PROFESSIONAL EXPERIENCE REPORT

Presented

To
Council for the Regulation of Engineering in Nigeria
(COREN)

By
DASIETIMA THEOPHILUS ORUPABO
B.Eng. (Hons) Mechanical Engineering
Federal University of Technology, Owerri, Imo State

OF

PETRA SERVICES LIMITED.

IN FULFILMENT OF THE REQUIREMENT FOR
REGISTRATION

Into

Council for the Regulation of Engineering in Nigeria

(COREN)

April, 2018.
 ATTESTATION

I certify that the information as contained in this report is to the best of my knowledge, the true

practical experience of Mr. Theophilus Orupabo.

NAME: ________________________________________________________________

DESIGNATION: _________________________________________________________

REGISTRATION No: _____________________________________________________

SIGNATURE: ___________________________________________________________

DATE: _________________________________________
 ABSTRACT

This technical report summarized my engineering experience in fulfillment of the requirement for
registration for the Council for the Regulation of Engineering in Nigeria. The report was
structured in three sections .Introduction chapter introduced the profile of the author and the
purpose of the document. Chapter one summarized the detail of “Design Of The 8” X 5.206km
New Delivery Line From Ibigwe Flowstation To Lact (With Receiver And Launcher) Unit At
Assa”. Chapter two focused on “The Construction of Approximately 27.5km
Of Flowlines at Oza Field, Abia State.”.The report of the project in each of the main chapters (1
and 2 ) contained: title of the project, statement of the problem, solution provided, problems
encountered, conclusion and recommendation. In each of the projects reported, the objectives of
carrying out the exercise were fully met. For Design of the 8” X 5.206km New Delivery Line from
Ibigwe Flowstation to Lact (With Receiver and Launcher) Unit at Assa, a 8” Pipeline that is
expected to transport about 5000 to 15000 BOPD was successfully designed based on pipeline
systems Codes, Standards and Specification. For the Construction of Approximately 27.5km
Of Flowlines at Oza Field, Abia State.”, the objective was met which involved managing the
scheduled construction work for the period.
 CONTENTS
1. INTRODUCTION................................................................................................................................... 3
1.1 Project Overview....................................................................................................................... 3
1.2 Objectives ................................................................................................................................. 3
1.3 Definitions ................................................................................................................................. 3
1.4 General Information .................................................................................................................. 4
1.5 Abbreviations ............................................................................................................................ 4
1.6 Software ................................................................................................................................... 5
1.7 Units ......................................................................................................................................... 5
1.8 Facilities.................................................................................................................................... 5
1.9 Project Requirement ................................................................................................................. 5
1.10 Rules and regulations ............................................................................................................... 6
1.11 CODES, STANDARDS AND SPECIFICATION ......................................................................... 6
1.11.1 Codes and Standards ............................................................................................................... 6
1.12 Project Documents and Specifications...................................................................................... 8
2. SITE CHARACTERISTICS ................................................................................................................... 9
2.1 Geodetic Reference .................................................................................................................. 9
3. DESIGN BASIS .................................................................................................................................. 10
3.1 Design Objective..................................................................................................................... 10
3.2 Design Data ............................................................................................................................ 10
3.3 Battery Limit............................................................................................................................ 12
3.4 Pipeline Specification.............................................................................................................. 12
3.5 Pipeline Route ........................................................................................................................ 12
3.6 Pipeline Trenching/Burial ........................................................................................................ 12
3.7 Hydrostatic testing and Commissioning .................................................................................13
3.8 Pipeline Crossing .................................................................................................................... 13
4. PIPELINE SYSTEM DESIGN.............................................................................................................. 14
4.1 Pipeline Routing...................................................................................................................... 14
4.2 Pipeline Design and Operating Parameters ............................................................................ 14
4.3 External Corrosion Coatings ................................................................................................... 15
4.4 Field Joint Coating. ................................................................................................................. 15
4.5 Pipeline flange & Fittings ........................................................................................................ 15
4.6 Insulating Joints ...................................................................................................................... 15
5.1 Design Considerations............................................................................................................ 16
5.2 Pipe Wall Thickness Calculation ............................................................................................. 16
5.3 Minimum Elastic Bending Radius............................................................................................17
5.4 External Corrosion Protection ................................................................................................. 17
5.5 Road Crossing ........................................................................................................................ 17
5.6 Hydrostatic Testing and Pre-Commissioning ..........................................................................
5.7 Inspection Maintenance and Repair (Pigging Philosophy)
6. REFERENCE DOCUMENTS .............................................................................................................. 19
 INTRODUCTION
INTRODUCTION
This report summarizes my professional experience gained from various projects I have worked
on after my graduation in August 2008. The experience covers diverse areas of engineering as the
engineering profession involves interactions between various engineering disciplines while
working on projects. My experience comprises of work in a multi-discipline environment in oil &
gas engineering projects. Specific works include the design and construction of flowlines and
Pipeline systems for downstream of the oil and gas industry. Also I have worked with technical
bids and commercial bids, majorly in evaluating quotes and other technical submissions in order to
meet specific project needs as may stated in the invitation to tender documents.
Finally, I have also lead technical team in construction works on site for various projects that have
earn mutual financial benefits for my company and our clients.
It must be stressed here that for reasons of time and space constraints, this report is made as vivid
as possible such that some engineering details are ignored. I wish to stress further that this
document is not a chronicle of all the engineering activities I encountered, but a part of a whole,
specifically presented for the purpose of meeting up with the requirements for registration as a
member of the Council for the Regulation of Engineering in Nigeria (COREN).
Extracts of these experiences are put together in this document to represent a small portion of my 9
years practice as a Mechanical Engineering in the Oil and Gas industry.

SUMMARY OF EXPERIENCE
I graduated from Federal University of Technology, Owerri in 2007 with a second class lower
grade in Mechanical Engineering. He has since then after my National Youth Service Scheme, I
have been involved in engineering projects delivery. I first worked with Lambert Electromech in
Victoria Island, Lagos State between January, 2009 and October, 2011. I later joined the workforce
of Vandrezzer Energy Services Limited as a Field and Planning Engineer in January, 2012.
Vandrezzer Energy Services Limited is an oil and gas servicing company with over 15 years’
project experience in engineering construction in oil and gas sector. In August, 2012, I became a
Field Engineer and HSE officer for a period of 3 months with Abbey court Nigeria Limited. I then
joined Petra Services Limited in January, 2013 to date, a company with over 25years experience in
Flowline/Pipeline Construction, Marginal field development, Leak repair, Upgrade of oil and Gas
facilities, support services and canalization/Channelization projects. I joined Petra Services Limited
as a Field/Site Engineer and was later promoted to as Projects and Bids Engineer.
Abbreviations and Definitions

Acronym Meaning
API American Petroleum Institute
ASME American Society of Mechanical Engineers
BOPD Barrels of Oil Per day
FEED Front End Engineering Design

CA Corrosion Allowance
CP Cathodic Protection

ID Inside Diameter

KP Kilometre Point

3LPE 3 Layer Polyethylene Coating

MMSCFD Million Standard Cubic Feet per Day
NACE National Association of Corrosion Engineers
OD Outer Diameter

Psi Pounds per Square Inch

TN True North
WSP Waltersmith Petroman
SAIL Second Adams International Limited
HAZID Hazard Identification
HAZOP Hazard Operability

CARRER OVERVIEW
Petra Services Limited
From September 2013 to date I have been working with Petra Services Limited as a Field
/Planning, Site Engineer and Projects Engineer/ Bids Engineer. Petra is an indigenous engineering
design and construction company providing Engineering, Procurement, Construction and Project
Management (EPCM) services to the Nigerian oil and gas Industry.
Capabilities exist in the engineering group for Downstream (Marginal Field Development, Flare
systems, Flowline, Pipeline Construction and Mechanical Fabrication, Tanks Construction, Leak
repair, Equipment supply/Leasing) in the following areas:
  Conceptual Engineering Design
 Front End Engineering Design (FEED)
 Detailed Engineering Design
 As Built Engineering Services
 Project Management Services
 Support Services

