Pipeline Installation Procedure

IOCL-OS-PL-PR-0040
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PIPELINE INSTALLATION PROCEDURE Rev. : C0
Date : 02-Dec-10
Revision History
Revision Date Description Remarks

I 2010.11.05 Inter Disciplinary Check
C0 2010.12.02 For Comments and/or Approval
Project No : SO 18011
IOCL / Integrated Offshore Crude Handling Facilities
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18011197 INTEGRATED OFFSHORE CRUDE HANDLING FACILITIES PROJECT

RESPONSE TO CLIENT COMMENTS ON "PIPELINE INSTALLATION PROCEDURE (IOCL-OS-PL-PR-0040).
IOCL/EIL REF :
IOCL/EIL Comment HHI Response
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CONTENTS
1. INTRODUCTION............................................................................................................................6
1.1. General .............................................................................................................................................6
1.2. Field Layout .....................................................................................................................................7
1.3. Scope OF Offshore Installation........................................................................................................8
1.4. Purpose Of Document ......................................................................................................................8
1.5. Pipeline Installation Sequence..........................................................................................................8
1.6. Reference Document ........................................................................................................................8
1.7. Abbreviation...................................................................................................................................10
2. GENERAL INFORMATION AND OFFSHORE MANAGEMENT ...........................................11

2.1. Material Data..................................................................................................................................11
2.2. Environmental Data........................................................................................................................12
2.3. Pipeline Data ..................................................................................................................................13
2.4. Organization ...................................................................................................................................18
2.5. Installation Schedule ......................................................................................................................21
2.6. Communications & Correspondences ............................................................................................23
2.7. Responsibilities ..............................................................................................................................24
2.8. Marine Spread Data........................................................................................................................27
3. PIPELINE INSTALLATION ENGINEERING ............................................................................32

3.1. Installation Cotrol...........................................................................................................................32
3.2. Allowable Stress.............................................................................................................................32
3.3. Offpipe Input Data Summary .........................................................................................................33
3.4. Offpipe Output Data Summary ......................................................................................................34
3.5. Engineering Software.....................................................................................................................34
4. PIPELINE INSTALLATION PROCEDURES..............................................................................36

4.1. Vessel positioning / mooring..........................................................................................................36
4.2. Pipeline Alignment.........................................................................................................................36
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4.3. Operating Weather Criteria ............................................................................................................37

4.4. Work Station & Activity Description.............................................................................................37
4.5. Pipelaying Procedure......................................................................................................................42
5. CONTINGENCY PROCEDURE ..................................................................................................44

5.1. General ...........................................................................................................................................44
5.2. Abandonment .................................................................................................................................44
5.3. Recovery ........................................................................................................................................46
5.4. Dry Buckle .....................................................................................................................................46
5.5. Wet Buckle.....................................................................................................................................47
5.6. Failure of Tensioner System ..........................................................................................................47
5.7. Failure of Anchors and Anchor Lines ............................................................................................47
5.8. Breakdown of positioning system ..................................................................................................47
APPENDICES
Appendix A Specification of Vessels
A-1 HD-2500
A-2 AHTs
Appendix B Drawings
B-1 Pipeline Basic Engineering Drawings (By EIL)
B-2 Pipeline Installation Drawings (By HHI)
Appendix C Initiation & Termination Head Calculation
Appendix D OFFPIPE Analysis Output Summary Table
Appendix E OFFPIPE Analysis Input & Output for Maximum Barge Tension Case
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1. INTRODUCTION
1.1. GENERAL
M/s Indian Oil Corporation Limited (IOCL) is setting up a grass root refinery complex at Paradip,
Orissa, India, to process 15 MMTPA of crude oil. The integrated crude oil handling facilities at
Paradip is proposed to have three nos. of SPM (1 existing & 2 new) and offshore/onshore pipelines
for offloading of crude and feeding to refinery and Paradip-Haldia pipeline. The crude oil shall be
handled through a marine offloading system designed for 37 MMTPA. Presently the existing SPM-
I and offshore/onshore pipeline is handling 11 MMTPA of crue oil offloading which is just meeting
the present requirements of Paradip-Haldia pipeline. To meet above additional requirement, it is
intended to develop an integrated offshore crude oil handling facilities including SPM-II & III,
associated offshore and onshore pipelines to handle a total capacity of 37 MMTPA crude
requirements for the proposed grass-root refinery at Paradip, Paradip-Haldia pipeline and also the
additional future requirement of its inland refineries. The crude oil shall be offloaded from a VLCC
tanker upto 320,000 DWT moored to either SPM-I or SPM-II or SPM-III system (CALM type) and
transported through sub-sea PLEMs (Pipe Line End Manifold) and offshore/onshore pipelines each
approximately 21 km long). The water depth at the proposed SPM-II & SPM-III location is
approximately 32 meters below chart datum. Following facilities envisaged are part of integrated
crude handling facilities:
(a) Single Point Mooring (SPM-II & III) terminals for handling very large crude carriers (VLSS)
ar Paradip, Orissa and associated PLEMs (II & III) and 48 dia offshore pipelines from
respective SPM to Land Fall Point (LFP) as well as 48 dia offshore pipelines inter-connecting
SPM-I to SPM-II & SOM-II to SPM-III.
(b) Onshore pipelines of size 48 dia, from respective LFP to COT.
(c) Onshore Crude Oil Terminal (COT) including scraper traps, all piping, pigging pumps and
associated facilities at Paradip, Orissa.
.
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1.2. FIELD LAYOUT
SPM Dic ha rg ni g M ani of dl

460000 mE
462000 mE
464000 mE
466000 mE
468000 mE
470000 mE
472000 mE
474000 mE
LFP-III
Area
ed
Construct
D harthy
i nI
B ase S t at o
EXISTING
M ar ki ng p li l ar
LFP -I
TO IO CL PLANT
VC-43 VC-85
VC-01
LFP-IIA
VC-44
VC-86
VC-02
LFP-IIB
VC-87
VC-45
VC-03
V C-88
VC-46
VC-04
2236000 mN VC-89 2236000 mN

VC-05 V C-47
VC-90
VC-48
VC-06
VC-91
VC-49
VC-07
VC-92
VC-50
TP1
VC-08
TP1
VC-93
TP1
VC-51
VC-09
14" Existing(As-laid) VC-94
VC-52
V C-10 TP2
VC-95
V C-53
2234000 mN VC-11 2234000 mN

VC-96
T P2 TP2
VC-54
VC-12 VC-97
V C-55
V C-98
VC-13
VC-56 VC-99
VC-14
VC-100
VC-57
VC-15
VC-101
2232000 mN V C-58 2232000 mN

VC-16
VC-102
VC-17
V C-59
VC-103
PROPOSED PIPELINE ROUTE 3
LFP-III TO SPM-III
V C-60
VC-104
V C-18
VC-61 VC-105
VC-19
VC-106
VC-62
VC-20
2230000 mN VC-107 2230000 mN

VC-63
VC-21
V C-108
VC-64 PROPOSED PIPELINE ROUTE 2

VC-22 VC-109
LFP-IIB TO SPM-II (PLEM II-B)
VC-65
VC -110
VC-23
VC-66 VC-111
VC-24
VC-112
VC-67
2228000 mN VC-25
2228000 mN
VC-113
VC-68
VC-26
VC-114
VC-69
VC-27
VC-115
VC-70
VC-116
VC-28
48" Existing (Extrapolated)

VC-117
VC-71
VC-29
V C-118
2226000 mN VC-72
2226000 mN
VC-30
VC-119
VC-73
VC-31
VC-120
VC-74
VC-121
VC-32
VC-75
VC-122
VC-33
VC-123
VC-76
VC-34
2224000 mN 2224000 mN
VC-124
VC-77
VC-35 SPM-III(PLEM)
PROPOSED PIPELINE ROUTE 1 VC-125
LFP-IIA TO SPM-II (PLEM II-A) VC-36

VC-78 SPM-III
474 984.139 E VC-126
VC-79 2 222 642.565 N

VC-37 V C-127
2006'08.400" N
V C-80 8645'38.400" E
SPM-II V C-38
VC-144
VC-143
471 340.035 E
2222000 mN 2 220 730.172 N
VC-81
SPM -II (PLEM II-B) VC-142
2222000 mN
VC-39
2005'06.000"N VC-141
)
VC-82
L EM
SPM-I 8643'33.000"E IN E ( P
PL M -III
VC-40 VC-140
467 852.977 E OO SP
D L TO 1 KM
VC-139
SE )
V C-83
2 219 945.724 N SPM -II (PLEM II-A) 4

P OM II -D = 4 .0
VC-41
V C-138
O
2004'40.281" N P R(P LE G T H
PROPOSED LOOP LINE VC-137
I N
8641'32.963" E SPM-I TO SPM-II (PLEM II-C) M -I L E
VC-136 SP
LENGTH = 3.614 KM VC-135
TP2
VC-134
SPM -II (PLEM II-D)

460000 mE
462000 mE
464000 mE
466000 mE
468000 mE
470000 mE
472000 mE
474000 mE
VC-133
2220000 mN VC-130
VC-132 2220000 mN
VC-131
VC-128 VC-129 TP1
SPM -II (PLEM II-C)
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1.3. SCOPE OF OFFSHORE INSTALLATION
The brief scope of work for the subject project includes the following.
- Installation of three (3) nos. 1219mm (48) diameter pipelines, each approx. 21km long submarine
pipeline with 120mm thick concrete coating (overall diameter 1459mm) including laying in shore
approaches.
- Installation of two(2) nos. 1219mm (48) diameter pipelines, each approx. 4km long submarine
pipeline with 120mm thick concrete coating (overall diameter 1459mm) for SPM interconnection
between SPM-I / SPM-II and SPM-II / SPM-III.
1.4. PURPOSE OF DOCUMENT
The purpose of this procedure is to describe how the pipeline installation work to be conducted.
This procedure shows the overall execution plan of pipeline work, the laying equipments, and
laying method for each pipeline, etc. to ensure that the Pipeline installation work sequence and
typical laying method associated with equipments are proper and efficient to this project.
This procedure will also be submitted to the MWS for approval.
1.5. PIPELINE INSTALLATION SEQUENCE

The pipe laying sequence will be as below;
Shore Approach for Route 1 Pipeline

Temporary Laydown the Route 1 Pipeline
Temporary Laydown the Route 2 Pipeline
Continuous Normal Laying for Route 3 Pipeline to SPM-III (Total 21.524km)
Recovery Route 2 Pipeline, Normal Laying to SPM-II (Total 20.768km)
Recovery Route 1 Pipeline, Normal Laying to SPM-II (Total 20.734km)
Normal Laying for Loop line from SPM-I to SPM-II (Total 3.614km)
Normal Laying for Loop line from SPM-III to SPM-II (Total 4.042km)
Flooding, Cleaning, Gauging & Caliper Pigging for All Pipelines.
1.6. REFERENCE DOCUMENT
1.6.1. International Codes and Standards
[1] DNV,1981 Rules For Operations, Planning and Execution
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1.6.2. Project Specification
[2] A005-001-16-71-TR-21 Scope of Work for Installation of SPM System, Pipelines & COT
Facilities
[3] A005-001-16-56-EC-02 Environmental Design Criteria for SPM (II & III)
[4] A005-001-16-71-TR-22 Annexure-2, Pipeline Designation
[5] A005-002-16-71-SP-01 Piping Material Specification & Annexure I (Piping Material

Specification General Notes)
[6] 6-71-0063 Standard Specification for Trenching and Backfilling of

Submarine Pipelines
[7] A005-002-16-56-SI-011 Site Information
[8] 6-71-0045 Standard Specification for Field Joint Coating for Submarine
Pipelines
1.6.3. Reference Procedure
[9] IOCL-OS-PL-PR-0010 Trenching & Backfilling Procedure
[10] IOCL-OS-PL-PR-0020 Shore Approach Procedure
[11] IOCL-OS-PL-PR-0030 Anchor Handling Procedure for HD-2500
[12] IOCL-OS-PL-RP-0050 Coated Pipe Transportation Analysis
[13] IOCL-OS-PL-RP-0060 Mooring Analysis for HD-2500
[14] IOCL-OS-PL-PR-0070 Pipeline NDT Procedure
[15] IOCL-OS-PL-PR-0080 Diving Procedure
[16] IOCL-OS-PL-PR-0090 Pipeline Field Joint Coating Procedure
[17] IOCL-OS-PL-PR-0100 Pre-construction Survey Procedure for Pipelines
[18] IOCL-OS-PL-RP-0102 Pre-construction Survey Report
[19] IOCL-OS-PL-PR-0104 Survey Procedure for Pipeline Installation
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1.7. ABBREVIATION
SMYS : Specified Minimum Yield Strength
LAT : Lowest Astronomical Tide
MSL : Mean Sea Level
HAT : Highest Astronomical Tide
PLEM : Pipeline End Manifold
LFP : Land Fall Point
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2. GENERAL INFORMATION AND OFFSHORE MANAGEMENT

2.1. MATERIAL DATA
2.1.1. Line Pipe Material Data
The material data for line pipe are summarized in below;
Description Units Parameter
Youngs Modulus of Steel Gpa 207
Poissons Ratio - 0.3
Density of Steel kg/m3 7850
SMYS of Steel Mpa 448
SMTS of Steel Mpa 531
2.1.2. Concrete Coating Properties

The concrete properties are summarized in below;
Description Unit Parameters
Concrete Thickness mm 120
Outside Tolerance mm 6
Weighing Accuracy % 0.5
Minimum Strength in 7 days Kg/cm2 246
Minimum Strength in 28 days Kg/cm2 328
Concrete Density kg/m3 3044
Concrete Density Tolerance - + 5% ~ -2 %
Water Absorption % 4
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2.2. ENVIRONMENTAL DATA

2.2.1. Tidal Range
The following table presents the tidal range data to be used for the IOCL Paradip Project.
It contains the highest and lowest astronomical tides relative to MSL.
Description Units Parameters
HAT m 3.50
MSL M 1.66
LAT m 0.00
2.2.2. Current Data

The following table presents the current data to be used for the IOCL Paradip Project.
Current Speed m/sec 0.7
Prevail Direction degree 60 / 240
2.2.3. Wave Data

The following table presents the wave data to be used for the IOCL Paradip Project.
Significant Wave Height m 0.5 ~ 3.4
Maximum Wave Height m 0.6 ~ 6.32
Wave Period sec 8 ~ 15
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2.3. PIPELINE DATA
There are 3 pipelines to be laid between LFPs and PLEMs. And 2 pipelines to be laid between
SPM-I and SPM-II. & between SPM-III and SPM-II.
The pipeline data are summarized in below;
Route 1 Route 2 Route 3

