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CONTRACT No.
(OOK) 6600026283 / (IK) 6600026284
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 1 of 13
Approved
Rev. Date Description of Revision Prepared Verified Approved
(PIM/PM)
ARABIYAH & HASBAH OFFSHORE AND ONSHORE
FACILITIES
CONTRACT No.
(OOK) 6600026283 / (IK) 6600026284
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 2 of 13
Amendment
Date Page Description Project Director
and revision
X1 19/11/2012 All Issued for IDC GS
ARABIYAH & HASBAH OFFSHORE AND ONSHORE
FACILITIES
CONTRACT No.
(OOK) 6600026283 / (IK) 6600026284
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 3 of 13
INDEX
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 4 of 13
1. INTRODUCTION
The Wasit GasEoIProgram (WGP) will produce approximately 2,500 MMSCFD of Khuff gas from the Arabiyah and
WoI Hasbah offshore fields to meet increasing IK demand for sales gas. The gas will be produced and transported
through a series of offshore/onshore pipelines to Wasit gas Plant (WGP) onshore facilities.
Arabiyah and Hasbah offshore facilities are being developed by the Northern Area Projects Department/ Offshore
Mega Project Division of Saudi Aramco under the subject Requisitions. The Wasit Projects Department of Saudi
Aramco will develop the WGP onshore facilities.
The primary facilities of Arabiyah and Hasbah Offshore/Onshore Facilities are based on Lump Sum Turn Key
(LSTK) Contract Requisitions to cover the design, procurement, transportation, fabrication and installation of the
Arabiyah and Hasbah offshore platforms, pipelines, submarine cables and Wellhead Hook ups and pre-
commissioning. The primary facilities are listed as follows:
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 5 of 13
includes a dredged shore approach and onshore cable tie-in at Abu Ali GOSP
o One (1) composite submarine cable (15-kV power with an internal fiber optic core) from ARBI TP-
1 to ARBI TP-2 (Intermediate injection platform) (with a total length of 74-km long)
o Eight (8) ICCP systems for ARBI TP-1
o Two (2) ICCP systems for ARBI TP-2 (Intermediate injection platform)
o Four (4) ICCP systems for each wellhead platforms
o Six (6) Wellhead Hook ups, pre-commissioning and SCADA integration for Arabiyah Wellhead
Platforms
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 6 of 13
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 7 of 13
2. DEFINITIONS
1.1 ABBREVIATIONS
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 8 of 13
N/A
CONTRACTOR Documents
CONTRACTOR Documents
/5/ 45-ZA-E-I77665 Manual UT Procedure For Carbon Steel Sealines (Including "Piggy Back")
/6/ 45-ZB-A-I80229 Castoro II Work Station Layout 36in HSBH T/L & 6in Piggyback Solvent Sulphur Line
/7/ 44-ZB-A-I76726 Castoro II 6 Piggyback Sulphur Solvent Line Support Rollers Layout - As Built
5.2 Ton Metallic Buoyancy Tanks For Shorepull Installation Details 36" HSBH TL + 6in
/8/ 45-ZB-A-I80026
Sulphur Solvent Line
/9/ 45-ZB-A-I80373 36" HSBH Trunkline + 6" Sulphur Solvent Line Piggyback Saddle Arrangement
ARABIYAH & HASBAH OFFSHORE AND ONSHORE
FACILITIES
CONTRACT No.
(OOK) 6600026283 / (IK) 6600026284
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 9 of 13
3. SCOPE OF DOCUMENT
This document describes an operational procedure that will be implemented onboard DLB Castoro II during
performance of 36in ILUC and PFM in-house tests with internal protections. The aim of tests is to prevent any
damages of internal coating FBE of 36in ARB/HSBH pipelines during offshore installation, with below objectives,
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 10 of 13
36in PFM operations will be performed to demonstrate no damages occur during activities where equipment is in
contact with the internal FBE coated surface. For such test following procedure shall be followed,
Each line pipe is taken from Castoro II deck storage area and lowered onto longitudinal conveyor
Pipe joints transfer to beadstall
Pipe ends bevelling as per WPS TL-3, by using PFM AZ XXXXX with internal protectors
Once the bevelling is completed, coating thickness gauge and holiday detector will verify the integrity of
the internal coating at contact locations between PFM and pipe joints
Same operation shall be executed for other two joints (both ends) to be welded.
At the end of the activity, an internal report by Castoro II QA/QC department shall be issued to register the main
data of the operation and obtained results.
36in ILUC tests will demonstrate that no damages occur during activities where equipment is in contact with the
internal FBE coated surface. The test shall include a verification during ILUC running, coupling and expansion.
For such tests following procedure shall be followed,
Two line pipes are bevelled and preheated before root & hot welding pass performance
The 36in ILUC is inserted in position
Once the welding is completed, ILUC operator shall run the ILUC forward & aft several times over the
weld
ILUC to be removed from the pipe string
Pipe string cutting at field joint in two pieces for coating thickness gauging and Porosity inspection.
As a minimum, of internal FBE will be executed from pipe edge up to 2000mm inside line pipe
Same operation shall be executed twice in different pipe ends.
At the end of the activity, an internal report by Castoro II QA/QC department shall be issued compiling the main
data of the operation and obtained results.
Pre-heating (mandatory heating coils) as per WPS TL-3 (target preheating temperature: 140 degrees)
ARABIYAH & HASBAH OFFSHORE AND ONSHORE
FACILITIES
CONTRACT No.
(OOK) 6600026283 / (IK) 6600026284
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 11 of 13
36in +6in SSL shall be ensemble such as to establish the interaction between both pipelines at the several
working stations. This test will confirm the possible interference among both lines and will demonstrate clear
passage over all piggy back rollers. The test for the 36in+6in piggy back installation arrangement shall confirm the
following:
Interference among both pipelines is as per project installation method.
Clear passage for 6in over all piggy back rollers is feasible.
No clash exists for Buoyancy Tank passage.
Installation arrangement as per drawing 45-ZB-A-I80026 is feasible.
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 12 of 13
At the end of the activity, an internal report by Castoro II QA/QC department shall be issued compiling the main
data of the operation and obtained results, i.e. to identify the clear distance between the top of buoyancy tank and
the firing line frames or any structural obstruction .
4. REPORTING
After the completion of the tests, an internal report shall be issued by Castoro II QA/QC. Photos are
complementary to the report.
ARABIYAH & HASBAH OFFSHORE AND ONSHORE
FACILITIES
CONTRACT No.
(OOK) 6600026283 / (IK) 6600026284
Doc. No.
36IN + 6IN SSL OPERATIONAL TEST PROCEDURE 44-ZA-E-I75956
ONBOARD TEST PROCEDURE CASTORO II
Rev. X1 DATE 19/11/2012
ILUC, WELDING, PFM TESTS Sheet 13 of 13
ATTACHMENT A
Piggy Back
Installation Procedure(DRAFT-TRELLEBORG).pdf