Work Experience/Project Executed

As a Project/ Bids Engineer, I have been involved in construction of flowlines and pipelines and
Upgrade of oil and gas facilities for IOCs and Marginal field operators.
As a Project/Bids Engineer, I have been able to combined Project management with Mechanical
engineering for oil and gas downstream projects.
My responsibilities included:
 Technical/ Commercial bidding, project scoping, site visits/inspections, integrity checks,
project kick-off/call-off contract meetings, involved in project planning, budget prepare and
pre-mob of equipment.
 Prepare contract mobilization package (work schedule, work scopes, work method
statement, HSE plan, Security plan, ITPs, Sleeving procedure, Hydro-test procedure, JHA,
quality plans, etc).
 Ensure that client’s technical requirements are met, co-ordinate the project technical team
by means of regular meetings, interface control, design monitoring, quality control,
milestones review, initiation and project files maintenance.
 Review of PFDs, GAs, ISO Drawings, As-Built drawings and prepare MTOs from
drawings; QA/QC project documents, supports in WPQT, WPS and PQR prepare for
pipeline welding and mechanical modification works, project execution plans and
procedures, and take up other responsibilities as assigned by superiors at various site
locations.
 Supports Pipe line route survey, probing and line measurement, bush clearing, trace-off all
vegetation, excavation of the flow line trench along the right of way (R.O.W),
backfilling/restoration of site, thrust-boring/road crossing etc.
 Supervise the tie-ins of line pipes at various sections and river crossings, fabrication and
installation of risers, approaches and hook-ups at both flow station and wellhead ends.
  Observing strictly the provisions of the PTW and other relevant complimentary/entry permits and
suspending unsafe activities.
 Plan all works daily and in advance, giving particular emphasis to work scopes and job hazards.
 Ensure that suitable quality records are maintained, up-to-date maintenance and calibration of
equipment and seeking improvement to the quality system.
 Initiate flow line flushing as well as step-wise hydro-testing of both flow lines and wellhead
hook-up arms.
 Receive and monitor all Project materials, consumables and equipments.
 Supervise all third party activities involve in the Projects.
 Supervise depressurizing, draining, venting of the Pipe line, backfilling, site clean-up, besides
prepare close-out reports, hand-over to client and demob of work spread.
 Plan, Budget, control and supervise construction and installation of temporary (Chiksan) hook up
pending rig demobilization.
 Plan, Budget, control and supervise construction and installation of permanent hook up after rig
demobilization.
 Generation and transmission of Daily, Weekly and Monthly Progress reports to Clients and
Operations Manager.
In the last nine years I have been involved in the following engineering projects:
PROJECT
CONTRACT/PROJECT TYPE
S/No. COMPANY/ POSITION CLIENT DATES
TITLE
OZA EPF PIPELINE PETRA SERVICES
MILLENIUM OIL AND GAS FEB,2017- APRIL,
1. INSTALLATION LIMITED/PROJECT-SITE
COMPANY LIMITED 2017
PROJECT ENGINEER
PIPING
MODIFICATIONS TO PETRA SERVICES
WALTERSMITH PETROMAN OIL
2. ACCOMMODATE GAS LIMITED/PROJECT-SITE DECEMBER, 2016
COMPANY
LIFT COMPRESSOR 3 ENGINEER
OPERATIONS
INSTALLATION OF
MANIFOLD, PIG PETRA SERVICES
MILLENIUM OIL AND GAS APRIL 2016 –
3. LAUNCHER AND LIMITED/PROJECT-SITE
COMPANY LIMITED JUNE, 2016.
RECEIVER AT OZA ENGINEER
FIELD, ABIA STATE.
OZA ( 6” X 800M) EPF-
OZA LACT UNIT PETRA SERVICES MILLENIUM OIL AND GAS NOWEMBER, 2015
4.
PIPELINE LIMITED/PROJECT-SITE COMPANY LIMITED – JANUARY 2016.
CONSTRUCTION ENGINEER
CONSTRUCTION AND
INSTALLATION OF
TEMPORARY HOOK- PETRA SERVICES
5. WALTERSMITH PETROMAN OIL OCTOBER, 2015.
UP ARMS (CHIKSAN) LIMITED/PROJECT-SITE
COMPANY
FOR IBIGWE- WELL 9 ENGINEER
AND 10.
IBIGWE-9
WELLHEAD/GAS LIFT PETRA SERVICES
6. HOOK UP, LIMITED/PROJECT-SITE WALTERSMITH PETROMAN OIL JUNE, 2015 –
INSTRUMENTATION ENGINEER COMPANY AUGUST, 2015.
WORK AND
 FLOWLINE
CONSTRUCTION.
IBIGWE, IMO STATE.

THE CONSTRUCTION
OF APPROX. 27.5KM
OF FLOWLINES AND
FABRICATION PETRA SERVICES
7. INSTALLATION OF LIMITED/PROJECT-SITE MILLENIUM OIL AND GAS AUGUST, 2013-
MANIFOLD, PIG ENGINEER COMPANY LIMITED MAY, 2014.
LAUNCHER AND
RECEIVER AT OZA
FIELD, ABIA STATE.
24” X 4KM
REPLACEMENT OF
DAMAGE SECTIONS PETRA SERVICES LIMITED/ JANUARY, 2013-
8.
FROM OGBANIBIRI TO SITE ENGINEER TOPLINE/NAOC AUGUST, 2013
OB/OB. BAYELSA
STATE.
AWOBA NW WELL 1
FLOW LINE
ABBEYCOURT NIGERIA
SECTIONAL AUGUST,2012-
9. LIMITED/ FIELD ENGINEER- SPDC
REPLACEMENT 4” X OCTOBER, 2012
HSE OFFICER
5KM L/S. RIVERS
STATE
CONSTRUCTION AND
INSTALLATION OF VANDREZZER ENERGY
JANUARY 2012-
10. 10”X 1.6KM PIPELINE SERVICES/FIELD/PLANNING FRONTIER/UNIVERSAL/NETWORK
JULY 2012
CONTRACT. IBENO, ENGINEER
AKWA IBOM STATE.
CONSTRUCTION AND
INSTALLATION OF
FIRE FIGHTING
LAMBERT
HYDRANT LINES-
ELECTROMECH/JOAMED SEPTEMBER,2009-
11. TOTALFINA HOUSING TOTALFINAELF
SERVICES LIMITED/ OCTOBER, 2011
EXTENSION EKO
SUPERVISOR
TOWERS. VICTORA
ISLAND LAGOS
STATE.

I have undergone various local trainings such as:

2018: CWSIP 3.2 (In view)
2013: American Society of Non- Destructive Testing (ASNT II) level II- Visual Testing (VT),
Penetrant Testing (PT), Magnetic Particle Testing (MT), Ultrasonic Testing (UT) and Radiographic
Film Interpretation (RFI).
2010: HSE Competence Certification (Level 3), Nigerian Institute of Safety Professional, Port
Harcourt.
2009: HSE Competence Certification (Level 2), Nigerian Institute of Safety Professional, Port
Harcourt.
2009: Proficiency Certificate in Management, Nigerian Institute of Management (NIM).
 CHAPTER ONE
DESIGN OF THE 8” X 5.206KM NEW DELIVERY LINE FROM IBIGWE
FLOWSTATION TO LACT (WITH RECEIVER AND LAUNCHER) UNIT AT ASSA

1.1 Introduction/Project Overview

Waltersmith Petroman Oil Limited a marginal field operator, operating under the OML16 in Imo state
proposed to construct Ibigwe pipeline transporting 5000 to 15000 barrels of crude oil from Ibigwe
field to Asa LACT unit. This line is aimed at replacing the already congested 4” Crude oil delivery
line. Waltersmith Petroman decided to invest in the design and construction of 8” x 5.206 km
Pipeline to transport crude from Ibigwe to Asa Lact Unit. To this end, Petra Services Limited was
contracted to c a r r y out a Front End Engineering (FEED) for actualizing the facility at Ibigwe
based on a Scope of work provided by Waltersmith. To this end Petra Services Limited was
awarded with the Design, Procurement and Construction of the 8” X 5.206km New Delivery line
from Ibigwe Flowstation to Lact Unit (with receiver and Launcher) Unit at Assa. Petra Services
Limited on the other hand subcontracted the design aspect of the Project to SAIL. During the
design the entire design process that last for a two months period, I was seconded to SAIL as a
Mechanical Engineer.

1.4 General Information

The proposed Asa- Ibigwe Pipeline is located in Imo State; the scope is divided into two parts. One
is Front End Engineering (FEED) and then other is DETAILED design. These two parts is given
below:
1. FEED Verification of 8” Crude Oil Pipeline
2. Detailed design of 8” Crude Oil Pipeline.
1.6 Software
Software
The following software packages are used for the 8’’ Asa Ibigwe pipeline design
Aspen HYSYS V6.0 –
 To obtain stream conditions and physical properties of process fluid. The following
parameters and inputs are used in above listed software for calculations and modeling.
 Compositions and conditions for the stream are based on HYSYS simulation (IB-4L D2.0
Composition sample)
 Peng Robinson EOS for thermodynamic properties
 Beggs and Brill for hydraulics

AutoCAD 2004
 Generation of Process drawings
AUTOPIPE
 stress calculation
 Stress calculation of buried pipeline and above ground pipeline
 Petra Spread Spread Sheet
 Calculation of pressure drop

EXCEL
MATHCAD
1.7 Units

The units of measurement used on the project are t h e International System of Units (SI). Additionally,
standard oilfield units were used where appropriate in bracket following the SI unit.
Units used will be indicated throughout the design documents where applicable.

1.8 Facilities

1.8.1 Existing 4” Pipeline:

Pipeline Outside Pipeline Wall Pipeline Pipeline

Diameter thickness Length Minimum
(inch) Inch (mm) (Km) Bend radius

8.625 hold 5.206 hold

1.9 Project Requirement

The main requirement for this project was to design an 8” Pipeline that will transport crude oil from
Ibigwe to Asa. This 8” Pipeline is expected to transport about 5000 to 15000 BOPD.

1.10 Rules and regulations

The Ibigwe field Project shall comply with all mandatory requirements of applicable Nigerian regulations.
If not covered by Nigerian regulation, contractor shall use reasonable and customary industry
practices agreed with COMPANY.

The Department of Petroleum Resources (DPR) is the primary regulatory body entrusted with the
responsibilities and power to regulate operations and activities to ensure compliance with legislative
requirements in the oil and gas industry in Nigeria.

The following rules and regulations applies within the Nigerian:

 Federal Republic of Nigerian Official Gazette: Oil Pipelines Act (CAP. 338 LFN), Oil and Gas
Pipeline Regulations 1995.
 Mineral Oil Regulation Act 1997.

 Government Notice No.49 SI 14 Oil and Gas Pipelines Regulations

 Oil Pipelines Act Chapter (CAP.) 338, Laws Of the Federation of Nigeria (L.F.N.) 1990

 Mineral Oils safety Regulations (MOSR) 1997

 Environmental Impact Assessment (EIA) Decree 1992

The following guidelines issued by DPR were be complied with.

 Guidelines and Procedures for Construction, Operation and Maintenance of Oil and Gas
Pipeline and Ancillary Facilities

 Environmental Guidelines and Standards (EGAS) 1991

1.11 CODES,STANDARDS AND SPECIFICATION

1.11.1 Codes and Standards

The pipeline systems were designed in accordance with the latest edition of the following codes and
recommended practices, unless otherwise noted.

Number Title
ASME B31.8 Gas Transmission and Distribution Piping Systems
Pipeline Transportation Systems for Liquid Hydrocarbons and
ASME B31.4
Others Liquids
ASME VIII Boiler and Pressure Code - Pressure Vessel
ASME IX Welding Code
ASME V Non-destructive Testing
ASME B16.34 Valves – Flanged, Threaded and Welding End
ASME B16.5 Pipe Flanges and Flanged Fittings NPS ½ Through NPS 24
ASME B16.47 Large Diameter Steel Flanges NPS26 Through NPS 60
ASME B16.9 Factory-Made Wrought Butt Welding Fittings
ASME B16.11 Forged Fittings, Socket - Welding and Threaded
Metalic Gaskets for Pipe Flanges
ASME B16.20

Table 1.1 Primary Design Codes

The following supplementary codes were be used as required.

