3

3

$200,000 to $1,000,000 >$10,000 to $200,000 $1,000,000

II

Critical

Severe Injury or illness

III

Marginal

IV

Negligible

Probability Rating A Frequent

B Reasonably Probable

C Occasional

D Remote

E Extremely Improbable

F Impossible

Potentially harms or adversely affects the general public and has the potential for widespread public concern of Halliburton operations. Can have serious economic liability on the operation.

1

1

1

2

3

3

$200,000 to $1,000,000

Potentially harms or adversely affects trained employees and the environment. Requires specialised expertise or resources for correction.

1

1

2

3

3

3

Minor Injury or Illness

>$10,000 to $200,000

Presents limited harm to the environment and requires general expertise and resources for correction

2

2

3

3

3

3

No Injury or Illness

$1,000,000

II

Critical

Severe Injury or illness

III

Marginal

IV

Negligible

Probability Rating A Frequent

B Reasonably Probable

C Occasional

D Remote

E Extremely Improbable

F Impossible

Potentially harms or adversely affects the general public and has the potential for widespread public concern of Halliburton operations. Can have serious economic liability on the operation.

1

1

1

2

3

3

$200,000 to $1,000,000

Potentially harms or adversely affects trained employees and the environment. Requires specialised expertise or resources for correction.

1

1

2

3

3

3

Minor Injury or Illness

>$10,000 to $200,000

Presents limited harm to the environment and requires general expertise and resources for correction

2

2

3

3

3

3

No Injury or Illness