PIPELINE REPAIRS AND MAINTENANCE

Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

JV

TECHNICAL QUESTIONNAIRE:

For
PROVISION OF INTEGRATED PIPELINE REPAIR
AND MAINTENANCE SERVICES

Tender No.CW809655
THE SHELL PETROLEUM DEVELOPMENT

COMPANY OF NIGERIA (“COMPANY”)

ES/NCDMB/SPDC – TITT/260224/UPD
ES/NCDMB/ SPDC –CITT/262224-UPD

APPENDIX- A1 - TECHNICAL BID QUESTIONNAIRE

3.0 TECHNICAL CAPABILITIES

3.5 PROJECT CONTROLS

Rev Date Description Issued by Checked by Approved by

A0 19-05-2024 Issued for Information B.B. Obaji C. Kelvin C. Ifeakachukwu

1
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

TABLE OF CONTENT

1. Controlling schedule, cost including progress monitoring, reporting, Change & Risk

Management, 3

2. Training Plan for personnel 25

3. Industrial Relations Management Plan

26

4. Commitment to Sustainable Community Development Policy,

28

5. Community Affairs Plan

30

6. Interface management plan 33

7. Project execution plan 48

8. Logistics execution plan

108

9. Mobilization and demobilization plan

109

10. Security management plan

130

* Standard Template of a detailed Work Breakdown structure (Typical Pipeline Repair/

replacement Activity complete with Resources Loading) .

141
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

1. CONTROLLING SCHEDULE, COST INCLUDING PROGRESS MONITORING, REPORTING,

CHANGE & RISK MANAGEMENT,

Project management

ENERGYRAY INTEGRATED SERVICES LIMITED shall assign a project engineer who is thoroughly
conversant with this kind of task; they

shall have full responsibility for project delivery and be the single point of contact for SPDC for
all correspondence. Draft copies of the project management structure and project schedule
planning documents shall be prepared and submitted as part of the technical proposal.

The Project engineer shall liaise with the SPDC in all the project activities. ENERGYRAY
INTEGRATED SERVICES LIMITED is also

fully and completely responsible for any subcontracted or purchased sub-system and services.

SPDC shall also nominate a single point of contact for the project and advise ENERGYRAY
INTEGRATED SERVICES LIMITED.

These services include but not limited to the following:

 Manifold Works Manifold Piping Works

 Civil structure repairs / maintenance Valve maintenance

 Valve replacements Manifold Cage works

 Pipeline Repairs

 Oil and gas lines Emergency Repairs Planned Pipeline Upgrades / Repairs Composite
repairs

3
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Cathodic Protection Upgrade Repairs Cathodic protection upgrades/repairs Coating

surveys and Repairs

 Manifold Protection Systems Installation/Maintenance

Documentation

Requirements of drawings and documents for SPDC review and approval shall be as per the

following list of documents below.

This list is not intended to be exhaustive, and any document required within the CONTRACT,
necessary

for the execution of work, shall be prepared by ENERGYRAY INTEGRATED SERVICES LIMITED
and made available for SPDC

review and approval.

ENERGYRAY INTEGRATED SERVICES LIMITED shall prepare and submit for approval the Master
Document Register (MDR), on which

shall be marked the classification of documents Class (1, 2, or 3) based upon the classification
guidelines

provided hereafter.

ENERGYRAY INTEGRATED SERVICES LIMITED is required to mark each document issued with a
stamp for “Documentation Class” and

to enter the appropriate class number.

CLASS OF APPROVAL

Class 1 for review and approval

All class 1 document and drawings shall be submitted to SPDC for review and approval. The

SPDC will return documents and drawings APPROVED or issue for comments or instructions

in the times established in the contract documents and during the kick –off-meeting (KOM)
from

documented receipt by SPDC.

Class 2 for review (approval not required)

All class 2 documents and drawings shall be submitted to SPDC for review and comments. If

4
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

SPDC has any comments and/or instructions these will be issued ENERGYRAY INTEGRATED
SERVICES LIMITED in the times

established in the contract documents and during the kick-off-meeting (KOM) from
documented

receipt by SPDC. If no comments and/or instructions are received by ENERGYRAY INTEGRATED

SERVICES LIMITED after

this time, SPDC is deemed to have no comments to the submitted Class 2 documents and

drawings.

Class 3 for reference only

All class 3 Documents and drawings shall be issued to SPDC for reference. After issue to

SPDC, ENERGYRAY INTEGRATED SERVICES LIMITED can continue with the work.

SAFETY.

All the necessary work permits shall be obtained prior to begin of the works. All works shall
be done in accordance with the SPDC Safety rules and regulations. Only authorized and
qualified personnel shall operate motorized equipment.

Prior to commencing any work, a work permit must be obtained from and signed by a SPDC
authorized person.

All key personnel on this section of works are to be experienced in work and shall be inducted
into this method statement.

Work procedures shall be in accordance with the HSE risk managements. These shall be
presented at a toolbox meeting prior to commencement of these works and then at regular
intervals.

Records of attendance at the toolbox meeting shall be kept and filed on site.

All plant and equipment are to be inspected and approved as required by the contract
requirement.

All plant and equipment, together with the working areas, are to be regularly inspected and
audited.

Protective gloves shall be used as required during work.

5
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

The work area and storage areas shall be barricaded and separated from adjacent walkways
and other construction areas

QUALITY RECORDS.

In accordance with Quality control Plan, all quality record shall be filled up during stages of
work, duly signed by the inspectors and shall be maintained for final dossier according for
the Contract.

During installation/maintenance, any deviation from the drawings has to be approved by

SPDC and shall be incorporated in the As-Built drawings. All drawings used for the
construction shall be marked up (in colour) during and after the end of activities, clearly
indicating with “As Built” marking and submitted to SPDC. If no change is made, this shall
be recorded as “No Change”. Any damage that occur on the shall be documented using
appropriate CTQ and NCR forms and any necessary repairs shall be first approved by SPDC.

WORK SCHEDULE.

The Work Schedule shall consists of the work activities, durations; milestones etc to be tracked
during the execution of the Contract. A detail Works Schedule programme shall be prepared
and presented to SPDC for approval before the commencement of the Contract.

STAFF RECRUITMENT AND RETENTION PLAN

Introduction:

The workers that ENERGYRAY INTEGRATED SERVICES LIMITED shall engage for this Contract are
hereby classified into four (4) categories with the Technical Requirements of this Contract in
view. These categories consist of Management staff, Supervisory staff, supporting staff and ad-
hoc staff. These categories are as follows:

Category A:

Management Staff

6
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Contract manager
 Human Resources Manager
 Contract Procurement Manager
 QA/QC Manager
 HSE Advisor

Category B:
Supervising staff
 Project Engineer
 Site Engineer/Supervisor
 Design Engineer
 Electrical and Instrumentation Engineer
 Finance Officer
 HSE Officer
 Lead Design Engineer
 Material Coordinator
 Planning and Scheduling Coordinator
 Contract Accountant
 QA/QC Engineers/Inspectors

Category C:
Supporting staff

 AutoCAD Operators  Welders /Mate

 Dispatchers  Fitters/Mate
 Document Controller  Wrappers
 Drivers  Logistics Officers
 Finance Clerk  Office Assistants
 Electricians  Painters
 Contract Admin Officer
 Contract Planner
 Safety Officers/First Aiders
 Store Keepers

Category D:
Ad hoc staff

7
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Labour

Staff Recruitment Process:

The following are the steps ENERGYRAY INTEGRATED SERVICES LIMITED shall take in the
recruitment of staff in this Contract:

8.2.1 Sourcing.
8.2.2 Interview/Selection.
8.2.3 Letter of Appointment.
8.2.4 Community Clearance.
8.2.5 SPDC Plant HSE Induction

Sourcing of Staff in their Categories

In this contract, the following categories shall be sourced in- house by ENERGYRAY
INTEGRATED SERVICES LIMITED, the retainer hospital and from the community as follows:

Category A: The staff in this category shall be sourced in-house by ENERGYRAY INTEGRATED
SERVICES LIMITED.

Category B: 40% of the staff in this category shall be sourced from ENERGYRAY INTEGRATED
SERVICES LIMITED list while 60% shall be sourced from the community through the BIRC.

Category C: 30% of the staff in this category shall be sourced from the ENERGYRAY
INTEGRATED SERVICES LIMITED list while 70% shall be sourced from the community through
the BIRC.

Category D: This Category of staff are required only when needed for a particular task to be
completed within a short duration and discharged upon close out of task. The staff shall be
sourced 100% from the Community through the BIRC and directly by ENERGYRAY INTEGRATED
SERVICES LIMITED not through a Sub Contractor or Labour Contractor.

NOTE: Category D staff shall be drawn from the Community through the BIRC, if they meet the
required qualification for the position, minimum of which shall be Trade Test Certificate.

8
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Interview/Selection

In this process, a letter shall be sent to the BIRC requesting for candidates that could be
suitable for the roles in Categories B, C and D. ENERGYRAY INTEGRATED SERVICES LIMITED
shall conduct interviews for the recommended candidates and select the most suitable
candidates for the roles in Categories B, C and D.

Welders/welders mate and Fitters/fitters mate in Category C must undergo pre-qualification

tests which must be confirmed by third party Inspection Companies (SGS) before they can be
cleared to work on site. Any one that does not pass this pre-qualification test shall not be
allowed to proceed on SPDC Plant HSE Induction.

Letters of Employment:

Letters of employment shall be issued to staff before commencement of work which shall
indicate the job role, job description, department and pay package. Staff acceptance of terms
of engagement shall be indicated on copy of employment letter to minimize complaints, if any
in the future while under the ENERGYRAY INTEGRATED SERVICES LIMITED Employment.

Community Clearance

ENERGYRAY INTEGRATED SERVICES LIMITED shall obtain community clearance for selected
staff at the Employment Bureau. This shall be handled by the ENERGYRAY INTEGRATED
SERVICES LIMITED C.L.O in charge of community matters to ensure that there are no invaders
that may deny the community employment choices.

SPDC Plant HSE Induction

ENERGYRAY INTEGRATED SERVICES LIMITED shall engage selected staff for SPDC HSE
Induction. This shall be supervised by ENERGYRAY INTEGRATED SERVICES LIMITEDs HSE
Advisor from Category A with ENERGYRAY INTEGRATED SERVICES LIMITED CLO in attendance.
The SPDC Plant HSE induction is Mandatory for all staff before they obtain access badges to
work within SPDC Facilities (NO SPDC INDUCTION, NO ACCESS).

Retention of Staff:

9
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

It is imperative that ENERGYRAY INTEGRATED SERVICES LIMITED retains staff so as to reduce

labour turnover within a short period. In other to retain staff, ENERGYRAY INTEGRATED
SERVICES LIMITED shall adhere strictly to the following; this shall be in correlation with the
Personnel Policy:

 Professional Development.
 Beneficial Pay packages.
 Prompt Salary Payment
 Open Communication.
 Value system.
 Work-life balance.
 A Fair Grievance procedure
 Counseling of workers
 Transportation.
 Accommodation and Messing.
 Time-off.
 Salary Advance
 Leave
 Medical
 Incentives

Professional Development:
ENERGYRAY INTEGRATED SERVICES LIMITED shall train staff in their respective fields. The
categories involved shall be from A-C respectively.

Beneficial Pay Packages:

The benefits that shall be offered by ENERGYRAY INTEGRATED SERVICES LIMITED in their pay
packages shall include:

 Leave Allowances.
 End of Contract pay off.
 End of year Bonuses.
Prompt Salary Payment:
Staff salaries shall be paid in good time (24th day of every month) to avoid staff losing
concentration on the job.

Open communication:

10
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

The ENERGYRAY INTEGRATED SERVICES LIMITED shall give staff the opportunity to do the
following:

 Speak their minds freely without intimidation.

 Share their ideas with regards to the project.
 Participate in addressing conflicts and grievances that may arise.
Value System:
ENERGYRAY INTEGRATED SERVICES LIMITED shall have a system that ensures staffs are treated
fairly and that there is consistent acknowledgment of staff for a job well done. These shall be in
form of bonuses, promotions and gifts.

Work – Life Balance:

ENERGYRAY INTEGRATED SERVICES LIMITED shall encourage staff to prioritize healthy
workloads, thereby, reducing the possibility of stress. This shall be by encouraging staff to
have a balanced life during and outside working hours by ensuring they take enough rest and
care for their families. The ENERGYRAY INTEGRATED SERVICES LIMITED HSE Controller and
Human Resource Manager shall ensure staffs have a work-life balance.

Fair grievance procedure:

ENERGYRAY INTEGRATED SERVICES LIMITED shall handle grievances from staff from all
categories when it arises. The grievance procedure shall be thoroughly handled by the
ENERGYRAY INTEGRATED SERVICES LIMITED Human Resource Manager. The procedure shall be
in line with the Personnel policy of ENERGYRAY INTEGRATED SERVICES LIMITED. The final
decision shall be given by the ENERGYRAY INTEGRATED SERVICES LIMITED Management. Staff
in this case, reserve the right to appeal any decision given by the Management in writing.

Counseling of workers:
The ENERGYRAY INTEGRATED SERVICES LIMITED HR Manager in conjunction with the
immediate line supervisor of the defaulting worker (who does not meet task and target or has
any other work related issue) shall set up a counseling session for the staff in order to harness
his/her potentials on the job.

Transportation:
ENERGYRAY INTEGRATED SERVICES LIMITED shall provide transportation for staffs to site at the
commencement, lunch time and closure of work.

PERFORMANCE EVALUATION

11
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

ENERGYRAY INTEGRATED SERVICES LIMITED holds Staff performance in high esteem.

It is the responsibility of ENERGYRAY INTEGRATED SERVICES LIMITED to ensure that all
staffs perform excellently and above expectation by strictly adhering to the following:

 Establishing goals
 Quarterly Performance Review
 Consistent Feedback to staff
 Employee Development
 Performance Dialogue
 Competency Building
 Resolving Poor Performance
 Managerial Training
 Appraisal forms

Establishing goals and objectives:

ENERGYRAY INTEGRATED SERVICES LIMITED shall set realistic goals for staff which shall
outline what is expected from staff at different stages of the Contract. The goals are as
follows:

 Job description goals: ENERGYRAY INTEGRATED SERVICES LIMITED Managers from

Category A shall set a pre-established set of job duties from the description. These
goals are expected to be accomplished continuously until the job description
changes.
 Project goals: ENERGYRAY INTEGRATED SERVICES LIMITED shall set goals for the
project. All staff are to align their goals to that of the project goals.
 Behavioural or Attitudinal goals: ENERGYRAY INTEGRATED SERVICES LIMITED
shall set goals on staff behaviour and attitude to work.

Quarterly Performance Review:

ENERGYRAY INTEGRATED SERVICES LIMITED shall implement a quarterly performance review

on this project assessing staff progress on the goals and targets set. Strengths and weaknesses
of all staff shall be recorded regularly by ENERGYRAY INTEGRATED SERVICES LIMITED
Management so that an informed and accurate decision regarding staff contribution, career
development, training needs, promotional opportunities, pay increases can be made where
necessary.

Consistent Feedback to staff:

12
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

After the quarterly review, ENERGYRAY INTEGRATED SERVICES LIMITED Managers shall give
regular feedback to staff in other to break old habits and encourage them to learn new
behaviors in attaining excellence in their job role and in the project as a whole.

Employee Development:

ENERGYRAY INTEGRATED SERVICES LIMITED Management shall recommend that staff

(Particularly in Category A, B and C) develop continually to improve their performance,
increase their knowledge, skills, experience and capabilities, and progress on their jobs in the
Contract.

Performance Dialogue:

ENERGYRAY INTEGRATED SERVICES LIMITED shall encourage regular dialog between

employees and managers about expectations, progress, accomplishments, performance and
development needs. This shall be done so that staff can constantly be set on achieving the
projects goals.

Competency Building:

ENERGYRAY INTEGRATED SERVICES LIMITED shall assist through the Category A staff to
cultivate the organizational and job-specific competencies on each staff and the need for high
performance and success on this Contract.

Resolving Poor Performance:

ENERGYRAY INTEGRATED SERVICES LIMITED shall provide support for an under-performing staff
by counseling the staff towards achieving high performance which shall be supervised by the
ENERGYRAY INTEGRATED SERVICES LIMITED Human Resource Manager and the Line supervisor.
However, if the staff consistently under-performs after sessions of counselling, he/she may be
subject to disciplinary measures and procedure which may lead to termination of appointment.

Managerial Training :

ENERGYRAY INTEGRATED SERVICES LIMITED shall encourage managers in Category A and B to

undergo leadership trainings in performance management. These training shall include how to
help managers orient their goals around corporate strategy, coaching employees about career
paths and opportunities, and committing to regular feedback mechanism.

Appraisal forms:

13
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Appraisal forms shall be used by ENERGYRAY INTEGRATED SERVICES LIMITED as a way to

measure performance of workers on site. This shall be used by ENERGYRAY INTEGRATED
SERVICES LIMITED as a feedback mechanism on all staff in the various categories. Any staff
that falls below average in the appraisal shall be noted to be an underperforming staff.

LIST OF REPORTS OR TEMPLATES OF REPORTS

 HSE Statistics
 Progress Summary
 Document Status
 Weekly Progress Report
 Daily Maintenance Report

HSE STATISTICS

SW SW
Parameters Man-hours FAC MTC LTI NM IR UA/UC Drills
(NLNG) (DAIIK)

Last Week 100 0 0 0 0 0 0 0 0 0

Week under review 1,160 0 0 0 0 0 0 0 0 0

Cumulative 1,260 0 0 0 0 0 0 0 0 0

PROGRESS SUMMARY

PROGRESS Cum Previous Cum To Progress this

SUMMARY: Week Date Week
Overall Planned
Progress :
Overall Actual
Progress :
Varianc
e:

DOCUMENTS STATUS

Item Arch. Civil Electrical Mechanical HVAC Structure IT/Telecom

Issue Close Issue Close Issue Close Issue Close Issue Close Issue Close Issue Close

14
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

d d d d d d d d d d d d d d

ETQ

CTQ

With
ENERG
YRAY
INTEGR
Issue With
S/N Document Type ATED AFC Remarks
d SPDC
SERVIC
ES
LIMITE
D

Total:

Site Instruction Status

Issued Closed Outstanding Remarks

15
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

WEEKLY PROGRESS REPORT

DATE: ...........................................................................................

Contract No: ……………………………………………………………………..

Contract Name: ………………………………………………………………………

SPDC: ………………………………………………………………………

1. HSE Issues :
2. Procurement Status:

3. Fabrication Report:

4. Quality Issue:

5. Contract Schedule/Progress Report: As per revised

(% Plannedvs% Actual):

16
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

WEEKLY % Planned % Actual

MOBILIZATION

CONSTRUCTION/INSTALLATION
WORKS

COMMISIONING

DEMOBILIZATION

OVERALL

a. Look Ahead Plan:

b. Concerns/Challenges:
c. Follow-Up Action:

DETAILS OF PROPOSED PLAN TO ENSURE AND ASSURE ON SUSTAINABILITY.

The proposed plans to ensure and assure sustainability in the Contract are as follows;

1. To employ competent personnel.

2. In house training for the skilled and unskilled workers.
3. To provide incentive where necessary.
4. Effective supervision

APPLICABLE WORK MANAGEMENT TOOLS.

The applicable work management tools for the effective delivery of the Contract are as
follows;

1. Effective PTW (Permit to work).

2. Job Hazards Analysis (JHA).
3. Tool box talk.
2. Last minutes risk assessment (LMRA).
3. Pre Job briefing.
4. Effective supervisor.
5. Post job briefing.
6. Journey management plan.
7. Defensive driving.

Also other applicable work management tools (Software) for the Contract are as follows;

17
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

1. AUTOCAD Plant 3D 2013

2. Microsoft Word 2010

3. Microsoft Excel 2010

4. Microsoft Project 2010

5. Microsoft Power Point 2010

MATERIALS HANDLING AND STORAGE MANAGEMENT

The designated Contract Engineer will prepare the detailed Bill of Quantities for all materials
and material requirements. The resulting Bill of Quantities shall be reviewed and approved by
the Contract Manager. On approval by the Contract Manager, and the SPDC Representative,
the Bill of Materials shall be compiled on Material Summary Sheets.

The Sheets shall state, as a minimum, the following information:

 Product Description with all documentation and traceability requirements.

 Material grade, quantity and units of measurement.
 References.
 Required date.
ENERGYRAY INTEGRATED SERVICES LIMITED’s Supplied Material

For Materials to be procured by ENERGYRAY INTEGRATED SERVICES LIMITED, It is the

responsibility of ENERGYRAY INTEGRATED SERVICES LIMITED ENGINEERING procurement
Supervisor and / or Contract Engineer to ensure that:

 All Materials ordered are of the required quality and quantity.