Description Units
(from SPM-II to (from SPM-II to (from SPM-III to
LFP-IIA) LFP-IIB) LFP-III)
Originating Point - PLEM-II PLEM-II PLEM-III
Terminating Point - LFP-IIA LFP-IIB LFP-III
Approximate Pipeline
km 21 21 21
Length
mm 1219 1219 1219

Pipeline Out
Diameter
inch 48 48 48
Pipeline Material
- Carbon Steel Carbon Steel Carbon Steel
Specification
Pipeline Material API 5L API 5L API 5L

Grade -
Gr. X-65 Gr. X-65 Gr. X-65
Pipeline Wall
mm 22.2 / 20.6 22.2 / 20.6 22.2 / 20.6
Thickness (Note-6)
Service - Crude Oil Crude Oil Crude Oil
Design Pressure kg/cm2 19 19 19
Design Temperature degree 45 45 45
kg/cm2 23.75 23.75 23.75

Offshore Hydrotest
Pressure
bar 23.3 23.3 23.3
Corrosion Coating
a) Material - Coal Tar Enamel Coal Tar Enamel Coal Tar Enamel
b) Density kg/m3 1400 1400 1400
c) Thickness mm 4.8 4.8 4.8
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Concrete Coating
High Density High Density High Density

a) Material -
Concrete Concrete Concrete
b) Density kg/m3 3044 3044 3044
c) Minimum
mm 120 120 120
Thickness
Burial of Pipeline (Note-5)
1.4 1.4 1.4

a) Length km
(KP0 at LFP to KP (KP0 at LFP to KP (KP0 at LFP to KP
1.4) 1.4) 1.4)
b) Pipeline Cover
m 2.5 2.5 2.5
(minimum)
c) Backfilling Required Required Required
Approximate Water
Depth W.R.T C.D. at m 32 32 32
PLEM
Coordinates
a) Originating Point - SPM-II SPM-II SPM-III
- Northing m 2220704.929 2220766.226 2222642.565
- Easting m 471285.188 471388.352 474984.139
b) Terminating Point - LFP-1 LFP-2 LFP-3
- Northing m 2237264.318 2237271.782 2237277.006
- Easting m 459281.119 459291.831 459299.935
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Unit Loopline from SPM-II Loopline from SPM-II to

Description
s to SPM-I SPM-III
Originating Point - SPM-II SPM-II
Terminating Point - SPM-I SPM-III
Approximate Pipeline Length km 3.6 4.1
mm 1219 1219
Pipeline Out Diameter
inch 48 48
Pipeline Material Specification - Carbon Steel Carbon Steel
Pipeline Material Grade API 5L API 5L

-
Gr. X-65 Gr. X-65
Pipeline Wall Thickness mm 22.2 22.2
Service - Crude Oil Crude Oil
kg/c
Design Pressure 19 19
m2
degr
Design Temperature 45 45
ee
kg/c 23.75 23.75

m2
Offshore Hydrotest Pressure
bar 23.3 23.3
Corrosion Coating
a) Material - Coal Tar Enamel Coal Tar Enamel
kg/
b) Density 1400 1400
m3
c) Thickness mm 4.8 4.8
Concrete Coating
a) Material - High Density Concrete High Density Concrete
kg/
b) Density 3044 3044
m3
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c) Minimum Thickness (Note-7) mm 120 120
Coordinates
a) Originating Point - SPM-II SPM-II
- Northing m 2220673.932 2220714.679
- Easting m 471325.649 471394.925
b) Terminating Point - SPM-I SPM-III
- Northing m 2219945.724 2222574.695
- Easting m 467852.977 474983.045
Notes:
1. Pipeline lengths mentioned are approximate and shall be finalized after pre-construction
survey
2. The co-ordinates of SPMs and LFPs are based on Universal Transverse Mercator (UTM),
Zone 42, Central Meridian 69E, False Easting 500,000m and spheroid WGS-84.
3. Number of crossings and free spans shall be firmed up on the basis of as-laid survey.
4. Line pipe material for 48 pipeline conforms to specification no. 6-71-0002 Rev. 2.
5. Pre-trenching shall be carried out for submarine pipeline from KP 0.0 (LFP) to KP 1.4
Pipeline shall be installed in pre-trench with minimum cover of 2.5 m from top of
concrete coated pipeline in shore approach area. The trench shall be backfilled with
backfill material. The burial requirement / cover / backfilling details shall be as per scope
of work document.
6. Pipeline thickness shall be 22.2mm from PLEM to KP 17 and 20.6mm from KP 17 to
LFP (KP 0.0)
7. Bends for Tie-in spool shall be coated with corrosion coating (heat shrink sleeves) &
concrete coating of 120mm thickness.
8. Installation engineering carried by contractor shall follow the guidelines of Det Norske
Veritas (DNV) Rules for submarine Pipeline System 1981. The design, loading
conditions and design criteria shall be as defined in section 3 & 4 of the above rules.
Constant and coefficients to be used for the design calculations for installation
engineering shall be taken from these rules except as specified below.
Loading Condition A : 72% of SMYS

Loading Condition B : 85% of SMYS (1)
During Hydrotest : 90% of SMYS
Notes:
1) Stress in sag bend area shall not exceed 72% of SMYS for loading condition B
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2) SMYS stands for Specified minimum yield strength of material.

3) Von Mises Stress criteria shall be used for determining combined stress
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2.4. ORGANIZATION
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C CP U CP U
Integrated Offshore Crude Handling Facilities at Paradip Project
1. HD-2500 PIPE LAY (PHASE-I)

( Shore Pull :10' 12.29 ~ 11' 01.13 : 16 Days ) (0)
( Pipe Laying :11' 01.14 ~ 11' 03.12 : 58 Days ) PM
J.K. Nam ( )
1
OIM /SUPERINTENDENT
Y.J. Go
3 3
Q.A/ Q.C. HSE
Manager Bencio Nobleja Manager Frankie Anak D
Inspector Surya Subramm Officer Suresh Kumar
Inspector Chomesvaran A HLO Officer Gayah Anak Ja
4 46 (00:00 ~ 12:00) 1 (12:00 ~ 24:00) 1 1

ADMINISTRATION SUB CONTRACTOR "A" SHIFT ASS'T SUP'T "P" SHIFT DESIGN ENGINEER EQUIP' MGR
C/Admin J.J. Kim Survey 4 B.K. Kim Y.H. Kim Y.T. Kim
Ldr Admin Jijo Jose Kaipa Diving 15
Admin Satheesh S Na Autoweld 5 2 2
B/Clerk Hari Narayanan NDT 9 FIELD ENG'R FIELD ENG'R
FJC 2 Field Eng G.J. Im Field Eng Lancy Benjami
Gas 1 Assist Field Sumesh EN Field Eng Y.B. Park
2 2 1
BARGE FMN BARGE FMN CHIEF ENGINEER
B/Fmn K.D. Lee B/Fmn D.C. Jang Chief Eng K.H. Kim
B/Fmn Baya Sigau/Ap B/Fmn Lukas Anak Je
8 19 12 14 19 12 14 7 7
SUPPORT TEAM WELDING TEAM RIGGER TEAM OPER. TEAM WELDING TEAM RIGGER TEAM OPER. TEAM ENGINE ROOM ELECTRIC A. H. Tug (1)
MTRL Ct
Ctrl S.C. Sin W.FMN J.W. Son RIG
G FMN J.S. Jung ( A/FMN
/ Geo
George ge Harriso()
a so() W.FMN J.M. Kang RIG
G FMN K.B.
K. . Han ( A/FMN
/ Tony
o y Harrison
a so () 1st
st Engineer
g ee Johny
y Anto C ect
CHIEF Elect Naveen W. TBA ((14))
Warehouse Deepak CT W.FMN Thawatchai Ho RIG FMN(1) Ngelambai Ana W/Optr Wayne Anthon () W.FMN Surapol Sujari RIG FMN(1) Ding Wan W/Optr Micheal Jackso() 1st Engineer Shibu Palipattu ELECT Fmn S.H. Oh
Warehouse Jomon V Georg Stn #1 Peerapong Hor RIG FMN(2) Joseph Jalong W/Optr Tony Doyle () Stn #1 Tanongsak Yoo RIG FMN(2) Ngerong Layok W/Optr Ismail K.M.Moh() Oiler Ldmn Biju Cherian From SP K.Y. Kwon A. H. Tug (2)
Medic Debadatta Das Stn #1 Surasit Sujarit RIG LDM(1) Pangabang Da M/Crane Y.G. Jung Stn #1 Kanong Rodpra RIG FMN(3) Undan Anak Ka M/Crane Y.T. Ham Oiler Shibhojith Aree Electrician Ummini Nalla E TBA (14)
Radio Optr Deepak Bharad Stn #1 Pipat Sujarit RIG LDM(2) George Ak Bar D/Crane Patrick Athony Stn #1 Suriya Hunsri RIG LDM(1) Henry Anak Ab D/Crane Sili Anak Unga Oiler Purushothama Electrician Francis Saldan
Radio Optr Burhan Maskur Stn #1 Nikhom Norkha Rigger(1) Stanley Martha Tension'r Shaji Elavunka Stn #1 Rakchai Sonra RIG LDM(2) Christopher An Tension'r Yudas Jangin Oiler Sebastian Naya Electrician Joseph Kaipara Material Barge
Korean Cook Churamani Bel Stn #2 Thawatchai Me Rigger(2) Edwin Ding Ara Line-Up Shaisindh Puth Stn #2 Rungsak Singc Rigger(1) Lian Sigau Line-Up Jomi George Oiler Rama Shanker Electrician Meppad Prade TBA
Thai Cook Pech Vichien Stn #2 Sompotch Krits Rigger(3) Frankie Engan SPACER Jeerasak Thon Stn #2 Surat Wongpak Rigger(2) Lawai Njau SPACER Winai Angtun 13 Electronic Cyril Merwine S
Stn #2 Sombat Patha Rigger(4) Anthony Jalong SPACER Thawatchai Su Stn #2 Somchai Matth Rigger(3) Nelson Agus S SPACER Natthawat Thet MECHANIC From SP, Elect Ting Aung Myin Supply Boat
CATERING Stn #3 Kanjanawat Ph Rigger(i)(1) Raju Lingappa Convey Preejith Manikk Stn #3 Montree Thaint Rigger(i)(1) Harish Chandra Convey Jaya Thoolikatt MECH Fmn S.H. Kim From SP, Elect Abdul Kadir TBA (14)
Catering Campboss Stn #3 Seksan Sanitkh Rigger(i)(2) Sivaprasad Ch Stinger Optr Jeevan Rajiv Stn #3 Somkhit Sutthin Rigger(i)(2) Pappachan Ch Stinger Optr Radhakrishnan From SP S.J. Park From SP, Elect Rolando
Korean Cook Kim Wonjun Stn #3 Bunsong Ard-h Rigger(i)(3) Rajesh Onden L/Clamp Optr Unnikrishnan S Stn #3 Suchat Pramwo Rigger(i)(3) Bahuleyan Nar L/Clamp Optr Thankachan C CHIEF Mech 5
Catering 25(Caterer) Stn #4 Prareewut Rom From SP, R/L Anthony G FM,R/Lmn Wesely Maran Stn #4 Sa-Ngob Tahyu From SP, R/L Dominic Chang FM,R/Lmn Jok Uchat Mech Ldmn Rajeswar Rao BARGE REPAIR
Stn #4 Sanan Jaiman From SP, RIG TBA FM Optr Srijith Thengil Stn #4 Pongpun Boon From SP, RIG TBA FM Optr Timothy Leslie Mech Ldmn Martin Anak Ab FMN Anoop Mooliyil
Stn #4 Jaroon Raktha From SP, RIG Udayamohana Tallyman Giju Vazhappill Stn #4 Manoo Jiahlim From SP, RIG Syed Nayeemu Tallyman Ranjith M Nair Mechanic Saravanamari Repairer Sukirman
Repair W (1) Phichet Sangkh From SP, RIG Solaman P.J 5 Repair W (1) Weera Homkha From SP, RIG Vikas Valappile 6 Mechanic Salat Beliw Carpenter Ashok S.
Repair W (2) Preecha Poolp 8 A/WELDING TEAM Repair W (2) Jeerawat Phua 8 A/WELDING TEAM Mechanic Chinni Krishna A/C Man Danilo . B
B/Weld (1) Phatthana Srib DOPE TEAM A/W Leader Junaldo Monte B/Weld (1) Vichan Sangkh DOPE TEAM Supervisor J.H. Choi Mechanic Daniel Nirim A/C Man Junifer Lara Pe
B/Weld (2) Wicha Soontho DOPE FMN Mangaldas Nal A/W Tech (E) Eduardo Cafifg B/Weld (2) Sangkhom Phi DOPE FMN Benny Vazhap A/W Leader Anthony Marian Mechanic Jeffry Saleh 1
13 Dope (1) Vijay Sakharam A/W Tech (E) Luis Sagun 13 Dope (1) Thomas Abrah A/W Tech (E) Prem D' Silva Mechanic Mawan Rajau BARGE CLERK/ORION
WELDER HELPER Dope (2) Santhanandan A/W Tech (M) Manulal Nellyo WELDER HELPER Dope (2) Joseph Abraha A/W Tech (E) Nerjo Situmpol Mechanic Juk Jau Clerk Carlo C.Bandojo
W/H, P/C (1) Babu Kuttappa Dope (3) Rajindersingh B A/W Tech (M) Lardge Gullava W/H, P/C (1) Pramod Raman Dope (3) Dineshan Kuni A/W Tech (M) Joey Javellana Machinist Duryodhana Su
W/H, P/C (2) Jinu Varuvathil Dope (4) Ajaykumar M. V W/H, P/C (2) Sheethal Nama Dope (4) Dhanajirao Shr A/W Tech (M) TBA Machinist Nading Anak Im
W/H, P/C (3) Nikhil Das Mala Dope (5) Santhosh Kum W/H, P/C (3) Vishwas Sadas Dope (5) Majo Johny Va Mechanic Manoj Xavier
W/Helper (1) Sumesh Kuma Dope (6) Sureshan Kaya W/Helper (1) Farid Ahmad Dope (6) Mundakathil Pu From SP, Mech Aswin
W/Helper (2) Jishnu Kalloor Dope (7) Ramesh Mooth W/Helper (2) Yadava Poojar Dope (7) Peethambaran From SP, Mech Hussein
W/Helper (3) Hrishikesan Na 4 W/Helper (3) Praveen Valiya 4 From SP, Mech Nahru Bakki
W/Helper (4) Joykutty DECK TEAM W/Helper (4) Subhash Chan DECK TEAM
W/Helper (5) Subramonian K Fitter(1) Premod Thiyye W/Helper (5) Raghu Palakun Fitter(1) Suseelan Krish
W/Helper (6) Vikraman Vazh Fitter(2) Rajan Raman W/Helper (6) Naveen Kumar Fitter(2) Shyju Parayath
W/Helper (7) Mangalan Diva Fitter(3) Vidya Sagar Ti W/Helper (7) Shijan Pathap Fitter(3) TBA
W/Helper (8) Hajith Lal Gopa Deck Welder Kriangkri Rakth W/Helper (8) Suresh K.P Deck Welder Pisan Yahatta
W/Helper (9) Joseph Kandam From SP,Ftr Vidya Sagar Ti W/Helper (9) Raveendran N. From SP,Ftr TBA
W/Helper (10) Parvatisam Su W/Helper (10) Manoj Kakken
From SP,WH Saji Kuriasseril From SP,WH Santosh Mannb
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C CP U CP U
Integrated Offshore Crude Handling Facilities at Paradip Project
2. HD-2500 F.C.G. (PHASE-I)

