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JANUARY, 2016 DOCUMENT NUMBER:

[K2S-NG01007551-SOKG1-MX6180-00003]

Shell Petroleum Development Company of Nigeria

Classification Status: [Restricted]

FABRICATION AND INSTALLATION OF END FACILITIES AT THE SOKU GAS


PLANT
[METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN]

Proprietary Information: This document contains proprietary information and may not be partly or wholly reproduced without prior written
permission from Shell Petroleum Development Company

The Process Manager for this procedure is the Major Projects General Manager, the Process Owner is the Major Projects Project Services
Manager

Revision Date Description Originator Checker Approver

R01 14.01.2016 Issue for Internal Review FELIX ANYANELE T.S. PACURARIU IKENNA ONYEKONWU
ADDITIONAL AGREEMENT/APPROVAL RECORD
PARTY REF IND. NAME SIGN DATE

Revision Philosophy
All revisions for review will be issued at R01, with subsequent R02, R03, etc as required.
All revisions approved for issue or design will be issued at A01, with subsequent A02, A03, etc as required.
Documents approved for Construction will be issued at C01, C02, and C03 respectively.
Documents or drawings revised as As built will be issued as Z01, Z02 Z03 etc.
Narrative sections revised from previous approved issues are to be noted in the table below and/or highlighted in
the RH margin (using the appropriate revision status) thus: | A02
Previous revision highlighting to be removed at subsequent issues.
Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected areas and by
the use of a triangle containing the revision status.

Revision History

REVISION NO. DATE OF REASON FOR CHANGE


ISSUE

K2S-NG01007551-SOKG1-MX6180-00003 METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN


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TABLE OF CONTENT

S. NO. DESCRIPTION PAGE


NOS.

1. INTRODUCTION 4

2. SCOPE 4

3. REFERENCES 4

4. RESPONSIBILITIES 5

5. MANPOWER, MACHINERY AND EQUIPMENT 6

6. HSE REQUIREMENTS 7

7. PROCEDURE 7

8. ATTACHMENT 17

K2S-NG01007551-SOKG1-MX6180-00003 METHOD STATEMENT FOR TIE-IN WORKS DURING SHUTDOWN


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1.0 INTRODUCTION

This method statement provides operational guidance and methods to be adopted in carrying out
Tie-in activities during shutdown for the EPC FOR KOLO CREEK TO SOKU GAS EXPORT
PIPELINE Project as per the technical specification and standards applying best industrial practice
and applicable technical specifications and standards.

2.0 SCOPE

The scope is to define the detailed activities for the identified tie-ins during plant shutdown of SOKU
Plant. This shall include the installation of connecting piping works for the shutdown.

3.0 REFERENCES

Project Quality Plan K2S-NG01007551-SOKG1-AA5759-00001

Project HSSE Management plan K2S-NG01007551-SOKG1-HX5798-00001

Construction Plan K2S-NG01007551-SOKG1-BA5736-00002

Procedure for Radiographic Examination K2S-NG01007551-SOKG1-MX6180-00005

Procedure for Ultrasonic testing K2S-NG01007551-SOKG1-MX6180-00009

Procedure for Magnetic Particle Inspection K2S-NG01007551-SOKG1-MX6180-00006

Procedure for Tie-in K2S-NG01007551-SOKG1-MX6180-00001

Approved WPS

Piping General Requirements DEP 31.38.01.11-Gen.

Piping Classes - Refining and Chemicals DEP 31.38.01.12-Gen.

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4. RESPONSIBILITIES

CONSTRUCTION MANAGER

Shall be responsible for:


The construction team by coordinating the various tie-in activities involved during
construction.
The implementation of the Work Procedure and the Inspection and Test Plan during
the shutdown window.

LEAD FIELD SUPERVISOR

Shall be responsible for:


Managing all the resources, developing and managing procedures and processes.
Ensuring that the construction works is sufficiently supported and conducted in
accordance with approved procedures, documents and drawings.
Shall report to the Construction Manager.
Shall be responsible for all raw data quality checks and coordinate with the QA/QC
Inspector in the implementation of the checks as mentioned in the Inspection and
Test plan (ITP).