 These materials are supported by the Calibration Certificates and all appropriate
documentation.
 Materials are properly inspected and approved by the designated SPDC representative.
 Packaging and correct tagging of all items.
 Delivery dates are kept and are monitored.
 Timely Shipping arrangements are implemented.
 Compilation of all necessary documentation to enable timely clearance from the
Nigerian Ports.
The Procurement Supervisor will communicate the expected arrival dates of the vessels
assigned to transport the materials within, and to Nigeria (if required) and provide copies of
the Shipping List.

18
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Based on the information provided on the expected arrival dates for these materials, the
Contract Engineer shall submit a revised construction schedule reflecting any new delivery
dates and changes thereof.

Material Receiving and Inspection (ENERGYRAY INTEGRATED SERVICES LIMITED

ENGINEERING Supplied Material)

On receipt of the materials in ENERGYRAY INTEGRATED SERVICES LIMITED ENGINEERING

Fabrication Yard, the Warehouse Manager and the designated Quality Control / Assurance
personnel shall:

 Ensure that materials are received in accordance with the Packing List.
 Inspect Materials and verify with the corresponding Mill/calibration Certificates.
 Tag appropriately any non-conforming items and raise Non Conformance Reports
(NCR’s).
 Compile Material Receiving Reports based on the above information.
Materials shall be stored in the ENERGYRAY INTEGRATED SERVICES LIMITED ENGINEERING
Construction Warehouse Storage areas until required. Materials shall be received from the
Warehouse with the use of Material Movement Reports (MMR’s) as per the Material Control
Procedure. Material Status Reports shall be provided on a weekly basis.

Material shall be properly stored, tagged and marked with pre-approved colors to avoid
material mix-up, and ease retrieval from the storage area.

CONTRACT PROGRESS MEETINGS / MONITORING

ENERGYRAY INTEGRATED SERVICES LIMITED Meetings

Prior to the commencement of work each day, in-house meetings shall be held with the
Contracts assigned key personnel. The essence of these daily meetings is to ensure that:

 Works are conducted in a timely manner.

 Works are performed in accordance with the Contract’s Quality Guidelines.
 Resolution of any work or material problems.
 Review of allocated resources.

19
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Weekly Contract Meetings.

In accordance with the requirements of the SPDC, Weekly Contract Progress Meeting shall be
held between the SPDC and ENERGYRAY INTEGRATED SERVICES LIMITED designated personnel
inclusive of the Contract Manager. All issues relating to the Contract shall be reviewed at these
Weekly Meetings. All issues raised at these Meetings shall be documented and action noted
with responsibilities indicated and response time also [Link] INTEGRATED
SERVICES LIMITED shall prepare all Minutes of Meetings for SPDC review and approval.

LOAD-OUT AND TRANSPORTATION

ENERGYRAY INTEGRATED SERVICES LIMITED ENGINEERING shall provide the transportation for
the Load-Out of material and equipment at site. The provision and installation of lifting slings
for Load-Out shall be ENERGYRAY INTEGRATED SERVICES LIMITED ENGINEERING responsibility.

The provision and pre-installation of lifting slings and for the load-out from Port Harcourt base
shall be by ENERGYRAY INTEGRATED SERVICES LIMITED ENGINEERING

A comprehensive List shall be compiled for all ship loose items during transportation to site.
This List shall also act as a checklist to ensure that all required items are complete.

AS-BUILT DRAWINGS

ENERGYRAY INTEGRATED SERVICES LIMITED NIGERIA LIMITED’s Engineering Department shall

utilize AutoCAD Release 2013 for its drafting operations. Facilities are also available for the
provision of copies of these drawings.

Released Construction drawings shall be marked up during the Construction activities to reflect
any changes. All “As-built” Drawings and Quality Control Documentation shall be submitted to
SPDC within the contractual specified period.

PROPOSED CHANGE MANAGEMENT AND COST CONTROL MANAGEMENT PLAN

The proposed change management Plan for the Contract shall be carried out based upon the
following:

 Effective Schedule Control, monitoring and updating to ensure that the maintenance
works are completed within the scheduled completion date and KPI.
 Developing an efficient and effective Call log system’.
 Employing and retraining of skilled personnel.

20
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Measurement of Work progress, Forecast of schedules and Planning of corrective

actions

COST CONTROL

The proposed cost Control Plan is to ensure that Costing of works shall be as per specific prices
of items in the approved Contract document. Also important shall be the use of skilled labour,
adequate supervision and budget tracking.

Thus, with effective Schedule and Cost Control plan, Profit shall be achieved.

19.0 PROPOSED RESOURCES; EQUIPMENT LIST

The under-listed Equipment/Tools will be required to carried the works:

S/N DESCRIPTION OF EQUIPMENT QUANTITY

1 DIGITAL MULTIMETER (PREFERABLY FLUKE SERIES) 1

HART COMMUNICATOR (475 PREFERRED OR SIMILAR

2 CAN BE CONSIDERED) 1

3 LOOP GENERATOR/ CALIBRATOR 1

4 MEGOHMETER 1

5 DECADE RESISTANCE BOXES 1

6 TUBING BENDERS 1

7 CLAMP AMMETER 1

8 CORE MARKING MACHINE 1

9 CABLE TAGGING MACHINE (METAL TAGGING) 1

10 INSTRUMENT TOOLBOX 1

11 POST WELD HEAT TREATMENT MACHINE 1

12 CUTTING AND BENDING MACHINE 1

13 TOOL BOX 1

14 CREW BUS 1

15 4 X 4 WD HILUX PICK UP 1

21
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

16 LINCON WELDING MACHINE 400A 1

17 OXY-ACETYLENE CUTTING SET 1

18 TOOL BOX - ELECTRICAL LOT

19 MANUAL TORQUE WRENCHES LOT

20 HAND SAWS OF VARIOUS TYPES AND SIZES LOT

21 HAMMERS OF VARIOUS TYPES AND SIZES LOT

PLIERS OF VARIOUS TYPES AND SIZES E.G. END

CUTTING NIPPERS, PINCERS, WIRE STRIPPERS, GAS
22 PLIERS, GRIP, INSULATED ,CABLE STRIPPERS ,ETC LOT

HAND PLANES OF VARIOUS TYPES [Link], SMALL

23 BLOCK, SMOOTHING PLANES ETC LOT

24 SHOVELS AND SPADES LOT

25 WHEEL BARROWS 1

26 MEASUREMENT TAPES OF VARIOUS SIZES LOT

27 CROWBARS 3

28 DIAMOND GLASSCUTTERS 1

22
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

S/N DESCRIPTION OF EQUIPMENT QUANTITY

29 SPIRIT LEVELS OF VARIOUS TYPES AND SIZES LOT

CRAMPS AND BRACES OF VARIOUS TYPES AND

30 SIZES E.G. G-CRAMP, C-CRAMP, SASH CRAMP ETC LOT

FILES OF VARIOUS TYPES AND SIZES E.G. ROUND,

31 FLAT FILES LOT

32 SOLDERING IRON 2

33 TROWELS OF VARIOUS TYPES AND SIZES LOT

34 WRENCHES OF VARIOUS TYPES AND SIZES LOT

35 RETRACTABLE BLADE KNIFE LOT

36 TABLE VICE 1

37 HEXAGON KEYSA/F &METRIC SIZES LOT

38 MEASURING TAPE,50FT L 2

39 HOLE SAW SETS 4

40 RATCHET SCREWDRIVER/SOCKET SET LOT

41 3 PIECE VDE PLIER SET LOT

42 INSULATED SCREWDRIVER SETS LOT

43 COMBINED SOCKET SETS LOT

44 SCREWDRIVER/ SOCKET SET LOT

45 CRIMPING TOOL LOT

46 CRIMPING PLIER LOT

PROCUREMENT OF MATERIALS/EQUIPMENT AND DELIVER TO SITE

A Request for Quotation (RFQ) for all Approval Material Technical Specifications shall be send to
manufacturer or Vendor specifying the actual requirement per product for procurement.

Data sheets and specification of all materials required for the Contract shall be submitted to
SPDC for review and approval before such materials will be purchased.

23
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

All materials supplied shall be verified, inspected and accepted based on the quality specified in
the relevant standards, and specifications by SPDC before use.

All certificates and supporting documents shall be presented before the inspection process.

A sample of material to be purchase locally shall be submitted to client for approval before full
procurement shall commence.

Materials not conforming to specifications and other statutory regulations shall be rejected at
the cost of the Contractor and clearly marked REJECTED and quarantined. Other free issue
materials shall be supplied by SPDC.

Presentation of Material Data Sheet (MDS)

ENERGYRAY INTEGRATED SERVICES LIMITED shall present the material data sheet for materials and
equipment for the Contract for SPDC approval. This process undergoes various stages of approval
(from issue for comment (IFC) to Approve for Construction (AFC)

Procurement of Material

The duration for the Procurement of Material and its delivery to Site shall be as
per the proposed Procurement Plan for the Contract.

SAFETY.

All the necessary work permits shall be obtained prior to begin of the works. All works shall be
done in accordance with the SPDC Safety rules and regulations.

Only authorized and qualified personnel shall operate motorized equipment.

Prior to commencing any work, a work permit must be obtained from and signed by a SPDC
authorized person.

All key personnel on this section of works are to be experienced in the job and shall be inducted
into this method statement.

Work procedures shall be in accordance with the HSE risk managements. These shall be presented
at a toolbox meeting prior to commencement of these works and then at regular intervals.

Records of attendance at the toolbox meeting shall be kept and filed on site.

All plant and equipment are to be inspected and approved as required by the Contract
requirement.

24
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

All plant and equipment, together with the working areas, are to be regularly inspected and
audited.

No smoking or use of free flames is allowed close to working areas.

Protective gloves shall be used as required during work.

The work area and storage areas shall be barricaded and separated from adjacent walkways and
other construction areas.

QUALITY RECORDS.

In accordance with Quality Control Plan, all quality record shall be filled up during stages of
work, duly signed by the inspectors and shall be maintained for final dossier according to ITP
(Inspection and Test Plan) for the Contract.

During installation, any deviation from the drawings has to be approved by SPDC and shall be
incorporated in the As-Built drawings. All drawings used for the construction shall be marked up
(in colour) during and after the end of activities, clearly indicating with “As Built” marking and
submitted to SPDC. If no change is made, this shall be recorded as “No Change”. Any damage
that occurs on the cables shall be documented using appropriate CTQ and NCR forms and any
necessary repairs shall be first approved by SPDC.

2.0 TRAINING PLAN

25
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

INDUSTRIAL / COMMUNITY RELATIONS

Industrial Relations Plan

OBJECTIVE

The aim and objective of ENERGYRAY Industrial Relations Plan is to provide guidelines for any
such matters as relates to industrial actions and unionist activity for the scope of the project for
Change Out of Catalyst and Sand Beds at NIGERIA LNG and identify possible mitigating measures
and responsibilities to ensure such activities neither negate nor disrupt work progress.

SCOPE OF WORK

 Manifold Works
 Manifold Piping Works
 Civil structure repairs / maintenance Valve maintenance
 Valve replacements Manifold Cage works
 Pipeline Repairs
 Oil and gas lines Emergency Repairs Planned Pipeline Upgrades / Repairs Composite repairs
 Cathodic Protection Upgrade Repairs Cathodic protection upgrades/repairs Coating surveys and
Repairs
 Manifold Protection Systems Installation/Maintenance

POLICY IMPLEMENTATION.

For the purposes of this Industrial relations plan ENERGYRAY Industrial relations policy and
SPDC terms of agreement shall be the guiding practice. This Management Plan applies to all
personnel engaged on the project.

Purpose

The purpose of this Instruction is to ensure that the employees and personnel performing work
are aware of ENERGYRAY policy and strategy for

ensuring robust employer-employee relations and that Industrial dispute are avoided or mitigated
in the interests of the ENERGYRAY and SPDC.

26
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

EMPLOYEE RELATIONS

Employee Relations is integral to the overall business development plans for the successful
completion of the

project and key features of the overall strategy are as follows:

• ENERGYRAY provides Facilities that will significantly improve the productivity of its personnel
which are
provided at license rates that are competitive with comparable standards within the village.

Employment terms that complement these advantages are required.

• ENERGYRAY shall ensure a stable, safe and secure environment, free of sovereign risk issues
in terms.
of industrial relations, overall cost, and schedule performance.

• To achieve this, recruited personnel and their Unions will promote a harmonious workplace,
based.
on openness, transparency, and timely negotiations.

• All parties will promote adherence to the project objectives and to effective dispute resolution.
PROCEDURES.

 ENERGYRAY must be in a position to effectively coordinate the activities of recruited personnel

working concurrently at SPDC Facility in order to ensure fair utilization of the facilities and that efforts are
focused towards “the greater good” encourage employment terms that enhance overall productivity
and cost competitiveness; promote stability, openness between parties and confidence in the
industrial relations .

27
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

ENERGYRAY as an entity promotes an industrial relations environment based on fairness and

equity and states its

preference that works at the facility should be based on SPDC industrial agreements as a
minimum.

ORGANISATION

ENERGYRAY shall designate its representative in the capacity of project manager to coordinate
Industrial relations activities, if required.

The project manager is required to liaise with the following authorities, groups and bodies on
industrial and employee relations matters.

Terms and Conditions of Employment

Terms and conditions shall be defined by negotiations and guided by the ENERGYRAY and SPDC
agreements with their best practices.

Pay rates and conditions will be determined by the normal processes between ENERGYRAY and
its employees.

They must reflect the works to be performed and the working conditions involved. There will be no
special

allowances or other measures that discourage work. In addition.

The terms and conditions of employment must satisfy all legal and regulatory requirements and in
particular meet or exceed.

 Terms specified by SPDC.

 Occupational, health and safety laws; and

 Any other laws or regulations governing work practices.

Terms and conditions of employment shall also recognize existing standards for employment

28
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

conditions as obtainable within the community for related services. Workplace Agreement

Working Hours

Working hours shall be as follows Nine (9) working hours from 0800 to 1700hours with one-hour
break.

Commitment from Employees

All employees must commit to comply with

 Health Safety & Environment Management Plans (HSE) and procedures applicable to the
facility
 Minimize any adverse consequences or disruptions their actions may have

 Specific requirements and directions e.g. (Emergency Response). Management of Disputes

Dispute handling procedures shall include reconciliation and arbitration processes which are as
defined by the

agreement and negotiated conditions.

Disputes shall be managed such that it would have no adverse effect on other activities not related
to the

project.

No significant departure from the industrial agreements shall be conducted without the endorsement
of

concerned parties

INFORMATION TRANSMITTAL

ENERGYRAY shall promptly inform SPDC of all issues or potential issues that could adversely affect
project.

activities. With SPDC representatives establishing a cooperative work environment and shall be
required to attend monthly co-ordination meetings to ensure effective planning and information
sharing.

29
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

DISCIPLINARY PROCEDURE

Disciplinary measures to be implemented on this project shall be according to ENERGYRAY

Employee Handbook, Law of the federal Republic of Nigeria and SPDC Rule and Regulations.

INTRODUCTION

In recent years, great awareness has swept through the people-mostly youths of oil producing
Areas in Niger Delta at the whole, due to the high expectations and scarcity of paid jobs. This
awareness omitted, has led to a lot of jobs being disturbed or disrupted.

To forestall the disruption of this project and improve our image and relationship with the communities
within the vicinity of this project, this plan on community relation was drawn up.

This plan has to do with:

The duties or functions of ENERGYRAY to the community in Niger Delta Area, promoting, caring and
encouraging progress with the community in the area, establishing gainful mutual and symbiotic
relationship with the host community within the area, the whole idea of this plan is to set standards
procedures for community Affairs for the dictates and progress of the project.

INTERFACE MANAGEMENT

Introduction

In today’s flat world, many major oil and gas projects involve multiple project participants from different geographic
locations including one or more Engineering, Procurement and Construction (EPC) companies performing process and
facilities design, a variety of third party suppliers providing products and services and a broad range of external and
internal customers needing to exchange information between themselves and other project stakeholders. Critical elements
in the successful operation of major oil & gas facilities are the automation, control and electrical power systems and for these
systems to have a common “look & feel” throughout the facility owner/operators are increasingly adopting the concept of Main
Automation Contractor (MAC) and Main Electrical Contractor (MEC) where major vendor/equipment suppliers take on an
expanded role in the design, manufacture, installation, commissioning and initial operation of the facilities. An important
aspect of the MAC/MEC role is promoting effective and timely communication and exchange of information between
participants since this is a prerequisite to the ultimate success of a project.

30
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

MAC/MEC brings value to the end user by providing advanced technology solutions and integrated products. In order for
the solutions and integration to be implemented successfully it is essential that a common framework of communications is
established which permits the timely exchange of relevant and accurate data between the involved parties. To achieve
this ABB employs Interface Management, a key process within our project execution model and an essential element in
delivering flawless project execution.

Requirements

A major factor impacting the exchange of information is the contracting structure employed on the project. There are a
variety of different contracting models that can be used ranging from direct contracts with the owner to various
prime contractor/ subcontractor/supplier relationships between the owners, engineers etc.

Irrespective of the contracting model used, these large projects will involve multiple participants most likely in different
geographical locations, resulting in cultural and language differences and the necessity to collaborate and work together
over multiple time zones. In situations such as this it is essential for the MAC/MEC to have the ability to interface and
coordinate information to minimize the risks associated with ongoing design development, project changes and late and
erroneous data. This requires the establishment of a process to coordinate activities directly with other project participants to
ensure an effective exchange of critical information.

The process must be robust and it must be managed. This requires a management structure with the ability to cross
the relevant participant boundaries without impacting the overriding contractual relationships. The nomination of an
interface representative position within each entity’s project organization achieves this. The Project Interface Manager has
overall responsibility for implementation and maintenance of the interface management process throughout the project
life cycle by developing and implementing project specific Interface Management work processes, capturing the
necessary interface agreements, monitoring progress, ensuring that schedule requirements are maintained and identifying/
initiating any change requests that may arise out of the interface requirements. Depending on the size of the project the
MAC/MEC Project Interface manager may also have a team, of project interface contacts (technical liaisons) embedded
in the location of other external entities to be the interface liaison with the owner and EPC’s Interface Representative or
other persons and departments required by the owner.

Definition

The objective of the Interface management process is to facilitate agreements with other stakeholders regarding roles
& responsibilities, timing for providing interface information and identification of critical interfaces early in the project
31
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

through a structured process. Energyray overall goal is the early identification of issues with potential for impact to
cost or schedule, to minimize or remove their impact and promote clear, accurate, timely, and consistent communication
with other organizations for exchanging interface

32
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

INTERFACE MANAGEMENT WITH ENGINEERING, VENDOR ACTIVITY, AND FABRICATION

YARDS AND CONSTRUCTION SITES

INTRODUCTION

The purpose of this plan is to establish an interface management process to manage key
interfaces that arise during the planning and execution of the project in order for the project to
eliminate waste (time and capital), interfaces must be managed. The interface management
process consists of planning, identification, approving, auditing, and closing-out interfaces. Closing
out these interfaces is critical to the successful implementation and execution of the project. This
procedure addresses the following:
Outline the process for successfully coordinating and managing all key interfaces.
Define the responsibilities for each of the teams involved with the interface requests such that the
individuals are accountable to follow up the required actions.
Define how key interfaces are identified, logged into an interface register and tracked until
completion.
Logging all key interfaces into an accessible register, and actively keep the interface register up to
date.
Define the workflow that interface requests will follow throughout their life cycle.
Establish the process to monitor the status of the interface requests contained within the register,
and actively make certain that all requests are closed-out in a timely manner.
Implement the system by which the parties coordinate their interface activities.
Facilitate communications between parties, including conflict resolution.
Promote clear and consistent communication among the involved project team members for
transmitting interface information.
1.1 Objectives
The primary objectives of this procedure and its implementation are as follows:
Identify the appropriate personnel who will be responsible for each interface request and for
resolution of the interface request.
Provide a system which will facilitate the identification of interfaces, and address the specific
interface request requirements.

33
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Establish a procedure that promotes efficient management of interface issues from initiation to
close out.
Define methods for communication and coordination of interface requests between various parties.
Facilitate clear and frequent communications amongst parties.
Facilitate the agreement of a schedule for interface request resolution and close-out.
Define a means for the control, expediting, and reporting of progress on the transfer of interface
requests.
Define processes of assurance that interface requests are effectively identified and managed.