Number Title
API-5L Specification for Line Pipe
API 6D Specification for Pipeline Valves
API 6FA Fire Test for Valves
API RP 2A- Recommended Practice for Planning, Designing and
WSD Construction of Fixed
DnV RP F107 Risk Assessment for Pipeline Protection
API 600 Steel Gate Flanged and Butt Welding Ends

Table 1.2 Supplementary Design Codes

 1.12 Project Documents and Specifications

The following project documents were referenced throughout the detail design of the pipeline
systems. In addition to the documents listed in, other COMPANY documents were referenced to as
necessary.

SA-12-IB-PL-RS-4-WSP-001 PIPELINE ROUTE SELECTION Rev. D

SA-12-IB-PL-PC-4-WSP-002 PIPELINE CALCULATION (ONSHORE) Rev D
SA-12-IB-PL-DB-4-WSP-003 PIPELINE DESIGN BASIS Rev. D
SA-12-IB-PL-RL-4-WSP-004 PIG LUNCHER AND RECEIVER Rev. D
SA-12-IB-PL-DB-4-WSP-001 PIPELINE DESIGN BASIS Rev. D
SA-12-IB-PL-CN-4-WSP-002 PIPELINE THICKNESS CALCULATION Rev. D
SA-12-IB-PL-CN-4-WSP-003 PIPELINE STRESS ANALYSIS REPORT Rev. D
SA-12-IB-PL-CN-4-WSP-004 PIPELINE CORROSION COATING SPECIFICATION Rev. D
SA-12-IB-PL-CN-4-WSP-006 PIPELINE WALL THICKNESS REPORT Rev. D
SA-12-IB-PL-CN-4-WSP-007 SPEC AND DATA SHEET FOR CORROSION COATING Rev. D
SA-12-IB-PL-CN-4-WSP-008 SPEC AND DATA FOR PIPELINE VALVE Rev. D
SA-12-IB-PL-CN-4-WSP-009 SPEC AND DATASHEET FOR INDUCTION BEND Rev. D
SA-12-IB-PL-CN-4-WSP-010 SPEC AND DATA SHEET FOR FLANGES Rev. D
SA-12-IB-PL-CN-4-WSP-011 SPEC FOR CLEANING, FILLING AND HYDROSTATIC TEST Rev. D
SA-12-IB-PL-CN-4-WSP-012 SPEC AND DATA SHEET FOR HEAT SHRINKABLE SLEEVE Rev. D
SA-12-IB-PL-CN-4-WSP-013 DATA SHEET FOR CARBON STEEL LINE PIPE Rev. D
SA-12-IB-PL-CN-4-WSP-014 DATA SHEET FOR 8" INDUCTION BEND Rev. D
SA-12-IB-PL-CN-4-WSP-015 PIPELINE MATERIAL TAKE OFF Rev. D
SA-12-IB-PL-CN-4-WSP-016 SPEC AND DATA SHEET FOR PIG LUNCHER AND RECEIVER Rev. D
SA-12-IB-PL-CN-4-WSP-017 PIGGING HANDLING SYSTEM Rev. D
SA-12-IB-PL-CN-4-WSP-018 TYPICAL RIGHT OF WAY Rev. D
SA-12-IB-PL-CN-4-WSP-019 ROUTE MAP Rev. D
SA-12-IB-PL-CN-4-WSP-020 TYPICAL PIPELINE TRENCH Rev. D
SA-12-IB-PL-CN-4-WSP-021 ALIGNMENT SHEET Rev. D
SA-12-IB-PL-CN-4-WSP-022 TYPICAL MARKERS AND WARNING SIGNS Rev. D
SA-12-IB-PL-CN-4-WSP-023 PIPING AND SUPPORT DRAWING Rev. D
SA-12-IB-PL-BD-4-WSP-024 BEND DETAIL DRAWING Rev. D

Table 1.3 Project Deliverable List

 2. SITE CHARACTERISTICS

The Project location is onshore Nigeria having a land approximately 5.206km long within
concession OML 16 situated within Ohaji/Ebgema LGA of Imo State, the route of which
traversed dry land and is shown verged in red in the Company’s plan ref. PP01A.

The width of the Right of way is approximately15metres. Starting from the existing Ibigwe Oilfield.
All that strip of land approximately 5.206 km starting at Ibigwe Oil field location whose Nigeria
Coordinates are N592160.00 metres; E260738.00 metres; 52.00 metre Height above sea level
and whose Geographic Coordinate are Lat 50 21’ 14”. Long 60 50’ 28” E.

2.1 Geodetic Reference

Minna Datum, Zone 32 extending to Intersection Point IP1 on an approximate bearing of 3050 53’,
also to IP2 on bearing 3540 24’, IP3 on bearing 3260 34’, IP4 on bearing 3050 20’, IP5 on bearing
2920 33’, IP6 on bearing 2780 21’, Finally to the en point whose Nigeria Coordinate are
N593353.958 metres; E256071.864 metres; 53.14 metres Height above sea level whose
Geographic Coordinate are Lat. 50, 21’ 53” N Long 60 47’ 56’ E.
3. DESIGN BASIS

3.1 Design Objective

The overall project is to provide the facility to handle the transporting of 5000 to 15000 BOPD of
crude oil.
In achieving the above objective, the following sub- objective will apply:
 To minimize site work thereby reducing construction duration, cost and
social/environment impact of the project.
 To consciously define components and designs to allow suitable parts of the project to be
procured, fabricated and/or constructed in Nigeria m e e t i n g t h e N i g e r i a n L o c a l
Content bill.

3.2 Design Data

2. DESIGN DATA
2.1 Design Flowrates, Pressure and Temperature

DESIGN
FLOWRATE KG/HR DESIGN PRESSURE TEMPERATURE
(BARREL/DAY) (BAR) (OC)

82,500 (16,000) 98 60

Table 2.1 Shows the design flowrate, pressure and temperature of flow: This
flow rate is based on process simulation.
The operating pressure and temperature of the flow lines are shown below

Operating Temperature
Flow line Operating Pressure Normal/Max (0C)
Description (Bar )

Hydrocarbon Flow 20 (Maximum back 25/40

lines pressure downstream
choke at the
wellhead)

Table 2.3 Shows the operating pressure and temperature of flow lines

Description Values
Start Location Ibigwe
End Location Asa
Pipe OD (mm) 203.2
Nominal Wall Thickness hold
Nominal O.D (in) 8.625
Design Pressure (psi) 1421
Design Temperature (0C) 60

Table 3.1 – Pipeline Design Parameters

3.3.1 Design Life of the Pipeline

Ibigwe – Asa 8” Pipeline and associated facilities is designed for 30 years period.

3.3.2 Crude Compositions for the Different wells in Ibigwe field.

IB-1L F1.3 IB-1S C 6.4 IB- 2T IB- 4L D2.0

S/N COMPONENT
Mol % Mol % Mol % Mol %
1 C1 0.00 0.00 0.00 0.00
2 C2 0.09 0.17 0.00 0.09
3 C3 0.63 0.12 0.00 0.05
4 i-C4 0.50 0.42 0.00 0.09
5 n-C4 2.21 0.46 0.10 0.06
6 i-C5 0.93 0.17 0.00 0.19
7 n-C5 1.68 0.21 0.00 0.19
8 C6 13.72 0.59 4.91 2.96
9 C7 12.64 1.46 9.15 3.86
10 C8 7.11 4.70 0.00 10.75
11 C9 6.88 7.29 0.62 10.78
12 C10 6.67 9.04 5.33 9.14
13 C11 5.53 16.33 5.13 7.21
14 C12 4.20 9.78 7.51 6.51
15 C13 5.37 8.63 11.45 7.65
16 C14 4.84 6.50 11.80 7.99
17 C15 3.67 4.11 8.83 5.72
18 C16 2.36 6.29 4.17 4.63
19 C17 3.44 3.31 2.34 3.68
20 C18 1.79 3.12 1.27 2.98
21 C19 1.33 1.24 1.18 2.34
22 C20 0.73 1.03 0.97 1.69
 23 C21 0.51 0.88 0.90 1.44
24 C22 0.41 0.68 0.68 1.11
25 C23 0.30 0.58 0.56 0.64
26 C24 0.25 0.46 0.38 0.46
27 C25 0.18 0.38 0.23 0.33
28 C26 0.11 0.26 0.17 0.24
29 C27 0.06 0.22 0.15 0.20
30 C28 0.05 0.15 0.11 0.14
31 C29 0.04 0.14 0.09 0.09
32 C30+ 11.77 11.28 21.97 6.79
TOTAL 100.00 100.00 100.00 100.00
Mol Wt
211.07 236.66 300.89 207.53
(g/mol)
Density
0.8727 0.8805 0.9207 0.8579
(g/cc)
Table 3.1 – Liquid Composition

3.3 Battery Limit

This design basis is valid from Insulating joint Ibigwe to Insulating Joint at Asa node

3.4 Pipeline Specification

No. Subject Specification

1. Size 8”
2. Length 5.206 km *
3. Origin Ibigwe
4. Destination Asa
5. Design Pressure 98 bar
6. Maximum Temperature 60oC
7. Pipeline rating 600#

Table 3.3– Pipeline specification Ibigwe to Asa Pipeline

3.5 Pipeline Route

The Pipeline route was shown in the full detail topographical survey which was undertaken as part of
this project. A preliminary route survey has been undertaken, which confirmed that the length of the pipeline is
5.2km from the proposed tie – in point at Ibigwe to Asa equipment layout. The pipeline is located on the
onshore area of Imo State in Ohaji/ Egbema local government. The pipeline route for the propose 8” with the
tie-in at Ibigwe to the equipment plant at Asa lies N592160 Meter;E260738.00 meters; 52 meters Height above
Sea Level. The Geographical coordinates are Lat. 50 21’14”S; Long.60 50’28”E. The survey data indicate
thick vegetation and scanty settlement of the right of ways (ROW) and the design year for the Asa- Ibigwe is
30years which by implication shows class one (1). Years of the design shall affect the class of right of ways
which shall also affect the design factor that will be required for the calculation of the pipe wall thickness.

Among other issues, the pipeline route were based on the following:

W here pipeline were to be installed alongside an existing pipeline; the minimum separation shall
not be less than 5m.