QA/QC MANAGER
Shall be responsible for:

Preparation of quality plans to ensure the required quality of WORK is attained in accordance
with applicable DEPs, and project specifications.

Verification of activities to ensure shutdown work is in compliance with the procedures or method
statement.

Preparation, monitoring and execution of the Quality Audit Programme.

Liaison with COMPANY representative on all matters relating to the shutdown work and the
planned quality delivery.

QA/QC INSPECTOR
Shall be responsible for:
Reporting to the QA/QC Manager.
Carrying out all field inspections and checking as specified in the ITP in addition to
coordinating with the Company representative.

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HSE COORDINATOR
He shall be responsible for:
Coordinating safety programs regarding the work.
Enforcing safety regulation and maintains safety records
Developing and maintaining the Project Safety Plan.
Verifying program and implementation of HSE procedure by conducting audits.

5.0 PERSONNEL, MACHINERY & EQUIPMENT

5.1 Personnel

S. NO. Personnel

1. Qualified Welders (Structural & Piping)

2. Supervisors (Structural & Piping)

3. Fitters

4. Welder Mates

5. HSE Officers

6. QC Inspectors

7. Hydrotest Team

8. Torquing Team

9. Scaffolders

10. Approved NDT Party

11. Painters (where applicable)

12. Operators (crane, manlift)

5.2 MACHINERY & EQUIPMENT:

S. NO. DESCRIPTION

1. Crane

2. Welding Machines

3. Baking Ovens

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4. PPEs

5. Loader Truck

6. Man Lift
Hydrotest equipment e.g. pressure pump,
7.
chart recorder, gauges, hose, manifold etc)
8. Torque Wrench

6.0 HSE REQUIREMENTS

Prior to commencing the works a detailed Job Hazard Analysis shall be carried out. After all
known, suspected or potential hazards and risks have been identified, the work force shall be
informed of the hazard and control measures that must be put in place to eliminate or control the
hazard and potential risk.
All personnel involved in the shutdown activity shall receive safety training induction
All personnel to be engaged in this work shall be properly mobilized and inducted. This is to
enable them to appreciate the risk hazards involved in the operations.
All workers shall be medically fit to work.
The health, safety and environment of all personnel shall be safeguarded to avoid injuries and
illness.
There shall be a qualified first aider, fully equipped with first aid drugs required in the first aid
administration.
Dedicated site HSE officers shall man all work sites.
An authorized Gas Tester shall carry out Gas Monitoring tests before any isolation work is carried
out, and will then continuously monitor the work atmosphere, he shall ensure that gas monitoring
records are kept.
Warning signs and barriers shall be positioned around all work areas.
All personnel shall wear the appropriate PPE reference Job Specific JHA. All the work force shall
comply with the Contractors Health, Safety and Environment requirements as per the HSE plan.
Only authorized personnel shall be allowed into the work area. All necessary measures as per
Clients requirements or manufacturers recommendations shall be adhered to.

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PTW and the JHA shall be signed off.

7.0 PROCEDURE

Before beginning any shutdown activities Client and Contractor shall agree the programme for the
shutdown work and all the Tie-in area has been verified and checked by the SPDC Operation
Representative.

7.1 Flanged Tie -In:

7.1.1 Production Manifold

Tie-in No. From To existing


TP-006A 12-P-11901-153451 20-P-10502-15350X
TP-006B 12-P-11902-153461 20-P-11902-K2S153834

The mode of operation for the above mentioned tie-in is as indicated in the below table:

S/No TASK STEPS STEP DESCRIPTION REMARKS


Ensure that the lines to be tied into are
well isolated and free of hydrocarbon. SPDC/ Nestoil responsible
Conduct Gas test prior to the for purging of
1 Work area Inspection
commencement of the operation. hydrocarbon if necessary.
Ensure that hot work permit is obtained
prior to start of work. Use of appropriate PPE
Personnel to work
carefully at all times.