PRINCIPLES
ENERGYRAY INTEGRATED SERVICES LIMITED expectations and Procedure are to:
 Ensure internal interfaces are identified and managed early via a structured process.
 Ensure agreement between CONTRACTOR and CONTRACTOR groups on roles,
responsibilities and timing for providing such information;
 Promote clear, accurate, timely and consistent communication with CONTRACTOR
groups for transferring internal interface information required to progress the Services;
 Identify internal interface issues with potential for impacts to cost or schedule quickly
and communicate to all relevant CONTRACTOR groups, including Company, in order
to minimize their impact;
 All participants within the CONTRACTOR and CONTRACTOR groups are responsible
for identifying and communicating internal interface issues to their lead supervisor,
manager, or the designated
Interface Coordinators: I
 nternal interface issues will be identified, catalogued, assessed for impact, assigned
and managed throughout the duration of the PROJECT;
 Internal interface issues will be resolved at the appropriate working level within the
Project organization to minimize rework (for example, engineers responsible for the
design and design verification);
 Regularly advise Company on the status of resolution of internal interface issues;
 Internal interface activities will be coordinated with other CONTRACTOR work groups
and process such as Management of Change, HES, QMS, and Risk Management to
improve process efficiencies and avoid duplication of efforts.

34
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 All internal interfaces, whether with subcontractors or suppliers or consultants, shall be

established through written procedures. These procedures shall ensure:
 Development of comprehensive internal interface matrices and registers
 Full understanding of work scope accountabilities and responsibilities by all personnel
 Information distribution through a formal system at the required times

Regular, documented meetings and other communication to complete internal interface

agreements and agree on assignments, actions, and dates for tasks to be completed
Single-point accountability for internal interfaces

INTERFACES

An interface is defined as a point of connect between entities working on a common project. This
point can be:
Physical - Physical interaction between components
Functional - Functional Requirements between systems
Contractual - Interactions between subcontractors/suppliers
Organizational - Information exchanged between disciplines
Knowledge - General information exchanged between parties
Resource - Points of dependencies between equipment, material, and labor suppliers

INTERNAL INTERFACE
An internal interface is one where the complete responsibility lies within CONTRACTOR’s scope of
work.

EXTERNAL INTERFACES
Any part of the Scope of Work under the responsibility of NEWCROSS which may influence, or be
influenced by, the scope of work covered by any other contract related to the PROJECT.

KEY INTERFACES

35
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Key interfaces are interfaces that are managed by the Project. Interface Management Team
nominated leads and/or interface coordinator. The project Interface Coordinator will oversee and
monitor these interface activities and will provide proactive support to the nominated focal points
for coordinating interfaces within each discipline. Key interfaces will be entered in the project
WIMS and tracked to completion.

ROLES AND RESPONSIBILITIES

INTERFACE MANAGER
 Develops and implements the Interface Management Procedure.
 Ensures consistency in the project wide application of the Interface Management
Procedure.
 Oversees and monitors project wide internal and external interface management
activity.
 Maintains the master Interface Request Register.
 Regularly reports on status of key interface activity.

INTERFACE COORDINATOR
 Participate in Interface Meetings with affected/involved parties as required to manage
interfaces.
 Review outgoing interface requests and serve as interface request approver
 Ensure resolution of inbound interface requests
 Actively monitor interface request register to: expediting requests and
open/update/close requests on behalf of their team
 Provide collaborative interface resolution support.
 Serve as PMT liaison between contractor and operating plant point of contact.
 Inform Interface Manager of potential impacts due to unsatisfactory resolution
response.

REQUESTING PARTY
Individual submitting an Interface Request for a response

36
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

RESPONSIBLE PARTY
Individual responsible for responding to an Interface Request.

information. Interface Information is a requirement that associates two distinct entities, either
internal or external, that is necessary for an entity to generate its own deliverables.

Interface Agreements result in exchange of any project information generated by one party that is
needed by another party in order that the other party can continue with its scheduled project tasks.
This can include but not limited to the engineering drawings, specifications, design reports and
calculations, equipment details and project schedule information.

There is no limitation on the source of interface agreements. They can arise from several
sources including members of the project team, contract requirements, responsibility
matrices, customer requirements, third party vendors/suppliers and other project contractors
and project stakeholders.

37
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Whatever the source, information requests on an Interface Agreement

have two basic rules:
 They should be specific and primitive in nature and should not be capable of further
breakdown in to more items.
 They should have a specific requirement date.

To simplify the process and make the tracking and monitoring efficient all Interface Agreements
should to be unidirectional from the first party (receiver) to the second party (supplier). If the
second party requires the return of data then this should be the subject of a separate interface
agreement from the second party to the first party.

The Receiver is the party that initiates the request for information and the supplier is the party
that is responsible for providing the requested information. During project execution all
participants may adopt the role of receivers and suppliers at some point.

38
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Interface Agreement is unidirectional

Process

The interface management process is designed to provide a method to formally document and track
the exchange of information between project participants and to monitor the performance of all
participants in making available the required information. The process involves
• Identification and recording an interface
• Creating an interface agreement
• Agreeing / Resolving Conflict
• Monitoring the status
• Reporting the status
• Closing the interface agreement

Information required is identified by the receiving party and advised to the interface manager, whom
in turn will develop an electronic register of all identified interfaces, usually in a database format,
with each interface agreement having its own identification code such that the receiver and supplier
are easily identified. For example, in the case of an external party, MAC/MEC-EPC1-001 depicts an
interface agreement that MAC/MEC is requesting from an EPC1.

A formal interface Agreement document is generated from the Interface Management database by the interface
manager and signed by the receiver and issued to the supplier via formal document management process
with the necessary data elements such as Interface Agreement Identification Number, Priority (whether it is

39
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

highly critical or information only), Date Raised, Supplier Organization and Interface Contact, Date information
needed by the receiver and date agreed by the supplier and the status of the Interface Agreement as either
being OPEN or CLOSED.

Once the created Interface Agreement is issued by the “Receiver” the “Supplier” will either accept it or will ask
for a discussion for clarification. The Interface Agreement is then discussed with the “supplier” and either
accepted, modified, or deleted. If there is a dispute over the legitimacy of an identified interface, the
interfacing parties will make every effort to resolve the issues. The client may intervene to provide final
arbitration of any unsettled issues. The supplier will sign the Interface Agreement by a formal signature on
the form and issue it back to

“receiver” The database is modified as required. In order to simplify the process an Interface Agreement
may be revised only once.

Each Project Interface manager monitors the status of the interface agreements on a regular basis by having
periodic Interface Meetings or teleconferences between the parties to review the progress on the Interface Registers
that are derived form the Interface Database. The Interface Agreements with “Critical” Status are prioritized and the
respective Project Managers will develop contingency plans for the “critical” data that is deemed to be “late to
minimize the impact of the critical late data.

The interface manager is responsible for producing regular reports from the electronic log indicating the interface
progress. The frequency of reports will depend on the project reporting requirements however, as a minimum
a status report will be generated monthly and included in the monthly project progress report. Reports can be
either in a tabular format as an Interface Register or in a statistical format as a high level report.

When the “Receiver” receives the requested information by the required date and considers it acceptable then
the “Receiver” can sign the Interface Agreement as “Closed” and issue it back to the “Supplier”. In turn, the
“Supplier” signs the interface agreement form as “Closed” and the document is recorded as such in both the
“Supplier’s” and the “Receiver’s” interface databases. The “Closed” interfaces are omitted from future
Interface Agreement reporting.

Advantages

40
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Using a formal Interface Management process has many advantages, particularly when there are numerous
participants and stakeholders involved in a project. Having a structured process for the exchange of
information means that performance in satisfying the requirements can be monitored in detail and any
shortcomings highlighted and addressed immediately they become apparent. A secondary benefit of
implementing the process is that it encourages meaningful communication between the supplier and receiver
participants. The requirement to provide specific, detailed requests

41
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

that are not capable of further decomposition means that the party making the request must give careful
thought to the detail of the information requested and to the timing of the delivery of the information. The
requirement for both parties to sign the formal agreement means that a dialogue regarding the information and its
delivery must take place between the parties in order that agreement can be reached. If the receiving
party asks for too much, too soon in the data generation cycle, agreement with the supplier party is
unlikely to be reached. The supplier party will require further decomposition of the data into more defined
parts resulting in detailed discussions/negotiations between the parties regarding the information required.
The formal interface agreements are the product of this communication process.

Fostering this communication between project participants early in the design cycle is an important factor
in achieving execution excellence. Very often the information a participant requires is either ill defined
resulting in confusion and lack of focus, or it is all encompassing resulting in the delivery being unable to
be achieved. This leads to conflict within the team and gives rise to unproductive finger pointing or laying
blame for something not happening rather than cooperation to ensure that the work progresses to meet the
schedule objectives. Examples of this are the MAC requesting delivery of the AFC P & ID’s from the process
designer by a certain date. This is an ideal situation but in today’s fast track projects the process designer
is very often unable to deliver all P & ID’s at the same time. By focusing on the actual data needed, the
MAC and the process designer can reach an accommodation that will provide the necessary data in an
acceptable timeframe. The use of the interface process captures the details of these agreements, makes
them visible to all participants and tracks them to a successful conclusion.

Conclusion

Effective exchange of information is crucial to the successful execution of any project and the larger the
project and the more participants there are, the more difficult it is to achieve this. Use of the Interface
Management Process allows early identification of critical interfaces through a structured process leading to
early definition of issues with potential for impact to cost or schedule. Once identified, action can be taken

42
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

to minimize any impact and with constant monitoring areas of criticality that deviate from the plan can be
quickly addressed and brought under control.

Interface Management also encourages communication between the participants providing each with an
understanding of the constraints inherent in their respective data generation cycles. Identifying specific
data requirements and understanding the importance of the requirement leads to more effective
cooperation and thus an improvement in execution performance.

The Interface Management process can only be effective if all project participants embrace the concept and
incorporate it into their work processes making it a formal project communication method that benefits all
involved in achieving flawless execution.

43
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

PROJECT EXECUTION PLAN

1.0 PURPOSE
The Purpose of this document is to develop an appropriate Maintenance and
repair procedure that satisfies the specified standards and requirements for
proper provision of Specialized Pipeline maintenance and Repair services for SPDC
pipeline. It will also serve as a guideline for the employees who will be carrying
out the inspection cum maintenance works.

This document is applicable to the Maintenance for the provision of Specialized

Pipeline maintenance and repair services for SPDC pipeline.

2.0 WORK OBJECTIVES

To ensure that the provision of Specialized Pipeline maintenance and repair
services for SPDC pipeline are carry out in accordance with SPDC standards.

3.0 SCOPE OF WORKS

The works to be performed under this Maintenance include all work necessary for
the Provision of Specialized Pipeline Maintenance and Repair Services for SPDC
pipeline.

The Scope of Works for this Maintenance shall include but not limited to the
following.

a. Mobilization
i. Pre-mobilization
ii. Mobilization
iii. Transition
b. Valves maintenance and repair including periodic servicing of pipeline
valves, repairs, valve sealing, provision, and replacement of defective and
passing pipeline valves.
c. Provision of maintenance and repair services on pipeline ancillary
equipment and components such as barrel doors and accessories, barrel
door seals, non-intrusive pig signalers, pressure gauges, valves etc.
d. Minor and medium pipeline repairs including rectification of large free
spans, riser flex joint repair, vortex induced vibration (VIV) strake repla,
anodes retrofitting.
e. Pipeline Manifold/Riser/Jumper Coating repairs
f. Cathodic protection repairs
g. Process commissioning/maintenance

44
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

h. Decommissioning, isolation, and re-commissioning of pipeline after a leak

repair
i. Nitrogen purging activities/Auxiliary pumping activities.
j. Tooling for SPDC pipeline repair including pipe cutting tool, concrete
weight coating removal tool, corrosion coating removal tool, weld seam
removal tool, ovality and straightness gauges,
k. pipe end preparation tool, excavation tool
l. Fabrication of steel members/spools/structures
m. As built drawing, Maintenance close out documentation.
n. Demobilization

4.0 OVERVIEW
SPDC requires ENERGYRAY INTEGRATED SERVICES Limited to perform the
provision of Specialized Pipeline maintenance and Repair services for SPDC
pipeline. ENERGYRAY INTEGRATED SERVICES Limited is expected to provide
adequate resources to ensure that the Maintenance and repair works is
attainable, within accepted timelines and quality.

ACTIVITY SCOPE SUMMARY DIMENSION

Manifold piping 1. Manifolds Paintings [blasting and painting of Up to 48’’

works manifolds]. diameter
pipelines max
2. Scraper trap repairs / upgrades.
on land terrain
3. Installation of sampling points/ other specialized points.
Up to
4. Manifolds piping supports repairs/ replacements
48’’diameter
5. Manifold piping repairs/upgrades pipelines max in
Swamp terrains

Civil & Structural 1. Upgrade/maintenance of existing access roads. All manifold

Works civil works
2. Dredging works
All size
3. Land Manifold [M/F] civil works [hard standing areas,
cofferdams [24 m
drains, saver pits, pipe supports].
long x 12 m
4. Pipeline Repairs supports [cofferdams, shorings, special
wide x 24 m
access]
deep max]
5. Construction/repairs of Warning signs, valve operating
All Swamp M/F
platforms
extensions
6. Construction/maintenance of swamp manifold guard huts

7. ROW Hardening using Citadel and other approved

45
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

materials

Manifolds 1. Design, install and repair enhanced manifold cages. All scope
Protection [enhanced cage
2. Design, install and maintain pipeline facilities intruder
Systems anti- tamper
detection/remote monitoring systems
locks etc] for all
3. Design, manufacture, installation, and maintenance of
land and swamp
valve anti-tamper systems
manifolds.

Valve Replacement of flanged valves 48” Diameter

replacements max on land and
48"
Diameter max in
Swamp

Replacement of welded valves 48" diameter

max land and
swamp

Valve 1. In-situ valve maintenance All scope land

maintenance and swamp
2. Major offline valve repairs
[1/2" - 48"
valves ranging
from Class
150LB to 1500
LB]

Gas lines Repairs Repairs by installation of bolted split sleeve clamps. Clamping and

Repairs by screwed plugs. Repairs by composites [4"

Composites. - 48"] including

Repairs by sectional replacements [using mechanical major

connectors e.g weld plus ends and welding]. cofferdams

andriver
Repairs by installation of welded bolted split sleeve clamps.
crossings. – wet
Repairs by installation of welded split sleeve tee.
gas lines
Repairs by installation of Split sleeve
sectionalreplace
ment [up to
48”
diameter max]

Major 1. Sectional replacements using line flushing Delivery and

Trunkline [48”
2. Sectional replacements using freeze plug isolations,
sectional max]
mechanical plugs etc
replacements of
3. Sectional replacements using hot tap and stopple
46
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

oil lines isolations

including 4. Sectional replacement by drain and plug
welded valves

Riser burials 1. Removal of existing riser system and replacement with 4” to 48”
completely buried system. Diameter

2. Replacement of existing corroded/damaged risers pipelines land

and swamp

River crossings 1. River crossing sectional replacements 2. River crossing Crossings 3km
emergency repairs wide max and
upto48" diameter
pipelines

Road crossings 1. Casing replacements/ repairs Up to 48”

pipeline
2. Construction of new road crossings
diameter max
3. Repairs to existing road crossings
and open cut

Emergency 1. Repairs by installation of bolted split sleeve clamps. Clamping +

Pipeline Repairs screwed plugs
2. Repairs by screwed plugs.
for Oil and on all pipeline
3. Repairs by Composite
Condensate sizes [4" to
Pipelines 4. Repairs by sectional replacements [using mechanical 48"]Sectional
connectors e.g weld plus ends and welding]. replacements
on4”–

48”diameter
pipelines max

1. Repairs by installation of bolted split sleeve clamps for defect

repairs

3. Repairs by Composites.

4. Repairs by sectional replacements [using mechanical

connectors e.g weld plus ends, replacement by welding of
pipe sections, e.t.c].
Planned Repairs
5. Repairs by installation of welded bolted split sleeve
and Upgrade for
clamps.
Oil and
Condensate
6. Repairs by installation of welded split sleeve tee for non -
leaking illegal connections
Pipelines
7. Repairs by installation of Split sleeves for defect repairs

47
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

8. Repair of Post IP defects/ Defects using methods approved

by The Company

Composites Application of composite repairs approved by the All sizes [4" to

Repairs / company 48" diameters]
Upgrades

Decommissionin 1. Removal of stagnant oil including provision of water and 4" to 48"
g / water supply lines diameter
Abandonment of 2. Excavation and removal of pipelines and end facilities pipelines Land
disused and Swamp
3. Disposal of effluents / provision of flushing chemicals. 4.
pipelines and
Purging of disused gas lines.
manifolds

CP Systems All scope

Upgrade / [ground
Repairs beds,surveys,
test
posts,solar
systems,
sacrificial
anodes]

Coating 1. Coating surveys All diameters

except where
2. Repairs to damaged/deteriorated coatings
Survey and major
3. Supply of coating materials
repairs cofferdams are
required

5.0 APPLICABLE STANDARDS, GUIDELINE AND ABBREVIATIONS.

ASME B31 Piping Codes
ASME B16 Dimensional Codes
ASME B36 Piping Component Standards
ASME B31.1 - Power Piping, 2014
ASME B31.3 - Process Piping, 2012
ASME B31.4 - Pipeline Transportation Systems for Liquids and Slurries, 2012
ASME B31.8 - Gas Transmission and Distribution Piping Systems, 2012
DEP [Link] – Gen: Structural design and engineering of onshore structure
DEP [Link] GEN -Piping General Requirements
DEP [Link] Pipe Supports
DEP [Link] Pre-commissioning of Pipelines
DEP [Link] Pipeline Leak Detection
48
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

6.0 ABBREVIATIONS
DGPS Differential Global Positioning System
QHSE Quality Health Safety and Environment
JSA Job Safety Analysis
ENERGYRAY INTEGRATED SERVICES Limited ENERGYRAY
INTEGRATED SERVICES Limited Engineering Limited
QA/QC Quality Assurance and Control
WGS World Geodetic System
SI The vessel Investigation
SPDC Shell Petroleum Development Company
GI Ground Investigation
NPS Nominal Pipe Size
DN Nominal Diameter
ID Inside Diameter
OD Outside Diameter
SCH Schedule (Wall Thickness)
STD Standard Weight Wall Thickness
XS Extra Strong Wall Thickness
XXS Double Extra Strong Wall Thickness

7.0 ROLES AND RESPONSIBILITIES.

7.1 MANAGING DIRECTOR

To direct and control the company's operations and to give strategic guidance and
direction to the board to ensure that the company achieves its mission and
objectives.

Responsibilities:
 Developing and executing business strategies to achieve short and long-term
goals.
 Reporting to the board, providing market insights and strategic advice.
 Developing and implementing business plans to improve cost-efficiency.
 Maintaining positive and trust-based relations with business partners,
shareholders, and authorities.
 Overseeing the company's business operations, financial performance,
investments, and ventures.
 Supervising, guiding, and delegating executives in their duties.

49
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Ensuring company policies and legal guidelines are clearly communicated.

 Assessing, managing, and resolving problematic developments and situations.
 Building and enhancing the company's public profile at events, speaking
engagements, etc.

7.2 MAINTENANCE MANAGER

The Maintenance Manager shall have overall control of the Maintenance and
repair works. His responsibilities include, but are not limited to the following:
 Approval of all documents which are issued to the Client.
 All communication with the Client.
 Implementation of Maintenance Audit procedures and corrective actions.
 Administrative activities of the Maintenance and repair works.
 With the assistance of the Quality Control Engineer, develop the specific
Maintenance Quality Plan and ensure its implementation throughout the
duration of the Maintenance.
 The Maintenance Manager shall ensure that only suitably qualified
personnel are assigned to the Maintenance.
 Control of all Maintenance Documentation.

7.3 PROJECT ENGINEER

The Project Engineer shall report directly to the Project Manager. His
responsibilities include, but are not limited to the following:
 Management of Engineering, Materials, Cost and Scheduling activities of
the Maintenance.
 Development of a Maintenance Work Plan.
 Development of Maintenance Procedures.
 Preparation of Fabrication Design and Shop Drawings
 Preparation of Rigging Analysis.
 Supervising Load Out.
 Other Engineering activities

7.4 CORROSION MATERIAL ENGINEER
The Corrosion Material engineer shall report to the Maintenance Manager. As a
materials and corrosion engineer, responsibilities include helping clients optimize
resources while minimizing costs and risks. Inspection of maintenance equipment
and pipelines integrity and to give businesses recommendations for corrosion
control and material selection regarding tool/Pipeline maintenance and repair.
Other responsibilities include, but are not limited to the following
 Materials selection and technical advice for Maintenances, operations,
modifications and maintenance

50
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Welding and other joining technologies

 Fitness for service assessments against a range of degradation
mechanisms
 Refractories, Linings and Coatings
 Prediction, modelling and mitigation of materials degradation
 Corrosion mitigation (inhibition, cathodic protection (CP), corrosion under
insulation (CUI) etc.)
 Collection and analysis of the Maintenance technical specifications issued
by the Oil /Gas Company and International Standards Bodies etc. (EN, ISO).
 Transfer of the corrosion strategy to the discipline responsible of CP /
Painting and Coating design.
 Design of the chemical treatment and CRA.
 Corrosion failure analysis upon Maintenance/ Assets request.
 Interfacing with Installation Engineering Functions to solve the anti-
corrosion problems of different Maintenances.