W here the pipeline shall cross existing pipeline, cables, power lines, roads, railways
and waterways it shall be at angle between 60 and 90 degrees

Pipeline lengths shall be minimized while maintaining adequate radius of curvatures.

There shall be enough access for maintenance.
 3.6 Pipeline Trenching/Burial

Pipeline shall b e t r e n c h e d /buried. The r e c o m m e n d e d minimum cover f o r o n s h o r e

pipelines is in table 3.4. However the values given in the table been modified for increased safety margins.

Location Minimum cover (m) in Minimum cover

Normal ground (m) in Rock
Class 1 0.8 0.6
Class 2 1.0 0.8
Class 3 and 4 1.2 1.0
Public roads and
1.5 1.2
railways crossings

Table 3.4 - Recommended Minimum Covers for Buried Pipelines

For the purpose of this design, a minimum cover of 1m was adopted.

3.7 Hydrostatic testing and Commissioning

Pipelines shall be tested at pressure of 1.25 times the design pressure Ref. [1]

3.8 Pipeline Crossing

 A minimum vertical separation of 0.3m outside diameter to outside diameter shall be

maintained between the 4-inch pipeline
 A minimum vertical separation of 0.3m outside diameter to outside diameter shall be
maintained between the 4-inch pipeline and any existing pipeline at each crossing.
 For external (unburied) pipelines, distance between supports at crossings shall not be
greater than the calculated pipeline allowable span under installation, hydrotest and
operating cases.

4. PIPELINE SYSTEM DESIGN

4.1 Pipeline Routing

The Pipeline is a static arrangement of pipes transporting about 5000 BOPD to 15000
BODP. The proposed case route for pipeline Length of 8” x 5.206 km shall be taken from width of 12km
from the existing 4”x 5.206km.

Lines Location Approx. Approx.

From To Length Buried
(km) depth
(m)
8“X 5.206KM IBIGWE ASA 5.206 1

Table 4.1 - Pipeline Location

The pipelines routes shall be optimised during the detailed design phase to account for installation and
operating constraints. Route deviation, if required, shall be within the COMPANY approved corridor, and to
be approved by COMPANY.
4.2 Pipeline Design and Operating Parameters

Description Values
Start Location Ibigwe
End Location Asa
Pipe OD (mm) 203.2
Nominal Wall Thickness hold
Nominal O.D (in) 8.625
Design Pressure (psi) 1421
Operating Temperature (0C) 40
Hydrotest Pressure (psi) hold
Density of Steel hold
Young’s Modulus hold
Poisson’s ration hold
Specific Minimum Yield Strength hold
Longitudinal Expansion Coefficient hold

Table 4.2 – Pipeline Design and Operating Paremetres

4.3 External Corrosion Coatings

Design Requirements
 The 3LPE coating shall be capable of withstanding a maximum continuous operating temperature (i.e.
design temperature) of 70 ºC.
 The 3LPE shall be capable of withstanding the cyclic operating temperature range between 20 ºC and 50
ºC over the design life.
 The total coating thickness shall be not less than 3.2 mm (3200 microns).
 The 3LPE coated pipe will be installed using conventional lifting and laying equipment.
 The axial bond between the FBE, and outer HDPE coating shall be adequate to withstand the shear
forces that may be inflicted during the course of transportation and installation.
 Petra shall at the time of bidding state and guarantee the maximum interfacial shear stresses between
FBE/HDPE before failure can occur on the coated pipe for evaluation and acceptance by the DPR.

On this basis the following assumptions were made:

The pipeline shall be externally protected with three layer polyethylene (3LPE) coating. The minimum coating
thickness shall be 3200 microns (3.2 mm) consisting of

 150 microns Fusion Bonded Epoxy (FBE)

 300 microns Copolymer Adhesive
 2750 micron High Density Polyethylene ( HDPE)

The basis of choice of this coating shall be fully detailed in the Corrosion Coating Specification and
Datasheet.

The following Table 4.3 summarizes the pipeline material data for the CP System design.

Outside Buried External

Pipe Wall Thick.
Pipeline Diameter Length Insulating
Material (mm) inch(mm) Coating
(km)

8-inch
API 5L X52
Pipeline 219.1 5.2 3LPE
DSAW
Asa - Ibigwe

Table 4.3 - Pipeline Data for Corrosion Coating

 4.4 Field Joint Coating.

The field joint coating will have external coatings of heat shrink sleeves.

4.5 Pipeline flange & Fittings

Flanges & Fittings shall meet the requirements of ASME B16.5 & ASME B 16.9 respectively.

4.6 Insulating Joints

Insulating joints are required for electrical isolation of the cathodically protected section of the pipes from
the top side piping covered by painting specification.

5. PIPELINE DESIGN METHODOLOGY

This section presents methodology for the main activities to be performed during detailed design of the
pipeline.
The design of the 8-inch Asa – Ibigwe Node pipeline will be carried out as per the latest edition of
ASME code for Pressure Piping; ASME B31.4 Ref.[1].

5.1 Design Considerations

The following design conditions are identified for the pipeline systems
 Hydrotest
 Operation

The basic combinations are shown in Table 4.1

Load Combination

LOAD CASE Dead Environmental Design Thermal Hydrotest

Load Load Pressure Load Pressure
OPERATION X X X
TEMPORARY X X
(HYDROTEST)
Table 4.1 - Basic Load Combination

5.2 Pipe Wall Thickness Calculation

The pipeline wall thickness shall be calculated as per ASME B31.4 Ref [1] using the formula shown
below:
D.P
t0= 2S Y F
Where:
t0 = Nominal wall thickness for a given design pressure
P = Permissible design pressure, psi
SY = Specified Minimum Yield Strength (SMYS), psi
D = Nominal outside pipe diameter, inch
F = design factor. Value depends on location class, which in this case is
taken as 0.6 – Location Class 2.
0.72 (Location Class 1)
 0.6 (Location Class 2.)
0.5 (Location Class 3)

However the actual wall thickness t, is selected from standard wall thickness table in API 5L.
t tm
Where:
tm = t0 + ICA
ICA = Internal corrosion allowance.

5.3 Minimum Elastic Bending Radius

The minimum elastics bending radius is given by:
ED
Rmin =
2 y
Where:
 Rmin = minimum Bending Radius
E = Modulus of Elasticity
D = Pipe Diameter
σy = Yield Stress
5.4 External Corrosion Protection
The pipelines shall be externally protected with 3LPE coating. This shall be supplemented by cathodic
protection of the Impressed Current type. The system shall be capable of operation immediately
following the construction of the pipeline. The design of the CP shall be as per the Wenner Method,
which is according the Work Procedure for Soil Resistivity Survey and Cathodic Protection System
Statutory Inspection/Evaluation Rev [6] and shall be based on maximum operating temperature of
pipeline, the Anode capacity and potential design shall be provided by the anode manufacturer and
shall consider Temperature and burial.

5.5 Road Crossing

A minimum of 1.5m covers shall be applied between top of pipeline and road surface. Trenching,
stringing, backfilling and restoration of road surface at every crossing shall be so scheduled to avoid
interruption of traffic.
Local authority (Federal, State, municipality or others) regulation applying to such areas shall be
strictly adhered to during the construction period.
The bottom of the trench shall be prepared such that the pipe will be bedded uniformly throughout the
whole length of the trench. The coated pipe shall be placed on a sand bed not less than 15cm thick in
rocky areas and shall be surrounded with similar well-compacted material to at least 15cm above the
top of the pipe. A 20cm thick compacted layer of assorted sand and gravel shall be placed in the
trench. For pipeline and cable crossings a reinforced concrete slab shall be placed over the entire
length of the pipeline/cable crossing. The slab shall be a minimum of 10cm thick.

5.6 Hydrostatic Testing and Pre-Commissioning

After installation of the pipelines, the cleaning, gauging and hydrostatic testing and pre- commissioning
of the pipelines shall be conducted. The following shall apply after installation.
The pipeline (trap to trap) shall be flushed, cleaned and gauged with filtered water. Steel gauging
plates and/or steel body pigs shall not be used. After successful gauging, hydrostatic testing of the
pipelines shall be performed. The pipelines shall be dried after hydrostatic testing with methanol or
glycol swabbing.

5.7 Inspection Maintenance and Repair (Pigging Philosophy)

Pipelines shall be designed to accommodate a variety of pipeline pigs including intelligent tools,
brush pigs, disc pigs, and mandrel pigs with gauge plates. All valves within the pigging run shall be
full bore and shall be designed to accommodate pigging. As much as possible, all sections of
pipeline shall have uniform internal diameter, where this is not possible, difference between
internal diameters of the different sections shall not exceed 0.125”. A minimum bend radius of 5 x
Nominal diameter (5D) shall be adopted to accommodate the various types of pigs.

Safety in Construction

Since work has to be carried out and the pipeline is to be laid, possible hazards to the general public and
traffic are to be included in the safety consideration during the construction stage. These will include:
i. Marking of the trenches with fluorescent or reflective markings to notify the public of the trench
hazard.
ii. Trenches shall be properly prepared and free of all stones, debris and other materials, which can
cause damage to pipeline coating.
iii. Following the safety practices, recommended clothing and gear to be used by the workers.

iv. Pipelines shall be laid following good construction practices so as to avoid overstressing the line
pipe and other piping components.
v. Proper welding procedures to be followed and safe distances from possible flammable
sources to be implemented. Proper precautions such as availability of extinguishers at hand are also
proposed to be taken.

2.2 PIPELINE MARKER

The pipeline marker which shall be fluorescing and it shall be placed at a minimum distance of
250m along the pipeline route. This ensures the safety of the pipeline and it shall include where
applicable;
The Right of Way Boundary Marker.