( F.C.G : 11' 03.13 ~ 11' 03.21 : 9 Days ) (0)
PM
J.K. Nam ( )
1
OIM /SUPERINTENDENT
Y.J. Go
3 3
Q.A/ Q.C. HSE
Manager Bencio Noble Manager Frankie Anak
Inspector Surya Subram Officer Suresh Kuma
Inspector Chomesvaran HLO Officer Gayah Anak
4 43 (00:00 ~ 12:00) 1 (12:00 ~ 24:00) 1

ADMINISTRATION SUB CONTRACTOR "A" SHIFT ASS'T SUP'T "P" SHIFT EQUIP' MGR
C/Admin J.J. Kim Survey 4 B.K. Kim Y.T. Kim
Ldr Admin Jijo Jose Kaip ROV 5
Admin Satheesh S N Diving 23 2 2
B/Clerk Hari Narayan NDT 4 FIELD ENG'R FIELD ENG'R
MWS 1 Field Eng G.J. Im Field Eng Lancy Benjami
Client 5 Assist Field Sumesh EN Field Eng Y.B. Park
FMC 1 2 2
BARGE FMN BARGE FMN 1
B/Fmn K.D. Lee B/Fmn D.C. Jang CHIEF ENGINEER
B/Fmn Baya Sigau/Ap B/Fmn Lukas Anak Je C/Eng K.H. Kim
8 5 10 5 5 10 6 7 7
SUPPORT TEAM WELDING TEAM RIGGER TEAM OPER. TEAM WELDING TEAM RIGGER TEAM OPER. TEAM ENGINE ROOM ELECTRIC A. H. Tug (1)
MTRL Ctrl S.C. Sin W.FMN J.W. Son RIG FMN(1) Ngelambai A A/FMN George Harriso() W.FMN J.M. Kang RIG FMN(1) Ding Wan A/FMN Tony Harrison () 1st Engineer Johny Anto CHIEF Elect Naveen W. TBA (14)
Warehouse Deepak CT W.FMN Thawatchai H RIG FMN(2) Joseph Jalon W/Optr Wayne Anthon () W.FMN Surapol Suja RIG FMN(2) Ngerong Layo W/Optr Micheal Jackso() 1st Engineer Shibu Palipat ELECT Fmn S.H. Oh
Warehouse Jomon V Geo Welder (1) Peerapong H RIG LDM(1) Pangabang D W/Optr Tony Doyle () Welder (1) Tanongsak Y RIG LDM(1) Henry Anak A W/Optr Ismail K.M.Moh() Oiler Ldmn Biju Cherian Electrician Ummini Nalla A. H. Tug (2)
Medic Debadatta D Welder (2) Surasit Sujari RIG LDM(2) George Ak B M/Crane Y.G. Jung Welder (2) Kanong Rodp RIG LDM(2) Christopher A M/Crane Y.T. Ham Oiler Shibhojith Are Electrician Francis Salda TBA (14)
Radio Optr Deepak Bhar Welder (3) Pipat Sujarit Rigger(1) Stanley Marth D/Crane Patrick Athony Welder (3) Suriya Hunsri Rigger(1) Lian Sigau D/Crane Sili Anak Unga Oiler Purushotham Electrician Joseph Kaipa
Radio Optr Burhan Mask 4 Rigger(2) Edwin Ding A 3 4 Rigger(2) Lawai Njau Tallyman Ranjith M Na Oiler Sebastian Na Electrician Meppad Prad Material Barge
Korean Cook Churamani B WELDER HELPER Rigger(3) Frankie Enga DOPE TEAM WELDER HELPER Rigger(3) Nelson Agus 3 Oiler Rama Shank Electronic Cyril Merwine TBA
Thai Cook Pech Vichien W/Helper(1) Sumesh Kum Rigger(4) Anthony Jalo DOPE FMN Benny Vazha W/Helper(1)Farid Ahmad Rigger(4) Dominic Cha DOPE TEAM 13 5
W/Helper(2) Jishnu Kalloo Rigger(I1) Srijith Tengil Dope (1) Thomas Abra W/Helper(2)Yadava Pooja Rigger(I1) Harish Chand DOPE FMN Benny Vazha MECHANIC BARGE REPAIR Supply Boat
CATERING W/Helper(3) Hrishikesan N Rigger(I2) Raju Lingapp Dope (2) Joseph Abrah W/Helper(3)Praveen Valiy Rigger(I2) Pappachan C Dope (1) Thomas Abra CHIEF Mech Yudas Jangin FMN Anoop Mooliy TBA (14)
Catering Campboss W/Helper(4) Joykutty W/Helper(4)Subhash Cha Dope (2) Joseph Abrah MECH Fmn S.H. Kim Repairer Sukirman
Korean Cook Kim Wonjun 2 2 Mech Ldmn Rajeswar Rao Carpenter Ashok S.
Catering 25(Caterer) DECK TEAM DECK TEAM Mech Ldmn Martin Anak A A/C Man Danilo . B
Fitter(1) Premod Thiyy Fitter(1) Suseelan Kris Mechanic Saravanamar A/C Man Junifer Lara P
Fitter(2) Rajan Raman Fitter(2) Shyju Paraya Mechanic Salat Be 1
Mechanic Chinni Krishn BARGE CLERK/ORION
Mechanic Daniel Nirim Clerk Carlo C.Bandojo
Mechanic Jeffry Saleh
Mechanic Mawan Rajau
Mechanic Juk Jau
Machinist Duryodhana
Machinist Nading Anak
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2.5. INSTALLATION SCHEDULE
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2.6. COMMUNICATIONS & CORRESPONDENCES
2.6.1. Telephone, Fax, and Satellite Communications

HD-2500
MVSAT Telephone(*A): 82-52-203-5473
MVSAT Telephone(*B) : 82-52-203-5431
Fax : 82-52-203-5477
SSB (stdby)-TX/RX : 6262 KHz
VHF (stdby) : Channel 69 & 73
Note : (*A) for COMPANY, (*B) for CONTRACTOR
2.6.2. Subcontractors And Subcontractor Administration
Each Subcontractor will be sorted and administrated by HHI and its scope of work will be executed
by the Subcontractor with direction by HHI while complying with the relevant specifications and
guidelines.
At the time of this writing, the Subcontractors responsibility for specialized disciplines is as
follows:
Vessel / Navigation Survey:
Subcontractor will provide well-trained and experienced personnel for offshore job and proper
equipment to track the anchor handling tug and spread positioning anchors of HD-2500. Prior to
mobilization of equipment and personnel, Subcontractor will submit personnel resume, equipment
list, specifications, calibrated data sheet (if any) to HHI for review and approval.
Diving:
All diving equipments will be fully maintained and serviceable at all times so that it is safe while
being used. Diving personnel will be adequately trained, qualified and experienced in the tasks to
be undertaken, and maintain their qualifications up-to-date. Prior to mobilization of equipment and
personnel, Subcontractor will submit personnel resume, equipment list, specifications, calibrated
data sheet (if any) to HHI for review and approval
Non-Destructive Test:
Subcontractor will provide experienced personnel and well operating equipment and all kinds of
accessories for X-ray, -ray, U.T, MPI, etc. related material to test on welding place to meet
Companys requirements. Prior to mobilization of equipment and personnel, Subcontractor will
submit personnel resume, equipment list, specifications, calibrated data sheet (if any) to HHI for
review and approval.
Field Joint Coating:
Subcontractor will provide personnel, equipment and proper tools necessary to perform field joint
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coating and infilling on construction barge, HD-2500. Prior to mobilization of equipment and
personnel, Subcontractor shall submit personnel resume, equipment list, specifications, calibrated
data sheet (if any) to HHI for review and approval.
Trenching / Dredging / Backfilling:
Subcontractor will provide personnel, equipment and proper tools necessary to perform trenching /
dredging / backfilling work on construction site. Prior to mobilization of equipment and personnel,
Subcontractor shall submit personnel resume, equipment list, specifications, calibrated data sheet (if
any) to HHI for review and approval.
2.6.3. Weather Estimates And Forecasting
The HD-2500 is linked with the weather service from the special agency, HHI contracted to
Aerospace & Marine International, to receive weather information. Weather forecasts will be
provided normally 1 time per day site-specific forecasts including monitoring and updating services.
But if HHI requires more data AMI will provide weather data 3 times per daily.
2.7. RESPONSIBILITIES
Barge Superintendent
Barge superintendent shall be responsible for HSE, quality, and installation progress for the project
relevant to production and construction. Barge superintendent shall ensure that all construction
activities comply with the project specific requirements and/or international codes and standards
under his supervision. Barge Superintendent shall liaise with the project management team for
project execution and planning and with representatives with respect to all barge project activities.
Barge Foreman
Barge foreman shall be responsible for organization, and supervision of all construction activities
on his shift to ensure that construction complies with HSE and project specific requirements. Barge
foreman shall be supported and assisted by all departments in order to expedite construction
activities. Barge foremen shall coordinate with barge below and above deck crews for scheduling
assistance and support between all parties.
Barge Safety Manager
Safety Manager shall be responsible for ensuring and monitoring Safety input for the planning,
organization, and supervision of all barge activities. Besides activities conducted on barge, Safety
Manager shall ensure all support vessels and other work sites comply with Safety, Health, and
Environmental requirements. HSE manager shall liaise with all personnel on board, PMT, and
Company representatives in order to meet the HSE requirement.
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Barge QA/QC Manager
QA/QC Manager oversees the planning, organization, supervision of multi-disciplined QC and

NDT personnel during offshore installation. QA/QC Manager shall liaise with the project
management team and shall conduct daily audits of QC and NDT related activities. QA/QC
Manager shall liaise with Barge Superintendent, inspection team, Project management team and
Company personnel to deliver the Quality required by the contract.
Barge QA/QC Inspector
QA/QC inspector shall organize and supervise the work and inspection activities to ensure that
construction activities comply with the project specific and industry requirements and standards.
QA/QC inspector shall ensure that all work is planned and monitored in compliance with the project
specific requirement.
Design Engineer
Design Engineer shall be responsible for engineering, coordinating and ensuring all construction
activities are in compliance with project specific contract and technical requirement. Design
engineer shall be responsible for providing engineering support of all deviations and modifications
occurring during project execution
Field Engineer
Field engineer shall supervise and liaise with all departments on the barge in order to maintain
construction activities in line with project requirements. Field engineer shall be responsible for
monitoring the work. Field Engineer shall liaise with Company and the Project Management Team
for any project related issues.
Equipment Manager(EQM)
EQM shall be responsible for all operational issues. EQM shall ensure that the barge meets project
and international safety standards for all equipment and operational issues. EQM shall liaise with
barge superintendent and project management team in order to ensure barge operations comply with
international and project specific safety and security requirements.
Captain shall communicate and coordinate with the port authority and offshore field managers to
ensure ship/barge/boats comply with international safety and maritime standards/requirements.
Chief Engineer
Chief engineer shall be responsible for the maintenance of all barge and support equipment for
construction activities. Chief engineer shall plan and organize all below deck and above equipment
maintenance activities for supporting construction activities. Chief Engineer shall ensure that all
equipment is ready and able to perform the various activities required for construction work.
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Chief Mechanic
Chief Mechanic shall be responsible for organizing, planning and maintaining all major
construction equipment i.e. tensioners, A&R winch, anchor winches, welding and pipe handling
equipment, etc. Chief Mechanic shall ensure that construction equipment is in proper condition
for construction activities. Chief Mechanic shall coordinate with the construction crew above deck
to ensure that all equipment is suitable for construction requirement.
Anchor Foreman
Anchor foreman shall be responsible for planning, maintaining and preparing all materials, tools,
and equipment relevant to the barge mooring system. Anchor foreman shall liaise with captain, deck
foreman, field engineer, and support anchor handling tugs for all barge mooring activities. The
anchor foreman reports to the superintendent for construction activities and to the captain with
regard to maritime safety and operations.
Welding Foreman
Welding foreman shall be responsible for planning, organizing and supervising all welding activities
relevant to installation work. Welding foreman shall ensure that all welding activities comply with
project specific requirements and at the same time shall improve project productivity and Quality.
Welding foreman shall liaise with field engineer, barge foremen, barge superintendent, and QA/QC
supervisor and inspectors to ensure that all welding required for construction activities satisfies or
exceeds project requirements.
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2.8. MARINE SPREAD DATA
2.8.1. Marine Spread Requirements
Installation spread will satisfy with the requirements in HSE and Offshore Pipeline Installation
Specification. Prior to mobilization of marine spread, the inspection will be conducted by MWS and
IOCL Marine & Safety.
2.8.2. HD-2500 and Pipelaying Equipment Data