Carefully position required equipment Ensure the use of correct


Position the equipment and spool on designated work space. tools and the right PPE.
2
& pipes Lift the spool into position and align it to
the tie-in position. Ensure that all hand held
tools and equipment are
in a good working
condition.
Slack Bolts and remove the existing blind Personnel to work
flange on 20-P-10502-15350X & 20-P- carefully at all times.
10840-153832.
Connect the 12 spool as well as double Ensure the use of correct
block and bleed valves for TP006A (10-BV- tools and the right PPE.
3 Operation 132, 10-BV-133 & 10-BV-134) & TP006B
(10-BV-135, 10-BV-136, 10-BV-137) in Ensure that all hand held
closed position to the existing flanges. tools and equipment are
Ensure bolts and blind flange are properly in a good working
installed and torqued to the approved condition.
values.

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7.1.2 Process flow line from fiscal metering (EGGS-1) to slug catcher

Tie-in No. From To existing


TP-015 2-P-11904-91412 24-P-36009-91410-H

The mode of operation for the above mentioned tie-in is as indicated in the below table:

S/No TASK STEPS STEP DESCRIPTION REMARKS


Ensure that the lines to be tied into are SPDC/ Nestoil responsible
well isolated and free of hydrocarbon. for purging of
Conduct Gas test prior to the hydrocarbon if necessary.
1 Work area Inspection
commencement of the operation.
Ensure that hot work permit is obtained Use of appropriate PPE
prior to start of work.
Personnel to work
carefully at all times.

Carefully position required equipment Ensure the use of correct


Position the equipment and spool on designated work space. tools and the right PPE.
2
& pipes Lift the spool into position and align it to
the tie-in position. Ensure that all hand held
tools and equipment are
in a good working
condition.
Personnel to work
Slack Bolts and remove the existing 2
carefully at all times.
blind flange from line 24-P-36009-91410-
H.
Ensure the use of correct
Connect new 2 spool including a double
tools and the right PPE.
3 Operation block and bleed valves in closed position
(11-BV-008, 11-BV-009, and 11-BV-010).
Ensure that all hand held
Ensure bolts and blind flange are properly
tools and equipment are
installed and torqued to the approved
in a good working
values.
condition.

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7.1.3 Chemical line

Tie-in No. From To existing


TP-001 2-C-64319-151412 2-C-64564-151410

The mode of operation for the above mentioned tie-in is as indicated in the below table:

S/No TASK STEPS STEP DESCRIPTION REMARKS


Ensure that the lines to be tied into are SPDC/ Nestoil responsible
well isolated and free of methanol. for freeing the system of
Conduct Gas test prior to the methanol if necessary.
1 Work area Inspection
commencement of the operation.
Ensure that hot work permit is obtained Use of appropriate PPE
prior to start of work.
Personnel to work
carefully at all times.

Carefully position required equipment Ensure the use of correct


Position the equipment and spool on designated work space. tools and the right PPE.
2
& pipes Lift the spool into position and align it to
the tie-in position. Ensure that all hand held
tools and equipment are
in a good working
condition.
Personnel to work
carefully at all times.
Loosen blind on line 2-C-64564-151410.
Install 2 spool with double block and
Ensure the use of correct
bleed valves (64-BV-001, 64-BV-002, and
tools and the right PPE.
3 Operation 64-BV-023).
Ensure bolts and blind flange are properly
Ensure that all hand held
installed and torqued to the approved
tools and equipment are
values.
in a good working
condition.

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7.1.4 Blow down line to HP Flare

Tie-in No. From To existing


TP-007 20-B-11905-13451 24-B-66001-1149

The mode of operation for the above mentioned tie-in is as indicated in the below table:

S/No TASK STEPS STEP DESCRIPTION REMARKS


Ensure that the lines to be tied into are SPDC/ Nestoil responsible
well isolated and free of hydrocarbon. for purging of
Conduct Gas test prior to the hydrocarbon if necessary.
1 Work area Inspection
commencement of the operation.
Ensure that hot work permit is obtained Use of appropriate PPE
prior to start of work.
Personnel to work
carefully at all times.