Kilometre marker

Aerial marker

Direction marker

Navigable waterway Pipeline crossing warning sign

 23

6. REFERENCE DOCUMENTS

1) ASME B31.4-2006; Pipeline Transportation Systems for Liquid Hydrocarbons and

other liquids, 2006 Edition
2) API 5L; Specification for Line Pipe 42nd Edition, January 2000
3) API RP 1111 - Design, Construction, Operation, and Maintenance offshore
Hydrocarbon
Pipelines (Limit State Design). Third Edition, July, 1999.
4) API 5L - Specification for Line Pipe. Forty-third Edition, March 2004.
5) Stock Tank Oil Analysis Report
6) The Statutory Inspection and Evaluation of the Cathodic Protection System and
Remaining
Wall Thickness Measurement Report
7) Government Notice No.49 SI 14 Oil and Gas Pipelines Regulations

8) Oil Pipelines Act Chapter (CAP.) 338, Laws of The Federation Of Nigeria
(L.F.N.) 1990

9) Mineral Oils safety Regulations (MOSR) 1997

10) Environmental Impact Assessment (EIA) Decree 1992

11) Guidelines and Procedures for Construction, Operation and Maintenance of

Oil And Gas Pipeline and Ancillary Facilities

12) Environmental Guidelines and Standards (EGAS) 1991

CHAPTER TWO
 24
THE CONSTRUCTION OF APPROXIMATELY 27.5KM
OF FLOWLINES AT OZA FIELD, ABIA STATE.

INTRODUCTION/PROJECT OVERVIEW:
The Oza marginal field located onshore Niger Delta was handed over to the Millenium Oil and
Gas Company Limited in 2004. Following this handover, MOGCL assumed operatorship of the
field located in the northern part of OML 11 in the eastern Niger Delta from Shell Petroleum
Development Company of Nigeria (SPDC). The Oza field measuring approximately 20km2 was
discovered in 1959 by SPDC and is primarily located within the Oza communities in Abia State of
Nigeria.
Four wells were drilled between 1959 and 1964 targeting three sands out of eleven (11)
hydrocarbon bearing zones. At the time, the wells Oza 1, 2 & 4 had a cumulative production of
approximately 1MMBO mainly from the M5.0 sand.
MOGCL's growth into a significant marginal field operator is predicated upon close co-operation
with key stakeholders, industry players and its joint venture partners; Hardy Oil Nigeria Limited
and Emerald Energy Resources Limited each holding a 20% interest in the Oza asset. .

The Oza field development strategy employs a phased approach as follows:

Phase I, which has commenced, includes the re-entry of Oza well 2, re-entry of Oza well 4, laying
of pipeline, installation of an Early Production Facility (EPF) and the eventual hook up of the EPF
to a neighboring flow station via pipeline to enable crude production.
Phase II will involve the work over of well 1 and the data gathering and studies to optimize
selection of up to six additional well locations to fully appraise the Oza concession.
Phase III will involve the drilling of additional wells and the installation of additional pipelines.

Under the phase 1 development, Petra Services Limited was contracted to Construct 3” Interwell
flowlines from well 2 and Well 4 of approximately 1.2km linking the proposed manifold area and
construction of 6” pipeline and 3” test line of about 11km each to the proposed Early Production
Facility at Isimiri.

During this project I acted as the Project Engineer/ Bids Engineer from the tender stage to the
execution stage.
 25

SCOPE OF WORK FOR THE INSTALLATION OF FLOWLINES/PIPELINES:

The scope of work for the project as stated in the tender documents includes the following which
has been broken down into level four as generated by the Microsoft Project.

Task Name
1. PRELIMINARIES
1.1 PROJECT KICK-OFF MEETING
2.1 PREMOBILISATION
2.1.2 Inspection of Land Equipment
2.1.5 Location of Site Accommodation for the Project Personnel
2.1.6 Site Inspection and Pre-preparation Works
2.1.5 Calibration of welding Machines, Gas Tester etc.
2.1.6 Premobilization of Equipment
2.2 PREPARE, REVIEW AND APPROVAL OF PROJECT DOCUMENTATION
2.2.1 Prepare of JHA
2.2.2 Prepare of HSE PLAN
2.2.3 Prepare of Security Plan
2.2.4 Prepare of Journey Management Plan
2.2.5 Prepare of Waste Management Plan
2.2.6 Prepare of Quality Plan
2.2.7 Prepare of Project Execution Plan
2.2.8 Prepare of Welding Procedure Specification
2.2.9 Prepare of Road Crossing Procedure
2.2.10 Prepare of River Crossing Procedure
2.2.11 Prepare of Quality Report Forms
2.2 12 Prepare of Project Organizational Structure
2.2.13 Prepare of Coating and Sleeving Procedure
2.2.14 Prepare of Radiographic Procedure
2.2.15 Prepare of Inspection and Test
2.2.16 Prepare of Community Relations Plan
2.2.17 Prepare of Post Weld Heat Treatment Procedure
2.2.18 Pipe Cleaning and Pig Run Procedure
2.2.19 External Painting Procedure
2.3 WELDING PROCEDURE AND WELDERS QUALIFICATION
2.3.1 Prepare of WPS for 5G, 5G-R, 6G, 6G-R
2.3.2 Approval of the WPQT for 5G, 5G-R, 6G, 6G-R
2.3.3 WPQT for 5G, 5G-R, 6G, 6G-R
2.3.4 Visual inspection and Radiography of the WPQT coupons
3. MOBILIZATION
3.1 Mobilization of Excavation Team / Crew
3.2 Mobilization of Excavation Equipment, other heavy machineries and ancillaries
4. COLLECTION AND TRANSPORTATION OF LINEPIPES FROM WELL 1
4.4 Transfer of linepipes 6 " and 3” from well 1 to Pipeline ROW
5. SITE CONSTRUCTION
5.1 PRE-LAY SURVEYS OF THE PIPELINE ROUTE, DEVELOPMENT OF THE RIGHT-OF-WAY
UTILISATION PLAN
5.1.1 Survey the Pipeline route
5.1.2 Probing the Pipeline route
5.1.3 Pegging of the Pipeline route on the right-of-way
 26
5.2 BUSH CLEARING, MARKING, PREPARATION OF ROW AND PREPARATION OF RIDGES
5.2.1 Cutting down of bushes, shrubs and grasses
5.2.2 Marking of the ROW width
5.2.3 Preparation of Ridges
5.3 STRINGING AND WELDING OF SECTIONS
5.3.1 Stringing and Welding of the Pipeline to positions and Welding of 6" Sch.80 Pipeline to each
other
7.4 NON DESTRUCTIVE TESTING (NDT)
7.5 SURFACE/JOINT PREPARATION, FIELD JOINT COATING AND WRAPPING
5.5 EXCAVATION OF ROW
5.6 LOWERING-IN
5.7 TIE IN OF SECTIONS
5.8 ROAD CROSSINGS (THRUST BORING ACTIVITIES)
5.9 PIPELINE CATHODIC PROTECTION
5.8.1 INSTALLATION OF TEST POST
5.8.2 POTENTIAL MEASUREMENT
5.10. PRE-COMMISSIONING
5.10.1 FLUSHING AND CLEANING OF PIPE LINE
5.10.2 PRESSURE-TEST TO SPECIFICATIONS
5.10.3 HOOK-UP TO PIPELINE SCOPE BY OTHERS WITH GOLDEN WELD
5.11 BACKFILLING
5.12 AS BUILT DOCUMENTATION
5.13 DEMOBILIZATION

OBJECTIVE:
This report intends exposed the operation of various components used in the construction of
flowlines and pipelines. The technical report will also serve as a teaching aid on the basic
principles of construction and installation of flowlines and pipelines.

METHODOLOGY APPLIED ON THE PROJECT:

In carrying out the Construction and Installation of 27km of Flowlines and pipelines at Oza field,
the following considerations, criteria and methods were put into use. Then after award of
job/contract a Kick- off meeting takes place. This is after Petra Services has passed through
rigorous Technical /Commercial bidding with other Companies.

PROJECT KICKOFF MEETING:

The kickoff meeting sets the agenda for the execution of the construction works. Issues disscuss
were as follows:
 Clarification of Scope of work of the entire project.
 Review of Survey and Design details
 Review of Material Take Off
 List of project deliverables which involves plans and Procedures on how Petra intends to
execute the entire project.
 Community Issues which involves Community workers engagement, Endorsements and
Homage to Community that will be affected by the construction works.

PREMOBILISATION
 27
Premobilization of Equipment involves testing, calibration and certification of Equipment.
This involves the following :

 Each equipment procured, and delivered to Petra Yard at Port Harcourt.

 All equipments and Tools delivered to shall be inspected by the QA/QC coordinator and
the materials coordinator to ensure that they are in good working condition and are serviceable.
 All welding and monitoring equipments for the project (welding machines, clamp meters,
temperature gauges, electrode ovens and quivers, etc.,) shall be calibrated by a third party
recognized by contractor and company.
 All lifting Equipments and accessories for the project (including cranes, lifting belts, slings,
clamps, shackles, etc.,) shall be tested, certified and colour coded by a third party recognized by
contractor and company.
 All major equipments (vehicles, excavators, bull dozers, trucks, cranes, generating sets,
etc.,) shall have survey certificates
 All calibrated and tested equipments shall have calibration and/or test certificates as well as
stickers indicating the duration of the certificates.

Pre-mobilisation certificates issued for all inspected equipment prior to the commencement of the
actual transportation to site.

Premobilization of Personnel involves subjecting a personnel medical examination to ascertain

he/she is properly fit to undertake the job by Qualified Medical Doctor. A premobilization activity
ensures the Health and safety of workers are guaranteed and also that project does not get any loss
time due to equipment failure.

PREPARE, REVIEW AND APPROVAL OF PROJECT DOCUMENTATION

This forms part of the project deliverables before mobilization to site. It clearly details both the
Technical and Social parts of the project. It details how the project is intended to be executed the
on schedule. Some of the project deliverables include:

 JOB HAZARD ANALYSIS

 HSE PLAN
 Security Plan
 Journey Management Plan
 Waste Management Plan
 Quality Plan
 Project Execution Plan
 Welding Procedure Specification
 Road Crossing Procedure
 River Crossing Procedure
 Quality Report Forms
 Project Organizational Structure
 Coating and Sleeving Procedure
 Radiographic Procedure
 Inspection and Test
 Community Relations Plan
 External Painting Procedure

WELDING PROCEDURE AND WELDERS QUALIFICATION:

 28
This involves composing the Welding Procedure Specifications (WPS) based on the work at hand.
Qualify the WPS by carrying out a Procedure Qualification Test. Cut out test specimens from the
weld pieces and carry out destructive tests on the specimens. Record the result of the destructive
test on procedure Qualification Record (PQR) forms. Accept the WPS as the welding specification
for the project if the results are in line with the pipeline stress calculations. The welders that
welded the test pieces automatically become qualified to weld in line with that specification. Carry
out Welder Qualification Tests for other welders with different WPS’s as required.