7.5 MECHANICAL ENGINEER

Mechanical engineers research, design, develop, build, and test mechanical and thermal
sensors and devices, including tools, engines, and machines.

Responsibilities for Mechanical Engineer

Plan, conceptualize, and create mechanical designs for new products
Develop testing processes, and perform testing and validation of new designs
Generate working prototypes for beta testing and customer demonstration
Perform engineering calculations to support design work
Create and review technical drawings, plans, and specifications using computer
software
Collaborate with multi-disciplinary engineering teams, and work with vendors and
contractors
Perform detailed documentation to track project development and design process
Ensure project timeline is met and project stays within budget

7.6 CAD OPERATOR

The CAD Designer shall be responsible for all the drafting jobs on the Maintenance
and producing drawing (As Built) in accordance with Maintenance requirement.

He shall collect processed data from the Party chief and produce drawings as
required from red markups.

51
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Interpreting project briefs and meeting with clients, engineers, and

architects to ensure all blueprints and technical drawings are completed to
specifications.
 Producing rough sketches and using CAD software to prepare detailed
drawings, plans, and blueprints.
 Visiting sites to gather information and determine limitations and feasibility
of designs.
 Ensuring drawings are compliant with building regulations and engineering
principles.
 Communicating potential design issues to engineers and architects.
 Conducting research when required.
 Updating software, drawings, and other documents.
 Remaining professional when feedback is delivered, and implementing any
changes to drafts as soon as possible.

7.7 QUALITY CONTROL MANAGER

 The Quality Control Manager and his Department shall ensure that all work
is performed in accordance with the Clients Specifications, Quality Control
Guidelines and applicable Industry Codes.
 He shall develop all Maintenance Quality Control Procedures and Proforma.
The Quality Control Manager shall be responsible for all activities of the
Maintenance i.e. Non Destructive Examination firms etc.
 The Quality Control Manager shall liaise with the designated Client
Representatives with request to all quality matters.
 He shall assign a crew of Quality Control Inspectors during the entire phase
of the Maintenance to conduct Field Audits, thereby ensuring that the
quality of the work produced is in accordance with the Client requirements

7.8 LEVEL 3 ROPE ACCESS SUPERVISOR

Ensures safety protocols are followed and ultimately responsible for the whole
Rope Access team on the job.

Responsibilities include:
 L3 supervisor must demonstrate an ability to lead effectively, plan
efficiently, and execute perfect safety protocol on all work the vessels.
 Ensuring that all technicians fully comply with the requirements of the
RAMS (Master Risk Assessment) on the vessel.
 Keeping up to date with relevant work techniques and legislation

52
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 An ability to demonstrate all the skills and knowledge required of levels 1

and 2
 They must lead daily safety meetings to go over hazards on the vessel.
 In charge of planning detailed rescue plans and ensuring all technicians
understand and follow the Work and Rescue plan.
 Must always consider pre-rigged and or releasable systems (rigging for
rescue) complies in duct cleaning services.
 Supervisor must ensure all work area has been cordoned off and clear of
hazards.
 Carry out work area and rope anchor inspections before anyone
commences on operations.
 Oversee that their whole team is following procedure and safety protocols.
If anything is off track, they immediately stop all work until the situation
has been fixed.
 Responsible for monitoring new Rope Access technicians.
 Must report and investigate any minor or major incidents.
 If an emergency arises, the L3 supervisor is responsible for conducting the
vessel emergency and rescue procedures.
 They must lead daily safety meetings to go over hazards on the vessel.
 In charge of planning detailed rescue plans and ensuring all technicians
understand and follow the Work and Rescue plan.
 Responsible for equipment inspection records and must appropriately deal
with any damaged or failed equipment.
 Ensure everyone in their team have the correct experience, skills, and
capabilities for the task at hand. This means that all paperwork and
logbooks must be inspected beforehand, and the Supervisor has to ensure
that their team is comprise with the correct number of L2’s and L1’s.
 Prepare an efficient Maintenance Master Schedule and maintain knowledge
of all key Maintenance milestones.
 Supervise the teams associated with respective service line (including
Painting and at height works)
 Identify and escalate priority issues.
 Monthly schedules to be prepared in prior of next month.
 Coordinate with clients for permits and the vessel access documents for
team.
 Ensure the reports are generated and submitted to Division controller for
review.
 Meet qualitative and quantitative targets.
 Other duties as assigned from time to time.

53
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

7.9 QA/QC ENGINEER

The QA/QC engineer shall ensure that all works are performed in accordance with
the Clients Specifications, Quality Control Guidelines and applicable Industry
Codes.

He shall develop all Maintenance Quality Control Procedures.

 The Quality Control Engineer shall also be responsible for all activities of
the Maintenance (if any) i.e. Non Destructive Examination firms etc.
 The Quality Control Engineer shall liaise with the designated Client
representatives with request to all quality matters.
 He shall assign a crew of Quality Control Inspectors during the entire phase
of the Maintenance to conduct Field Audits, thereby ensuring that the
quality of the work produced is in accordance with the Client requirements.

7.10 HSE MANAGER

The HSE manager shall be responsible for the implementation of safety
procedures on the vessel and to ensure that Job Safety Analysis within this
method statement is followed. Prepares and implements HSE Plan as per specific
requirements according to scope of work and its demand. He shall assign a
competent Safety Officer to enforce these procedures and to provide guidance to
operations where applicable.

7.11 MAINTENANCE PLANNER

The Maintenance Planner shall be responsible for the following while reporting to
the Maintenance Manager.
 Prepare the Maintenance Plans and schedule for the execution of the
Maintenance with timelines.
 Provide regular Maintenance updates to the Maintenance Manager,
 Maintain contact with maintenance team at the vessel.
 Maintain and monitor schedules and keep Maintenance resources on track
while taking note of order errors and problems in order to develop
solutions and recovery schedules.
 Analyze and evaluate with Maintenance Team issues that put Maintenance
delivery at risk and perhaps comprising Maintenance results and targets,
and develop plans to mitigate them.
 Respond to emergency issues and problems in order to develop solutions
for them.
 Monitor all inventory orders using a documented data on orders to analyze
the Maintenance supplies and demands to allow for inventory

54
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Maintenance. In doing so, the Maintenance Planner will liaise with the
Procurement and Logistics Manager.

7.12 PROCUREMENT AND LOGISTICS MANAGER

The procurement and logistics manager who should have good analytical
interpersonal skills shall be responsible for organizing and evaluating the
provision of transportation of materials, tools and equipment for the execution of
the Maintenance from point of purchase to maintenance and maintenance at the
vessel. Also, to be responsible for the followings.
 Movement of personnel to and from the vessel on schedule
 Ensure serviceability of all trucks and equipment before being engaged for
the execution of work at the vessel.
 Identify and develop strategies for addressing any logistics barriers, while
monitoring the utilization of material and ensuring good record keeping.
 Negotiating and strategizing with materials and equipment suppliers and
vendors in order to acquire timely the most cost-effective deals with the
aim of reducing procurement expenses and stay within budget.
 Ensuring inventory controls and safe storage of materials, equipment and
tools in stores, open spaces within laydown area.
 Implementing operational policies and procedures as well safety of tools
and equipment while participating in premobilization of these equipment
and tools before commen of utilization.
 Ensure control and optimization of processes in place for timely delivery of
Maintenance materials.
 Ensure operational communication facilities are effective, serviceable and
available for utilization by personnel at the vessel.

7.13 ROV OPERATOR

Navigating the ROV's route, avoiding hazards such as moving parts of the ship.
operating robotic arms (if your vehicle has them), to perform simple tasks such as
picking up items from the seabed. judging the changing weather conditions, if
necessary, altering the dive program at short notice.

Duties and Responsibilities:

 Operating ROVs to complete remote installations.
 Operating cameras and sonar display that support navigation and
inspection.
 Maintaining and servicing machinery.
 Replacing modules and repairing assets.

55
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Reporting faults.
 Relaying, recording and interpreting data during and after dives

7.14 MAINTENANCE FOREMAN/PIPE-FITTER/WELDER/PAINTER.

They shall select and use appropriate tools, equipment, and skills designated and
approved for the maintenance works. They shall understand the scope of the
work. They shall carry out visual inspection services and ensure to carry out
maintenance functions as per approved standards. They shall also ensure
compliance to this procedure and the maintenance guidelines.

General - There shall be a Toolbox Meeting daily prior to the maintenance works.
The scope of the work and safety use of the equipment to be used during the
maintenance activity shall be explained to all personnel that are involved by the
Maintenance supervisor.

8.0 LIST OF EQUIPMENT/TOOLS AND PERSONNEL

8.1 LIST OF EQUIPMENT

S/N EQUIPMENT MODEL STATUS

1 Low Profile Torque Wrenches OWNED
2 Square Drive Torque Wrenches OWNED
3 Modular Torque Wrenches OWNED
4 Torque Checkers OWNED
5 Torque Locks OWNED
6 AIR COMPRESSORS ATLAS CORE OWNED
7 Back Up Spanners OWNED
8 Bolt Tensioners OWNED
9 WELDING MACHINE LINCOLN OWNED
10 Nut Splitters and Cutters OWNED
11 Flange Alignment Tools OWNED
12 Flange Spreaders OWNED
13 Cylinders and Jacks OWNED
14 Flange Facing Machines OWNED
15 Clamshell Cutters OWNED
16 Hot Tapping Machines & Line Stop Actuators OWNED
17 Pipeline Isolation Tools OWNED
18 Air Driven Hydraulic Foot Pumps OWNED
19 Air Hydraulic Torque Wrench Pumps OWNED

56
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

20 OWNED

8.1.1 LIST OF PERSONNEL

S/N PERSONNEL DESIGNATION QUANTITY NATIONALITY
1 Managing Director 1 NIGERIAN
1 Maintenance Manager 1 NIGERIAN
2 Project Engineer 1 NIGERIAN
3 Corrosion/Material Engineer 1 NIGERIAN
4 Mechanical Engineer. 1 NIGERIAN
5 CAD Operator 1 NIGERIAN
6 QA/QC Manager 1 NIGERIAN
7 Level 3 Rope Access Supervisor 1 NIGERIAN
8 QA/QC Engineer 1 NIGERIAN
9 HSE Manager 1 NIGERIAN
10 Maintenance Planner 1 NIGERIAN
11 Procurement/Logistics Manager 1 NIGERIAN
12 ROV Operator TBA NIGERIAN
13 Welders TBA NIGERIAN
14 Pipefitters TBA NIGERIAN
15 Grinder TBA NIGERIAN
16 Rope Access Technicians TBA NIGERIAN
16 Painters TBA NIGERIAN
18 Foremen TBA NIGERIAN
19 Safety Officers TBA NIGERIAN
20 The vessel Nurse TBA NIGERIAN
21 Helper TBA NIGERIAN
22 Operator 4 NIGERIA.

57
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

9.0 SITE SPECIFIC ORGANOGRAM

MD

Maintenance Manager

Maintenance
Planner

Cost Control
Engineer
Proc. &
Corrosion Mechanical Project Engineer Logistic HSE Manger
Engineer Engineer Manager QA/QC
L3 Rope Access CAD Operator Drivers/ Manager
Supervisor Safety Officers
Op9erators

L1 &L2 Rope Access Drafts ROV Operator

Man

Technicians

58
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

10.0 HEALTH, SAFETY AND ENVIRONMENT

Handle with care all the material and tools before and during use.

Observe all safety labels on packaging and glue containers

Consult Material Safety Data Sheets [MSDS] and follow all local or national Safety
regulations.
All required Safety Protective Equipment: Helmets, Safety boots, Nose Masks, Eye
goggles, Hand gloves shall be worn during Works.

10.1 SAFETY AND RESCUE

One of the most important parts of working on an FPSO is safety. Every action has
to be done as safe as possible. Therefore, strict regulations are made so that the
chance of accidents is minimized.

11.0 DETAIL ENGINEERING AND DOCUMENT ISSUING

11.1 DOCUMENT MANAGEMENT AND CONTROL
Reference documents, data, and others shall be stored in the individual
computers, back up and hard copies made available for those that do not have
access.

Quality Management documents such as calibration certificates, material

inspection forms, field inspection forms etc. shall be in custody of the
maintenance Supervisor, while the others approved document by client such as
Method Statement, material Submittal etc shall be with the Document Control
Centre (DCC) for easier transmittal to respective parties.

Also, all the records generated on the Maintenance e.g., test results, inspection
reports, signed inspection forms etc. shall be compiled and stored with the
maintenance Supervisor and DCC for eventually handover to the COMPANY at the
completion of the Maintenance.

11.2 CORRECTIVE MAINTENANCE JOB HANDOVER

At the completion of a corrective maintenance job order, the work shall be
handover to the COMPANY representative. All the records generated on the job
e.g., Test results, Inspection reports and Certificates, shall be compiled and
handed over to the company.

59
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Handing over shall be done after due satisfaction and approval by Company
representative that all the works done are completed and acceptable.

11.3 INSPECTION OF TESTING EQUIPMENT

ENERGYRAY INTEGRATED SERVICES Limited shall set out requirement and
responsibilities for the control of inspection and testing equipment and to ensure
that the equipment in place shall be fully serviced.
ENERGYRAY INTEGRATED SERVICES Limited shall ensure quality control
measurements and checks for testing and measuring equipment used in
maintenance work activities.

The steps to be followed in order to ensure that all the testing and measuring
equipment in used is calibrated in accordance with manufacturer's instructions
and applicable standards for the works.

This measure shall address the requirements of:

 Equipment Registration and Identification
 Equipment storage
 Frequency of calibration
 Traceability to International Standards
 Calibration record
 Responsibilities
 Calibration Method.
All the equipment for the Maintenance will be inspected, tagged and have valid
calibration due date.
Faulty devices and equipment noticed shall be taken out of the vessel.

11.4 WORKS MONITORING/INSPECTION

Maintenance works shall be performed in accordance with applicable technical
specifications, procedure, instruction, code, and standards.

The maintenance supervisor shall perform in-process inspection; instruction,

checklist, or standard to verify that the quality level required is properly
accomplished in accordance with the applicable procedure. Prior to each
inspection and test, he shall prepare the Quality Control Form according to the
applicable procedure, instructions, standards and ITP, which shall be endorsed by
the relevant SPDC representatives.

11.5 COMMUNICATION

60
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

ENERGYRAY INTEGRATED SERVICES Limited shall provide effective communication

(VHF radios, GSM phones, Thuraya phones, etc.)
as applicable to the specific vessel condition during working hours on the vessel.
This shall be for communication on board the vessel, ENERGYRAY INTEGRATED
SERVICES Limited’s base and SPDC. This communication gadget would be capable
of reaching ENERGYRAY INTEGRATED SERVICES Limited 's base and the vessel
anywhere during hours of work on the vessel.

The specific communication mode for each Maintenance shall be agreed with
SPDC Maintenance Engineer prior to mobilization to the vessel and maintained
throughout the duration of the Maintenance.

ENERGYRAY INTEGRATED SERVICES Limited shall key into the communication

protocols in use on the vessel and/or equip the OFFICE with communication
gadgets, stationeries, printer/scanners and other office equipment that may be
required.

Progress meeting shall be held to discuss and report on the progress and
challenges (if any) encounter during the course of the Maintenance.

Invitation or reminder for meetings shall be by official email addresses or

telephone conversation.

11.6 PUNCH LIST INSPECTION

A punch list inspection shall be arranged between SPDC and the ENERGYRAY
INTEGRATED SERVICES Limited representative. This will ensure the completeness
of the work and to enable all corrective measures and repairs to be carried out.

12.0 MATERIAL PROCUREMENT

Material procurement shall be handled by the Logistic & procurement manager. A
Request for Quotation (RFQ) for all Approval Material/technical Specifications shall
be send to manufacturer or Vendor specifying the actual requirement per product
for procurement.

Data sheets and specification of all materials required for the Maintenance shall
be submitted to SPDC for review and approval before such materials will be
purchased. All materials supplied shall be verified, inspected and accepted based
on the quality specified in the relevant standards, and specifications by SPDC
before use.

61
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

All certificates and supporting documents shall be presented before the inspection
process.

A sample of material to be purchase locally shall be submitted to client for

approval before full procurement shall commence.

Materials not conforming to specifications and other statutory regulations shall be

rejected at the cost of the Maintenance or and clearly marked REJECTED and
quarantined. Other free issue materials shall be supplied by SPDC.

12.1 MATERIAL IDENTIFICATION AND TRACEABILITY:

All procured material for the maintenance works shall be as per Approval Material
Specification or standards. Materials shall be properly package with label for
identification and traceability.

The Maintenance Supervisor shall schedule inspection of all incoming materials or

equipment to be incorporated in the works according to delivery status issued by
Logistics Department.
All Maintenance materials are to be inspected and approved by SPDC prior to use.

The Maintenance Supervisor shall ensure that all required documentation like test
certificate from the manufacturer is attached and available for sighting during
inspection. .

Material to be used in the Maintenance shall be store properly following the

manufacturer recommendation to avoid damages and malfunction. Delicate
Material shall be protected from direct impact, moisture, dust etc. by preserving it
in its original container until the time it is required for maintenance. Moreover,
during maintenance material should be handled with utmost care to avoid
damage.

The request for inspection of material shall be log in with the COMPANY but not
less than 24hrs before the actual inspection.

12.1.1MATERIAL STORAGE, HANDLING AND PRESERVATION

The Procurement/Logistic Officer shall be responsible for material procurement;
the Central Storekeeper will be responsible for the Storage, Handling and
Preservation of critical and sensitive material & equipment to be used in the
maintenance works.

62
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

He shall set up maintenance procedures and related safety elements. Only

inspected materials shall be stored in the store.

Non-conforming products e.g., in terms of quality, dimension, damage etc. will be

identified and stored separately to be treated in accordance with non-conformity
procedure.

The Maintenance Manager shall define precautions to avoid deformation of stored

products such as paints, metal plates, Pipes, iron rods and Hard ply wood etc.
Materials shall be properly identified with traceability records maintained.

12.2 NON-CONFORMANCE:
Non-conformance Report shall be generated whenever there is a Non-
conformance. Non-Conformance is deviations and non-compliances from the
Maintenance specifications/standards and Maintenance Quality Plan during
maintenance works.

Non-conforming items found during inspection and test activities shall be

identified and documented in accordance with the requirements of this
Maintenance quality plan. All non-conformances shall be closed before the end of
Maintenance activities.

12.2.1CONTROL OF NON-CONFORMANCE
During all phases of the maintenance, ENERGYRAY INTEGRATED SERVICES Limited
shall control the non-conformities of materials in compliance with ISO 9001-2008

The Non-Conformance Form is attached with FORM No ENERGYRAY INTEGRATED

SERVICES Limited-NCR-1 Appendix 1. When Non-Conformity is discovered, a non-
Conformity report is raised by the QAQC Manager/Engineer who proposes a
solution to resolve the non-conformity. This examination is also performed by the
Maintenance Manager. In the non-conformity report, the decision to repair or
accept this non- conformity is taken by SPDC, after proposal made by ENERGYRAY
INTEGRATED SERVICES Limited Maintenance Manager.

The Maintenance QAQC Manager/ Engineer is responsible for the transmission of

the non- conformity report to the responsible person of the works, and the
verification of the re-works. When an NCR is originated by SPDC, SPDC shall be
contacted for the close –out of the NCR after implementation of the corrective
action.

63
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

All finished non-conformity reports are filed by the QAQC Manager/Engineer and
are studied, in general during the periodic meeting of the working committee.

In general, implementations of the corrective and preventive actions are

implemented internally by ENERGYRAY INTEGRATED SERVICES Limited to
eliminate the causes of actual non-conformities or the potential deficiencies in the
following cases.
 Non-conformity with a risk of person or materials’ safety.
 Some repeated non-conformities
 A process of Implementation in non-conformity with its procedure
 A Complaint filed by SPDC

12.3 ENERGYRAY INTEGRATED SERVICES LIMITED’S OFFICE AND STORES

ENERGYRAY INTEGRATED SERVICES Limited shall provide and maintain on the
vessel, throughout the duration of the work, a fully functional office. The office
shall be partitioned to have as a minimum an office for the exclusive use of SPDC
Maintenance supervisor and Company vessel Representative (CVR) and another
office for ENERGYRAY INTEGRATED SERVICES Limited personnel.

These offices shall be adequately lit, furnished with a table and two chairs and
lockable. Utilities and conveniences shall be provided by the client and used in
accordance with the vessel’s rules and regulations.