2.8.2.1. HD-2500
Name of Vessel HD-2500
Dimension of Vessel 130 m x 36m x 10.5m
Operation Draft 5.5 m
Winches 10 x SKAGIT
Positioning Line Pull 148 Tons x 16.9 m/Min.
Equipment Wire Size x Length 65 mm x1500 m
Anchors / Type 15 Tons(Air Weight) / Flipper Delta
Main Generator/Engine 4 x 1600 kW
Aux Generator/Engine 1 x 900 kW
Auxiliary Emergency Generator/Engine 2 x 1000 kW
Equipment 2 x 150 /Hr @ 25 Kg/
Compressor
1 x 4.5 /Hr @ 25 Kg/
Water Maker 180 /Day
Tensioner 2 x 200 Kips + 1 x 100 Kips
A/R Winch 1 x 500 Kips
2 x Bevelling Station
Pipelay 1 x Lineup Station
Equipment 6 x Welding Stations
Work Stations
1 x NDT Station
2 x Field Joint Station
1 x Piggyback Clamping Station
Devit Crane 5 x 45 Tons
Radar 2 x JRC/JMA-2144, JRC/JMA-2254
Gyro Compass 1 x TOKYO KEIKI/ES-11A
Navigation Echo Sounder 1 x SKIPPER/ED-162
Equipment GPS 1 x KODEN/KGP-193
Navtex 1 x SARACO/NR-93A
Weather Fax 1 x JRC/JAX-9
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2.8.2.2. Anchoring and Mooring
The 10 delta flipper anchors and associated mooring system have been designed considering the
soil condition of IOCL work area.
The capacity of delta flipper anchor is summarized as below;
Anchor Air Weight (ton) 15
Ultimate Anchor Holding Capacity (ton) 189
* For anchor holding capacity details, refer to the Document No. IOCL-OS-PL-PR-0030, Anchor
Handling Procedure for HD-2500.
Anchoring and mooring equipment will be equipped with control system to monitor the tension
forces in mooring lines paid out at all times during the pipeline laying.
Each anchor winch will be video monitored whilst the vessel is in the field.
2.8.2.3. Pipelay Stinger
The project will be performed using 37m stinger.
The stinger rollers are adjustable, and it will be set to a fixed heights for all the pipelines as per the
engineering results. These settings will be set prior to pipelaying activity. The lay stress analysis
results produce the anticipated roller loads on the stinger rollers.
Stinger Data
Number of Support Number of Roller for

Length Weight
Point Each Support Point
37 m 4 Points 4 Rollers / 8 Rollers 260 ton
Depth gauges will be installed as appropriate on the stinger to allow continuous monitoring of the
stinger roller configuration.
The stinger tip rollers will be fitted with load cells for measuring horizontal and vertical reaction
loads. All load cell readings will be continuously recorded on a strip chart recorder.
The stinger will be equipped with suitable video equipment to monitor the separation between the
last stinger roller support and the pipeline. A video monitor will also be installed in the COMPANY
site representatives office.
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2.8.2.4. Pipelay Tensioner
There are 3 tensioners on HD-2500, which have 500Kips (2224KN) capacity of the total tension
(200Kips x 2 + 100Kips x 1).
Derated Capacity Max. Pipelay Tension

Tensioner No. Max. Capacity (Kips/kN)
(Kips/kN) (kN)
Tensioner-1 100 / 445 80 / 356
Tensioner-2 200 / 890 160 / 712

1000
Tensioner-3 200 / 890 160 / 712
Total 500 / 2225 400 / 1780
Control systems shall be provided to monitor the tension force being achieved by the tensioners.
Tension monitoring and recording will be continuous, with readout available in the control tower.
Pre-calibration of the tensioners using A&R winch will be performed prior to the commencement of
pipe laying.
2.8.2.5. Pipe Support Rollers
All pipe barge and stinger rollers will be coated with 50 Shore A hardness rubber or equivalent to
minimize damage to the pipeline coating.
2.8.2.6. Abandonment and Recovery Facility
A & R winch equipped on HD2500 have 500Kips capacity which is the same as tensioner capacity.
The A & R winch control systems will be provided to monitor the forces being exerted. The tension
in the A & R cable will be continuously displayed in the control room and have a recording facility.
A & R head will be designed according to the required tension,
2.8.2.7. Load Cells
Load cells will be tested and calibrated throughout the expected range of pull tensions. The load cell
will be capable of emitting a visual and audible alarm when the pull tension exceeds the specified
safe limit.
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2.8.3. Sub-Contractors equipments on HD-2500
Air Diving system
An air diving spread will be made available on the barge in supporting survey and constructions.
All critical systems such as communications, heating, launch/recovery, and breathing gas
supply/scrubbing shall have built in redundancy to provide immediate independent back-up in case
of failure.
Diving logbooks will be maintained and casualty reports will be prepared as per local regulations.
Individual dive sheets shall be prepared giving details for each dive/bell run. All documents will
contain the names of diving personnel, and be signed by the on-duty and any relief diving
supervisors.
Diving procedures which includes required diving equipments will be issued separately
subcontractors diving procedure separately.
Survey system
The HD-2500 and associated support tugs will be positioned by the onboard survey team.
The installation spread will be equipped with the necessary survey, sonar, and acoustic equipment to
position the pipelay vessel for accurate installation of the subsea pipelines. A PC based navigation
system shall be used such that a monitor constantly shows a visual display of the field including
existing pipelines, cables, structures, lay barge, pipeline route and pipeline corridors. It will also
display the position of the barge anchors and the anchor handling tugs. The monitors with the visual
display will be prominently positioned in the anchor control room and on the bridge of the anchor-
handling vessels.
For detail procedure which includes survey equipment refer to subcontractors survey procedure.
Field Joint Coating and Infilling Equipment
For field joint coating of pipeline, field joint coating equipment will be on board. For the detail
procedure which includes field joint coating and infilling equipment, refer to the field joint
coating procedure.
NDT Equipment
To guarantee the condition of pipeline welding, the NDT will be conducted. For detail procedure
which includes NDT method and equipments, refer to the subcontractors Pipeline NDT procedure.
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2.8.4. Support Vessels
The following Vessels & Barges are mobilized for the pipe laying work:
(Detail specifications for the Spreads are provided in APPENDIX A.)
SPECIFICATION
VESSEL
ROLE LxBxD BHP/BP
NAME Built
Remark
Year
(m x m x m) (ton)
NO.1 AHT BRITOIL 50 45.0 x 11.8 x 5.6 90 2003 -
NO.2 AHT MELODY 5 49.9 x 12.6 x 5.75 68 2010 -
CREST
Supply Boat 53.0 x 48.7 x 12.0 40 2008 -
RADIANT 3
Material
CREST 252 76.2 x 24.3 x 4.8 - 2006 -
Barge
TOWING TUG :
BRITOIL 5 - 2004
BRITOIL 26
TOWING TUG :
BRITOIL 7 - 2005
BRITOIL 15
TOWING TUG :
BRITOIL 14 - 2006
BRITOIL 29
Coated Pipe
85.9 x 27.4 x 5.4
Transportation TOWING TUG :
BRITOIL 6 - 2004
BRITOIL 12
TOWING TUG :
BRITOIL 13 - 2006
BRITOIL 27
MARITIME TOWING TUG :

- 2004
HOPE MARITIME RATNA
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3. PIPELINE INSTALLATION ENGINEERING
Installation Engineering will meet the requirements of DNV (1981).

3.1. INSTALLATION COTROL
During installation, the pipelaying will be monitored and following essential information will be
recorded in the HHI standard excel sheet, and it will be submitted to client rep. on board.
Tension from each tensioner and the combined tension will be displayed on a direct readout dials
and continuously recorded on a strip chart.
Tension in buckle detector will be recorded.
Joint Number, Buckle Detector Load, Stinger tip depth and load on the stinger end roller will be
continuously recorded.
The heading of the barge each pull joint on each specific KP will be continuously recorded.
Barge trim angle will be continuously recorded.
3.2. ALLOWABLE STRESS
Pipeline installation is verified by using several engineering programs and HHI in-house calculation
sheets.
To control the pipe laying tension during laying operation, HHI used OFFPIPE static & dynamic
analyses for several cases.
The maximum stresses during pipeline installation operations shall not exceed the limits below;
Load Case Overbend Sagbend
Static 72% of SMYS
Dynamic 85% of SMYS 72% of SMYS
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3.3. OFFPIPE INPUT DATA SUMMARY
3.3.1. PIPE & COATING DATA
The pipe & coating data for normal laying, abandonment & recovery analysis same as the para. 2.3
Pipeline Data Table.
Normal Laying Analysis Case:
Case Water Depth (m) Wall Thickness (mm)

1 14
20.6
2 25
3 25
22.2
4 32
Abandonment & Recovery analysis Case:
Case Water Depth (m) Wall Thickness (mm)
1 25 20.6
2 32 22.2
3.3.2. BARGE DATA
There are 22 pipe supports include tensioners. The tangent point is just behind the first tensioner.
For pipelaying analyzes each support location is given by X-Y Coordinates system.
The roller supports are defined base on the bottom roller angle and roller bed length.
The roller supports X-coordinates are based on the barge stern, and Y-coordinates are based on the
main deck level.
And instead of input all the rollers on the roller set, only centerline location will be input and then
the roller bed length will be input.
For barge roller height setting details, refer to the attached drawing.
3.3.3. STINGER DATA
The 37m stinger will be used for IOCL Project. There are 4 sets of roller supports in the stinger.
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The roller support set are composed with 4 or 8 rollers, however instead of input all the rollers only
center line of X-coordinates and roller bed length will be input. And vertical roller support in the
last roller is also modeled.
The roller supports X-coordinates are based on the barge stern, and Y-coordinates are based on the
main deck level.
For stinger roller height setting details, refer to the attached drawing.
3.3.4. ENVIRONMENTAL DATA
The pipelaying analyses have been conducted using ISSC wave spectrum for 45 interval sea wave
(0, 45, 90, 135 & 180).
RAO data is extracted from mooring analyses report.
All the pipeline analyses are conducted significant wave height 1.4m condition, and the results are
satisfactory.
3.4. OFFPIPE OUTPUT DATA SUMMARY
OFFPIPE Output data is summarized in Appendix C.
3.5. ENGINEERING SOFTWARE
3.5.1. OFFPIPE
OFFPIPE is a widely recognized program for offshore pipeline installation analysis. The program
uses a sophisticated finite element method for modeling and structural analysis of non-linear
problems encountered in the installation of pipeline.
In OFFPIPE, the pipeline is modeled by a continuous string of beam-like pipe element that extend
from the line-up station on the lay barge to the point of the fixity on the seabed. The pipe elements
are supported on the barge and stinger by series of discrete pipe support elements. The pipe support
on the lay barge and stinger are modeled by OFFPIPE as frictionless, point supports. The lay barge
is modeled as a rigid body and the seabed is modeled as a continuous elastic foundation using linear,
elastic-frictional soil elements.
Modeling of the pipeline during pipe laying entails the specification of the pipe properties, the barge
and stinger roller support profiles, the lay tension and pertinent boundary conditions specified,
OFFPIPE performs the structural analysis and computes the deflected shape of the pipeline and the
induced pipeline stresses along the pipeline.
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This OFFPIPE program will be used for pipeline initiation, termination, and normal laying analyses.
3.5.2. MOSES
MOSES modeling language is richer than the norm, since it must cope with the demands of both
simulation and stress analysis.
It is able to compute hydrodynamic forces on a system via three hydrodynamic theories: Morisons
Equation, Two Dimensional Diffraction theory or Three Dimensional Diffraction theory.
With MOSES, connector are not simply restraints, but the way one connects different bodies. One
can select from catenaries mooring lines, tension-only and compression-only nonlinear springs,
rigid connectors such as pins and launch ways, and even true nonlinear rod elements. These
connectors are automatically applied during a stress analysis so that one can correctly perform a
stress analysis of several connected bodies.
MOSES allows for the basic computations traditionally performed by a naval architect. One can
compute the curves of form, the intact or damaged stability, and the longitudinal strength of a vessel.
MOSES, however, does not stop here. One can specify interactively, the ballast in any or all of the
vessels tanks and immediately find the resulting condition.
With MOSES, all aspects of the problem can be modeled.
This MOSES program will be used for pipe laying barge mooring analysis, coated pipe
transportation analysis, etc.
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4. PIPELINE INSTALLATION PROCEDURES
Prior to installation operation followings will be completed.
1) Check all the rigging materials are approved by 3rd Party.
2) Check that Risk Assessment has been completed and dispensed.
3) Check HSE Plan & HSEMS Interface document has been approved.
4) QA / ITP for Pipeline operation have been approved.
If all the above are checked and confirmed, the pipelaying operation will be commenced.
4.1. VESSEL POSITIONING / MOORING
Vessel positioning & mooring operation will be executed according to HSE requirements.
No anchor shall be placed closer than 100m from the existing pipeline / cable and the anchor
location measured along the line of pull shall not be closer than 200m to the pipeline / cable.
Minimum distance of 50m is acceptable to Company provided the anchor is not drawn towards the
pipeline during tensioning of the anchor line.
Anchor wires passing over existing pipelines or cables shall maintain a minimum vertical clearance,
for water depth > 25m, the minimum vertical clearance between wires and the pipeline / cable shall
be 15m. For water depth < 25m, the minimum vertical clearance between the wires and the pipeline
/ cable shall be half of water depth. Any anchor crossing a pipeline or cable shall be at least 150m
measured perpendicularly from an existing pipeline or cable (50m when that anchor has not
crossed the existing pipeline or cable).
For detail method for anchor handling, anchor patterns, refer to the Document No. IOCL-OS-PL-
0030, Anchor Handling Procedure for HD-2500.
4.2. PIPELINE ALIGNMENT
During normal laying operation the actual pipeline position will be within 2 meters on either side of
the pipeline route shown in the Company approved drawings for a distance of upto 1000 meter from
the Platform/PLEM or sub-sea installation. The tolerance for the rest of the area shall be 10
meters. However at shore approaches, the tolerance shall be 0.5metres. Company reserves the
right to seek realignment of the installed pipeline in case the above limits are not complied with.
Realignment if any shall be carried out by the Contractor to comply the above limits, at no extra
cost to Company.
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4.3. OPERATING WEATHER CRITERIA
Barge operating weather criteria is as below. However, final decision o f weather limitation will be
decided by the barge superintendent in liaison with IOCL/MWS Marine representative on board
with consideration of actual site condition.
The following summary is based on the mooring analysis report for pipelaying and also included
MWS and IOCLs comment and recommendation.
[Pipelaying Condition]
Weather Omni-Directional
Wave (Hs, m) 1.4
Wind (Knots) 21.6
Current (m/s) 0.7
This criteria is based on mooring analyses. Therefore, refer to the mooring analyses report for more
detail weather limitation.
4.4. WORK STATION & ACTIVITY DESCRIPTION
4.4.1. Material Transfer
Upon arrival of the pipe haul barge in the field, the HD-2500 will bring the haul barge alongside
and begin offloading the pipe in the order as required for normal pipelay. The pipe will be handled
with wire slings padded to protect pipe coating (wrap by polyrope/sack).
The maximum pipe weight per joint is 26.44tons which is 30.3% of selected lifting sling wire MBL.
For pipe transfer details and rigging arrangement, refer to the Document No. IOCL-OS-PL-RP-
0050, Coated Pipe Transportation Analysis
The pipe will be stored in the lay-barge storage racks until needed.
The pipe will be resting on wooden padding and each layer will be stripped with dunnage for
protection of the coating. Once in the transverse conveyors, the pipe is transferred forward via
powered rollers into the bead stall. At this point the pipe will be transferred transversely by the
pipe handling equipment.
Damage to the bevels will be repaired at this point. The pipe is then transferred into the stalking
shoes and aligned for welding using internal or external clamp.
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4.4.2. Preparation
- Pipe Receiving and inspection
All coated pipe and project materials will be received, inspected and documented upon arrival on
the lay barge. The line pipe will be tallied and inspected as it is being loaded onboard the lay barge.
The tally and inspection will be carried out as per the QA(Quality Assurance)/QC(Quality Control)
documents. The individual pipe information, heat number, length, etc., will be recorded on the tally
sheets and stored for final project documentation. A daily report which will contain a log of the days
activities and a recap of the tally will be generated.
Other reports will be generated as per the project specifications. The pipe information will be
recorded as the pipe is loaded onto the lay barge as mentioned above.
Subsequent checks will be performed during the pipeline assembly procedure. The individual pipe
joints will be tallied and inspected again as they enter the bead stall.
These checks will be compared against the original tallies to verify the information. The placement
of the pipe joints in the assembled pipeline will be registered in the bead stall. This information will
be checked as the pipes are placed in the bead stall ready racks and checked again as the pipes are
aligned and welded together. These records will be collected each shift and stored for the final
project documentation.
- Repair Coating or Bevels
During the inspection process, damage to the pipe coating or bevels will be noted. Any minor
damages to the coating will be repaired as the pipe is assembled. If the damage is assessed as major,
the pipe joint may be removed from ready rack and repaired at a later time.
The bevels on the pipe joints will be protected with bevel protectors. However this may not prevent
all bevel damages. If a bevel is found to be in need of repair, the end will be repaired in the bead
stall according to the COMPANY specification.
The inside of the joint will be blown clean with brush pig or equivalent by tugger. When ready, the
transverse conveyors will carry the pipe over and into the stalking shoes.
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4.4.3. Pipe Alignment at Stalking Station
- Pipe Alignment
The stalking shoe operator will manipulate the pipe in the stalking shoes so as to roughly align the
pipe with the section of pipeline in the pipe ramp firing line.
After the rough alignment, the reach rod for the internal clamps will be pulled from the joint
previously welded in the pipeline and into the joint just aligned. The clamps will be set or
activated on the pipeline side and the stalking shoe operator will slowly end the pipe up to the
pipeline.
The welding ground will be fixed to the end of the pipe. The spacers, in conjunction with the
stalking shoe operator, will make sure of the required fine adjustments for final alignment and the
internal clamp will be activated to clamp the pipeline to the newly aligned joint.
- Pipe Marking
During the above activities, the sequential pipe joint number will be painted on the end of the pipe
joint at the end of the bead stall. Successive joints of the pipeline will be consecutively numbered,
as they are installed. Using suitable quick curing marine paint, white numerals at least 200 mm in
height. Numbers shall be painted in the upper quadrant on one side of the joint and also on the
opposite side of the pipe(180 degrees apart). This shall be done at the line up station and touched up
after the pipe has passed through the tensioning device, if necessary.
4.4.4. Pipe Tally

