F-NC-174

Elephant Field Development Project - GOSP

AGIP Contract No. MFIA Job No.:
F-NC-174 PROJECT MANAGEMENT PROCEDURE 520 02 21270

PROCEDURE NO. GS-MO-Q-PR-00-60-01

TIE IN PROCEDURE NC115

Contents

1.0 PURPOSE ................................................................................................................................. 2

2.0 SCOPE...................................................................................................................................... 2

3.0 DEFINITIONS AND ABBREVIATIONS ......................................................................................... 2

4.0 RESPONSIBILITIES................................ ................................ ................................ ................... 2

5.0 PROCEDURE ............................................................................................................................. 3

6.0 REFERENCE DOCUMENTS........................................................................................................ 8

7.0 DISTRIBUTION .......................................................................................................................... 8

ANLAGE / ATTACHMENT

A01 SOPE OF WORK / CONSTRUCTION DRAWINGS ................................ ............................ 5 pages

A02 WELDING PROCEDURE ................................................................................................. 7 pages

01 10.12.03 S. Karsch J. Rittscher V. Tobolla Issue for approval

Rev. Date Prepared Checked Approved Description of revision

Page 1 of 6
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Tie-In Procedure NC115
Revision 01, dated 11.12.2003

1.0 PURPOSE

The purpose of this work instruction is to ensure that all activities related to Tie In works at
NC115 plant are carried out according to contract requirements and referred codes and
standards.

2.0 SCOPE

This work instruction applies to all pressure testing activities carried out by the MAN
FERROSTAAL Industrieanlagen GmbH, Oil & Gas division.

3.0 DEFINITIONS AND ABBREVIATIONS

3.1 Abbreviations

PQM - Project Quality Manager

SM - Site Manager

4.0 RESPONSIBILITIES

The Site Manager is responsible for the implementation of and the adherence to this work
instruction.

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Tie-In Procedure NC115
Revision 01, dated 11.12.2003

5.0 PROCEDURE

5.1 Preparation Works

5.1.2 General

Before the commencement of any activity the complete area must be surveyed for the
exact location of the existing aboveground and underground facilities.

It has to be ensured that all new equipment to be installed by … are in place.

All Tie-In points to the existing plant must be identified and inspected together with the
responsible Plant Representative to ensure the possibility for their installations. The Plant
and Client Representative must approve all necessary modifications in written form. All
Tie-In points shall be clearly marked to avoid any mistakes.

For any Tie-In to the existing systems the Plant will be informed in written form at leased
24 hours before the commencement of the Tie-In works.

5.1.1 Civil

• Area has to be graded and leveled as per approved Site Grading Plan.

• All Foundations and Pits must be installed as per approved Plot Plan.

• For all underground Tie-Ins the appropriate areas must be excavated wide enough to
ensure proper working space.

• All supports and structures have to be in place, aligned and grouted.

5.1.1 Mechanical

• All new Skids and Equipment shall be installed, aligned, leveled and grouted.

5.1.2 Piping

• All new pipe work shall be fabricated, tested and painted or wrapped.

• The aboveground and underground piping will be installed as far as possible to have
sufficient space for the Tie-In works to the existing systems.

• After the execution of all Tie-Ins to the existing systems the pipe work will be
completed as per approved construction drawings.

5.1.3 Electrical

5.1.4 Instrumentation

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Tie-In Procedure NC115
Revision 01, dated 11.12.2003

5.2 Safety Measures

Work Permit

Hot Work Permits are required in all areas where hazards or the potential of hazards
exist. Therefore obtain Hot Work Permit daily, prior any commencement of work. Client
Safety Officer will approve the commencement of each activity in consultation with the
Plant Representative, based on gas test results.
Depending on site conditions nitrogen purgin may be required.
Non sparking tools to be used for all flange connections inside existing plant.

Fire Prevention

Fire Extinguishers (12 kg Dry Powder, ABC) shall be available by the Contractor at each
working site.

One Fire Truck shall be on site during the execution of Tie-Ins to live systems. Client
Fire Department shall supply the Fire Truck with Crew.

Personnel availability

During the performance of Tie-Ins to the existing systems the following personnel will be
permanentlyavailable on working site:

• Discipline Supervisor in charge

• Contractor Safety
• Client Safety
• Client Representative

5.3 Piping Tie-In

5.3.1 Tie-Ins to existing 30” pipeline

Tie-In Philosophy

Existing Pipe shall be removed by cold cutting pipe at Tie-In 2 and opening existing
flange connections at Tie-Ins 1, 3 & 4. New flange must be welded at Tie-In 2 and new
pipe spool installed.

Tie-In Execution

The existing pipe work shall be handed over to the Contractor Oil & Gas free.

The Cathodic Protection System of the existing piping system has to be switched off
during the hold Tie-In works.

All existing valves up- and downstream of the new Tie-In location shall be closed by Plant
Operations and secured against unauthorized opening.

All required tools and machines should be placed beside each Tie-In point and checked
for their completeness and proper function.