As part of the mobilization to the vessel, ENERGYRAY INTEGRATED SERVICES

Limited shall provide mobile eye wash stations as approved by SPDC
Representative for use on the vessel. This shall be refilled with fresh/clean water
daily.

Storage of pipe materials shall be on platform location assign for the purpose, a
storage 20ft caravan shall be provided to contain materials that require sheltered
storage and controlled by a storekeeper.

12.4 ACCESS CONTROL

ENERGYRAY INTEGRATED SERVICES Limited shall provide and made available
buses for land transportation to takeoff zones. Drivers shall possess Nigeria driver
licenses and must obtain SPDC defensive drivers permit before being allowed to
drive within SPDC facility during drop offs. Personnel shall wear Identification tags
at all times to gain and maintain access at SPDC facilities/vessel and locations

64
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

13.0 MAINTENANCE WORKS METHODOLOGY

13.1 PRE-MAINTENANCE INVESTIGATION AND SURVEYS
13.1.1PIPELINE SURVEY
Pipeline survey shall be carried out at the vessel platform to provide information
regarding the integrity of the proposed pipeline maintenance and repair works to
ascertain the areas of concern, level of corrosion, deformity, etc.
If inspection of the pipeline is existing, records of findings shall be used for
confirmation and guidance during the survey.

The objective of the pipeline survey will be to:

1. Undertake a detailed pipeline survey to permit the evaluation of the vessel

surface Piping and profile within the scope of the Maintenance.
2. To determine the piping heights, closeness/spacing of the flowlines that
may affect the possibility of maintenance activities, entrances, working
space of the pipes within the scope of the Maintenance.
4. To carry out every other computation and processing including verification
of the existing reports, structural integrity of the pipeline under
consideration and AutoCAD drafting to produce plans of the Maintenance
as surveyed. This will include spacing, takeoff height, means of
accessibility/ means of access to use in maintenance and repairs works
and detail plans of the Maintenance area.

ENERGYRAY INTEGRATED SERVICES Limited shall carry out engineering surveys

and investigation at the VESSEL and confirm any data supplied by SPDC. This
includes pipeline surveys and access investigations. The surveys and
investigations shall be carried out in accordance with the relevant COMPANY
Specifications, Codes and Standards.

ENERGYRAY INTEGRATED SERVICES Limited shall carry out, as instructed by SPDC,

any study (ies) that is necessary for the successful execution of the work and shall
submit, for review two (2) sets each of all the studies and investigation reports.

13.1.2FLOWLINE PROBING
 ENERGYRAY INTEGRATED SERVICES Limited shall furnish SPDC with the
calibration certificate of all equipment used as well as details of the
scanner or probe equipment used for the WORK indicating the make,
model, mode of operation, capabilities, limitations, cost and any other
pertinent information.

65
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES


 ENERGYRAY INTEGRATED SERVICES Limited shall peg out the actual
positions of the identified flowlines and make a tolerance of +/-5m on both
sides of the positions using pegs. A detailed work method shall be
developed by ENERGYRAY INTEGRATED SERVICES Limited and jointly
reviewed with SPDC for operating around identified flowline.

13.2 PROVISION OF MAINTENANCE AND REPAIR SERVICES ON PIPELINE

ANCILLARY EQUIPMENT AND COMPONENTS SUCH AS BARREL DOORS AND
ACCESSORIES, BARREL DOOR SEALS, NON-INTRUSIVE PIG SIGNALERS,
PRESSURE GAUGES, VALVES ETC.

13.2.1BARREL DOORS AND ACCESSORIES

Closures are basically “doors” used for ease in gaining internal access to launchers and
receivers.

Barrel doors

The pig launcher and receiver and equipment with doors which are called end closures.
The end closure is welded to the major barrel and hence its material and end wall
thickness should always be compatible with the barrel materials.

End closures are of quick opening when the barrel is pressurized. The safety mechanism
on the closure may be specified to comply with the requirements of ASME Section VII
Division 1, UG-35.

66
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

The maximum swing position of the hinge should be free from obstruction. All the hinges
should be oriented on the same side of the pig trap area.

13.2.2BARREL DOOR SEALS

Seals are used to prevent the leakage of fluids in rotating equipment. A seal prevents
lubricants, such as oil and grease, from entering the environment and (dirty) water from
entering the installation. Thus, Buna (Nitrile) oil seals are the most widely used elastomer
in sealing. Nitrile oil seals have great resistance to petroleum oils and fuels, mineral oils
and greases, hydraulic fluids, water, steam, and alcohol.

Types Of Door Seals

 Door Brush.
 Felt Weatherstripping.
 Reinforced Foam.
 Rolled Vinyl.
 Tubular Rubber Strip.

Installation:
 Remove the Door. ...
 Place a Pry Bar Under the Weatherstripping. ...
 Remove the Weatherstripping. ...
 Remove Any Caulk or Sealant. ...
 Apply New Caulk. ...
 Take Your Measurements. ...
 Cut the Weatherstripping to Fit. ...
 Push the Weatherstripping Into the Groove.

13.2.3NON-INTRUSIVE PIG SIGNALERS

 Pipeline pigging involves launching a ‘pig’ tool into a pipeline to remove
unwanted waste materials. These pigs do more than just remove the
waste.
 Depending on the type of pig, they can also clean the pipeline, rid it of
debris, or provide information about the pipeline’s diameter, pressure, and
temperature. They are use also to seal the pipeline to allow for
maintenance work.
 Pig signalers are used to indicate the pig has left the launcher, arrived in a
receiver or passed a certain point in the pipeline

67
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

There are two types of Pig Signalers:

13.2.4PIG SIGNALER/DETECTOR
Intrusive pig detectors are permanently mounted to the pipe via a specialized fitting. A
probe that protrudes into the pipe is mechanically activated when the pig passes

Non-intrusive Pig Signaler

A non-intrusive detector, is not permanently mounted and usually senses the pig via
magnetic detection.

The non-intrusive pig signaler detects the movement of the pig through the use of a
magnet or ultrasonic detection through the pipe wall. It is attached temporarily to the
pipe using a band and strap.

Non-intrusive pig signalers can be installed quickly and easily to the pipeline. They can
also be removed without difficulty if maintenance is required, eliminating the need to
suspend production.

13.2.5PRESSURE GAUGES

68
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Pressure gauge is an instrument for measuring the condition of a fluid (liquid or gas) that
is specified by the force that the fluid would exert, when at rest, on a unit area, such as
pounds per square inch or newtons per square centimeter.

The following are the types of pressure gauges:

 Bourdon Tube Pressure Gauge.
 Diaphragm Pressure Gauge.
 Capsule Pressure Gauge.
 Absolute Pressure Gauge.
 Differential Pressure Gauge.
 Bellows Pressure Gauge.
 Manometer Pressure Gauge.
 Piezometer Pressure Gauge.

The International Standard unit for pressure is the pascal (abbreviated as Pa): N/m2, or
newton over square meter. 1 bar = 100,000 Pa. Pressure can also be measured in
atmospheres (atm), inches of mercury (in. Hg), millimeters of mercury (mm Hg), and torr
(about 133.3 Pa).

Tips for Correctly Installing Pressure Gauges

 Select the Right Gauge. Before you pull out a wrench, first make sure you have the
right type of gauge for the application. ...
 Apply Force on Wrench Flats. ...
 Seal the Deal. ...
 Use a Clamp Socket or Union Nut with Straight Thread. ...
 Leave Space for Blow-out. ...
 Vent the Gauge Case

13.2.6 VALVES
A valve is a device or natural object that regulates, directs or controls the flow of a fluid
(gases, liquids, fluidized solids, or slurries) by opening, closing, or partially obstructing
various passageways. Valves are technically fittings, but are usually grouped as a
separate category.

Types of valves:
69
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Isolation Valves: Ball, butterfly, diaphragm, gate, pinch, piston, and plug valves.
Regulation Valves: Ball, butterfly, diaphragm, globe, needle, pinch, and plug valves.
Safety Relief Valves: Pressure release and vacuum relief valves. Non-Return Valves:
Swing check and lift check valves.

Part of a valve - the body, bonnet, trim (internal elements), actuator, and
packing.

Valve

To Install Valves:
 Thoroughly clean all the carbon off of the valve before you install. ...
 Slide the valve up through the valve guide and through the valve seal.
 Place the valve spring around the valve guide. ...
 Compress the spring with your compressing tool till you can clearly see the tip of the
valve stem.

14.0 MINOR AND MEDIUM PIPELINE REPAIRS INCLUDING RECTIFICATION OF LARGE

FREE SPANS, RISER FLEX JOINT REPAIR, VORTEX INDUCED VIBRATION (VIV)
STRAKE REPLA, ANODES RETROFITTING

14.1 PIPELINE REPAIRS AND MAINTENANCE

14.1.1 METHODOLOGY
When a defect or anomaly is discovered in a pipeline that threatens the integrity of that
pipeline, a repair must be made using techniques that restore the pipeline to the original
design specification.

If the repair technique cannot restore the pipeline to the original design specification, the
maximum operating pressure of the pipeline must be reduced, or the pipe system must be
taken out of service.

70
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Repairs may be required as a result of a leak or release of product from a pipeline, or

because a defect or anomaly is discovered that threatens the integrity of the pipeline. The
latter may come to light through an integrity assessment as required by the integrity
management rule.

 Methods that may be used to remediate pipeline defects and anomalous conditions
that can present a potential threat to the integrity of the pipeline. These include.
 Removal and Replacement of Pipe
 Fillet Welded Patch
 Half Repair Sleeves
 Weld Overlay / Weld Deposition Repair


14.1.2 REMOVAL AND REPLACEMENT OF PIPE

Removal and replacement of defective pipe is always considered a good alternative to repair.
Most industry standards suggest making repairs to pipelines by replacing sections of pipe
whenever possible. Often an entire section of pipe is replaced - weld to weld - rather than
cutting out and replacing a smaller section. This requires more work, but it minimizes the
number of round or circumferential welds in the pipeline.

14.1.3 FILLET WELDED PATCH

Fillet Welded Patch can be used to repair Pressure Vessel temporary (Temporary repair) by
the Patch Plate cover the areas that have been damaged and welded to the Vessel by Fillet
Weld. This method applies to damage caused by Corrosion or Erosion which will cause the
Vessel's walls to become thinner (Local Wall Thinning).

14.1.4 HALF REPAIR SLEEVES

Sleeves are probably the most important and widely used method of general repair of pipeline
defects. Sleeves may be steel, type A (reinforcement) or type B (pressure retaining
reinforcement), or composite material.

Type A sleeve –is used to reinforce the area where a defect exists. The defect cannot be a
through wall defect. The type A sleeve is a full encirclement of the pipe. The sleeve halves
are normally welded together while the sleeve ends are not.

Type B sleeve –can be used to contain a leak or to reinforce an area where a defect exists.
The type B sleeve is like the type A except the sleeve is completely welded to the pipe.

Composite material – a fiber material is wound around the pipe in the area of a defect. This
material can be used in lieu of a type A sleeve and has proven quite effective in remediating
defects.
71
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

14.1.5 WELD OVERLAY / WELD DEPOSITION REPAIR

Weld overlay is a pipeline repair where a suitable metal is deposited through welding to the
pipe surface, valve body/trim, or a pipe fitting in the form of a layer. This may be used to
improve pipe strength or surface protection while keeping the base structure’s strength, e.g.,
as a guard against corrosion.

Weld overlay provides layering of an alloy metal different in material from that of base
pipelines and associated piping/fittings. Weld overlay is carried out by shielded metal arc
welding, Metal Inert Gas (MIG) welding/Tungsten Inert Gas (TIG) welding, Submerged arc
welding, CO2 welding or Plasma Transferred Arc (PTA) welding.

Weld deposition is best suited for difficult or complicated pipe configurations or contouring
pipelines. Weld deposition, in some instances, provide better corrosion and wear resistance
than sleeves with regards to galvanic corrosion. Weld deposition is also a proper repair
technique to inhibit crevice corrosion and fretting corrosion. While attempting weld overlay,
metallurgical considerations are essential due to excessive heat generation.

To avoid metallurgical defects during weld overlay selection of compatible electrode and
suitable welding procedure is critical. Often temper bead weld technique is used to minimize
hardening of heat affected zone through alternate layers of deposited metal through low and
high heat input. Alternating high and low heat input welding helps in controlling excessive
hardening of the heat-affected zone (similar to the annealing process).

14.1.6 COMPOSITE SLEEVES / COMPOSITE WRAPS

Composite sleeves or full composite wraps are the latest innovation in pipeline defect repair
where leakage or spillage has not started.

They are well suited for repairing contoured pipelines and sections of pipelines where fittings
are installed, such as small take-off points or metering points.

They can restore damaged pipelines to their original Maximum Allowable Operating
Pressure (MAOP), with the added benefit of coating the pipes to protect them from
corrosion. Today, commercially available prefabricated sleeves (designed and cured in a
factory for rapid installation on site and also wet sleeves that are wrapped and cured on
site as needed

14.2 METHOD TO PROVIDE A BRANCH OFF PIPELINE FROM EXISTING

MAIN PIPE IN-ORDER TO CARRY OUT MAINTENANCE.
72
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Using the below methodologies, ENERGYRAY INTEGRATED SERVICES Limited shall ensure
that the process flow is maintain and the integrity of the pipeline is restored during
maintenance.. We shall effectively apply required engineering standards to deliver on
quality and safety.

The methods include:

 Hot Tapping Services
 Plugging Services

73
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

14.2.1 HOT TAPPING SERVICES

ENERGYRAY INTEGRATED SERVICES Limited provides top-quality hot tapping services for
pipelines and pressurized systems without shutting down the system or interrupting material
flow. We take pride in providing safe, quick, and efficient service for pipeline repair,
maintenance, or replacement with our state-of-the-art line of hot tapping machines. With an
arsenal of industry-grade equipment and a variety of hot tapping service methods (shown
below), our in-house hot tapping specialists are well-versed in providing professional hot
tapping services for a large scope of pipelines and pressurized systems regardless of size,
scale, or complexity.

14.2.2 CONNECTING NEW BRANCH PIPE WITH VALVE INSTALLMENT

All-covered short O-let type

74
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Reinforce pad and short O-let type

75
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

76
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Low pressure short O-let type

77
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

78
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

79
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

14.2.3 CONNECTING NEW BRANCH PIPE WITH BLIND FLANGE

TAPPING FITTING

All-covered tapping fitting (blind flange) type

80
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Reinforce pad and tapping fitting (blind flange) type

81
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

82
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Low pressure tapping fitting (blind flange) type

83
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

84
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

85
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

14.2.4 CONNECTING NEW BRANCH PIPE ON NEW TEE INSTALLMENT +

SUSPENDED PLUGGING

With Bypass Line

86
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Without Bypass Line

87
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

88
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

With Bypass Line

89
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

14.2.5 PLUGGING SERVICES

Plugging services are essential when specific sections of a pipeline need repair or
replacement without system shutdown. Utilized with our hot tapping machines, we provide
effective sealing solutions for pipeline repair, maintenance, or replacement. Our service
methods (shown below) address a variety of plugging techniques unique to specific needs.

Plugging method can be used to work on a large scope of pipeline sizes, types, pressures,
and materials.

14.2.6 OUR PLUGGING PERSONNEL ARE RAISING THE STANDARD

Realize the benefits plugging method in pipeline repair ENERGYRAY INTEGRATED
SERVICES Limited is constantly pushing her manpower towards innovation, discovery, and
adaptability so as to be the leading force of plugging services and products for pipelines and
pressurize systems. Our plugging technology provides cutting-edge solutions for pipeline
sealing and our range of service methods ensure we can rise to the need of any customer or
Maintenance.

14.2.7 SUSPENDED PLUGGING METHODS

Single Line Stop

90
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Type A of Two-Line Stops

Type B of Two-Line Stops

91
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Type C of Two-Line Stops

Four Line Stops (it applies to long distance pipeline replacement)

92
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

CYLINDER PLUGGING METHODS

Single Line Stop

93
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Type A of Two Line Stops - (the max of transmission medium flow rate in the pipeline is
5m/s)

94
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Type B of Two-Line Stops

95
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Type B of Two-Line Stops

96
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

97
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Type D of Two Line Stops (the transmission medium flow rate in the pipeline
should be more than 5m/s)

Type E of Two-Line Stops (the max transmission medium flow rate in the pipeline is 5m/s)

Type F of Four Line Stops

(More suitable for long distance pipeline replacement at max transmission medium flow
rate of 5m/s)

98
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

99
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Type G of Four Line Stops

(More suitable for long distance pipeline replacement at max transmission medium flow rate of 5m/s)

14.2.8 PE PLUGGING METHODS

PE Double Plugging
Our standard hot tapping and plugging procedures are also suitable for the maintenance and
servicing of low-pressure PE pipelines with PE hot tapping and plugging equipment.

14.3 PAINTING
Painting involves not only total surface cover but also markings of various types such as line numbers,
fluid codes, flow arrows, equipment numbers etc. Painting specification for the project is given by the
Client in FEED or MEP (Maintenance Engineering Plan). It is to be updated by material engineer on
the project.

14.3.1 PURPOSE
Protective coatings prevent corrosion by acting as a barrier, preventing the pipe's metal from directly
contacting its surrounding environment. Coatings also serve other purposes such as protecting
against wear, weather proofing or resistance, and thermal or electrical insulation

100
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

14.3.2 PAINTING METAL PIPES

Unless provided or required specification, usually, Check the color and weight of the pipe to find out
what it is made of. Metal pipes are usually either copper or galvanized steel, although they can be
made with other types of metal. Each metal has some specific traits you can spot by close inspection.
Note the pipe’s color, then touch it, picking it up if it isn’t already installed. Look for discolorations or
other identifying markers. Use this information to choose a compatible paint or primer.

Select an enamel or oil-based metal paint and primer. Metal pipes require a specific type of paint that
seals it against rust.

To get the paint to stick to the metal, a compatible primer is applied first. Make sure both products are
compatible with the type of pipe being painting. Generally, metal paint and primer comes in both
spray-on and paint-on varieties that work on almost any type of metal surface.
 Oil-based paints and primers are more resistant to stains and damage. Enamel and
acrylic products are both oil-based, so they still work well with metal.
 Enamel self-etching primers work very well on aluminum or any bare surfaces. It’s
good for smoothing out rough surfaces for a very consistent finish.

14.3.3 APPLY A METAL PRIMER FROM TOP TO BOTTOM ON THE PIPE.

The easiest way to apply primer is with a microfiber foam roller with 3⁄8 in (0.95 cm) nap, or a 2 in
(5.1 cm) stiff-bristled paint brush. Pour the paint into a roller tray and add it gradually so it does not
drip. Then, cover the entire pipe in a consistent layer of paint from top to bottom.

If the pipes are yet to be installed. Stand them up on a post or another object that allows it to be
reached on both sides. Otherwise, paint the sides one at a time.
 For pre-installed pipes, spread a liquid primer and paint with a brush to cover tight
areas. Work slowly to avoid getting the paint on nearby surfaces.
 When painting using a spray-on primer, hold the canister about 6 in (15 cm) away
from the pipe. Sweep it from side to side while gradually moving down, taking care
not to overlap the primer.
 If painting is done on one side of the pipe right away, paint it and let it dry. Once it is
dry,
 Wait about 24 hours for the primer to dry. Oil-based products dry at a relatively slow
rate.
 Always keep the pipe safe from moisture or anything else that could damage the
finish.
 Make sure the primer is dry to the touch before attempting to paint over it. To ensure
proper curing that should allow the paint to stick very well to the metal.
 Coat the top edge of the pipe first and gradually work toward the bottom.
 Use a clean roller or brush to finish the pipe with liquid paint.
101
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Use a metal spray to paint the pipe from top to bottom.

 Apply the paint consistently to avoid drips
 Avoid overlapping any spots that has already been painted.

Allow the paint to dry for at least 6 hours. The drying time can vary a lot depending on the
product of the paint

Some paints can take as long as 24 hours to surface dry, Thus, the it is appropriate to check
the manufacturer’s instructions for specifics.

Always wait for the paint to become dry to the touch before recoating the pipe.
 The paint must dry, but it does not have to fully cure.
 Metal paints tend to take a while to cure, it is better to leave that until painting is
finished.
 Repaint the pipe as needed, letting each layer dry in between. Expect the pipe to
need at least one additional coat of paint for a quality finish.
 Take care not to accidentally overlap any finished areas. For each layer, go over the
pipe once.

14.3.4 PRECAUTION
 The weather conditions affect how well paint holds up and dries on pipes. For the
best result, paint during a day with low humidity and a temperature between 50 to
85 °F (10 to 29 °C).
 Pipes are easiest to paint before they are installed.
 Cut to correct size unused pipes before painting and use.
 Pipes should always be cold or at least lukewarm while painting.