Pipeline tally sheets will be completed, which include pipe joint number, length, pipe material
specifications, location of all pipeline anodes, etc.
4.4.5. Field Welding
After alignment of line pipes, the root bead and hot pass for additional strength will be welded in
the bead stall. The internal clamps or external clamps may be released after the complete bead and
hot pass has been finished. Upon completion of this hot pass, the welder will push the button of the
ready light which will indicate to the tower that the bead stall is complete and ready or the pipe to
be pulled down the ramp to the next station.
After the first weld has been aligned to the 2nd station, partial fill pass will be performed.
4.4.6. Barge movement
After the tower receives ready lights from all stations in the pipeline ramp, the barge will be moved
ahead one pipe length. Successive welding passes will be put in the weld in the remaining welding
stations and the weld will be capped.
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4.4.7. NDT Station
After the weld is completed on a joint, all production welds shall be visually inspected and radio
graphed. The COMPANY representative and CONTRACTOR will monitor and the
SUBCONTRACTOR will interpret the radiograph after development. If required, the weld will be
repaired and re-radio graphed. The field weld joint will be inspected in accordance with the NDT
Procedure approved by COMPANY.
4.4.8. Field Joint and Repair Coating Station
After each joint has been successfully radio graphed at the NDT station, the pipe will be pulled in
the field joint coating station where the joint coating to be applied.
A corrosion protection tape wrap (Heat Shrink Sleeves) in width will be applied over the bare.
For field joint coating method details, refer to the attached drawing.
The cutback length of external corrosion & Concrete Coating is as below;
Corrosion Coating Cutback Concrete Coating Cutback
225 (+25, -0) 350 (+25, -0)
After wrapping, the high voltage holiday detector will be passed over the entire coating. Any
holidays in the coating will be marked and repaired as per the approved vendor details procedure.
4.4.9. Dope Station
When the joint arrives at the dope station the field joint coating infill material HDPF will be
applied in accordance with the approved vendor details procedure.
A pre-cut plastic sleeves with a hole will be then wrapped around the field joint using intra-fuse.
Polymeric foam mixture from the injection pump is then injected into the hole to fill up the field
joint. The hole is then plugged temporarily for the foam material to set. The process described
above is then repeated for successive joints.
After all the above activities, the pipe joint is ready for laying.
4.4.10. Barge Move-Up Procedure
Upon completion of the activities in each station, the ready light will be activated. This light will
give the tower foreman a green light indicator in the tower. All stations showing a green light will
signify that the cycle for one complete joint has been completed and that the barge is ready for the
pulling ahead. When the last ready light is activated, the anchor operator in the tower will signal
barge movement by giving a blast on the air horn and or by announcing on the intercom that they
are pulling the pipe.
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4.4.11. Pipeline Numbering and Traceability
When a pipe leaves the mill it is given a unique pipe number. This number is generally hard
stamped and painted on the pipe together with its length, cast number and material grade.
This unique number assigned at the mill is used to identify the pipe through the coating process and
finally onto the laybarge.
As each pipe on the laybarge is stalked on in the bead stall it is assigned a sequential number
painted on the outside of the concrete coating adjacent to the respective field joint. This is to enable
subsea traceability, of a particular pipe and where it was laid in the pipeline route.
This same number is assigned to the weld and will subsequently appear on the radiograph so that a
particular weld can be traced to a particular pipe to its location on the seabed.
It is therefore necessary to have pipe tally clerks on board whose sole purpose is to keep track of
such numbers so that they can be linked together to make up complete as-built records after
completion of pipelay.
4.4.12. Joint Sequence
The design of the pipeline will most certainly include pipe joints with pre-installed anodes.
Particular attention must be paid to the sequence of how each pipe joint is loaded onto the conveyor
system to give the correct anode spacing along the pipeline.
4.4.13. Tensioner
The barge tension will be continuously recorded and periodically, the barge maintenance personnel
will inspect the tensioners condition. Tension schemes for each pipeline will be included in
pipelaying procedures for each pipelines.
4.4.14. Buckle Detection
The buckle detector is used for pipelines to detect the occurrence of a buckle in the pipeline as the
pipe is being laid. It is pulled through the pipe when the barge pulls forwards and is located after the
touch down point.
The buckle detector shall have a pull force load cell with a constant display and continuous
recording of the load.
The buckle detector is located 50m behind of touch down point. Adequate wire will be provided to
ensure that the buckle detector rides 50m behind the touch down point of the pipe string. Buckle
detector will be inserted in presence of company representative and will be signed by him on the
gauging plate. If the buckle detector is pulled out at any stage during pipelaying for any reason,
company representative(s) on board to be informed prior to removal.
For buckle detector details and rigging arrangement, refer to the attached drawing.
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4.5. PIPELAYING PROCEDURE
4.5.1. Installation of DMA

The pipeline initiation will be performed dead man anchor (DMA) method to start pipeline
installation from the pipeline start point.
Once HD-2500 arrives at the initiation location, the barge positions according to the approved
anchor patterns and Anchor Handling Procedure.
8 Pipe Joints will be welded, and initiation head will be welded to the Pipe end.
4.4.1.1 Initiation at SPM-I
DMA initiation method is as followed Drawing No. IOCL-PL-0124.
4.4.1.2 Initiation SPM-III
DMA initiation method is as followed Drawing No. IOCL-PL-0125.
4.5.2. Normal Pipelaying
Once the initiation head touched down to the seabed, normal laying will be started along the
designated route.
4.5.3. Pipeline Termination

When it is approached to the pipe laying termination area, termination of pipe laying will be
prepared.
Calculation of termination location of pipeline

As the barge approaches to the proposed laydown location, the surveyors and onboard personnel
will begin to monitor and calculate the remained length of pipe.
And then the barge engineer will calculate the amount of pipe suspended off bottom and the
anticipated gain of the pipe, as it will be placed on bottom.
Connection of Termination Head & Load Transfer

Buckle Detector and other equipment in the pipeline will be removed.
The welding of final joint is completed, the termination head will be connected to the last joint.
Connect intermediate termination wire to the termination head.
The load on the tensioner will be transferred to A/R winch.
The barge moving forward until the termination head is located on the last station.
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Lay-down of Pipeline
A/R winch tension and barge movement will be controlled as per the pipeline termination
tension table for each pipeline.
Once all the tension in the A&R winch wire is 0, diver will disconnect the A&R wire from the
intermediate wire, and then connect marker buoy.
Diver will checks to confirm position of termination head by using USBL beacon.
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5. CONTINGENCY PROCEDURE
5.1. GENERAL
This section details the various contingency and emergency response procedures for the IOCL
Project.
5.2. ABANDONMENT
Temporary abandonment of pipelay operations may occur for a number of reasons; however
equipment failure and weather are the two most likely reasons to force a temporary abandonment.
HD-2500 Superintendent will assess the situation and determine if abandonment is needed. If
conditions or the situation allow, slow lay of the pipe will continue as long as viewed prudent by the
HD-2500 superintendent to do so. Company representative to be notified of any changes in the
pipeline production or pipeline.
When weather conditions are such that the barge or support vessels must cease operation, the
pipeline will be temporarily capped and placed on the seabed. This also applies when the weather
forecast indicates extreme weather conditions which would require the lay spread to depart location
or otherwise abandon normal operations.
In this case, the barge will lay out from under the pipeline by attaching a abandonment head to the
pipeline. All internal equipment excepted the buckle detector and the X-ray crawler stopper will be
removed from the pipeline and the head will be welded to the pipeline in the bead stall. The
termination head will then be shackled to the A&R winch wire.
Excess slack will be taken out of the A&R winch wire. The barge will then begin moving forward
as the tension is gradually transferred from the tensioner to the A&R winch wire. Lay tension will
be maintained throughout the procedure. The pipe-support of stinger will remain at the required
depth until the abandonment head has passed.
The length of wire paid out will be monitored and checked against the engineering calculations. The
barge will continue to move forward until the recommended length of wire has been paid out. The
barge will then remain stationary while excess wire is spooled off of the A&R winch. The survey
team will record the coordinates of the end of the pipeline for future recovery.
If the barge is to remain on location, the wire will remain connected to the abandonment head and
to the barge. The excess slack will be required to ensure that the movement of the barge due to sea
state is not transferred to the pipeline on bottom via the wire.
If the barge will be required to abandon the location, the A/R winch wire will be paid off from the
drum. A marker buoy will be attached to the end of the A/R winch wire for retrieval by the barge at
a later time. As an alternate, the pipeline may be laid on seabed and left without a buoy for recovery
by the barge using divers or ROV at a later date.
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5.2.1. Step By Step Procedure for Abandonment
If, for weather forecast reasons, the decision to abandon the pipe is taken by the superintendent of
the barge, steps are as follows;
1) Check and if necessary re-position anchor pattern for barge moving without anchor handling
during abandonment steps.
2) Finish all welds.
3) Recover line-up internal clamp, recover NDT crawler (Buckle detector will be remained in the
pipe string).
4) Weld the abandonment head, and NDT will be carried out.
5) Connect the A/R winch wire and spool the slack.
6) Transfer the tension from tensioner to A/R winch.
7) Once tension is transferred, fully open the tracks of tensioner to pass abandonment head.
8) Move the barge ahead until the abandonment head is reached to the last station of the barge.
9) It is recommended to keep the stinger in a median position while the abandonment head moves
from the laying ramp to the last roller of the stinger.
10) When the abandonment head leaves the barge, a pendant rope with a marked buoy is attached to
the abandonment head, and a mark is painted on the A/R winch wire at a distance equal to stinger
length.
11) As soon as the abandonment head leaves the stern of barge, start to adjust the stinger in a proper
position according to the results of stress analysis.
12) As soon as the abandonment head has left the stinger, stop the stinger operation and move the
barge ahead a predetermined distance as per the calculation for abandonment.
13) Pay out A/R winch wire by decreasing the tension of A&R winch until the pipe touches down
on the seabed. Then the wire is slacked and kept on board or released. If released, the wire is lifted
with a pendant buoy.
14) In all cases, the plotting of the barge route will be precisely made, in particular when the head
comes at the stern of barge.
15) If abandonment is required, according to the decision of the Barge superintendent, the stinger
will be disconnected or not.
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5.3. RECOVERY
1) When weather or other conditions are better, the barge will prepare to recover the pipeline from
the seabed. For this procedure, the barge will be positioned over the abandonment location in the
correct lay orientation. The marker buoy on the A/R winch wire will be recovered to the barge.
2) The A/R winch wire will be passed through the stinger, up the pipe alley and connected to the
A/R winch. The barge will now be moved ahead the minimum distance.
3) The barge will remain stationary and begin spooling in the A/R winch wire. As the wire tension is
set up the required lay tension, the barge will begin slowly back under the end of the pipeline while
maintaining this required tension.
4) The barge will continue back under the pipeline until the end of the pipeline is past the tensioners.
5) At this point, the tension will be transferred from the A&R winch to the tensioners. Once all the
tension is transferred from A&R winch to tensioners. When all the tension in A&R winch is
transferred to Tensioner, A&R winch wire will be disconnected from A/R head and A/R head will
be cut from main pipeline. The next joint of pipe will be ready to be welded.
6) Normal operations will commence at this time.
5.4. DRY BUCKLE
The location of the buckle and the extent of damage will be determined. The buckle will be
surveyed by diver and a conclusion will be made as to whether the buckled area can be recovered to
the barge.
If the buckle will pass through the pipe-support and onto the barge, the barge will begin back under
the pipeline in the reverse process of laying pipe.
As the pipe joints come into the bead stall, they will be cut from the pipeline and set aside for
rebeveling. As the buckled pipeline arrives in the line-up station of lay ramp, it will be cut out. The
barge will then begin stalking on the pipe joints and normal lay will resume.
If the buckle will not pass through the pipe-support or can not otherwise be recovered to the barge,
the abandonment head will be welded on the end of the pipeline. The pipeline will then be laid
down to the seabed as per the termination procedures.
The barge will then lift the pipeline alongside the port side by using the davits or by using a single
point pickup if possible. The buckle will be cut out and the recovery head will be welded on the
pipeline(If required to recover the pipeline by using davit, the analysis and detail method statement
will be done by field engineer on board.).The pipeline will then be placed on seabed and recovered
as per the recovery procedures. Once on the barge, normal pipelay will resume.
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5.5. WET BUCKLE
The location of the buckle and the extent of damage will be determined. The buckle will be
surveyed by diver and a conclusion will be made as to whether the buckled area can be recovered to
the barge.
The pipeline will be pulled back onto the barge. If the buckle or damage has allowed water to enter
the pipeline, the pipeline will be laid on the seabed as per the abandonment procedures.
When the pipe is touched down on the seabed, the buckle will be located and again surveyed.
Divers will cut the pipeline at the damaged area. Divers will then insert pig stopper bars in the cut
end of the pipeline. The barge moves to the initiation area, and pipeline will be air pumped in the
start up end of the pipeline so as to dewatering pig inserted in initiation head can dewater from start
point to the damaged area.
The pipeline will then be recovered to the barge as per the recovery procedure while pressurizing
until the buckled joint comes up to the surface.
5.6. FAILURE OF TENSIONER SYSTEM
The tensioner will be checked and monitored regularly. And if there is any abnormal findings, the
pipelaying operation will be stopped and then be waited until it is fixed.
However, tensioners have their own shut down system for emergency case. Therefore if there is any
unexpected situation occurred, tension will can be kept until the tensioner is fixed.
If the situation requires that the tension on the tensioner needs to be released from the pipe, the A/R
head will be attached and connected to the A/R winch wire.
The tension will be transferred to the A/R winch and then the tensioner release the tension and then
to be fixed.
5.7. FAILURE OF ANCHORS AND ANCHOR LINES
HD-2500 has 10 anchoring system. If any failure of anchoring system is found, the pipelaying
operation will be stopped.
The detail procedure for anchor winch trouble and anchor line failure will be described in the
Anchor Handling Procedure.
5.8. BREAKDOWN OF POSITIONING SYSTEM
Once the positioning system is broken down, the laying operation will be stopped and then be
waited until it is fixed.
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Appendix A Specification of Vessels

