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ASSEMBLING AND TESTING SUB-SEA HOSE STRING

1.

OBJECTIVE
The object of this procedure is to ensure that personnel involved in the assembly of the two Submarine Hose Strings, are aware of the methods to be employed.

NOTE 1:

NO DEVIATION FROM PROCEDURE IS ALLOWED WITHOUT APPROVAL OF THE COMPANY SITE REPRESENTATIVE& MARINE OPERATIONS MAINTENANCE MANAGER.

2. PRELIMINARY VISUAL INSPECTION Step Task


1 2 3 4 5 6 Prior to commencing work visually examine all hoses in the warehouse (or other location) for signs of damage, including hose bores. If necessary use a certified crane to gain all-round access. Using a hand torch, or similar, examine the exterior cover of each hose for signs of cuts, gouges, abrasion etc. mark as appropriate Check white and orange floatation modules are attached in correct location as per the appended float plan Check the orange floatation modules for signs of damage and mark as appropriate. Examine the steel clamps and hinges for damage and ensure that the locking (split) pins are all in place and further check that the turn-buckle screw is in the centre and not touching the hinge pins. Ensure that temporary white floatation modules (or other) are firmly attached using 8mm nylon rope, and or, cargo straps. Examine the flanges and steel fittings at the end of each hose for damage, in particular check the flange face seal area for scratches, gouges, dents etc. Check the leak detector valve assembly, or device, on each hose for damage, look for bends/twists in pipe-work and valves etc. Ensure that no parts are missing and that valves are in the CLOSED position. Check the bore of each hose and ensure that each is clean and that no foreign bodies are inside. Look for cuts, gouges, ovality, or unusual signs

Action

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2.1 PREPARATION OF WORK AREA Step Task


STOP BEFORE PROCEEDING TO STEP 12: IF THERE IS ANY SIGN OF ANY DAMAGE WHATSOEVER THEN IT MUST BE PHOTOGRAPHED, RECORDED AND BROUGHT TO THE IMMEDIATE ATTENTION OF THE SUPERVISOR, AND CLIENT M REPRESENTATIVE AND MANUFACTURER Prepare assembly area - clear and tidy work area ensure there are no sharp protrusions in the lay down or handling area. Prepare Storage area clear and tidy. Check security of floatation modules, re-secure as necessary Prepare and check lifting equipment, cranes and transport facilities Erect exclusion/safety barriers where necessary. HOSES MUST ONLY BE LIFTED USING A LOAD TESTED AND CERTIFIED SPREADER BEAM COMPLETE WITH NEW CERTIFIED WEBBING STROPS WITH MINIMUM LENGTH 3 METRES, LIFTING EQUIPMENT AND SHACKLES RATED TO 3 TONNE SWL. OR A SUITABLE LIFTING LIFTING SLING ARRANGEMENT. DO NOT USE WIRE STROPS ON THE HOSE CARCASS. Using overhead crane, trailer and or pedestal crane etc. transfer the hoses to the appointed assembly area. HOSES MUST ONLY BE LIFTED USING A LOAD TESTED AND CERTIFIED SPREADER BEAM COMPLETE WITH NEW CERTIFIED WEBBING STROPS WITH MINIMUM LENGTH 3 METRES, LIFTING EQUIPMENT AND SHACKLES RATED TO 3 TONNE SWL. OR A SUITABLE LIFTING LIFTING SLING ARRANGEMENT. DO NOT USE WIRE STROPS ON THE HOSE CARCASS. Using overhead crane, trailer and or pedestal crane etc. transfer the hoses to the appointed assembly area.

Action

11 12 13 14 15 STOP

15 STOP

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2.2 SUB-SEA HOSE STRING ASSEMBLY Step Task


STOP BEFORE PROCEEDING TO STEP 18 REFER TO SUB-SEA HOSE FLOAT PLAN. SELECT THE APPROPRIATE HOSE TYPES (4 OFF) TO MAKE UP ONE SUBMARINE HOSE STRING. PREPARE 3 OFF UMBILICAL SUPPORT CLAMPS The hose selected to be nearest the SPM (1st off SPM hose) should be moved and laid down first as the hose string will be towed from this end. (i.e. with towing flange nearest sea) It may be necessary to rotate hoses in order to align the white lines on each hose. IT IS IMPORTANT TO ENSURE THAT THE WHITE LINE ON EACH HOSE IS IN LINE WITH THE ADJACENT HOSE PRIOR TO ASSEMBLY. Insert 20g of fluorescent dye into the flange furthest from the Buoy end. SUB-SEA HOSE STRING ASSEMBLY (Continued) Using a suitable certified crane, slings and rigging adjust and align the respective flange bolt holes. BEFORE PROCEEDING TO STEP 18 REFER TO SUB-SEA HOSE FLOAT PLAN WP06/DS01 Fit correct type stud-bolts & gasket type. Recommended stud-bolts 1 dia. PTFE coated 5.5 long except for the umbilical support brackets. Fit one umbilical support bracket on the 3 flanges in accordance with the above plan Pre- tension stud-bolts in accordance procedure manufactures procedure. Check all float modules and umbilical support brackets and re-secure if necessary.