14.3.5 SAFETY
 The fumes given off by paint and cleaning products can be dangerous, always
ventilate the workspace.
 Sanding pipes releases a fine dust that is hazardous to breathe in. Wear a dust mask
and also put on safety glasses for additional protection.

14.3.6 CLEANING AND SANDING THE PIPES

 Dust mask or respirator
 Safety glasses
 Plastic sheets
 220-grit sandpaper
 Clean cloth
 Water
 Acetone (optional)
102
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Painter’s tape (optional)

Applying Paint to PVC Pipes

 Plastic primer
 Plastic paint

Painting Metal Pipes

 Metal primer
 Metal paint
 Paint brush or roller (optional)
 Wire brush (optional)

14.4 PIPELINE/RISER/JUMPER COATING REPAIRS

14.4.1 Riser
Riser is the vertical or near-vertical segment of pipe connecting the facilities above water to the SPDC
pipeline. The riser portion extends (as a minimum) from the first above-water valve or isolation flange
to a point five pipe diameters beyond the bottom elbow, based on codes.

14.4.2 Riser installation method,

 providing a first vessel situated over a hydrocarbon well.
 supporting a hydrocarbon transfer duct from the first vessel by a first end that is
attached to a lowering device on the first vessel.
 attaching a second end of the hydrocarbon duct to a second vessel, at a position near
the first vessel.
 lowering the transfer duct via the lowering device.
 increasing the distance of the second vessel from the first vessel by sailing the
second vessel in the direction of a third vessel, which is moored in a mooring position
at a distance from the first vessel, while pulling the transfer duct until the second
vessel is near the third vessel.
 contacting a section of the transfer duct with the seabed at a position between the
first and second ends of the transfer duct;
 displacing a second end of the transfer duct over a distance from the first vessel,
seen in the length direction of the transfer duct, which is larger than the distance
between the first vessel and the mooring position of the third vessel;
 returning the second end of the transfer duct to mooring position of the third vessel;
and

103
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 bringing the second end of the hydrocarbon transfer duct in fluid communication with
the third vessel.

14.4.3 PIPELINE JUMPER COATING REPAIRS

Short segment of flexible pipe with a connector half at either end. A jumper is commonly used
to connect flowlines and/or subsea facilities together, e.g. a subsea flowline to a hard pipe
riser installed on a production platform.

Jumpers provide a means of connecting two terminals with one solid piece thus saving
assembly time and normally used on terminal blocks

Work Plans
 Pre-Installation Activities by ENERGYRAY INTEGRATED SERVICES Limited
 Jumper Lifting, Deployment and Landing
 Recovery of Jumper Rigging and Preparation for Subsequent Jumper Installation

Step #1 Pre-Installation Activities by ENERGYRAY INTEGRATED SERVICES Limited

Initial Status
 Radio communication between vessels was established.
 Vessels were in Safe Handling Zone.
 Scope of each vessel was clearly identified and is known onboard each vessel.
 Confirmed with SPDC that ROVs on MSV are ready to dive.
 Pressure caps was removed (by SPDC).
 Corrosion inhibitor and dye sticks was injected into hubs (by SPDC).
 Connection hubs was checked free of obstacles (by SPDC).
 Hubs was cleaned and were covered with a debris cap/inhibitor injection cap.
 MSV and Material Barge were in vicinity (by SPDC).
 SIMOPS Procedure with MSV in place.
 HIRA Stage 3 was completed.
 PTW/ toolbox talks/ JSA with relevant personnel were in place.
 Weather forecast was assessed.
 A&R wire 109mm OD re-routed through A-Frame sheave with the open spelter socket
reinstated.
 A-Frame set to the required angle.

Preparation of Rigging
 Assemble transfer rigging on deck.
 LCE located in Safe Handling Zone (SHZ)SHZ has been specified in SPDC drawings.
 When the load transfer is complete, adjust Crane master height to allow personnel on
hang-off platform to disconnect main crane stinger from the Crane master.
104
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

SAFETY NOTE:
 Ensure crane wire is slack before disconnection.
 Remove control lines from Crane master, if any attached.
 Retract the hang-off platform.
 Payout A&R winch to deploy Crane master into water depth of approximately 50m
(elevation of hook below Crane master), sufficiently away from incoming material
barge hull.
 Connect Main Crane and A&R Wire to Jumper Rigging
 Bring material barge alongside with the jumper to be lifted closer to main crane.
Keep approximately 5m safe distance between barge stern and stern extruded
thrusters

 NOTE: All barge mooring operations, lifting, over boarding (even rigging over
boarding), lowering to 50m above seabed should be carried out in safe handling zone
Transfer relevant personnel to the material barge (equipped with pre-installation
checklist), using the rigid Billy Pugh, for rigging connection and inspection of the
jumpers.
 Perform final inspection of jumper, rigging and CVC’s prior to lift-off, install secondary
locking bolt (by SPDC). Complete pre-deployment checklist,

IMPORTANT NOTE: DO NOT OPEN VALVE ON MEG PLUG.

 Dismantle scaffolding on both ends of the jumper.
Use the main crane to bring the transfer rigging to the material barge to connect to
the pre-rigged spreader bar rigging on the work platform.

NOTE:
A proposed method of connection is to utilize an additional shackle below transfer rigging to be
connected to the master link. Depending on the availability of the rigging, transfer rigging can
also be pre-rigged on the spreader bar at the top of the work platform on material barge, and
LCE main crane can hook up the transfer rigging.

Step #2 Jumper Lifting Deployment and Landing

Initial Status
 Toolbox talks/ JSA with relevant personnel are in place.
 Radio communication with MSV established.
 Weather forecast has been assessed.
 Crane master and rigging attached to the A&R wire.
 Jumper is connected to LCE main crane and control lines.
 CVC Running Tools are connected at each end of jumper.
105
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Jumper has been checked by SPDC during step #1 in case there is any issue to give
time to SPDC to carry out required remedial action.
 Confirm with SPDC that they surveyed landed area and there is no debris or existing
structure on landing area before start operation.
 Pre-deployment checklist has been completed

Task Description
 With all riggings connected, after SPDC’s final check and approval, remove
jumperseafastening on material barge.
NOTE: All barge mooring operations, lifting, over boarding (even rigging over
boarding), lowering to 50m above seabed will be carried out in safe handling zone.
 Deploy ROV (s) from MSV.
 Use the pipe transfer (starboard) crane to transfer personnel back to LCE, then haul
in main crane and lift the jumper clear from the jumper transportation stands on
material barge.
 Monitor the weight on main crane.
 Cast off material barge.
 Lower the jumper, when the lower connector touches the water surface, zero the
crane payout meter. (Any other reference as substitute is acceptable.)
 Continue to lower the spool using the main crane until the main hook touches the
water. At this point, the jumper lower connector will be at approximately 40m water
depth (depending on each jumper configuration)
 Disconnect the spreader bar control lines.
 Continue lowering main crane until the jumper lower connector reaches
approximately 90m water depth (depending on each jumper configuration). At this
point, the main hook will be at 50 meters water depth.
 Connect winch ROV Hook to transfer rigging.
 Lower the main crane gradually until the winch takes up the load.

NOTE:
Monitor behavior of Crane master during load transfer.
 ROV to disconnect main crane from transfer rigging at the 400 Te ROV hook.
 Recover main crane hook to deck.

NOTE:
The ROV hook will be re-used later for recovery of the spreader bar.
 After disconnection, ROV will, in sequence, open valve on MEG Plug, remove dummy
hot stabs and open valves on back seal test panels (by SPDC).

NOTE:

106
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

MEG valves opening, dummy hot stab removal and jumper back seal panel valve
opening shall be done before 90m WD, if possible.
 When main crane is clear, winch continues to lower the spool with ROV following the
descent until spool is approximately 50m above seabed.
 Monitor the weight on winch and Crane master behavior.
 Step LCE towards the edge of Safe Handling Zone

Step #3 Recovery of Jumper Rigging and Preparation of Subsequent Jumper

Installation
 After both connectors on the jumper have been soft-landed, ROV to disconnect
spreader bar lower rigging from the jumper (by SPDC).
 Haul in on A&R winch to lift the spreader bar away from the jumper up to 50m above
seabed.
 Step LCE away from spool location along access route to the safe handling zone. As
route shall avoid or limit when not possible, crossing with existing structure, LCE to
adjust route if necessary, based on last reviewed layout.
 Once LCE reached the SHZ, come up on A&R winch to lift the spreader bar to 50
meters water depth (main crane elevation).
 Meanwhile, deploy the main crane with 400 Te ROV hook to a water depth of
approximately 50m and standby for load transfer.
 ROV to assist the load transfer of spreader bar rigging from A&R winch to main
crane. ROV to connect 400 Te ROV hook to the recovery grommet on the transfer
rigging.
 Lower A&R winch wire to transfer load to LCE main crane. When wire is slack,
disconnect ROV hook from transfer rigging.
 Assemble load control lines with ROV hooks for recovery of spreader bar.
 Deploy spreader bar load control lines – ROV to connect them onto spreader bar
control points on each end.
 Recover Crane master above the water surface. Lift the Crane master below the A-
frame using the A&R wire to keep it clear of the yokohoma fender and cargo barge to
be moored alongside later. If necessary, bring the Crane master to LCE deck with the
help of knuckle boom crane.
 Moor material barge alongside LCE.
 Land spreader bar on either LCE deck or material barge deck back to its spreader bar
transportation then disconnect spreader bar upper rigging from the main crane
transfer rigging. This is so that the transfer rigging can be re-used for lifting the next
jumper.
 Unmoor material barge.
 LCE re-locates for subsequent jumper installation
 Repeat the jumper installation procedure from Step #1.2.
107
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

15.0 CONTINGENCY PLAN

15.1 FAILURE OF LCE DP/DGPS SYSTEMS
 The installation vessel being DP class 2, if there is a failure of the DP / DGPS during
operations, the secondary positioning system ensuring full workability shall take over.
In the unlikely event of a failure of both positioning systems causing a DP run-off, the
operations shall be stopped and the vessel shall move to the safe handling zone until
DP control is recovered.
 If the jumper is close to the seabed, it shall be lifted up to 50 m approx. above
seabed.
 If the jumper is already landed but the A&R wire not yet disconnected, the vessel
shall be held in position in manual joystick mode, the A-frame wire shall be paid out in
order to remain slack and the jumper rigging shall be disconnected subsea by ROV.
Then, the spreader bar shall be lifted up to 50 m approx. above seabed and the
vessel shall move to the safe handling zone until DP control is recovered.

15.2 A&R WINCH FAILURE

 A&R winch is function tested and load tested prior to mobilization. There are
adequate spares and competent winch technicians onboard. In the unlikely event of
A&R winch failure, vessel moves to safe handling zone until winch is repaired.
Special attention shall be paid to avoid clash with existing subsea structures if the
jumper is close to the seabed. If possible, it shall be lifted to 50m above seabed.

15.3 CATHODIC PROTECTION REPAIRS

Cathodic protection uses a low electrical current to prevent corrosion of metal structures such as
pipelines, tanks, steel-pier piles and offshore oil platforms. For protection of steel pipelines.

Types of cathodic protection.

 Galvanic anode and

 Impressed current cathodic protection.

Both provide a cathodic protection current flow from cathodic protection anodes placed within the
same electrolyte as the metal to be protected

15.3.1 PROBLEMS ASSOCIATED WITH CATHODIC PROTECTION

When the transformer output voltage and current are normal, but the cathodic protection criteria is not
achieved on the protected structure, the source of trouble may be abnormal coating deterioration, DC
stray currents, shielding, shorts in railroads and crossings casings, or a short in electrical isolation.

108
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

15.3.2 CAUSES OF CATHODIC CORROSION

For cathodic corrosion to occur, three conditions must be fulfilled: there must be two dissimilar metals,
an electrolyte of salt dissolved in water and a metal must maintain the electric connection. The type of
alloy used does not matter, although the most common metals used are steel and aluminum

15.3.3 REPAIR OF CATHODIC PROTECTION

The simplest method to repair cathodic protection is by connecting the metal to be protected with
another more easily corroded metal to act as the anode. Zinc, aluminum and magnesium which are
the metals commonly used as anodes.

15.3.4 THREE MODES OF CORROSION PROTECTION

 Barrier coatings - Barrier coatings aim to prohibit water, oxygen and other chemicals
from making contact with the substrate.
 Inhibitive coatings.
 Sacrificial coatings.

16.0 SUB-CONTRACTING PLAN

No consideration is being given to sub-contracting any part of the scope of this Project.
ENERGYRAY INTEGRATED SERVICES Limited is in full capacity to thoroughly and
holistically execute the contract to a completion state.

However, should the need arise for specialist services which cannot be immediately
carried out, the following principles shall apply:

 Recommended sub-contractor shall have proven capacity to execute the said

works and must be approved by SPDC.
 Preference would be given to indigenous entities capable of executing the
required activities
 Strict compliance to SPDC guidelines and procedures must be ensured.
 All activities must be carried out in a safe manner while ensuring optimum
quality of service delivery.

17.0 PROCESS COMMISSIONING/MAINTENANCE

Commissioning is a process – a systematic process of ensuring that a Pipeline
maintenance and Repairs works are performed in accordance with the design intent,
contract documents, and the owner's operational needs. Commissioning is fundamental
to the success of the whole-Piping network and design process.

It is the responsibility of ENERGYRAY INTEGRATED SERVICES Limited to develop the

109
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Commissioning Checklist which should be approved by SPDC. This should contain all the
items to be commission accepted to be complete.

17.1 THE COMMISSIONING PROCESS: A STEP-BY-STEP GUIDE

 Step 1 – Planning. There are several activities that take place off-site prior to the
commissioning team mobilizing to site during the design and construction phases of a
project. ...
 Step 2 – Factory Acceptance Testing. ...
 Step 3 – Mechanical Completion.

17.2 ROLE OF COMMISSIONING

 Assessing needs,
 Planning and prioritizing,
 Purchasing and monitoring health services, to get the best health outcomes of the
facilities

17.2.1 TYPICAL TASKS OF COMMISSIONING:

 Making improvements to, and offering advice about, operational procedures.
 Scheduling and coordinating work to tight deadlines.
 Ensuring that equipment works to its specification.
 Creating and carrying out test procedures.
 Investigating problems and diagnosing and repairing faults.
 Troubleshooting.

18.0 MECHANICAL COMPLETION

This is the maintenance period prior to handing over the facilities to the client and certified to
be in good health as required.

19.0 DECOMMISSIONING, ISOLATION AND RE-COMMISSIONING OF PIPELINE AFTER A

LEAK REPAIR

19.1 DECOMMISSIONING
Decommissioning involves the timely, safe and environmentally responsible removal of, or otherwise
satisfactorily dealing with, infrastructure from the offshore area that was previously used to support oil
and gas operations

This activity precedes reworks.

110
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

19.1.1 ISOLATION
Isolation is an important piece of corrosion prevention for pipelines and needs to be planned properly
to keep dissimilar metals from creating a galvanic cell and to keep cathodic protection within the
confines of the area designed to be protected.

Process piping and pipeline isolation is a key requirement for safe and efficient maintenance,
modification and repair of oil, gas and petrochemical facilities. Pipeline isolation plugs enable safe
modification of pressurized pipelines and in some cases while production is maintained.

19.1.2 RE-COMMISSIONING OF PIPELINE AFTER A LEAK REPAIR

Pipeline re-commissioning means introducing crude/ product/Gas in the pipeline from originating
station, filling the entire length, and then start delivering to the receipt system.

19.2 CHECKLIST FOR PIPELINE RE-COMMISSIONING PROCEDURES

 Pig the Line. The first phase to undertake in re-commissioning procedures is cleaning
out the pipeline.
 Gauge the Internal Diameter with a Caliper Tool.
 Perform Pipeline Integrity Tests.
 Fill and Stabilize the Line.
 Dewater and Dry the Line.

19.3 NITROGEN PURGING ACTIVITIES/AUXILIARY PUMPING ACTIVITIES

19.3.1 Different Types of Nitrogen Purging Processes

 Pressurization Purging: Pressure-Hold-Vacuum Method. Pressure Transfer of Liquids.
 Dilution Purging and Drying.
 Displacement Purging (Includes Pigging)

19.3.2 PROCEDURE OF NITROGEN PURGING

A cleaning component known as a “pig” is driven through the lumen of the equipment being cleaned
using pressurized nitrogen gas. During the pigging procedure, the pig and gas pass through each pipe
channel, purging the interior and removing gaseous and particulate impurities.

After maintenance completion the Recommended Purging Procedure for oxygen and moisture
removal is: 1. Pressurize each vessel with nitrogen in a downflow direction with dry, oxygen-free
nitrogen to 45 psi g (3.0 bar g).

Purging ensures that they is control over which gases are in the gas delivery system, and
therefore which gases are being exposed to internal components, sensors, or other
equipment. It also helps to prevent unwanted reactions from taking place, which can greatly
increase the service life of related component.
111
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

20.0 PROPOSED CHANGE MANAGEMENT AND COST CONTROL MANAGEMENT PLAN

The proposed change Management Plan for the Maintenance and Repair contract shall be
carried out based upon the following:
 Effective Schedule Control, monitoring and updating to ensure that the installation
works are completed within the scheduled completion date.
 Developing an efficient and effective Material log system’.
 Employing and retraining of skilled personnel.
 Measurement of Work progress, Forecast of schedules and Planning of corrective
actions

21.0 COST CONTROL

The proposed cost Control Plan is to ensure that Costing of works shall be as per specific
prices of items in the approved Maintenance document. Also important shall be the use of
skilled labour which enhances the chances of getting it done right the first time, adequate
supervision and budget tracking.

Thus, with effective Schedule and Cost Control plan, the Maintenance shall be delivered on
time and within the specified budget

22.0 TESTING/PRE – COMMISSIONING

ENERGYRAY INTEGRATED SERVICES Limited shall conduct cube test, continuity and earth
resistance test for earthing and lightning protection system. This test shall be carried out with
multimeter checking for continuity and digital earth tester for earth resistance test which
according to standard shall not exceed 1.0 ohm. and shall be witnessed by SPDC
representative.

SPDC representative shall conduct visual inspection for the maintenance works in
accordance to approved inspection and test plan

23.0 MAINTENANCE TECHNICAL QUERIES (CTQ)

These are technical queries or deficiencies, initiated during maintenance/ maintenance by the
ENERGYRAY INTEGRATED SERVICES Limited. CTQ shall be raised when deviations are
observed which require resolution. CTQ's may or may not have cost impaction to the
Maintenance.

All Completed maintenance reports, mark-up documents, test results, NCR CTQ etc. shall be
documented.

LOGISTIC PLAN

112
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

ENERGYRAY INTEGRATED SERVICES LIMITED NIGERIA LIMITED shall support and control
Logistics from Head Office and Central Workshop located at Port Harcourt toEkulama1, 2
and other locations.

The logistic reports shall be documented to the Contract Manager and Human Resource
Department for scrutiny and for information.

All initial kick-off demand and preliminary challenges shall be managed from the Head
Office, Port Harcourt before temporary facilities are fully set up in SPDC, EKULAMA1, 2
and other locations

Logistics Plan for the execution of the contract shall include as follows:

 Provision of Mobility [Covered Vehicle] for movement of the workforce as

required to and fro temporal facility base, Contract Site Location and SPDC
Focal Point/Authorized representative for specific Contract offices.
 Provision of mobility [Covered vehicle and Trucks] to carry materials and
equipment to and fro work location as required.
 Provision of mobility [Covered vehicle] to carry waste from work location and
temporary facilities.
 Provision of adequate and safe document dispatch system to SPDC, Sub-
Contractors and other related parties using Light Vehicles [e.g. cars and pick-
up/Bus].
 Provision of adequate communication facilities for workforce on site and in
particular those in charge of logistic services.
 Provision of documentation materials/forms for workforce on site and
movements.
The Logistics Plans for the contract shall be managed by a Logistics and Procurement
Officer to be located in Port-Harcourt, as support Service Personnel under the supervision
of the Project Manager.

24.0 MOBILIZATION PLAN

Adequate arrangement shall be made to ensure that all materials, equipment,
tools needed for the job shall be inspected, certified okay and tagged by SPDC
inspector before transportation to the vessel. These equipment and tools shall be
maintained and kept in good working condition throughout the duration of
Maintenance. Other temporary facilities like the OFFICE, packing bay, utilities and
conveniences, etc. shall be sorted at the vessel. All personnel required for the job
shall be recruited and made to undergo SPDC mandatory safety induction course
and obtain access badges for identification before being mobilize to the vessel.