A-1 HD-2500
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HYUNDAI-2500
HYUNDAI-2500
DERRICK/PIPELAY BARGE
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HYUNDAI-2500
SPECIFICATION PIPELAY CAPACITY

Registry Ulsan, Korea Max. O.D. 60
Classification A.B.S. + K.R
Length 130 m
Width 36 m
Depth 10.5 m PIPELAY EQUIPMENT
Light Weight 10,325 Tons Tensioners 2 x 200 Kips + 1 x 100 Kips
Operating Draft 5.5 m A/R Winch 1 x 500 Kips
Quarters 275 Persons (Full A/C) Work Stations 2 x Beveling Stations
Helideck 22.8 m Dia. Circular 1 x Lineup Station
Suitable for SIKORSKY S61NL 6 x Welding Stations
Gross Tonnage 14,967 Tons 1 x NDT Station
Net Tonnage 4,450 Tons 2 x Field Joint Stations
CONTROL TOWER
Fuel Storage 2,557 Tons Auto Welding 12 x SATURNAX
Fresh Water Storage 4,058 Tons Devit Crane 5 x 45 Tons
POSITIONING EQUIPMENT NAVIGATION EQUIPMENT

Winches Electric Motor Driven Radar 2 x JRC/JMA-2144, JRC/JMA-2254
10/SKAGIT/AED-250 Gyro Compass 1 x TOKYO KEIKI/ES-11A
Line Pull 148 Tons x 16.9 m/Min. Echo Sounder 1 x SKIPPER/ED-162
Wire Size 65 mm Dia.. GPS 1 x KODEN/KGP-913
Length 1,500 m Navtex 1 x SARACO/NR-93A
Anchors 10 x 15 Tons Weather Fax 1 x JRC/JAX-9
Type Delta Flipper
TENSIONER
AUXILIARY EQUIPMENT COMMUNICATION EQUIPMENT
Generator/Engine SSB Radio 2 x FURUNO/FS-5000
Main 4 x 1,600 kW 1 x ICOM/IC-M700
Aux 1 x 900 kW INMARSAT-A 1 x JRC/JUE-45A
Emergency 2 x 1,000 kW INMARSAT-B 1 x JRC/JUE-310B
Compressor VHF Radio 4 x SAILOR
Main 2 x 150m3/Hr@25Kg/cm2 RT-144C, RT-2047
Emergency 1 x 4.5m3/Hr@25Kg/cm2 RT-2048, RT-2047D
Water Maker 180 m3 /Day AEROVHF 1 x JOTRON, TR-6102
MAIN CRANE PILING EQUIPMENT

Maker / Model CLYDE/60-DE-235+30+15 Number / Type 1 x MHU 1700T
WELDING Fixed 2,500 S.Ton 1 x MHU 600B
Revolving 1,100 S.Ton 1 x VULCAN 5100
Auxiliary 350 S.Ton 2 x VULCAN 560
Whip 75 S.Ton 1 x VULCAN 530
1 x VULCAN 020
1 x MRBS 4600
Hydro Power Pack 1,600 lt/Min.
DECK CRANE DRILLING EQUIPMENT

Maker / Model AMERICAN HOIST/AH-9310A Maker WIRTH
Capacity 225 Tons Number/Model PBA 818 - 2500 - 300
PILE DRIVING HAMMERS
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HYUNDAI-2500
HYUNDAI-2500
DERRICK/PIPELAY BARGE
STBD PROFILE
-2500
SIGNAL MAST
-2500
H/DECK ROOM
OFFICE
CONTROL TOWER
-2500 OFFICE
-2500
B.L B.L
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
-2500
MAIN DECK PLAN
V.L
-2500
K
FAB M
STACK
FAN
FAN
STACK
DN M
VENT
M
VENT FAN FAN M.V
FAN M VENT
UP
HATCH
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LOAD AND HEIGHT CURVES

OF HYUNDAI-2500
RADIUS IN METERS FROM CENTER OF ROTATION

24 30 36 42 48 54 60 66 72 78 84 90
108
102
96
90
84
9623
78
-2500
17.7M TAIL SWING 2500

(ORIGINAL) 72 2400
12976 TIE-BACK
2300
FULL WATER
C
TIE-BACK
EMPTY WATER 66 2100
WATER
TANK 2000
NO TIE-BACK
FULL WATER 60 1900
1800
54 1700
10970 NO TIE-BACK 1600
REVOLVING EMPTY WATER
48 1500
LOAD CAPACITY IN S/TON

TIED BACK
HEIGHT IN METERS ABOVE DECK

991 1400
42
COF ROTATION 1300
1200
REVOLVING 36
FULL WATER 1100
WATER TANK
FULL 1400 K
REVOLVING
1000
EMPTY WATER
30
WTK 900
800
24
80
2570
700
13870
320
18 600
950
5915
500
AUXILIARY
400
2743
12
19490
300
EXISTING
BALLAST 6 200
9584
2210 K -2500 WHIP
100
0 0
24 30 36 42 48 54 60 66 72 78 84 90
5500 5000
14740
10500
WL
RADIUS IN METERS FROM CENTER OF ROTATION
10970
16735
18000
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IOCL-OS-PL-PR-0040
Page : 53 of 132
Date : 02-Dec-10
A-2 AHTs
53/132
BRITOIL OFFSHORE SERVICES PTE LTD
79 Tech Park Crescent, Tuas Techpark. Singapore 638068
Tel : +65-68621035 Fax : +65-68616234 Website : www.britoil.com.sg
SPECIFICATIONS - BRITOIL 50 / BRITOIL 51

Name of Vessel Fuel Bow Thruster Liferafts
BRITOIL 50 / BRITOIL 51 545 mt approx Brunvoll 500hp, 6T thrust 4 x 25 men
Radar
Registry Fresh Water Crane 2 x IMO approved X-band
133 mt approx North American Crane model marine radar c/w 6.5ft
Singapore
45 TM-14M/2.6T. 2.6T at 14m scanner, Furuno model
Freshwater Maker FR-1510MKIII & FR2115
Year of Delivery (96nm)
10 mt/day Anchor Windlass
2003
Hydraulic 7T at 0-15.5m/min SSB
Main Engines & Gearboxes BRATTVAAG
Type Radio console, FURUNO
2 x MAK diesel engines producing model FC-1500-IT-25-250,
Ocean Going / Anchor Handling / 3300 bhp each at 750 rpm c/w 24V DC/240V AC with manual
Anchors
Towing Tug 2 x Reinjtes WAF 4545 reverse 2 x 800kg stockless anchors cover to emergency supply
reduction gearboxes, ratio 3.957:1 antenna feeder through
Classification insulator, whip & standoff
Anchor Chain insulators, c/w DSC & NBDP
ABS + A1, Towing Vessel, (E) Generators
2 x 27.5m x 30mm diameter to meet GMDSS requirements.
+ AMS 3 x 400 kW, CAT 3412 Dita 380/3/50,
U2 steel stud link chain FURUNO SSB model
diesel driven generators. 1 x 99 kW,
FS-1562-25-250W-200chs
CAT 3306 Dita emergency generator
GRT / NRT / DWT Towing/Anchor Winch
777T / 233T / 605T BRATTVAAG double drum waterfall
VHF
Main Engine Consumption 2 x VHF/FM multi-channel
type SL150W-B2T hydraulic winch marine radio telephones.
18,000 litres MGO and 53 litres lube
Dimension with remote controls in wheelhouse. Furuno FM-8500-25W
oil per 24 hours at full power.
45.0m x 11.8m x 5.6m 10,000 litres MGO and 26 litres lube 150T pull at 0-10.2 m/min
20.5T pull at 0-32m/min Gyro & Automatic Pilot
oil per 24 hours at economic cruising
Wire Capacity:- 1 x Gyro-Tokimec TG6000.
Draft speed of 10 knots Autopilot-Furuno FAP-330
4.5m (Designed) / 5.5m (Max) 2 x 1200m x 60 mm dia (capacity)
Generator Consumption Brake holding: 275T at 1st layer Weather Facsimile
Clear Deck Space 360 litres MGO and 10 litres lube oil 1 x FURUNO model FAX-207
per 24 hours Tugger Winch
19.0m x 9.0m Other Navigation Equipment
2 x BRATTVAAG 11T line pull at
0-44m/min INMARSAT-C, EPIRB, Radar
Propulsion
Speed Transponder, P.A. System,
2 x 3200mm dia fixed pitch 4 bladed Navtex Receiver, GPS
13.0 knots Wire Storage Reels
manganese bronze propellers in Navigator, Anemometer,
kort nozzles 2 x 9.1T line pull at 0-51m/ min, Omni Direction TV Antenna,
Bollard Pull 1 x 18.2T line pull at 0-21 m/min, Echo Sounder, Battery
90T Steering Gear Wire Capacity: Powered Telephone,
Electro hydraulic, 9T torque 1200m x 60mm dia each, storage Inmarsat M.
Endurance reel will contain 1200m x 60mm dia
Fire Monitors
30 days Fuel Oil Purifiers spare wire & 1 reel will store various 2 fixed foam/water fire
Mitsubishi self cleaning fuel oil size pennant wires monitors of 10000 litres/min
Accommodation purifier SJ10F each at 120m head capacity.
Fully air conditioned for 21 men Fendering 1 x Fire pump of 1200 m/hr
Lube Oil Purifiers Flat bar doubler plates of each (engine driven)
Mitsubishi self cleaning lube oil 500mm x 40mm cross section
Lifesaving Dispersant Booms
purifier SJ10F welded to side shell
Comply to SOLAS requirement 2 x 4m dispersant booms
fitted
Towing Pins & Sharkjaws Cutting Equipment
Firefighting Karmfork combination unit with 2 bottles oxygen and Sewage Treatment Plant
Comply to SOLAS requirement 2 towing pins & 2 sharkjaws Taiko Kikai SBT-25 for 25 men
1 bottle acetylene c/w torch
Details given in good faith and are believed to be correct but not guaranteed
54/132
MELODY 5
5150 BHP
Anchor Handling / FireFighting Tug
SPECIFICATIONS
GENERAL: MACHINERY:
Flag : Singapore Main Engines : 2 x 2575 BHP @ 1600 rpm
Built : 2010, Malaysia Caterpillar 3516B
Auxiliary Engines : 2 x 250kW 415V 50Hz
Class : BV
CUMMINS QSM11-DM
Emergency Generators : 1 x 150 kW
PRINCIPAL PARTICULARS:
415V 50 Hz
Length Overall : 49.95 M Propellers : 2 x Fixed Pitch in Kort/Nozzies
Breadth Moulded : 12.60 M Bow Thruster : Kamome 640 BHP
Depth Moulded : 5.75 M Steering System : Electro Hydraulic c/w Joystick @
Draft (max) : 4.80 M Forward and Aft Consoles
GRT : 960
DWT : 842 T DECK MACHINERY:
Bollard Pull : 68 Tons
PERFORMANCE: Towing/Anchor Winch : Plimsoll
Speed (Max) : 12.0 Knots Line Pull 150 T
Break Load 200 Tons
Economical Speed : 10.5 Knots Towing Wire : 1000 M x 56 mm x 2 Nos
Type of Fuel : MGO Tugger Winch : 2 x 10 MT
Consumption : Approx 12.0 Tons/day Capstans : 2 x 5T
Crane : 3 MT @ 12.0 M
CARGO CAPACITIES: Shark Jaws : 200 Tons
Clear Deck Area : 22 M x 10 M Towing pin : 200 Tons
Stern Roller : 4200 x 1500 mm; 300 Tons SWL
Fuel Oil : 500 M3 Wire Reel : 1000 M x 54 mm
Fresh Water : 242 M3
Lub Oil : 25 M3 RADIO & NAVIGATION EQUIPMENT:
GMDSS (A3), VHF x 2, Radar x 2, Auto-Pilot, Gyro Compass,
Dirty Oil : 5 M3
Echo Sounder, Navtex, GPS, AIS, Weather Fax
FO Transfer : 1 x 70M3/hr @ 30 M Head
FW Transfer : 1 x 70M3/hr @ 50 M Head SAFETY & FIRE FIGHTING EQUIPMENTS:
Pumps x 2 : 1200M3/hr + 1700M3/hr
Freezer : 5 M3
70M3/hr @ 50 M Head
Chiller : 5 M3 Monitors - Water/Foam : 2 Nos
Spray Boom : 5 M x 2 Nos
ACCOMODATION:
3 x 1 berth : Fully Air-Conditioned MISC:
7 x 2 berth Dispersant Tank : 19 M3
2 x 4 berth Foam Tank : 16 M3
(Total - 25 persons) Oil Recovery : 126 M3
Note: All details believed to be correct but w.o.g.
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IOCL-OS-PL-PR-0040
Page : 56 of 132
Date : 02-Dec-10
Appendix B Drawings
B-1 Pipeline Basic Engineering Drawings (By EIL)
S.N. Drawing No. Rev. Drawing Title