MOBILIZATION TO SITE:
A great majority of the equipment intended for use for the job were initially assembled at our main
base in Port Harcourt. These equipments include cranes, welding machines, generators, portable
hand tools, etc.
Equipment were be lifted and positioned by the help of a crane or forklift onto a 30 ton flat bed
truck and / or a 5 ton self loader truck. Equipment like excavators, bulldozers and Swamp buggy
were loaded to a low bed. Equipment was being properly secured at all times and tied to the trucks
by the means of load binder and/or shackles. Equipment were be transported to the site only when
needed. The drivers shall be educated and shown the approved designated route to travel from the
Petra Services Port Harcourt Yard to site according to the Journey Management Plan for the
project. On Mobilization to the site, all personnel engaged for the project underwent a mandatory
safety induction program at Contractor training center at the Oza field.Petra Services Limited
arranged the use a 50 tons mobile crane with maximum safe working load capacity of 40 tons
positioned at the site for all her off-loadings. Irrespective of the origin of any material they shall be
carefully loaded by crane or forklift on trailer or self loader and transported to the approved
storage areas. Where any material or group of materials are observed to be unstable or have the
tendency to slide, the material will be securely wedge or tied to the floor of the trailer or self loader
as the case may be. Proper use of stanchions on the trailer is enforced. Small items of materials e.g.
tools and other miscellaneous items shall be stored and transported in containers and properly
stored according to their identification numbers for easy retrieval. Where necessary, timbering/
plating access will be installed before off-loading commences.

COLLECTION AND TRANSPORTATION OF LINEPIPES FROM WELL 1(PIPE

STACKING AREA)
Linepipes 6” and 3” were issued from stacking area to the Right of way. The transportation to the
Right of way was done by a Flat bed trailer. On each trip an issued Log was filled and signed. This
is to ensure traceability and proper records of linepipes leaving the Stacking area. Before each pipe
is loading visual dimensional check is done on each pipe. Dimensional checks involve the
following:
 Numbering of the pipes
 Measuring of pipe length
 Thickness of the pipe
 Damages on the pipe

PRE-LAY SURVEYS OF THE PIPELINE ROUTE, DEVELOPMENT OF THE RIGHT-

OF-WAY UTILISATION PLAN
This involves marking the limits of the approved work area i.e. construction ROW boundaries.
Before the pipeline trench is excavated, a survey crew stakes the centerline of the proposed trench.
The acquired ROW is 15metres in width by the 27.5km length.
 29
The scope of the survey team was to
 Carry out Preliminary investigation survey of the pipeline Right-Of-Way (ROW).
 Establish the existing pipeline ROW beacons.
 Carry out ROW profile leveling along the proposed pipeline route and cross section profile
at every 25meters intervals.
 Detail all manmade and natural features within 50meters either side of the proposed route.
 Set out the pipeline alignment for ditching and laying
 Carry out As- built (As-Laid) survey of the installed pipeline, and ascertain its conformity
with the design.
 Produce report including As-Built Drawings.

The method used by the survey team is as follows:

Reconnaissance
This being an important aspect of the field operation, the team shall be at the work site to
familiarize with the area and plan out where and how to start the job. During this operation,
controls within reasonable distance from the take of point are located and Insitu-check on them to
ascertain reliability. In the absence of any, the positions for GPS (Global Position System)
observations shall be determined.
Instrument Tests
As part of measures to ensure accurate measurement and result, necessary checks are conducted on
the survey equipment –collimation, index errors and calibration of EDM and total station and two
peg tests for level instrument.

Setting Out and Cutting/Demarcation

This shall base on the extracted coordinates and existing ones close to the site, otherwise GPS
observations shall be used to establish at least 3 points with which to locate the starting point of the
proposed pipeline. Using this information, the line is set and cut from the beginning to the end and
ROW beacons are emplaced at intervals of about 200meters.
Note: the sun shot or GPS points are observed along the route as cutting is going.
This is to control the pipeline route. As the line is being cut, the ROW pillars (beacons) in case of
full preparation survey shall be emplaced, corrected and numbered at specified intervals. A
theodolite shall be used with other distance measuring devices for the cuttings.

Traversing
The established R.O.W pillars (beacons) shall be coordinated by a standard traverse procedure
using Total station, GPS for controlling the traverse line route.
Distance and angular measurement are done using total station. The traverse observations shall be
done on two zeros and in close loops.
Leveling shall be done in close loops with automatic leveling instrument at the intervals of
25metres along the pipe alignment and R.O.W lines.
The conventional procedure of back sight, fore sight and intermediate sight shall be used.

Detailing/ Echo Sounding

All natural and manmade features within 50metres either side of the proposed pipeline shall be
picked with Ray Procedure. All Rivers, Creeks and other water bodies shall be sounded ascertain
bottom profile.

Computation/ Plotting
All the data shall be analyzed computed and coordinate values generated and plotted along with
details. The printing be sheets and in large scales (1:1000, 1:2500). Total area of the right of way
shall be determined.
 30
The accuracy of the traverse and level determined shall in be accordance with survey rules and
regulations specifications or as demanded by MOGCL.

BUSH CLEARING/DITCHING (PEGGING)

During construction, dedicated survey teams shall set out the pipeline alignment, width of clearing,
width and depth of ditching marking it with pegs to give the ditching team the necessary and
required direction.

AS-BUILT SURVEY
This shall be the final survey field work checking how well the pipe is laid in relation to the
design. The profile of the top of laid pipeline, and the ditch shall be recorded before back filling.
That profile of the top of the backfill shall be recorded.
These data were to be plotted to produce the pipeline As- Built Drawings and final report for
MOGCL review and approval.

All disturbed beacons and reference points shall be reinstated before demobilization. All temporary
beacons, reference and pegs shall be removed before demobilization.

BUSH CLEARING, MARKING, PREPARATION OF ROW AND PREPARATION OF

RIDGES.

Before clearing and grading activities are conducted, the community land owners are informed to
harvest their crops along the ROW. This is sent through the Community Liaison Officer
Grading was conducted to provide a reasonably level work surface. A record kept of any survey
pillars that are missing or have been damaged. The list of damaged or missing pillars will be
forwarded to the company surveyor and replaced. This is included in the as-built data and
numbered in a manner, to indicate that they have been re – installed.

STRINGING OF LINE PIPES

All lifting and handling equipment are maintained in good working order and stored according to
material instruction.
Pipes are loaded onto trailers with suitably protected goal posts / dollies to protect the pipe coating,
nylon straps or approved alternatives are used to secure the pipes. If coated pipes are stacked in
more than one layer three rubber bands are placed equidistantly along their length.
Pipes are unloaded at site by an excavator using a spreader bar lifting belts and recorded on the
off-loading tally report (Pipes shoes are adequately protected to prevent damage to both the pipe
and coating.)
Pipes lengths are strung end to end and staggered to enable grinding/cleaning of the bevel ends all
pipe lengths are identified and recorded on by the stringing foreman.
Stringed the pipes along the route on padded wooden sleepers according to line pipe characteristics
– such as wall thickness, pipe coating materials etc. – as indicated on the route alignment drawings
using excavators.
 31
WELDING OF SECTIONS

Welding is the process that joins the various sections of pipe together into one continuous length
by the use of shielded metal arc process as indicated on the welding procedure specifications. The
joints are welded together into long strings and placed on temporary supports. The pipe gang and a
welding crew are responsible for the welding process. The pipe gang uses special pipeline
equipment called side booms or Excavator to pick up each joint of pipe, align it with the previous
joint, and make the first part (a pass called the stringer bead) of the weld. Additional filler passes
are made by welders who immediately follow the stringer bead on what is called the welding firing
line. Stringer, hot-pass, and capping welders make up the firing line, and they are followed in
certain locations by tie-in welders.

NON DESTRUCTIVE TESTING (NDT) OF WELDED JOINTS

The Non Destructive Testing methods used are visual testing and Radiographic examination
testing for the welded joints.

Visual testing is the visual examination of the welded joints to check any defects such as:

Cleaning and dressing

 Check that all slag has been removed to avoid imperfections being obscured. •
 Verify that there are no tool impressions or blow marks. •
 When weld dressing is required, ensure that overheating of the joint due to grinding,
grinding marks, and an uneven finish are avoided. •
 Verify that fillet welds and butt welds to be dressed flush the transition of joint merges
smoothly with the parent metal without under flushing.

Profile and Dimensions

 Check the profile of the weld face and the height of any excess weld metal so that it meets
the requirements
 Ensure the surface of the weld is regular and also that the weld shows an even and
satisfactory visual appearance.
 Ensure that the weld width is consistent over the whole of the joint and that it meets the
requirements.

Weld root and Surfaces

 Verify for single-sided butt welds, the penetration, root concavity and any burnthrough or
shrinkage grooves are within the requirements.
 Verify that any undercut is within the requirements.
 Check after imperfections such as cracks or porosity, in the weld surface or heat affected
zones comply with the requirements.
 Verify any attachments temporarily welded to the object to facilitate production or
assembly and which are prejudicial to the function of the object or the ability to examine it
are removed so that the object is not damaged; the area where the attachment was fixed
shall be checked to ensure freedom of cracks.
 Check that any arc strikes are within the requirements
 32

On the other hand, Radiographic inspection is one of the most common methods of non-destructive
testing (NDT) used to detect discontinuities within the internal structure of welds. The obvious
advantage of this method of testing is the ability to help establish the weld’s internal integrity
without destroying the welded component. This method of weld testing makes use of gamma rays,
produced by a radioactive isotope. The basic principle of radiographic inspection of welds is the
same as that for medical radiography.

This procedure applies to the Radiographic examination of:

* Ø 3” Pipe and Ø 6”
*100% circumferential Butt Weld
*5mm Thick and above

EQUIPMENT
All equipment to be employed during execution of radiography shall be of recognized
manufacturer and approved by WSPOL prior to commencement of activity.