113
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

The pre-mobilization inspection applies to ENERGYRAY INTEGRATED SERVICES

Limited and includes, but is not limited to the following: -
 General observation, (housekeeping, P.P.E., staff etc.).
 Equipment/materials (mechanical, electrical and Corrosion control).
 Special equipment/facilities, lifting, scaffolding, testing and QC laboratory
equipment etc.).
 Land and Marine Transportation.
 Firefighting facilities.
 First Aid facilities.
 The OFFICE/accommodation facilities.
 Review/approval of ENERGYRAY INTEGRATED SERVICES Limited's HSE
management system, procedures and policies, contingency/evacuation
plan, insurance policies.
 Test certificates, licenses for equipment.
 Medical certificate of fitness for ENERGYRAY INTEGRATED SERVICES
Limited's Personnel.
 Swimming Certification & Helicopter Underwater Escape Training (HUET).
 Review/approval of work procedures and QA/QC plan.
 Review/Approval of Work Program.

114
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

25.0 DEMOBILIZATION
25.1 PUNCH LIST INSPECTION AND REPAIR
The punch list shall be arranged between the client (SPDC) and ENERGYRAY INTEGRATED
SERVICES Limited representative. This is to enable corrective measures and repairs to be
carried out. Handing over shall be done after due satisfaction of the client (SPDC)
representative that all the works done are completed.

25.1.1 HOUSEKEEPING
ENERGYRAY INTEGRATED SERVICES Limited shall clean up and removed all surplus and
injurious materials from the vessel. The waste materials shall be disposed to the area
instructed by client (SPDC).

25.1.2 CLOSED OUT AND HAND OVER

This shall be carried out after all the works had been completed. It involves the handover of
documentation of all activities that are involved in the execution of the job and various tests that had
been carried out and As-Built drawings.

At commissioning after mechanical completion and handover of the vessel to client (SPDC), all
equipment, materials, tools and personnel used for the maintenance and repair activities shall be
carefully demobilized from the vessel.
26.0 APPENDICES
 Control of Non-conformance form (NCR)
 Maintenance Technical Query (CTQ)

115
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

26.1 CONTROL OF NON-CONFORMANCE FORM

CONTROL OF NON-CONFORMANCE
CORRECTIVE / PREVENTIVE ACTION FORM.24. A
Maintenance No: DD/MMM / YYYY

Department/The vessel: Country: Nigeria

Maintenance work: No Yes Package: N/A
Origin: Audit Surveillance Review of NC External complaint Occurrence
Date of the incident: Process / Activity: Report prepared by:
Detected or potential deviation
Nonconforming product Organization Health and safety Environment
Near miss Incident Hazardous situation Abnormal situation

Classification: Minor Major

Facts:
Sketch / Photographs:
Consequences:

The vessel or task stoppage? The vessel Task Other decision: Report to be transmitted
to Insurer: Yes No
Cause:
Organization Means
Category: Improvement Processes Resources Competence Others
Methods Equipment
Explicit detail:
(Possible application of causal factor tree analysis)
Measures taken (restore to conformity)
WORKS Acceptance As Is Re-grading Re-work
:

1. Toolbox talk
2. Close supervision to ensure adherence to the approved JHA
Action plan (corrective action / preventive action)
Follow-up
New risks: Yes, No Assessment: Comments:
Responsible for the Verify. and confirmation of Confirmation of effectiveness
implementation completion
(closure)
Date Date Date
SPDC ACCEPTANCE OF CORRECTIVE/PREVENTIVE ACTION
Name: Verification of Corrective/Preventive Action
Comments: Satisfactory

Signature & Date: Unacceptable

116
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

26.2 MAINTENANCE TECHNICAL QUERY TEMPLATE

Reference No.:

MAINTENANCE TECHNICAL QUERY [CTQ] S/C No : N/A

Maintenance No: Location/Area: Unit: Page: 1 of 1

Organization/Department Originating CTQ: S/C's affected:

ENERGYRAY INTEGRATED SERVICES Limited N/A

ENGINEERING LIMITED/ENGINEERING

QUERY:

Subject:

NORMAL URGENT, Response by (Date):

Originator:

Name (Print): Signature: Date:

ENERGYRAY INTEGRATED SERVICES Limited ENGINEERING LIMITED PROPOSAL

Name (Print): Signature: Date:

Approved by:

Name (Print): Signature: Date:

SPDC Review required? Yes No AS-BUILTS required? Yes No

SPDC RESPONSE

117
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

THE MERITS AND DEMERITS OF THIS WORK EXECUTION PLAN.

The merit of the Work Execution Plan is in the application of the Work Execution Schedule. The work
execution schedule is made to track the Contract as regards the work progress during the entire
course of the Contract, which indicates the progress on site versus the progress tracked over time. It
will enable ENERGYRAY INTEGRATED SERVICES LIMITED execute the work with conscious of
quality, time and safety.

Essentially, the Work Execution Plan with respect to Work Execution Schedule is track-able with
measurable output.

The Demerit of this Work Execution Plan will occur when Work Execution Schedule is obstructed by
the followings:

1. Unsafe condition like Bad weather, Gas spill or leakage, fire breakout etc.

2. Community issues.

3. Workers unrest.

4. Safety incident occurrence that led to stop work.

5. Non-conformance in Safety and quality that led to delay in work progress.

WORK SCHEDULE.

This document consists of the work activities, durations, milestones etc. To be tracked during the
execution of the Contract and shall be presented for SPDC approval before the Contract commence.
It will also undergo various stages of SPDC approval.

118
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

PLANNING, PROGRESS MONITORING, COST REVIEW AND REPORTING METHODS

Importance of Project Monitoring and Control

Project monitoring and control are essential to completing a project on time, on budget, and within
scope. Monitoring and control processes identify deviations from the project plan. Project monitoring
and control ensure that performance is seamless, efficient, and on track.

Project Monitoring and Control Process

The monitoring and control process tracks performance metrics to keep a project on schedule, on
budget, and within scope. The process helps project teams discover problems before they occur.

 Monitor Key Performance Indicators (KPIs): Monitoring KPIs keeps project deliverables on
track and performance up to date. Project managers use data on timelines, budgets, and
quality to enable better decisions, make changes to avoid problems, and capitalize on
opportunities.
 Monitor Change Requests: Measuring project performance data helps reveal whether the
project is on track or if changes are necessary. If the project is off course, then a change
request will be submitted and implemented to make a course correction.
 Monitor Project Scope: This step helps ensure that any changes to the project scope are
verified and documented. You’ll need to update any relevant documents, such as a project
scope statement and work breakdown structure. You’ll also want to determine any timeline
and cost adjustments that are relative to a scope increase that can cause a shift in strategy.
 Identify Risks: Ideally, risk identification should occur throughout a project; when risks arise,
you have the relevant information available to make the right decision.
 Communicate with Team Members, Stakeholders, and Clients: Maintaining regular
communication keeps projects on track and helps avoid misunderstandings that cost time and
money. It’s vital that stakeholders and team members receive all relevant information in a
timely manner.

Project Monitoring and Control Implementation

Project managers use three to five key performance indicators to report monitoring data and define
objectives to keep the project on track. KPIs must be specific, measurable, attainable, relevant, and
timely.

119
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Monitor Project Parameters: The project plan will include the scope of the project and
measurements for success. Project managers use KPIs to track schedule, effort, and cost
and to ensure they align with the project plan.
 Monitor Stakeholder Involvement: By positioning and communicating with the project team,
management, and clients, you keep everyone engaged and on task.
 Monitor Risk: When your complete risk assessments throughout the life of the project, you
avoid issues and enable mitigating negative impacts on the project timeline and budget.
 Monitor Project Performance: Project managers use KPI dashboards to identify problems
and measure work progress.
 Take Corrective Action to Control Progress: Project managers use the project plan as a
baseline to control progress and track changes until resolution or the project enters the
closure phase.
 Monitor and Manage Data Documentation: Documenting performance and changes in the
project keeps stakeholders involved, mitigates issues, and informs future projects.

Project Monitoring and Control Best Practices

Project monitoring and control best practices require constant attention to detail. These best practices
can empower project managers and teams to balance time, cost, and budget.

 Define Project Management Team Roles: Make sure that team members know the
expectations and the timelines to meet.
 Identify a Point of Contact: When problems arise, there should be a dedicated person who
is responsible for tracking, documenting, and monitoring any issues.
 Determine the Frequency of KPI Reporting: When developing the project plan, decide how
often you’ll conduct KPI reporting and stick to that schedule. This data is essential for
monitoring and controlling performance.
 Define Variance Thresholds for Schedule, Budget, and Cost: Decide what percentage of
change is acceptable and the variance threshold figure that requires change.

 For schedule variance (SV), subtract planned value (PV) from earned value (EV).

 For budget variance (BV), subtract the money spent from the planned budget for
each line item and divide it by the original budget to calculate the percentage.

 For cost variance (CV), subtract actual cost (AC) from earned value (EV).

 Determine if Variance Cause Is Common or Unique: Work continues without change under
expected and acceptable variance. If the variance is caused by the unexpected, identify and
implement the proper change.
 Scrutinize Change Orders: Review documented change requests with the project team to
approve or reject them.

120
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Monitor and Control Scope Creep: Mitigate scope creep to maintain project parameters and
recognize that project change may impact outcomes.
 Conduct a Rigorous Approval Process at Completion: Make sure to document and file all
approvals appropriately.

Proposed Project Monitoring and Control Techniques

Project managers depend on monitoring and control to track, review, and report on project
performance. They rely on this phase to make informed decisions, avoid crises, and maximize
performance and opportunities.

Project monitoring and control techniques address three areas in project management:

 Project Plan Monitoring: Use the critical path method (CPM) to identify essential project
milestones and keep deliverables on schedule.
 Project Budget Monitoring: Use earned value management to assign project tasks
according to their cost.
 Project Status Monitoring: Use project status reports to standardize the reporting process
and identify completed tasks, key takeaways, risks, and real-time progress.

Project Monitoring and Controlling Strategy

Successful projects require diligence and precision in monitoring and control, so having the right
strategy can make all of the difference. A good monitoring and control approach looks at quality, risk,
and stakeholder engagement levels and communicates all project outcomes.

These tips can help you adhere to a project monitoring and control strategy:

 Establish a cadence and well-defined process for managing change requests.

 Tailor performance reporting to project needs.
 Do not overburden the project team with information requests.
 Position stakeholders where they are needed most according to their expertise.
 Prioritize performance data that is actionable and requires a decision.
 Consider how decisions impact the schedule, budget, and scope.
 Establish a transparent decision-making process and communicate and document outcomes.
121
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

TECHNICAL/INTEGRITY REVIEWS AND AUDITS.

Introduction

Technical regulations, which may incorporate or reference standards, are set by the government
and are mandatory. They are typically put in place to achieve health, safety, consumer information
and environmental objectives. However, because of their mandatory nature, technical regulations
have the potential to create significant barriers to trade.

The purpose of these guidelines is to provide a common framework and set of principles for APEC
economies for the preparation, adoption and review of technical regulations. It is intended that
promoting similar approaches to regulatory management within APEC can improve the consistency
and transparency of technical regulations, thereby reducing unnecessary obstacles to trade.
These guidelines define the process for the preparation, adoption and review of technical
regulations as:

 identify the problem (including its nature and magnitude).

 consider all the options to address the problem.

 if technical regulations are chosen as the preferred option, consider the effect
on obstacles to trade.

 consider adopting performance-based standards rather than prescriptive standards.

 consider consistency with international standards and obligations.

 consider compliance mechanisms.

 consider providing for the review and monitoring of the technical regulation; and

 ensure that adequate consultation takes place.

A checklist of the questions that should be addressed appears in section 10.

Problem Identification

The first step in the development process should be to clearly identify the problem that needs to be
addressed. The TBT Agreement states (2.2) that legitimate reasons for imposing technical
regulations are:

 national security requirements.

 the prevention of deceptive practices; and

 protection of human health or safety, animal or plant life or health, or the environment.
122
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

International Standards

As the entire use of international standards in regulation can have the effect of imposing unnecessary
costs on business, only their essential parts should be used in technical regulations. Voluntary
standards provide an important foundation for technical regulations in many sectors.
However, voluntary standards reflect a wide range of perspectives and needs, and for this reason
will often contain requirements which, while desirable, are not essential to fulfil the legitimate
objectives for technical regulations defined above. Calling up the entirety of these standards in
regulation can have the effect of imposing unnecessary costs on business.

Compliance

The effectiveness of technical regulations will depend on the level of compliance. Hence,
consideration of how compliance will be achieved is an essential element of the process.

Conformity assessment is the comprehensive term used for measures taken or required by
manufacturers, their customers, regulatory authorities and independent third parties to assess
conformity to standards or technical regulations.

Review and Monitoring

To ensure that technical regulations are no more trade restrictive than necessary, it is important
that provisions exist for the review of technical regulations. Monitoring is essential to assess
whether the circumstances or objectives giving rise to their adoption have changed. Monitoring is
also essential to assess whether the regulation is achieving the desired objectives.

One means of ensuring that technical regulations are reviewed in a regular, timely, and thorough
manner is to include a sunset clause in the regulation. A sunset clause establishes a specific date
on which the regulation will expire. If at the time at which the regulation expires the regulation is still
required then the regulation can be repromulgated.

Consultation

With all parties affected by the technical regulation is an essential element in the design and
implementation of technical regulations. Consultation should be carried out at all stages of the
process identified above. In particular, consultation:

 increases the transparency of the process;

 ensures that all perspectives on the issues have been considered;

 highlights alternative approaches to achieve objectives;

 can be a useful means of evaluating the accuracy of regulators’ assessment of the

123
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

costs and benefits; and

 enhances awareness and therefore encourages compliance.

124
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

TRACKING RECOMMENDATIONS FROM AUDITS AND REVIEWS AND PROVIDE EVIDENCE

OF THE SYSTEMS EFFECTIVENESS.

AUDIT RECOMMENDATION TRACKING

Tracking audit recommendations can make the audit function respected and influential. Failing to
track can turn audits into toxic waste.

Effective tracking keeps both management and auditors on their toes, even before an audit starts.

This article explains how tracking audit recommendations can work well. Like other Clear Lines
articles, it starts with the why. Once the why is Clear, the how is simple. There is one format that
makes everything fall into place.

Tracking audit recommendations well is not about choosing the right systems and software. You
probably don’t need automated support. Effective tracking is about maintaining accountability and
clear expectations. Achieving those needs very little technology. You can use the methods in this
article with a word processor, email, and a dependable filing system.

WHAT ARE AUDIT RECOMMENDATIONS

Audit recommendations describe a desirable change in the real world. Each recommendation is a
proposed real-world change to what management does. The change is proposed to meet
stakeholder expectations. Stakeholder expectations are represented by the audit committee, and by
the auditor.
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

The primary outcome of an audit is assurance to the stakeholders, via the audit committee—or the
opposite of assurance, a warning about a problem.

Whenever the audit cannot give assurance, there is an audit ‘finding’.

Before each recommendation, the audit report first describes and explains the gap between reality
and expectation. That gap is usually called the audit ‘finding’. Unlike the ‘findings’ of a court case,
audit ‘findings’ should be challenged. Also unlike a court finding, the audit ‘findings’ can change after
a challenge.

A ‘finding’ is a problem or a deficiency. The problem need not be serious. For every ‘finding’, the
auditor must make a recommendation. The recommendation is a ‘must’ because no-one takes the
auditor’s ‘finding’ seriously if the auditor cannot show a way to fix it. There are exceptions.

Audit recommendations are a secondary outcome of an audit.

The Chief Audit Executive must track all recommendations anyway, even if recommendations are
only secondary. Chief Audit Executive failure to track each audit recommendation all the way to a
proper resolution can lead to a near-complete failure of the audit function.

Audit recommendations themselves are not mandatory directions for management. Management is
accountable for closing the gap identified by the audit, or for showing that there is no gap to close.

It is mandatory for management follow through on any action commitments made at the time of the
audit, or to show that they have done something better for stakeholders. That’s why tracking audit
recommendations is so important.

Read more on what is an audit and what is an audit recommendation

 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Tracking audit recommendations is about management following through on

the commitments they have made themselves. Tracking is not about the original audit
recommendation, as framed by the auditor.

Management commits to a way forward in its response to the draft audit report. The management
commitment may match the audit recommendation exactly, or it may be to a different way of
addressing the underlying deficiency. The part that matters is that management is committed
to fixing the problem, the problem identified in the audit ‘finding’.

The way forward to which management commits might be an adequate response to the deficiency,
or it might not. Ideally the auditor will review the management response and raise any concerns
about its adequacy, before finalising the audit report. If the auditor is not available to review the
response, then the Chief Audit Executive must do it. At least one of them should be satisfied with
management’s commitments in the response before the audit report is seen by the audit committee.

It is the management commitment to fix the problem that is subsequently tracked in audit
recommendation tracking. To that extent, the words ‘recommendation tracking’ are misleading.
Ultimately, the Clear Lines recommend tracking of assurances, as along with findings,
recommendations and management actions.

The audit committee will be most concerned that the underlying deficiency is corrected, so the
‘finding’ is no longer in existence—whether or not the correction follows exactly the steps promised
by management in responding to the audit.

For less important deficiencies, there may be no commitment worth tracking, for instance if the audit
report clearly says the ‘recommendation’ is only meant as a suggestion, with no accountable
obligation attached.

The tracking cycle

 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Management are required to provide a progress report on implementing the open audit
recommendation on a regular cycle. Usually a manager is asked for a report on all open
recommendations within their responsibility at the same time.

The follow-up cycle might be quarterly, or tied to audit committee dates. But it must be boringly
repetitive and predictable, even slightly annoying. There can be no surprises, and no room to move.
Intervals should not be longer than a quarter, as there will be a tendency for memories to fade
between follow-up cycles. A very short cycle might also create a problem, a tendency to trivialise
each follow-up.

Successive management progress reports are visible to the audit committee, either directly or
through summary reporting from the Chief Audit Executive team. The Chief Audit Executive team
advises the audit committee with commentary and alerts about the progress of audit
recommendations. The Chief Audit Executive team also advises management about how the audit
committee is likely to view the progress report, and on how to report progress honestly and
effectively. It is not unusual for management’s draft reporting to be obscure, off-topic or even
incomprehensible for an audit committee audience.

When management believes the recommendation has been implemented and action is complete,
the progress report says so. If the audit committee agrees, the committee ‘closes’ the
recommendation and the tracking cycle ends. The Chief Audit Executive team will advise the
committee on the closure decision, and will usually support or oppose it.

The challenge for the Chief Audit Executive team is to keep the original purpose of the
recommendation in sight of management and the committee, and to maintain management’s
accountability for achieving that purpose. The purpose is almost always to rectify a deficiency
identified by the audit. Accountability is based on clear lines of sight between the management, the
committee, and the real world. Clear and transparent communication is the key, not only to
accountability, but to the ways in which the parties see each other and see themselves.

Forecast and target dates for implementing a recommendation

 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

When management gives its response to an audit recommendation, that response should commit to
a date by which the deficiency will be fixed. Policy should require such a commitment, with variations
for genuinely difficult cases.

If everyone is happy with that date, and the date is actually achieved, fantastic. If management
forecasts that the date will not be achieved, or the date just passes by, the shortfall must not be
ignored. The Chief Audit Executive may need to alert the audit committee.

Closure is not itself an action, nor a decision, made by management. Management reports that the
recommendation is implemented, the Chief Audit Executive reviews management’s report, then the
report goes to the audit committee with a Chief Audit Executive commentary. The committee then
decides whether they require further reporting or ‘tracking’. If they direct that there is no need for
further tracking, the recommendation is ‘closed’.

Closure of a recommendation is a decision by the audit committee at a point in time. That decision
can be reversed. Closure is not evidence of action taken by management, nor is it evidence that the
deficiency reported in the audit has been rectified. The audit committee may ask for such evidence
before (or after) closing the recommendation. It is better policy for the committee to rely on
management’s declarations most of the time, with the real possibility that those declarations will be
tested for truthfulness some time later. What happens after an declaration is found untrue is perhaps
best left to the imagination.

Transparency is the key to accountability and action. The insights and art are also important, but
insights and art are themselves enabled by the reporting format, so I call the format ‘magic’.

The magic format shows for each recommendation:

 The audit finding or deficiency.

 The auditor’s recommendation.
 The original management response and the original forecast date for full implementation.
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Each and every subsequent management status report on implementation, in date order,
each with full accountability details and an updated forecast date for full implementation. If
this section is long, repetitive, and annoying, so much the better. Long delays should be
obvious on the page, and they should irritate.
 The final audit committee decision to close the recommendation.

At a minimum, the Chief Audit Executive must:

 Advise the committee that the implementation of recommendations is monitored and give
details if asked.
 Report on any instances where management is accepting risk that may be outside the risk
appetite of the enterprise.
 Alert the committee to any developments that would work against committee assurance that
the enterprise is actually meeting stakeholder interests.
 Report instances of mis-behavior by management, such as overt dishonesty, or refusal to
report on the status of an audit recommendation.