Carefully position required equipment Ensure the use of correct


Position the equipment and spool on designated work space. tools and the right PPE.
2
& pipes Lift the spool into position and align it to
the tie-in position. Ensure that all hand held
tools and equipment are
in a good working
condition.
No AFC drawing from
Loosen 14 blind on line and remove. Nestoil
Install 14 valve and blind.
3 Operation
Ensure bolts and blind flange are properly
installed and torqued to the approved
values.

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7.1.6 Condensate from slug catcher to condensate drum

Tie-in No. From To existing


TP-005 8-P-11905-91432 12-P-51020-9143

The mode of operation for the above mentioned tie-in is as indicated in the below table:

S/No TASK STEPS STEP DESCRIPTION REMARKS


Ensure that the lines to be tied into are SPDC/ Nestoil responsible
well isolated and free of hydrocarbon. for purging of
Conduct Gas test prior to the hydrocarbon if necessary.
1 Work area Inspection
commencement of the operation.
Ensure that hot work permit is obtained Use of appropriate PPE
prior to start of work.
Personnel to work
carefully at all times.

Carefully position required equipment Ensure the use of correct


Position the equipment and spool on designated work space. tools and the right PPE.
2
& pipes Lift the spool into position and align it to
the tie-in position. Ensure that all hand held
tools and equipment are
in a good working
condition.
Loosen blind on line 12-P-51020-9143. Nestoil to provide AFC.
Install 8 spool with double bock and Isometric to confirm exact
bleed valves (11-BV-024, 11-BV-025, and tie-in position.
11-BV-026) in closed position.
3. Operation
Ensure bolts and blind flange are properly Ensure the use of correct
installed and torqued to the approved tools and the right PPE.
values.

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7.1.7 Instrument air

Tie-in No. From To existing


TP-017 2-A-68600-11412 2-A-68021-1841

The mode of operation for the above mentioned tie-in is as indicated in the below table:

S/No TASK STEPS STEP DESCRIPTION REMARKS


Ensure that the lines to be tied into are Use of appropriate PPE
well isolated.
Conduct Gas test prior to the
1 Work area Inspection
commencement of the operation.
Ensure that hot work permit is obtained
prior to start of work.
Personnel to work
carefully at all times.

Carefully position required equipment Ensure the use of correct


Position the equipment and spool on designated work space. tools and the right PPE.
2
& pipes Lift the spool into position and align it to
the tie-in position. Ensure that all hand held
tools and equipment are
in a good working
condition.
Personnel to work
carefully at all times.
Loosen 2 blind flange on line 2-A-68021-
1841. Ensure the use of correct
Install 2 isolation valve in closed position. tools and the right PPE.
3. Operation
Ensure bolts and blind flange are properly
installed and torqued to the approved Ensure that all hand held
values. tools and equipment are
in a good working
condition.

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7.2 Threaded Tie-In:

7.2.1 Instrument air

Tie-in No. From To existing


TP-018 3-A-68008-11412 3-A-68507-18410

The mode of operation for the above mentioned tie-in is as indicated in the below table:

S/No TASK STEPS STEP DESCRIPTION REMARKS


Ensure that the lines to be tied into are Use of appropriate PPE
well isolated and free of hydrocarbon.
Conduct Gas test prior to the
1 Work area Inspection
commencement of the operation.
Ensure that hot work permit is obtained
prior to start of work.
Personnel to work
carefully at all times.
Carefully position required equipment
Ensure the use of correct
and pipes to be welded on designated
Position the equipment tools and the right PPE.
2 work space.
& pipes
Lift the spool into position and align it to
Ensure that all hand held
the tie-in position.
tools and equipment are
in a good working
condition.
Ensure that the WPS to be used is Ensure the use of
Qualification of approved. Qualified Personnel at all
3. Personnel and WPS Ensure that the Welders are qualified in times
accordance with the approved WPS.
Personnel to work
Cut cap on line 3-A-68507-18410.
carefully at all times.
Thread existing line with dicing machine.
Install coupling on existing line.
Ensure the use of correct
4. Operation Tie-in 3 spool on existing line.
tools and the right PPE.
Ensure bolts and blind flange are properly
installed and torqued to the approved Ensure that all hand held
values. tools and equipment are

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in a good working
condition.