Action

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18 STOP 19 20 21

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2.3 SUB-SEA HOSE STRING PRESSURE TEST Step Task


25 26 27 28 Fit a 16 suitable ASA 150 blank with fire main filling connection and gasket to the SPM flange and pre-tension the bolts as per manufacturesprocedure Raise the PLEM end hose end approximately 1m. and support to allow venting of any entrapped air. Fit drip tray or similar under the hose end. Begin filling hose with water from fire main, a watchman is to placed at the raise PLEM end of the hose and when almost full with water STOP filling. Fit a suitable 16 ASA 150 pressure blank complete with venting valves and large scale gauge (8 or 200mm minimum dia), to the PLEM end and pretension the bolts as per manufactures procedure. Open vent valve and continue to fill hose string with water until all air is expelled THE VENT VALVE MUST NOT BE CLOSED DURING FILLING. When hose string is full of water/dye mixture and all air has been expelled stop filling and close all appropriate valves. Install/fit chart recorder to PLEM hose blank flange, paying close attention to the following: Chart is installed correctly Correctly aligned to the actual time of day The timer mechanism has been wound up fully The pen is installed and functioning. Install/fit pressure pump, c/w valves, hoses and fittings, to 16 end and to supply tank. Prime the pump, all hoses and valves by filling with water dye mixture. Open/close all appropriate valves, start pump and slowly raise internal pressure of hose string to 15 barg. OR, such pressure as designated by Shell. Stop pump and allow 15 minutes for pressure to stabilize. Use pump as necessary to top-up pressure to 15 barg. OR other pressure as appropriate Allow a further 15 minutes for pressure to stabilize, top-up as necessary The pressure test may commence once the test pressure (15 bar or other) has stabilized. The pressure should be recorded every 10 minutes over a period of 3 hours, logging the pressure against time and inserting the actual/physical time. (see graph in EXCEL. Upon successful completion slowly depressurize hose string to ambient pressure. Any contaminated water and or slops should be carefully removed, testing blanks removed, cleaned and safely stored All items of the inspection and testing will be recorded. Copies of the certification and hydrostatic graphs shall be held in a specific project file. History cards will be produced for the hoses and the test data will be recorded on specific data sheets by the UABSO Representative.

Action

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2.4 SUB-SEA HOSE STRING PREPARATION FOR TOWING Step Task


39 40 Attach the 16 towing blank complete with air injection ports to the first off the buoy end. Attach 40m of 40mm towing rope using a 13.5 ton bow type safety shackle, ensure that a split pin is inserted and fully splayed back to prevent loss of the pin/nut Attach the 16 towing PLEM end of the hose, (this is a contingency). Attach 40m of 40mm towing rope using a 13.5 ton bow type safety shackle, ensure that a split pin is inserted and fully splayed back to prevent loss of the pin/nut Attach a Norwegian pellet buoy if towing during daylight hours or a floating light if towing during hours of darkness Attach a 2.5 ton lifting bag to the nipple area on the PLEM side of the first off PLEM hose to centre hose flange using a 3 ton soft stop which is to be choked at the 12 Oclock position. Lifting bag is to be firmly attached using 8mm nylon rope with the inflation point facing away from the direction of tow so as not to inflate during the tow.

Action

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BUOY END

1.5m

BUOY END
TEMPORARY FLOATATION

DIRECTION OF TOW

HOSE CONFIGURATION MARK

TEMPORARY FLOATATION

DIRECTION TOW TEMPORARY FLOATATION RED 697 mm FLOAT MBC BREAKAWAY COUPLING PLEM END

RED 697mm Float

RED 697mm Float

MBC
RED 697mm Float 3m HOSE CONFIGURATION MARK RED 581mm Float RED 581mm Float RED 581mm Float RED 581mm Float RED 697mm Float 3m HOSE CONFIGURATION MARK RED 697mm Float RED 581mm Float TEMPORARY FLOATATION TEMPORARY FLOATATION 1.5m HOSE CONFIGURATION MARK

HOSE #1 PLEM END HOSE #3 HOSE #2

BREAK AWAY COUPLING