Alignment Sheet Proposed Pipeline Route-1 From LFP-
1 A036-11-0101 A
2A To SPM-II (PLEM II-A) KP 0.000 to KP 3.748
2 A036-11-0102 A
3 A036-11-0103 A
4 A036-11-0104 A
5 A036-11-0105 A
6 A036-11-0106 A
7 A036-11-0201 A
2B To SPM-II (PLEM II-B) KP 0.000 to KP 3.743
8 A036-11-0202 A
9 A036-11-0203 A
10 A036-11-0204 A
11 A036-11-0205 A
12 A036-11-0206 A
Alignment Sheet Proposed Pipeline Route-3 From LFP-3
13 A036-11-0301 A
To SPM-III KP 0.000 to KP 3.454
14 A036-11-0302 A
15 A036-11-0303 A
16 A036-11-0304 A
17 A036-11-0305 A
18 A036-11-0306 A
Alignment Sheet Proposed Loopline From SPM-I
19 A036-11-0401 A
(Existing) To SPM-II KP 0.000 to KP 3.614
Alignment Sheet Proposed Loopline From SPM-II
20 A036-11-0501 A
(PLEM II-D) To SPM-III KP 0.000 to KP 4.042
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IOCL-OS-PL-PR-0040
Page : 77 of 132
Date : 02-Dec-10
B-2 Pipeline Installation Drawings (By HHI)
1 IOCL-PL-0100 C0 Pipeline Overall Field Layout
2 IOCL-PL-0101 C0 Plan and Elevation of HD-2500
3 IOCL-PL-0102 C0 Working Station Detail of HD-2500
4 IOCL-PL-0103 C0 Main Crane Lifting Chart for HD-2500
5 IOCL-PL-0104 C0 Stinger Plan and Elevation
6 IOCL-PL-0105 C0 Stinger Buoyancy Tank
7 IOCL-PL-0106 C0 Stinger Handling Method
8 IOCL-PL-0107 C0 Stinger Radius and Stinger Roller Setting
9 IOCL-PL-0108 C0 Barge Roller and Roller Setting
10 IOCL-PL-0109 C0 Pipeline Abandonment Procedure (1 of 2)
11 IOCL-PL-0110 C0 Pipeline Abandonment Procedure (2 of 2)
12 IOCL-PL-0111 C0 Pipeline Recovery Procedure (1 of 2)
13 IOCL-PL-0112 C0 Pipeline Recovery Procedure (2 of 2)
14 IOCL-PL-0113 C0 Wet Buckle Recovery Procedure
15 IOCL-PL-0114 C0 Dry Buckle Recovery Procedure
16 IOCL-PL-0115 C0 Laybarge Tension Scheme for Normal Laying
17 IOCL-PL-0116 C0 Field Joint Coating
18 IOCL-PL-0117 C0 A&R Head
19 IOCL-PL-0118 C0 Initiation Head
20 IOCL-PL-0119 C0 Termination Head
21 IOCL-PL-0120 C0 Buckle Detector
22 IOCL-PL-0121 C0 Buckle Detector Rigging Arrangement
23 IOCL-PL-0122 C0 X-ray Crawler Stop Trolley
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IOCL-OS-PL-PR-0040
Page : 78 of 132
Date : 02-Dec-10
24 IOCL-PL-0123 C0 Flange Protection Method
25 IOCL-PL-0124 C0 Pipeline initiation Method at SPM-I
26 IOCL-PL-0125 C0 Pipeline initiation Method at SPM-III

Pipeline Initiation Rigging Arrangement at SPM-I &
27 IOCL-PL-0126 C0
SPM-III
28 IOCL-PL-0401 C0 Coated Pipe Transportation Route Map
29 IOCL-PL-0402 C0 Sea-fastening Detail (1/2)
30 IOCL-PL-0403 C0 Sea-fastening Detail (2/2)
31 IOCL-PL-0404 C0 Coated Pipe Hauling Method
32 IOCL-PL-0411 C0 Pipe Haul Barge Setting for HD-2500
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IOCL-OS-PL-PR-0040
Page : 111 of 132
Date : 02-Dec-10
Appendix C Initiation & Termination Head Calculation
111/132
PROJECT IOCL Paradip SPM Project SHEET OF
SUBJECT Initiation & Termination Head Design DESIGNED Y.HO. KIM DATE 2010. 11. 10
For 48" Pipe Line CHECKED Y.H. KIM DATE
THE APPLIED LIMITATION OF ALLOWABLE STRESSES FOR PULLING HEAD DESIGN
The beginning of any analysis requires the estimation of a suitable design load. This load should include the
weight to be lifted, a dynamic impact factor, a safety factor, sling angle, number of padeyes used in the lift, the
number of cheek plates, the distribution of sling loads and various other factors.
Stresses associated with plate tearing, pin bearing and pin pullout should be determined. These stresses can
be compared to the appropriate allowable stresses given by the American Insitute of Steel Construction (1989)
of 60% of yield stress for tension tearing, 90% of yield stress for bearing, and 40% of yield stress for pin pullout.
Allowable stresses in the padeye should not exceed the following maximum levels (taken from AISC rules),
where Fy = Specified Minimum Yielding Strength of the padeye material : -
Description Maximum Allowable Level AISC Ref.

Shear Stress, (Fv) 0.4 Fy F4.1
Bending Stress, Major Axis, (Fbx) 0.6 Fy F2.2
Bending Stress, Minor Axis, (Fby) 0.6 Fy F1
Bearing Stress, (Fp) 0.9 Fy J8.1
Tensile Stress, (Ft) 0.6 Fy D1
Combined Tensile & Bending ft fbx fby
+ + 1.0 H2.1
Stress (Unity Check) Ft Fbx Fby
Allowable stresses in the welds should not exceed the following maximum levels (taken from AISC rules), where
Fw = Nominal Tensile Strength of weld metal and Fy = Specified Minimum Yielding Strength of weld metal : -
Description Maximum Allowable Level AISC Ref.

Shear Stress, (Fv) 0.3 Fw, 0.4 Fy (lesser of) J2
Tensile Stress Parrel to Weld Axis Same as padeye material J2
Tensile Stress Normal to Effective Same as padeye material J2
Area for Full Penetration Weld Only
Tensile Stress Normal to Effective 0.3 Fw, 0.4 Fy (lesser of) J2
Area for Partial Penetration Weld
Only
* Applicable to fillet, partial penetration and full penetration welds.
OFFSHORE INSTALLATION DPT'T 1/6 Initiation & Termination Head.xls
112/132
1. PIPE DATA OF PULLING HEAD

1) Pipe Outside Diameter, (OD) : 1219 mm
2) Pipe Wall Thickness, (t) : 20.6 mm
3) Material Grade : API 5L X - 65
SMYS of API 5L X-65 : 4,570 kg/cm2
2. DESIGN PULLING FORCE

1) Maximum Pulling Force : 150 M.Ton
2) Factor of Safety : 2.0
3) Designed Pulling Force (Pd) : 300 M.Ton
3. SHACKLE DATA
1) Shackle Size : 150 Ton

2) Jaw Width (A) : 140 mm
3) Pin Dia. (D) : 108 mm
4) Inside Length (E) : 368 mm
5) Body Thickness (L) : 104 mm
[ G-2140 Shackle]
4. PADEYE PROPERTIES
113/132
1) Main Plate Thickness (t1) : 45 mm

2) 1st Cheek Plate Thickness (t2) : 20 mm
3) 2nd Cheek Plate Thickness (t3) : 12 mm
4) Radius of Main Plate (R1) : 200 mm
5) Radius of 1st Cheek Plate (R2) : 180 mm
6) Radius of 2nd Cheek Plate (R3) : 160 mm
7) Dia. Of Pin Hole (Dh) : 113 mm
8) Steel Grade (ASTM A572) Fy = 3,513 kg/cm2 ; ASTM A50
Total Thickness of Padeye (tall) = 109 mm Thus, O.K
Inside Length (E) + D/2 - Radius of Main Plate (R1) = 224.8 mm
5. STRESS CHECK FOR PADEYE

1) Bearing Stress Check
Actual Bearing Stress (Fbr) = Pd / (Pin Dia. X Total Padeye Thickness)
= Pd / (D x t)
= 2,549.60 kg/cm2
Allowable Bearing Stress (Fbra) = 0.9 x Fy

= 3,161.70 kg/cm2 Thus, O.K
2) Tensile Stress Check

Cross Sectional Area (A) = [ (R1-Dh/2) x t1+2 x (R2-Dh/2) x t2+2 x (R3-Dh/2) x t3 ] x 2
= 277.68 cm2
Actual Tensile Stress (Ft) = Pd / A

= 1080.36 kg/cm2
Allowable Tensile Stress (Fta) = 0.6 x Fy

2
= 2,107.80 kg/cm Thus, O.K
3) Shear Stress Check

Actual Shear Stress (Fs) = Pd / A
= 1080.36 kg/cm2
Allowable Shear Stress (Fsa) = 0.4 x Fy

= 1,405.20 kg/cm2 Thus, O.K
114/132
6. STRESS CHECK FOR MAIN PLATE
1) Tensile Stress Check
Width of Main Plate, (Bm) : 1269.0 mm

Thickness of Main Plate, (t1) : 45.0 mm
Height of Stiffener Plate, (Hs) : 612.0 mm
Thickness of Stiffener Plate, (t4) : 25.0 mm
Inside Distance of Stiffener Plate, (Ls) : 728.0 mm
Distance of Padeye Center to Pipe : 300.0 mm
End (Lb)
Actual Tensile Area (A) = [ (Bm x t1) + (Hs x t4) x 4 ] / 100

= 1183.05 cm2
Actual Tensile Stress (Ft) = Pd / A

= 253.58 kg/cm2
Allowable Tensile Stress (Fta) = 0.6 x Fy

= 1,897.02 kg/cm2 Thus, O.K
2) Bending Stress Check Due to Pull Inclination

Section Modulus Calculation ( X-X)
Member B H y A Ay Ay^2 Io = (BxH^3)/12

(cm) (cm) (cm) (cm^2) (cm^3) (cm^4) (cm^4)
4.50 126.90 63.45 571.05 36,233.12 2,298,991.62 766,330.54
61.20 2.50 101.10 153.00 15,468.30 1,563,845.13 79.69
61.20 2.50 101.10 153.00 15,468.30 1,563,845.13 79.69
61.20 2.50 28.30 153.00 4,329.90 122,536.17 79.69
61.20 2.50 28.30 153.00 4,329.90 122,536.17 79.69
Sub. Total 1,183.05 75,829.52 5,671,754.22 766,649.29
Inertia Moment (I x-x) = Ay^2 + I0 - (Ay)^2 / A

= 1,577,986.39 cm4
115/132
Netural Axis (y xx) = 64.10 cm
Section Modulus (Z x-x) = 24,618.87 cm3
Section Modulus Calculation ( Y-Y)
Member B H y A Ay Ay^2 Io = (BxH^3)/12

2 3 4 4
(cm) (cm) (cm) (cm ) (cm ) (cm ) (cm )
126.90 4.50 2.25 571.05 1,284.86 2,890.94 963.65
2.50 61.20 32.85 153.00 5,026.05 165,105.74 47,754.36
2.50 61.20 32.85 153.00 5,026.05 165,105.74 47,754.36
2.50 61.20 32.85 153.00 5,026.05 165,105.74 47,754.36
2.50 61.20 32.85 153.00 5,026.05 165,105.74 47,754.36
Sub. Total 1,183.05 21,389.06 663,313.91 191,981.09
Inertia Moment (I y-y) = Ay^2 + I0 - (Ay)^2 / A

= 468,589.45 cm4
Netural Axis (y) = 18.08 cm
Section Modulus (Z y-y) = 25,918.14 cm3
Assume, Pull Inclination = 15 Degree
Bending Moment (Mx = My) = Design Load x Sin 15 x Lb

= 2,329,371.41 kgcm
Bending Stress (Fbx) = Mx / Z x-x

= 94.62 kg/cm2 Thus, O.K
Bending Stress (Fby) = My / Z y-y

= 89.87 kg/cm2 Thus, O.K
Allowable Bending Stress (Fba) = 0.6 x Fy
2
= 2,107.80 kg/cm
3) Combind Stress Check
Combined Tensile & Bending Stress due to inclination of pulling direction in trench.
Ft Fbx Fby
+ + 1.0
Fta Fba Fba
Ft Fbx Fby
= + +
0.6Fy 0.6Fy 0.6Fy
253.6 95 90
= + +
2,108 2,108 2,108
= 0.21 Thus, O.K
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7. WELDING LENGTH CALCULATION

Total Thickness of Padeye, (tall) = 109 mm
1st Cheek Plate Thickness, (t2) = 20 mm
2nd Cheek Plate Thickness, (t3) = 12 mm
Shear Force Taken by 1st Cheek Plate, (Fs1) = 110.09 Ton

Shear Force Taken by 2nd Cheek Plate, (Fs2) = 66.06 Ton
Weld Length of 1st Cheek Plate, (Lw1) = 1,130.97 mm
Weld Length of 1st Cheek Plate, (Lw2) = 1,005.31 mm
Allowable Shear Stress, (Fsa) = 0.4 Fy

2
= 0.01 Ton/mm
Min. Fillet Weld Size of 1st Cheek Plate, = 10 mm
Min. Fillet Weld Size of 2nd Cheek Plate, = 7 mm
8. PIPE GRIPPING CHECK
1) Pipe Wall Thickness, (t) = 20.6 mm

2) Main Plate Length from Pipe End, (Lm) = 1,020.0 mm
3) Cover Plate Thickness, (tc) = 20.0 mm
4) Cover Plate Length, (Lc) = 1,219.0 mm
Total Butt Welding Length, = 6,518.0 mm
Designed Pulling Force, (Pd) = 300 M.Ton
Allowable Shear Stress, = 0.4 Fy