RADIATION SOURCE
Source shall be GAMMA-RAY: IRIDIUM 192 Approximate strength Of 734 Giga Bequerel (20
Curie).

FILMS
AGFA GEVAERT D7. Or equivalent. (10 x 24 / 10 x 40cm MFG), ASTM Class 2.

SCREEN
Lead screen of 0.125 mm. Thickness front and back shall be used in intimate contact with the film
(unless pre-packed film is utilized).

TECHNIQUE
Double Wall / Single Image.

GEOMETRIC RELATION
*Source focal spot: 2 x 1.5
*Film focus distance: Depending on pipe diameter and thickness

PENETRAMETERS
*SPEC. NO: DIN 62
*THICKNESS: 6-12 & 10-16
*MATERIAL: Fe placed on film side
*NO : 2 MIN. of penetrameters

EXPOSURE TIME
Exposure time shall depend on diameter, thickness of the joint to be radiographed and the actual
strength of IR 192 Source used.
 33
FILM PROCESSING
Manual Type

*Developing Bath: Gevaert G 135 or equivalent

Temperature: 20oC-24oC(68o F – 75o F)
Time: 4 min

*Fixing Bath: Gevaert G 335 or equivalent

Time: 6 min
Temp: 20oC (68oF)

*Rinse In: Running water

Time: min
Temp: 20oC (68oF)

*Final Wash In: Running water

Time: 6 min.
Temp: 20oC (68oF)

*Drying Automatic dryer

PROCESSING REQUIREMENTS
Frequency of developer change: After approx. 500 films
Frequency of Fixer change: After approx. 500 films
Frequency of Water change: Daily
Manual Developer level shall be maintained by adding replenisher
Film shall be manually processed within a chemical temperature of 18O C to 24O C (65oF to 75oF)

IMAGE QUALITY INDICATOR

The IQI shall be of the DIN Fe type for steel and corresponding material for non-ferrous
components
DIN 10/16 – For materials up to 20mm thick
DIN 6/12 – For materials up to 20 – 50mm thick
The IQI shall be placed on the film side.

FILM DENSITY AND SENSITIVITY

Film density on the image of the length of weld under examination shall be 2.0 – 3.0 as determined
by a densitometer or film density comparison strip.

Film sensitivity shall generally be 2% or better, dependent on geometry, thickness.

IDENTIFICATION AND MARKING OF RADIOGRAPHS

Each film shall be identified by the use of lead symbols to indicate the following information viz:
(See sketch below)
Job reference number/correlation number
Piping drawing number
Piping class
Weld number
Welder’s stamp number
Date
Film location
 34
Other relevant information as may be specifically required by the company representative

The film identification system is subject to the approval of the WSPOL’s representative.

QUALITY OF RADIOGRAPHS
All films shall be free from processing and other defects which interfere with accurate
interpretation.

ACCEPTANCE CRITERIA
As per ANSI B31.3, tables 341.3.2A & K341.3.2A; ASME BPV Section V, Article 2; or ASME
Section IX, QW-191 as applicable.

RADIOGRAPHIC EXAMINATION REPORT

Attached form shall be used to record radiographic examination results.

PERSONNEL QUALIFICATION
Qualification of NDT Personnel shall be as per SNT-TC-IA of ASNT
*Radiographs shall be evaluated by Technician qualified and certified as level II
*Radiographs shall be performed by operators qualified as level I.

RADIOGRAPHIC TEST METHOD

GAMMA RAY – DOUBLE WALL/SINGLE IMAGE
 35

The source shall be positioned so that the radiation beam passes through the centre of the section
under examination and shall be offset from the plane through the weld by the minimum distance
necessary to prevent the image of one side of the weld confessing the image of the other side. The
film shall be placed diametrically opposite the source with the minimum number of three (3)
exposures at 120O displacement for material up to schedule 100. Thereafter four (4) exposures are
required at 90O displacement.

SAFETY:
All radiographic work shall be carried out in strict accordance with WSPOL Standard Safety
Procedures and Specifications as specified in Standard Construction Specifications. In addition,
the Company’s Safety Officer or Inspector shall at his discretion conduct periodic safety audits at
all work locations. If not satisfied with the result of the audit, he shall ensure that adequate safety
measures are adopted.

EXCAVATION OF PIPELINE/FLOWLINE DITCH

The ditch/trench is excavated to a depth that provides sufficient cover over the pipeline after
backfilling. Typically, the trench is 1m X 1m according to the client’s specification. The
excavation uses an excavator to dig the pipe trench.
Excavation operations were performed after required clearing and stripping has been completed.
 The ditch excavated according to the surveyed line, as shown in Drawings or ROW and
Permit Stipulations and as staked on the ground by the Client.
 The Width and Height of the Trench for Excavation is 1m x 1m.
 Excavated areas shall be kept dry by appropriate dewatering equipment.
 All underground utilities, pipelines and other facilities were exposed by hand digging, prior to
mechanical digging in the area. This method is usually referred to as manual probing.
 During mechanical digging in the areas of underground facilities, mechanical excavators or
other mechanical equipment must not get within 3 meters of an underground utility or
pipeline. Only hand digging within 3 meters of all utilities and pipelines.
 The topsoil within the marked layout shall be excavated up to a depth of 20 cm to remove all
greenery and vegetation.
 When soft, compressible soils are encountered at such depths, this unsuitable sub grade soils
shall be removed and replaced with classified and approved backfill material, and compacted.
 The excavated topsoil/earth shall be tested and used for back filling. Excess excavated
materials shall be carted away to designated spoil heap.
 The left over excavated topsoil after distribution as per above shall be disposed off at the
 36
designated spoil heap.
 After topsoil excavation and disposal are completed, the subsoil shall be excavated to the
required depth using appropriate shoring system as per the relevant specification.
 Excavate to the required depth, and establish the invert level of trench. Bottom of the
excavation shall be compacted.
 Excavated area shall be kept dried using dewatering equipment.
 Walkways or bridges shall be provided where personnel are permitted to cross over
excavations
 All trenches 4 feet or more in depth shall be provided with a fixed means of egress. Spacing
between ladders or other means of egress must be such that a worker will not have to travel
more than 25 feet laterally to the nearest means of egress.
 Ladders shall be firmly secured and extended at a minimum of 36 inches above the landing
 Confined space permit procedures shall be followed for all excavation or trench greater than
1.5 meters/5 feet in depth
 The excavated sub-soil shall be preserved and back filled after completion of Flow line
construction.
 The ditch bottom will be graded to the required depth to provide continuous support to the
entire length of the pipeline and to minimize the necessity for pipe bending.
 After backfilling and compacting as appropriate, any left over, excavated sub-soil shall be
carted away to the designated spoil heap.
 The excavation shall be carried out mechanically using excavator(s). Regardless of the
volume to be excavated mechanical excavator will only be allowed in a safe and approved
location after sweeping the area to be excavated with an underground facilities detector) small
quantity excavation shall be carried out manually if need be.
 Materials excavated for the permanent work shall be graded into various types. The material
designated for use in the permanent work shall be properly segregated and stockpiled. The
material unsuitable for use in the permanent work shall be disposed of at designated area as
per approved waste management plan.
 Borrow material shall mean suitable fill material obtained from designated borrow pits off-
site.
 Over depth excavations shall be backfilled to specified grade with suitable backfill material
and compacted as per this specification.
 Excavation sides shall be constructed to ensure personnel safety and work protection.
 Excavation limits shall include provisions for seal slabs/blinding concrete. Seal
slabs/Blinding concrete shall be placed to the limits as shown on the drawings. Minimum of
75 mm. thick seal slabs shall be provided in all structural excavations whose concrete works
shall be delayed. This shall be done as per approved standard to preserve the integrity of the
foundation soil until the permanent work is placed.
 Special situation shall be given peculiar attention as appropriate according to WSPOL
specification. When the water table is high, acceptable dewatering methods shall be used.
 Approval shall be given by WSPOL before any deviation is affected.
 37

LOWERING-IN OF WELDED LINE PIPES

Prior to any lowering in, the trench is surveyed to ensure that all pre-formed fit the trench
bottom and backhoe operators (excavator / banks men are familiar with the operational
hand signals. A working procedure is developed that ensures pipe strings are lowered /
laid in a safe and controlled manner, causing the minimum amount of damage to pipe or
coating.

The pipe is lowered in by using excavators with a lifting capacity capable of handling the
pipe string in a safe manner.

The lifting equipment employed are e Nylon type heavy lifting belts.

During the lowering operations, the pipe is held in a gentle “S” curve, if for any reason a
string cannot be completely lowered in during that working day enough pipe is left on the
bank to ensure the “S” curve is maintained.

As the pipe is being lowered in the trench, holiday detection takes place behind the last
side boom and section of the pipe entering the trench; this ensures a final check prior to
backfill.

TIE IN OF SECTIONS
Connect rubber or canvas broadband slings to the proposed lifting equipment.

Lift the two sections to be welded with a side boom, excavator or winch on the tie-in
tripod frame whichever is suitable
Insert a working slab underneath the fitted pipes to provide a standing base for the fitter
and welder
Cut off extra lengths of pipe with a grinding machine fitted with cutting discs or with
oxy-acetylene cutting sets
Prepare the tie-in point surface by cleaning with power brush and beveling of the ends.
Clamp the two pipes together and tack –weld.
Weld the joint in line with the welding procedure specifications.
Radiograph the weld
Carry out repairs as necessary
Field joint coat the pipes with PE and holiday-detect the coated joint
Field joint coat the pipes.

5.0 SAFETY CONSIDERATIONS

The rubber/canvasbroadband slings should be properly attached to thelifting equipment
and should be adequate strength. This is to guard against accidentalbreakage of
thesling.Breakage of the sling willlead to damage to the working slab and serious injury
to thefitter and welders.
 38

ROAD AND RIVER CROSSINGS

During the construction process, the pipelines had to encounter some natural and human
facilities such as roads. These roads are group as minor (farm roads) and major roads
(tarred roads). However, minor farm roads were open cut while major roads shall be
thrust bored.