7.2 Weld Tie-In:

7.2.2 Closed drain from NAG slug catcher & Pig receiver

Tie-in No. From To existing


TP-015A/B 4-D-11904-11482 4-D-45092-91481

The mode of operation for the above mentioned tie-in is as indicated in the below table:

S/No TASK STEPS STEP DESCRIPTION REMARKS


Ensure that the lines to be tied into are Use of appropriate PPE
well isolated and free of hydrocarbon.
Conduct Gas test prior to the
1 Work area Inspection
commencement of the operation.
Ensure that hot work permit is obtained
prior to start of work.
Personnel to work
carefully at all times.
Carefully position required equipment
Ensure the use of correct
and pipes to be welded on designated
Position the equipment tools and the right PPE.
2 work space.
& pipes
Lift the spool into position and align it to
Ensure that all hand held
the tie-in position.
tools and equipment are
in a good working
condition.
Ensure that the WPS to be used is Ensure the use of
Qualification of approved. Qualified Personnel at all
3. Personnel and WPS Ensure that the Welders are qualified in times
accordance with the approved WPS.
Carry out probing for underground Personnel to work
facilities prior to the commencement of carefully at all times.
the excavation.
Excavate and expose the existing Ensure the use of correct
4. Operation
underground close drain piping. tools and the right PPE.
Cold cut the existing 4 portion of the pipe
where the new connection is to be welded Ensure that all hand held
and block the opening using clay in order tools and equipment are
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to prevent the gas from the line from in a good working
escaping. condition.
Connect the new line and execute the
field weld.
Flush the clay plug with water under
pressure.
Ensure that NDT is carried out as per the
inspection class and in accordance with
the project DEP.
Ensure bolts and blind flange are properly
installed and torqued to the approved
values.

7.2.3 Open drain from NAG slug catcher & Pig receiver

Tie-in No. From To existing


TP-016A/B 4-D-10310-11432 4-D-46101-11481

The mode of operation for the above mentioned tie-in is as indicated in the below table:

S/No TASK STEPS STEP DESCRIPTION REMARKS


Ensure that the lines to be tied into are Use of appropriate PPE
well isolated and free of hydrocarbon.
Conduct Gas test prior to the
1 Work area Inspection
commencement of the operation.
Ensure that hot work permit is obtained
prior to start of work.
Personnel to work
carefully at all times.
Carefully position required equipment
Ensure the use of correct
and pipes to be welded on designated
Position the equipment tools and the right PPE.
2 work space.
& pipes
Lift the spool into position and align it to
Ensure that all hand held
the tie-in position.
tools and equipment are
in a good working
condition.
Ensure that the WPS to be used is Ensure the use of
Qualification of approved. Qualified Personnel at all
3. Personnel and WPS Ensure that the Welders are qualified in times
accordance with the approved WPS.

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Carry out probing for underground Personnel to work
facilities prior to the commencement of carefully at all times.
the excavation.
Excavate and expose the existing Ensure the use of correct
underground close drain piping. tools and the right PPE.
Cold cut the existing 4 portion of the pipe
where the new connection is to be Ensure that all hand held
welded. tools and equipment are
4. Operation
Connect the new line and execute the in a good working
field weld. condition.
Ensure that NDT is carried out as per the
inspection class and in accordance with
the project DEP.
Ensure bolts and blind flange are properly
installed and torqued to the approved
values.

8.0 ATTACHMENT

Document No. Tie-in No.

a) K2S-NG01007551-SOKG1-MP2343-00002-001 TP-001
b) K2S-NG01007551-SOKG1-MP2343-00002-001 TP-005
c) K2S-NG01007551-SOKG1-MP2343-00002-001 TP-006A
d) K2S-NG01007551-SOKG1-MP2343-00002-001 TP-006B
e) K2S-NG01007551-SOKG1-MP2343-00002-001 TP-015
f) K2S-NG01007551-SOKG1-MP2343-00002-001 TP-017
g) K2S-NG01007551-SOKG1-MP2343-00002-001 TP-018
h) K2S-NG01007551-SOKG1-MP2343-00025-001 TP-016A/B
i) K2S-NG01007551-SOKG1-MP2343-00027-001 TP-015A/B

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