= 0.01 Ton/mm2
Butt Weld Length on Main Plate, = 5 mm
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IOCL-OS-PL-PR-0040
Page : 118 of 132
Date : 02-Dec-10
Appendix D OFFPIPE Analysis Output Summary Table
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SUMMARY OF ABANDONMENT & RECOVERY ANLAYSIS RESULT
(IOCL BY HD-2500)
Location Pipeline Working Barge Retain Wire

KP Point OD (inch) 48 Name HD-2500 OD (inch) 2.5
Water Dep. in MSL(m) 25 Wall Thk.(mm) 20.6 Barge Radius 380 MBL(tons) 276
Service Con. Thk.(mm) 120 Stinger Radius 380 Length (m) -
Pulling Head Location Barge Tension Stinger End Roller Max. Stress Level of SMYS H. Dist. Gain Touch Down Length
Step X Y Height fr. Sepa. Depth React. X Over X Sag. Touch Length fr. Stern fr. Line-Up
(kN) (Ton)
(m) (m) Seabed (m) (m) (kN) (Ton) (m) (%) (m) (%) Down (m) (m) (m)
1 99.54 6.41 31.41 200.00 20.39 0.00 -6.56 4.78 0.49 56.51 65.76 -48.30 0.00 -156.99 3.07 160.06 263.60
2 99.54 6.41 31.41 300.00 30.58 1.54 -5.05 0.00 0.00 56.51 65.89 -41.95 0.00 -229.81 2.18 231.99 335.53
3 99.54 6.41 31.41 400.00 40.77 0.63 -5.95 0.00 0.00 2.80 66.20 -48.70 2.59 -258.82 2.25 261.07 364.61
4 99.54 6.41 31.41 500.00 50.97 0.18 -6.39 0.00 0.00 56.51 66.15 -48.53 9.55 -234.52 2.89 237.41 340.95
5 99.54 6.41 31.41 500.00 50.97 0.15 -6.41 0.00 0.00 56.51 66.15 -84.03 14.72 -113.08 3.35 116.43 219.97
6 99.54 6.41 31.41 600.00 61.16 0.30 -6.27 0.00 0.00 56.51 66.28 -84.38 33.62 -136.96 2.86 139.82 243.36
7 99.54 6.41 31.41 600.04 61.17 0.25 -6.32 0.00 0.00 56.51 66.28 -96.39 48.82 -159.13 2.73 161.86 265.40
8 99.54 6.41 31.41 700.05 71.36 0.17 -6.39 0.00 0.00 56.51 66.40 -108.34 57.66 -170.15 2.81 172.96 276.50
* Note 1. Origin of the base coordinate is the barge stern.
2. Touchdown Length expresses pipe string from line-up station to touchdown point.
3. Horizontal length indicates horizontal distance between barge stern and touchdown point.
SUMMARY OF ABANDONMENT & RECOVERY ANLAYSIS RESULT

(IOCL BY HD-2500)
Location Pipeline Working Barge Retain Wire

KP Point OD (inch) 48 Name HD-2500 OD (inch) 2.5
Water Dep. in MSL(m) 32 Wall Thk.(mm) 22.2 Barge Radius 380 MBL(tons) 276
Service Con. Thk.(mm) 120 Stinger Radius 380 Length (m) -
Pulling Head Location Barge Tension Stinger End Roller Max. Stress Level of SMYS H. Dist. Gain Touch Down Length
(kN) (Ton)
(m) (m) Seabed (m) (m) (kN) (Ton) (m) (%) (m) (%) Down (m) (m) (m)
1 99.54 6.41 38.41 400.03 40.78 1.80 -4.79 0.00 0.00 56.51 65.90 -49.01 0.00 -341.04 2.41 343.45 446.99
2 99.54 6.41 38.41 499.98 50.97 1.63 -4.96 0.00 0.00 56.51 66.02 -41.97 0.00 -384.52 2.22 386.74 490.28
3 99.54 6.41 38.41 600.00 61.16 0.74 -5.84 0.00 0.00 2.80 67.79 -57.19 2.43 -397.96 2.42 400.38 503.92
4 99.54 6.41 38.41 700.00 71.36 0.25 -6.32 0.00 0.00 56.51 66.26 -72.27 6.19 -379.43 3.00 382.43 485.97
5 99.54 6.41 38.41 799.97 81.55 0.06 -6.51 0.00 0.00 56.51 66.38 -48.46 13.39 -317.17 3.82 320.99 424.53
6 99.54 6.41 38.41 900.00 91.74 0.03 -6.53 0.00 0.00 56.51 66.51 -95.56 24.04 -137.37 4.33 141.70 245.24
7 99.54 6.41 38.41 900.00 91.74 0.05 -6.51 0.00 0.00 56.51 66.51 -107.77 40.96 -160.57 3.86 164.43 267.97
8 99.54 6.41 38.41 1000.07 101.94 0.04 -6.52 0.00 0.00 56.51 66.63 -119.79 52.26 -182.98 3.72 186.70 290.24
2. Touchdown Length expresses pipe string from line-up station to touchdown point.
3. Horizontal length indicates horizontal distance between barge stern and touchdown point.
119/132
SUMMARY OF STATIC & DYNAMIC NORMAL LAYING ANLAYSIS RESULT
(IOCL BY HD-2500)
Location Pipeline Working Barge
KP Point OD (inch) 48 Name HD-2500
Water Dep. in MSL(m) 14 Wall Thk.(mm) 20.6 Barge Radius 380
Service Con. Thk.(mm) 120 Stinger Radius 380
Stinger Start Roller Barge Tension Stinger End Roller Max. Stress Level of SMYS H.Dist. Gain Touch Down Length
(Ton) (kN)
(m) (m) Seabed (m) (m) (kN) (Ton) (m) (%) (m) (%) Down. (m) (m) (m)
Static -7.41 0.21 14.21 1.76 -6.56 0.00 0.00 56.51 69.14 -97.50 45.25 -141.38 1.32 142.70 246.24
Dynamic (0) -7.41 0.21 14.21 2.64 -6.56 0.00 0.00 14.99 78.84 -97.52 69.95 -141.38 1.32 142.70 246.24
Dynamic (45) -7.42 0.19 14.19 2.45 -6.56 1.07 0.11 2.79 75.20 -85.35 60.91 -141.38 1.32 142.70 246.24
20.07 200.00
Dynamic (90) -7.42 0.16 14.16 2.27 -6.56 0.00 0.00 14.99 74.39 -97.51 60.64 -141.38 1.32 142.70 246.24
Dynamic (135) -7.41 0.20 14.20 2.58 -6.56 1.24 0.12 2.80 76.03 -61.11 57.90 -141.38 1.32 142.70 246.24
Dynamic (180) -7.41 0.20 14.20 2.63 -6.56 0.00 0.00 14.99 74.69 -85.35 59.59 -141.38 1.32 142.70 246.24
2. Touchdown Length expresses pipe string from line-up station to touchdown point
3. Horizontal length indicates horizontal distance between barge stern and touchdown point

(IOCL BY HD-2500)
(Ton) (kN)
Static -7.39 0.06 25.06 0.19 -6.56 0.00 0.00 56.51 69.79 -108.35 60.01 -169.38 2.80 172.18 275.72
Dynamic (0) -7.39 0.06 25.06 0.38 -6.56 0.00 0.00 -17.20 72.83 -120.47 71.58 -169.38 2.80 172.18 275.72
Dynamic (45) -7.40 0.06 25.06 0.35 -6.56 0.00 0.00 -17.20 71.64 -108.35 68.40 -169.38 2.80 172.18 275.72
70.25 700.00
Dynamic (90) -7.39 0.06 25.06 0.27 -6.56 5.07 0.51 -17.20 71.94 -108.36 65.80 -169.38 2.80 172.18 275.72
Dynamic (135) -7.39 0.06 25.06 0.34 -6.56 2.10 0.21 -17.20 71.40 -108.35 67.91 -169.38 2.80 172.18 275.72
Dynamic (180) -7.40 0.06 25.06 0.34 -6.56 0.00 0.00 -17.20 71.42 -108.36 68.53 -169.38 2.80 172.18 275.72
120/132
(IOCL BY HD-2500)
(Ton) (kN)
Static -7.39 0.06 25.06 0.18 -6.56 0.00 0.00 56.51 69.77 -108.34 60.66 -168.48 2.81 171.29 274.83
Dynamic (0) -7.39 0.06 25.06 0.36 -6.56 0.00 0.00 -17.20 72.55 -108.35 70.84 -168.48 2.81 171.29 274.83
Dynamic (45) -7.40 0.06 25.06 0.32 -6.56 0.00 0.00 -17.20 71.85 -108.34 69.52 -168.48 2.81 171.29 274.83
80.29 800.00
Dynamic (90) -7.39 0.06 25.06 0.24 -6.56 5.13 0.51 -17.20 71.75 -108.35 66.16 -168.48 2.81 171.29 274.83
Dynamic (135) -7.39 0.06 25.06 0.31 -6.56 2.39 0.24 -17.20 71.94 -108.34 68.77 -168.48 2.81 171.29 274.83
Dynamic (180) -7.40 0.06 25.06 0.31 -6.56 0.00 0.00 -17.20 71.34 -108.34 69.15 -168.48 2.81 171.29 274.83

(IOCL BY HD-2500)
(Ton) (kN)
Static -7.39 0.06 32.06 0.02 -6.56 0.00 0.00 56.51 70.01 -131.70 62.75 -191.31 3.83 195.14 298.68
Dynamic (0) -7.39 0.06 32.06 0.06 -6.56 157.38 15.79 -26.95 72.89 -131.71 71.79 -191.31 3.83 195.14 298.68
Dynamic (45) -7.40 0.06 32.06 0.05 -6.56 57.95 5.82 -26.95 71.69 -131.71 70.06 -191.31 3.83 195.14 298.68
100.36 1000.00
Dynamic (90) -7.39 0.06 32.06 0.05 -6.56 120.32 12.08 -26.95 72.28 -119.64 67.38 -191.31 3.83 195.14 298.68
Dynamic (135) -7.39 0.06 32.06 0.06 -6.56 142.15 14.27 -26.95 71.39 -131.71 69.25 -191.31 3.83 195.14 298.68
Dynamic (180) -7.40 0.06 32.06 0.06 -6.56 124.89 12.53 -26.96 71.42 -131.71 69.38 -191.31 3.83 195.14 298.68
121/132
IOCL-OS-PL-PR-0040
Page : 122 of 132
Date : 02-Dec-10
Appendix E OFFPIPE Analysis Input & Output for Maximum Barge Tension Case
122/132
123/132
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= 3
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= - H - -= O = C C E E I I ID N H E A P = P S D T T U S D C D O
=
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= P Y.D= D== T T R ANA T N NEEA B E P R = EPEE G G E R GDR E F
=PIBO NI= = E
T==S
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124/132
MM MMM
M
M
M
M M M
MM MMM M
MM
M
M
M M M M M
M M M M M M
M
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M
M
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M M
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M M M M M M ************************************
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18011197 INTEGRATED OFFSHORE CRUDE HANDLING FACILITIES PROJECT

2. GENERAL INFORMATION AND OFFSHORE MANAGEMENT ...........................................11

3. PIPELINE INSTALLATION ENGINEERING ............................................................................32

4. PIPELINE INSTALLATION PROCEDURES..............................................................................36

4.3. Operating Weather Criteria ............................................................................................................37

5. CONTINGENCY PROCEDURE ..................................................................................................44

(b) Onshore pipelines of size 48 dia, from respective LFP to COT.

1.2. FIELD LAYOUT

SPM Dic ha rg ni g M ani of dl

2236000 mN VC-89 2236000 mN

14" Existing(As-laid) VC-94

2234000 mN VC-11 2234000 mN

2232000 mN V C-58 2232000 mN

2230000 mN VC-107 2230000 mN

VC-64 PROPOSED PIPELINE ROUTE 2

48" Existing (Extrapolated)

LFP-IIA TO SPM-II (PLEM II-A) VC-36

VC-79 2 222 642.565 N

2 219 945.724 N SPM -II (PLEM II-A) 4

SPM -II (PLEM II-D)

SPM -II (PLEM II-C)

1.3. SCOPE OF OFFSHORE INSTALLATION

1.4. PURPOSE OF DOCUMENT

This procedure will also be submitted to the MWS for approval.

1.5. PIPELINE INSTALLATION SEQUENCE

Shore Approach for Route 1 Pipeline

1.6. REFERENCE DOCUMENT

1.6.1. International Codes and Standards

[1] DNV,1981 Rules For Operations, Planning and Execution

1.6.2. Project Specification

[4] A005-001-16-71-TR-22 Annexure-2, Pipeline Designation

[5] A005-002-16-71-SP-01 Piping Material Specification & Annexure I (Piping Material

[6] 6-71-0063 Standard Specification for Trenching and Backfilling of

[7] A005-002-16-56-SI-011 Site Information

1.6.3. Reference Procedure

[9] IOCL-OS-PL-PR-0010 Trenching & Backfilling Procedure

[10] IOCL-OS-PL-PR-0020 Shore Approach Procedure

[11] IOCL-OS-PL-PR-0030 Anchor Handling Procedure for HD-2500

[12] IOCL-OS-PL-RP-0050 Coated Pipe Transportation Analysis

[13] IOCL-OS-PL-RP-0060 Mooring Analysis for HD-2500

[14] IOCL-OS-PL-PR-0070 Pipeline NDT Procedure

[15] IOCL-OS-PL-PR-0080 Diving Procedure

[16] IOCL-OS-PL-PR-0090 Pipeline Field Joint Coating Procedure

[17] IOCL-OS-PL-PR-0100 Pre-construction Survey Procedure for Pipelines

[18] IOCL-OS-PL-RP-0102 Pre-construction Survey Report

[19] IOCL-OS-PL-PR-0104 Survey Procedure for Pipeline Installation

SMYS : Specified Minimum Yield Strength

LAT : Lowest Astronomical Tide

MSL : Mean Sea Level

HAT : Highest Astronomical Tide

PLEM : Pipeline End Manifold

LFP : Land Fall Point

2. GENERAL INFORMATION AND OFFSHORE MANAGEMENT

The material data for line pipe are summarized in below;

Description Units Parameter

Youngs Modulus of Steel Gpa 207

Poissons Ratio - 0.3

Density of Steel kg/m3 7850

SMYS of Steel Mpa 448

SMTS of Steel Mpa 531

2.1.2. Concrete Coating Properties

Description Unit Parameters