Thrust boring is to enable the crossing pipelines beneath roads and any other structure on
the ROW and to ensure that the required quality is achieved to project specifications,
codes, standards and contract. This aim is at reducing the cost of the project and limiting
less exposure of the work with the movement of vehicular movement and people. Manual
Thrust boring methods were used throughout the project because the size of roads
encountered is between 6m to 11m.

Equipment Requirement:
Mechanical Excavator
A-frame with stud and jack (Chain block)
Thrust boring materials and accessories
Pegs
Twine rope
Consumables

PROCEDURE FOR THRUST BORING OF MAJOR ROADS

Approval shall be gotten from CLIENT before commencement of activities

Survey area to be worked on and marked out accordingly with the use of a pipe locator
and other survey tools.

Commence excavation manually on both sides of the building depending on pipe location
report, to a depth of 1.8m _+ 0.3m and 1m from the walls of either side of the structure.
Excavation is to be carried out in such a way that the ditch wall will not collapse (slant
ditch wall and shore up when necessary).

Commence boring manually from both sides of the structure.

The thrust boring shall be carried out in such a way that aligns with the marked out path
for the bore.

Excavate from the approach to the building to a depth of 1.8m +- 0.3m and a length of
12m, enough to allow for the casing pipe to be pulled into the bore.

Commence pulling of casing into the bored section.

Backfill and compact horizontally any excess space between the bore and the casing pipe
with sharp sand.
 39

Pull the carrier pipe through the casing pipe after firmly securing the spacers to the
carrier pipe.
Install 2” vent on casing pipe at the IEA end only.

Pull in the casing pipe to position (spacers are to be secured tightly to carrier pipes before
insertion into casing).

Ensure soil stabilization and site restoration before demobilizing.

5.0m 16.0m

3.0m 3.5m

EXIT PIT ENTRANCE PIT

5m x 5m x 3.5m 16m x 5m x 3.5m
Typical Layout of an Entrance Pit showing Exit and Entrance Pit Dimensions

PIPELINE CATHODIC PROTECTION

Understandings of the basic principles of Cathodic Protection require some knowledge of
elementary corrosion reaction. When iron is in contact with moist soil or water solution
containing (H+) and (OH-) ions, the iron will tend to go into solution at anodic areas. At
the anode, iron atoms lose electrons and become positively charged iron ions which may
combine with negatively charged (OH-) ions in the solution to form, usually, ferrous
hydroxide Fe (OH)2. Ferrous hydroxide may react further to form ferric hydroxide Fe
(OH)3, which is the familiar rust.
However, after a pipeline is laid, it is imperative to protect it catholically, before or after
backfilled. If left unprotected for a period of time, an electronic current will flow from
pipeline anodic areas to pipeline cathodic areas, using the surrounding soil or water as
conductive medium, therefore causing the pipeline to corrode at areas where corrosion
current is being discharged.
The objective of using Cathodic Protection for the corrosion protection of the flowline is
to control the corrosion of metallic surface in contact with electrolytes by introducing
into the electrical circuit a metal that is more electronegative than the existing anodic and
Cathodic areas. The impressed current system method of cathodic protection is a
deliberately established electrolytic corrosion cell. The protection feature is obtained by
setting the direction of current flow so that the protected structure is the cathode of the
cell and some other material is the anode. It uses an external power source (Transformer)
 40

and an anode ground bed for the impress current. The anodes of an impressed current
system provide the means for the protective current to enter the electrolyte.

HDROTESTING OF PIPELINE
The pipeline was hydrostatically tested to ensure the system is capable of withstanding
the operating pressure for which it was designed. This process involves isolating the pipe
segment with test manifolds, filling the line with water, adding pressure to the section to
a level commensurate with the maximum allowable operating pressure and class location,
and then maintaining that pressure for a period. Due to the location of the pipeline, the
water used in a hydrostatic test was trucked to the site.
The equipment to be employed for pressure testing shall be of good working condition.
The equipments use in the hydrotesting of flowlines and pipelines include the following:-
 Flushing Pump
 Pressurising Pump
 Calibrated Test Instrument e.g. Pressure gauges, Thermometers, and Pressure and
temperature recorders.
 Water Filling Pump (Portable).

METHODOLOGY USED DURING TESING

PROGRAMME AND TESTING SCHEDULE

48 hours notice to stating actual date and time such tests, checks and inspections are due
to commence to the Company representative.

The test section shall clearly be identified by isometrics and P&I drawings. This is to
ensure that each has sufficient vents and drains.

PRE-TEST PREPARATION
Operations prior to introduction of Test Medium.

Prior to proceeding with any hydrostatic testing of Piping the following documentation
shall be prepared and where appropriate signed by both PETRA and MOGCL
representatives.
a) Checklist
b) Piping erection Report
c) Erection acceptance Report
d) Pipe Testing Reports
Two Pressure Gauges (calibrated) shall be installed with pressure rating not exceeding
1.5times of test pressure. The gauges where possible, shall be at the lowest and highest
elevation but shall be in any case at the maximum distance possible away from one
another.
 41

All valves in the test section shall be in the open position (Ball valves and plug valves ½
open) unless specifically directed otherwise in writing by MOGCL’s representative.
Relief valves and bursting discs shall be removed and their connections blanked off.
It shall be ensured that no movement, thrusts or forces can occur during the test.
Prior to flushing of pipeline, all control valves shall be removed and replaced with spool
pieces
Prior to flushing all isolating valves of the level gauges shall be in the closed position.
After flushing the isolating valves of the level gauges shall be opened where applicable.
All safety valves shall be removed before flushing and shall be checked by MOGCL for
piping” and sealing where applicable
All impulse line shall be disconnected from the process equipment or piping prior to
flushing and reconnected after completion of the hydro-tests.
Continuous recording of hydrostatic pressures and ambient temperatures throughout the
test duration on approved calibrated recorders.
The following items shall either be removed and replaced with temporary spool pieces or
isolated by blanks
Safety valves
Control valves
Equipment/machinery
Instrumentation
The items to be tested shall be adequately vented and drain facilities available where
possible.

PRESSURE TESTING AND INSPECTION

The hydro-pressure testing process shall progress as follows:
Water shall be introduced to the pipeline section to be tested from the lowest point and all
vents left opened until air has been expelled.

The pipeline shall be flushed until the flushing water leaving the pipeline is clean.

The pipeline shall then be pressurized at a moderate constant rate of 30 bars or 30% of
specified test pressure of 150Bar (whichever is lower) every 20 minutes, i.e.
pressurization is stopped and the pipeline checked for leaks at 20 minutes intervals.

After attaining 70% of test pressure, pressurize at a rate not exceeding 15% of test
pressure or 10bar/hr (whichever is lower) until the specified test pressure of 150Bar has
attained.

Carry a thorough visual inspection of all exposed pipeline sections.

Ensures the specified test pressure is arrived at about the warmest time of the day.
 42

Disconnect pressurizing pump and plug or cap off the connection. After establishing the
stabilized condition, start off new chart in 12hrs pressure recorder. Record test pressure for
12hrs, logging pressure and temperature readings at hourly interval.

7.1 If a loss in pressure occurs, identify the location of leak, repair it and
repeat the above test process.

7.2 On successful completion, depressurize at a rate not exceeding 20bar/hr of

1st hour and 60bar/hr thereafter.

DEPRESSURIZATION AND WATER DISPOSAL

On completion of the Test duration and acceptance obtained from MOGCL, the pipeline
tested shall be depressurised and the water used for the test disposed as follows:

 Open the pressure let-down valves slowly to depressurise the line at the rate
1bar/min. – so that vibration is not generated in the pipework – to 140 bars.

 Continue depressurization at 2bar/min. to a hydrostatic head of +1 bar so that air

does not enter into the pipeline.

The disposal of the test water shall be as directed by the MOGCL site representative.

Blinds shall be removed where applicable, and Gaskets & Bolts finally tightened.

COMPLETION OF HYDROTEST AND TEST REPORTS

Test reports and charts shall be submitted to MOGCL for approval after satisfactory

completion of the pressure test and the reports shall contain the following information:

- Confirmation of the starting time Date

- The pipeline under test and installation name
- The recorder element range
- Test start and stop signatures
- Who witnessed and accepted the test on behalf of MOGCL.
Test shall be started and stopped in the presence of the persons authorised to witness
these tests on behalf of MOGCL.
On no account shall closed valves be utilized for pressure containment in a pipeline under
test.
The containment shall be effected by suitably rated spades, blind flanges or welded on
dome end caps.
 43

Upon completion of the hydro-test of the piping pipeline, the leak-free tightness of any
valve specified as “100% tight shut-off” shall be verified.
BACKFILLING OF TRENCH AND SITE CLEAN UP AND RESTORATION

Backfilling involves locating the previous ditch spoils. Removing hard core from the
backfill material and using the excavator to backfill the trench. Manual backfill for
trench in the vicinity of above ground piping and structures. Locating a borrow pit to
collect more backfill material if the landfill is insufficient. Grade the right-of-way.
Reinstate the drains or rivulets covered during excavation as this may serve as a source of
erosion.
After backfilling, final cleanup begins as soon as weather and site conditions permit.
Trash and construction debris are cleaned up both during and after construction. Every
reasonable effort is made to complete final cleanup (including final grading and the
installation of erosion control devices) within 20 days after backfilling the trench.
Construction debris is cleaned up and taken to a disposal facility, and work areas are
final-graded. The crews restore the work areas to preconstruction contours. Appropriately
spaced breaks are left in the mounded topsoil and spoil piles to prevent interference with
groundwater runoff and irrigation. Segregated topsoil is spread over the surface of the
ROW, and permanent erosion controls are installed.

CONCLUSION
The project experience summary is not exhaustive, because there are some other ongoing
projects I am working on which is not included. But overall I have experience in the
consulting,construction (industrial, residential and commercial developments), oil and
gas engineering(Onshore and Offshore), at both design and project management levels.
Also, I have experience in offshore subsea engineering design and project management.
These experiences have challenging but rewarding since it has equipped me with valuable
skillsto function as both and Electrical Engineer and Subsea Control Systems engineer. I
have worked with both locally and internationally with Nigerian and Expatriate engineers
on various projects.The experiences that I have gained have been of immense benefit to
the Companies that I have worked for and to this great Nation.