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Tie-In Procedure NC115
Revision 01, dated 11.12.2003

The works will be carried out according the following sequence:

• The pipe on the proposed Tie-In 2 area should be checked to ensure that ovality is
within acceptable limits related to the fitting to be used.
• Paint shall be removed from the existing pipe in the proposed Tie-In 2 area.
• The pipe shall be visually examined for laminations, pitting and any sign of
mechanical damage.
• The area of pipe over the proposed weld location shall be examined ultrasonically,
using a „D“-meter to confirm adequat wall thickness.
• The Tie-In location will be marked on the pipe with the Tie-In number.
• The new Tie-In pipe spool shall be assembled and tested until the next new valve to
be installed.
• Take final measurement from new Tie-In spool and mark final location of Tie-In 2 on
existing pipe.
• Bridge the Tie-In cut with a suitable cable to avoid different potentials when cold
cutting the pipe.
• Install additional supports under the existing pipe at all Tie-In location.
• Mount cold cutting machine and test the correct function and alignment.
• Cut the existing pipe on the marked spot at Tie-In 2.
• Open existing flange connections at Tie-In 1, 3, 4 using non sparking tools.
• Remove existing pipe.
• Cover openings from Tie- In 1, 3, 4.
• Insert plug with vent to athmosphere in existing pipe at Tie-In 2.
• Fit-up new flange and adjust weld gap at Tie-In 2.
• Perform Tie-In weld 2 as per WPS 3910/14 & PQR 3910/04, Attachment 02
• After weld has cooled down perform radiographic test and develop films immediatly.
• Remove plug from existing pipe.
• Install new pipe spool.
• The spade at Tie-In 5 shall be in closed position.

After the installation of the new pipe spool and tightening all flange connections Plant
Operations shall purge the system with nitrogen.

Final leak test will be performed with nitrogen at approx. 4 BarG; any leaks will be
addressed accordingly.

5.3.2 Tie-In to existing 4” Drain system

Tie-In Philosophy

Part of existing GRP Pipe shall be cut out and new pipe spool installed.

Tie-In Execution

It shall be ensured by plant operation that during the Tie-In works no drain operations to
the existing header system are carried out.

• Prefabricate and test new pipe spool.

• Check if exposed area is wide enough for the Tie-In works.

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• Take final measurement from new Tie-In spool and mark final location of Tie-In 11 &
12 on existing pipe.
• Cut existing pipe with hacksaw on marked areas.
• Machine pipe ends of existing pipe as per manufaturer recommendation.
• Glue new flanges to the existing GRP pipe.
• Bolt up new pipe spool
• Install blind flange on Tie-In 10

5.3.3 Tie-In to existing 10” Firewater system

Tie-In Philosophy

Part of existing GRP Pipe shall be cut out and new pipe spool installed.

Tie-In Execution

Plant Operations shall depressurize and drain the appropriate firewater ring.

• Check location of opening in new Tie-In pit.

• Prefabricate and test new pipe spool.
• Take final measurement from new Tie-In spool and mark final location of Tie-In 6 &
7 on existing pipe.
• Cut existing pipe with hacksaw on marked areas.
• Machine pipe ends of existing pipe as per manufaturer recommendation.
• Glue new flanges to the existing GRP pipe.
• Bolt up new pipe spool
• Install blind flange on Tie-In 9.

After the installation of the new pipe spool and tightening all flange connections the fire
water system shall be pressurized and all flange connections observed for any sign of
leakages.

5.3.4 Tie-In to existing 2” Instrument Air system

Tie-In Philosophy

New Tie-In spool will be screwed in to the existing 2” valve

Tie-In Execution

• Prefabricate and test new pipe spool.

• Install new pipe spool to existing 2“ valve at Tie-In 8.
• Install blind flange at new ball valve.

5.3.5 Tie-In to new 24” pipeline

Tie-In Philosophy

All Tie-Ins to the new 24” pipeline are flanged connections.

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Tie-In Execution

The Tie-Ins shall be handed over from the Pipeline Contractor in dry and clean
conditions.

• Take final measurement from the Tie-In Points.

• Prefabricate and test new pipe spool.
• Bolt up new pipe spool

5.3.6 Tie-In to new Equipment Skids

Tie-In Philosophy

All Tie-Ins to the new equipment skids are flanged connections.

Tie-In Execution.

• Check orientation of Tie-In nozzles.

• Take final measurement from the Tie-In Points.
• Prefabricate and test new pipe spool.
• Bolt up new pipe spool

5.3 Electrical Tie-In

5.4 Instrument Tie-In

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Tie-In Procedure NC115
Revision 01, dated 11.12.2003

6.0 REFERENCE DOCUMENTS

6.1 Management Procedures

Inspection and Test Plans for all Disciplines

6.2 Regelwerke und Normen / Codes and Standards

ASME Code, B31.3 - ASME Code for Pressure Piping - Process Piping

6.3 Client’s Specifications

Contract Documents
Scope of Work

7.0 DISTRIBUTION

Originals (signed paper copies) of the procedure will be kept at DCC in Geisenheim
Availability to project members as follows:
• Geisenheim : Electronic files under
H:\Project\Lasmo_gosp\Quality.pqm \Procedures
• Office Tripoli : Issue of controlled copy documents
• Site Office : Issue of controlled copy documents to Site DCC.

Procedure - Tie-In to Existing Facilities.DOC