The audit committee might also get some value from:

 Numbers of open recommendations, compared with previous periods. Typically, such

numbers are also broken down by responsible management position (organization
division/branch etc.), by the importance of the recommendation, and by timeliness
categories (still on time, overdue, etc.). The absolute numbers are not meaningful on their
own, but it is wise to keep any eye on trends and abrupt changes.
 Alerts to instances when ‘agreed’ recommendations are not being implemented, or when
implementation may be delayed beyond reasonable expectations.
 Details and histories for those recommendations proposed for closure, even if other
recommendation histories are not routinely submitted to the committee.
 Aggregated numerical measures indicating timeliness of implementation, perhaps along the
lines of ‘average time to closure’ or ‘proportion of open recommendations that have been
open for more than one year’.
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Consistent reporting to the audit committee shows transparency across time, as well as
transparency between management and the audit committee.

The secret is management accountability—for the deficiency

For an audit recommendation to be effective, management must be accountable for the existence
and resolution of the deficiency. Management must know that the deficiency and actions will be
tracked to a resolution, no matter how long that takes, and that the accountability never goes away.

Management should understand the tracking process, and its rigidity, when an audit starts. That will
help management to understand that they are accountable to the audit committee, even while the
audit is barely underway. Managers who have been through previous audits should have had the
tracking process demonstrated already.

The most vulnerable stage in the life of an audit recommendation is at the end of the audit, before it
is finalised. Before the audit is finalised, management must acknowledge that the deficiency is real,
important, and within their own control. They must then commit to a specific resolution within a
defined time.

To reach the necessary state of commitment, management must be encouraged to challenge the
reality, importance, and ownership of the deficiency identified by the audit, as well as the specific
resolution proposed by the auditor. The auditor must respond properly to each challenge, which may
mean providing supporting evidence, or making adjustments. It is not unusual that a particular
recommendation is actually not within the control of the manager first identified, so there may be a
need for re-directing it. All of this negotiation takes time, and it is easily cut short by a ‘need’ to
finalise the audit expediently. But cutting out management’s challenges can easily open the way for
delayed or inadequate correction of real-world problems.

The auditor’s assertions and management’s position must be visible to the audit committee, along
with the management’s commitment to act. Accountability also requires that the assertions and
management challenges remain visible in the audit report for the indefinite future, along with names,
dates, and specific un-edited statements.
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

The tracking record after the final audit report must retain the link between the action commitment
and the deficiency that required it. The original reason for the recommendation must not be allowed
to slide back into the forgotten and disputable past. It is useful to forward management the original
audit report each time an update on a recommendation is requested, along with the later history of
management updates. That way there can be no excuses for forgetting, and management’s
accountability for every statement about every recommendation is plain to see.

To ensure that management directly feel the accountability, requests for management updates
should be regular and consistent, with no discretionary variations or gaps, and no indication of any
scope for evading accountability to the audit committee.

QUALITY MANAGEMENT SYSTEM REQUIRES PREPARATION OF A PROJECT

CLOSEOUT REPORT AS PART OF THE “PLAN-EXECUTE-ANALYSE-IMPROVE” LOOP.

The closeout process involves several steps. Below are eight activities generally required to close
out a project.

Substantial completion

Substantial completion is the point in construction when the owner and contractor agree a building is
ready for its intended use, even if minor work still needs to be done. Many projects, especially those
using contract documents from the American Institute of Architects (AIA), require a certificate of
substantial completion.
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Completion of Punch List Items

The punch list consists mostly of incomplete or deficient items found on the substantial completion
walkthrough. Generally, these are important issues that might be needed to obtain a certificate of
occupancy, meet local building codes, or adhere to building plans, but are manageable enough that
they shouldn’t keep closeout from continuing.

Determining what is included on the punch list and when items have been addressed can be
challenging. The graphic below shows a workflow for the many ways the process can go. The
general contractor usually assigns an item to the subcontractor responsible for that area of work.
When the item is completed, it’s submitted back to the owner or, depending on the work, the design
team. A punch item is closed when the owner, or whoever created the item, acknowledges it’s been
satisfactorily addressed.

Submission of Closeout Documents

Owners need all documents required to successfully manage and maintain the building. This
includes drawings that reflect final construction details, operation and maintenance manuals,
warranties, product data, and final affidavits. We will share details on each of these in the documents
section below.

Deep dive – Construction Closeout Documents: What's Included & Why

Final Inspection

The final inspection assesses the safety of buildings by checking for compliance with local building
codes and laws, and ensuring that any issues from previous inspections have been resolved.

Training
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Some equipment and systems installed during construction need training to operate and maintain,
particularly things that will be regularly used during the life of the building. Contractors or vendors
are often required to train the owner’s team before the handoff is complete. This is even included in
some contracts. A common training in many commercial buildings is for the air handler unit, which
might include instruction on how to restart the system or change an air filter.

Training is usually done in person and is often explicitly scheduled into a project’s timeline.
Documenting that a training occurred is often done by including a paper with key takeaways as part
of the closeout documents or including a video of the training itself. These serve the dual purpose of
demonstrating a contractor fulfilled their responsibilities while also creating a reference that can be
reviewed and shared in the future.

Final Payments and Release of Retainage

Many contracts define the deadline for final payments to a contractor as a project being
“substantially complete.” Some contracts allow for a retainage, which is a percentage (usually
between 5% and 10%) of a contract's value that is withheld from a contractor until the end of the job.

Transfer of Utilities and Facilities

The contractor often manages utilities during construction and transfers them to the owner once
work is complete. Projects under construction often receive temporary electricity, which is changed
to permanent power when the building is substantially complete, and the owner takes over. Similar
processes may be required for water, internet, or gas.
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

ISSUANCE OF CERTIFICATE OF COMPLETION

A certificate of Completion indicates successful scope close out.

DRAFT MOBILISATION PLAN

DURATION
ITEM ACTIVITY
DAY(S)

2.1.1 Contract Documentation and Signature 1

Kickoff Meeting, Setup Contract Execution review with Client,

2.1.2 Introduction of ENERGYRAY INTEGRATED SERVICES LIMITED 1
Contract Manager and other Team leaders

2.1.3 SPDC HSE Induction for Access Badges 5

Documentation process and review by SPDC, Tools and Equipment

2.1.4 Calibration/by ENERGYRAY INTEGRATED SERVICES LIMITED 7
and Certification by SPDC

MOBILIZATION STAGES

20% 2

2.1.5 45% 4

70% 6

100% 10

1. Security Management

Base

 Security for the activity shall be provided using civilian guards on site.
 Civilian Security Team leader shall liaise with the site leader and area security adviser
on all security issues.
 ENERGYRAY INTEGRATED SERVICES LIMITED shall familiarize with the ACP in
charge of Fire for Fire.
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 ENERGYRAY INTEGRATED SERVICES LIMITED shall be responsible for sourcing of

these securities and logistic for this exercise.
 Fabrication activities shall be carried out at the base yard.
 Night driving is strictly prohibited.
 All personnel entering the Base yard must be searched to prevent them from carrying
weapons and banned substances into the Base.
 Mobile policemen shall also be employed to buffer up security.
 All movement of good from the base must follow approved routes and properly
documented.

2. Security Personnel Roles and Responsibilities

 Provided guarding services at work site.

 Provide security escort for personnel and equipment.
 Patrol the site locations to void off any possible attack or invasion on site.
 Serve as buffer between ENERGYRAY INTEGRATED SERVICES LIMITED Sub-
contractor personnel and possible invaders.

3. Movement of Equipment

 Journey Management Plan must be adhered to in all cases of movement to and from
work site..
 Communication between equipment in transit and ENERGYRAY INTEGRATED
SERVICES LIMITED base must be effective and shall be maintained throughout.
 Curfew hours must be observed as all movement is expected to stop at 18.00hrs.
Movement shall commence at 06.30hrs the next day subject to weather conditions
(Night Journey is strictly disallowed).

4. Access Control

In view of the seriousness ENERGYRAY INTEGRATED SERVICES LIMITED attached to

security, the steps below shall be taken while a detailed Access Control Plan is also in place
to elaborate on strategies and methods.
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 All staff traveling from the ENERGYRAY INTEGRATED SERVICES LIMITED base to
site shall be checked to avoid taking to site dangerous weapons i.e. guns, dagger,
dynamites etc.
 All visitors to Base site must be properly checked / be on invitation and security
operatives shall ensure that unauthorized persons are not allowed in the work site.
 Third parties shall not be allowed to board transport provided for staff.
 All staff must be properly logged in the manifest with their luggage identified.
 Appropriate PPE and adequate safety gears shall be provided.
 Staff movement shall be logged in a register and authorized by the unit supervisor.
 Crew vehicles shall not depart the site without approval and authorization by the site
project Manager or journey manager.

5. Take Off From ENERGYRAY INTEGRATED SERVICES LIMITED Base Movements

 ENERGYRAY INTEGRATED SERVICES LIMITED staff must carry their Company, ID

cards at all times.
 Names of CREW are logged in the Journey Management logbook.
 No journey shall be embarked upon to or from the location outside curfew hours

6. Communication of Security Information

Security awareness information will be cascaded to the entire workforce regularly and daily,
this can be achieved using the following Medias;

 Daily tool box meetings.

 Mid weekly security meeting report (review of security situation with security operatives
and project team).
 Routine security report from neighboring communities/area.
 Daily site security check /information report on project
location.

16a. Communication Protocol:

Means of communication at site shall be by handheld radios, Base radio room and GSM
handsets.
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 All manned positions are to have a suitable means of communication to the Asset
Security Supervisor.

16b. Training, Instruction and Information

Jeyshawn has established the following principles on training, instruction and information
for all ENERGYRAY INTEGRATED SERVICES LIMITED employees with respect to
workplace safety and security.

All ENERGYRAY INTEGRATED SERVICES LIMITED employees, including managers

and supervisors, shall be provided training and instruction on general and job-specific
campus workplace security practices. A record of the training should be recorded.

Training and instruction shall be provided to all new employees and to other employees
for whom training has not previously been provided.

Information on workplace security and safe work practices, included in this Plan will be
updated and provided as necessary.

General ENERGYRAY INTEGRATED SERVICES LIMITED workplace security training

and instruction includes, but is not limited to, the following:

a) Explanation of ENERGYRAY INTEGRATED SERVICES LIMITED workplace Safety

and Security Policy and Plan including measures for reporting any violent acts or
threats of violence.
b) Recognition of workplace security hazards, including the risk factors associated
with the three types of workplace violence.
c) Measures to prevent workplace violence, including procedures for reporting
workplace security hazards or threats.
d) Ways to defuse hostile or threatening situations.
e) Measures to summon others for assistance.
f) Employee routes of escape.

7. Evacuation of Site

Site emergency evacuation may be required in any of the following situations:

 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 A medical emergency;
 Threat of a criminal invasion;
 An actual security incident occurs;
In any of the above scenarios, evacuation will be using personnel carrier vessel with
dedicated MPV to escort the personnel from the Work site to accommodation base or the
closest SPDC facility.

In such an emergency, the ERT must be informed, and they will handle the evacuation.

Order of Personnel Evacuation

 All injured personnel.

 All other personnel.

Loss Prevention

 Random Search of personnel and vessels/vehicle leaving the work site will be conducted in
line with the SOL.
 Property removal authorization passes will be required before company or contractor
property can be removed from the premises.
 The authority to approve the removal of Company property from facilities shall be limited to
the CSR or CMD and his or her designated representatives. Such delegations shall be made
in writing and updated annually.

8. Activity Crew/ Personnel

All CLIENT Staff and contracted employees have a personal responsibility for their own,
their colleagues and the Company’s Security. To that end personnel will:

 Maintain high Security awareness and vigilance;

 Wear and visibly display Company identification cards always whilst on Company
premises;

 Immediately report unauthorised access to the site and restricted areas to Security;

 Immediately report introduction of prohibited weapons, incendiaries and explosives to

Security;

 Immediately report unlawful acts that affect operations to Security;

 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

 Avoid discussing project specifics such as products handled, Security routines and
equipment with non-Company personnel;

 Restrict the distribution, disclosure and availability of information contained in this SP to

authorised personnel.

 Inform Security on organisational changes that affect contractor/visitors and full-time

employee (FTE) workforce about authorisation and revocation of access rights.

9. REACTION TO INCIDENTS

Priority in all incidents is to the safety of staff

o Route to venue/worksite blocked – Use alternate route/return to base location.

o Attack/Incident on route to/from venue – Return to Base Location/Summon
Security/GSF Assistance.
o Attack on venue – Lock Down work site, move staff to safe location, summon
Security/GSF assistance.
o Kidnapping of Staff – Account for remaining staff, Inform Security Representative,
Initiate Kidnap Management Team.
o Lost Comms – Use Alternate communications (GSM/VHF/messenger etc)
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

10. SECURITY EMERGENCY SCENARIOS AND TIER RESPONSE/CONTINGENCY PLAN

TIERS DEFINITION/SCENARIOS

Tier 0 Intelligence information on perceived criminal attack or community agitation

Tier 1 Blockade of route to worksite/community invasion

Tier 2 Criminal operation in progress behind or ahead of work crew

Tier 3 Criminal attack at worksite or attack on crew vehicle

Tier 4 Abduction of work crew or personnel kidnapping

Tiers of Action/Responsibility Responsible Party

Security
Respons
e

Tier 0 Intelligence information on perceived criminal attack or

community invasion
SJM
 Daily, send email to obtain Security Single Point
SJM
Authorization (SSPA).
 If authorization is not granted, inform CSR and don’t
depart on any movement;
SJM
 Authorization obtained? Yes, inform CSR and proceed as
below:
o Confirm local intelligence atmosphere, call DSS,
CRO, Escort Commander and CSR;
o If no threat is perceived, inform DSV and DSS/ASA,
then proceed to site for day;
o If perceived threat exists, inform DSV and ASA and
don’t move
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Tier 1 Blockade of route to worksite/community disruptions

 Politely engage community to ascertain reason for All Personnel

agitation.
DRIVER/SJM/DSS
 Advise CSR, contact CRO and ASA immediately,
communicate to SPDC office.
 Report to CSR and ASA.
DRIVER/SJM/DSS
 Report to contract holder and SPDC Security/ER Duty
Coordinators DSV/CSR

Tier 2 Criminal operation in progress behind or ahead of work

crew
Driver/All Personnel
 If within a safe distance, stop immediately and return to
Driver/All Personnel
base.
 If not safe to retreat, stop and leave the vehicles for
nearest safe haven/hard cover
Driver/All Personnel
 If already at the scene, never reverse; surrender and co-
operate with the protesters /attackers.
 Once in a safe place, report incident immediately to the
DRIVER/SJM/DSS
CSR/TOTAL Office/CH/ASA

Tier 3 Criminal attack at worksite or attack on crew vehicle

 Respond to instructions calmly and promptly without All Personnel

questioning.
All Personnel
 Do not resist or attempt to retaliate.
 Avoid eye contact All Personnel
 Do not make sudden physical movements.
All Personnel
 Keep your hands visible: hands out of pockets, raise up
hands. All Personnel

 If you must move, ask for and receive permission before

All Personnel
doing so.
 In case of sporadic shooting by attackers, take cover and
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

crawl to safety.
 For sudden gunshot attack while on transit, security
All Personnel
escort to apply deterrent measures and communicate with
survey crew on what to do. Security Escort
 On arrival at a safe place, do a roll-call to ensure no one
is missing.
 Report incident immediately to the ASA/TOTAL CSR/DSS
Office/CH/Duty Manager/Security Control Centre.

CSR/DSS

Tier 4 Abduction of work crew or personnel kidnapping

 Apply ‘stay put’ mode and remain calm. All Personnel

 Co-operate with the abductors.
All Personnel
 Preserve and avoid making negative utterances.
 Conserve information as much as possible. All Personnel
 If asked for contact, give only useful contact (not SCC).
All Personnel
 Contact SPDC Office/CSR/CH/Duty Manager/SCC for
necessary action. All Personnel

CSR/DSS

11. Welfare

 All medical cases shall be conveyed to ENERGYRAY INTEGRATED SERVICES LIMITED

retainer clinic.
 Staff shall be accommodated and fed by ENERGYRAY INTEGRATED SERVICES LIMITED
when working at site.

12. Communication

ENERGYRAY INTEGRATED SERVICES LIMITED Office and key personnel can be

contacted with the phone numbers included in the contact list.

ENERGYRAY INTEGRATED SERVICES LIMITED shall use dedicated lines for security
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

matters while CLIENT site communication equipment shall be used during the installation
phase, Mobile phones will be used while en route and at base to make all necessary
communications.

13. Government Security Agencies

ENERGYRAY INTEGRATED SERVICES LIMITED shall endeavor to maintain cordial

relation with Government Security Agencies, and where necessary and in conjunction with
SPDC, request their assistance in providing additional security for the Project.

When required to offer service to the Project, they must follow approved rules of procedure
and follow clear lines of command.

The assigned Officer-in-charge (OC) is responsible for the actions of his men and must
institute disciplinary action against anyone of them who contravenes the agreed rules of
procedure.

14. Security Incident Reporting

All security incidents that occur during the execution of the project shall be reported as
follows:

Immediate: The senior manager at the site of the incident must provide an initial verbal
report to the security manager as soon as the situation permits. The Security Officer will
advise the Project Manager as soon as possible of an ongoing incident.

Follow- up: Follow up information should be provided to the Security Officer as the
situation progresses. This should occur as often as necessary, with as much detail as is
possible, to ensure he has full understanding of the incident.

Detailed: Within 48 hours of closure of incident, a detailed report must be submitted to the
Project Manager by the Security Management Team. The Project Manager will then decide if
the occurrence requires investigation and/ action.

Reporting Procedure and template report formats are available in other documents.

24b. Incident investigation

 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

The following principles have been established for investigating incidents of workplace
violence, or threats of physical injury, which include:

 Review all previous incidents.

 Visit the scene of an incident as soon as possible.
 Interview threatened or injured employees and witnesses.
 Examine the workplace for security risk factors associated with the incident,
including any previous reports of inappropriate behavior by the perpetrator, as
appropriate.
 Determine the cause of the incident

15. Monthly Security Report

A Monthly Security Report shall be compiled by the Security Coordinator as part of the SHE
statistics report.

The report shall contain major activities in the month, and review of performance utilizing
predetermined performance indicators

16. ENERGYRAY INTEGRATED SERVICES LIMITED Operation Emergency Contact List

NAMES TITLE WORK TEL NOS. HOME TEL.

NOS.

Chineyemba Ifeakachukwu Managing director 08175555552 08035408612

CHIDIEBERE EBI HSE 07069737824 07069737824

ENERGYRAY
INTEGRATED SERVICES
Port Harcourt 08035988697 08186005066
LIMITED LTD.

Plot 36 Okujagu, Trans-

Amadi, Port Harcourt
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Dr. Onyekesi Retainer Clinic 084-610892 08033103672

ANCHOR HOSPITAL
ELEME JUNCT. PH

Dr . Okereke NEW ORLINS Hospital, 3 08037078692 -

Etim okpoyo close, Opp
Air force market, beside
total filling station, PH Aba
express way.

Dr .E .A Bazuaye HUMANITY HOSPITAL, 3 07017272299 08066740701

humanity close,off enerhen
road, effurun, Warri, Delta
state

STRATEGY
As part of its operational philosophy, ENERGYRAY Integrated Services Limited recognizes
the fact that to pursue its business of oilfield-related work in the area, it must work in
harmony with the host communities and must assist them in attaining some benefit from
development activities that take place in their lands.

To this end, ENERGYRAY Integrated Services Limited instituted a Community Relations

Program. The Project Community Relations Program involves maintaining regular contact
with the communities in the area irrespective of whether operations are currently being
carried out in their area. ENERGYRAY Integrated Services Limited will sponsor community
festivals in the area and give employment and training opportunities to the youth of the
various communities.
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Detailed Work Schedule to be submitted 7 days after contract award.

 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

RESOURCE LOADING
Days
Activity
1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 3
1 2 3 4 5 6 7 8 9 0 1 2 13 4 5 6 7 8 9 0 1 2 23 4 5 6 7 8 9 0

Manifold piping works 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6

Civil & Structural Works 2 2 2 2 2 2 2 6 6 6 6 6 2 2 2 6 6 6 6 2 2 2 1 6

Manifolds Protection Systems 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6

Valve replacements 3 3 3 4 4 4 4 4 4 4 4 4 4 2 4 4 2 2 4 4 4 4 4 4 2 2

Valve maintenance 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 6 6

Gas lines Repairs 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6

Major sectional replacements of oil

lines including welded valves 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 6

Riser burials 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 6

River crossings 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 6

Road crossings 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 6

Emergency Pipeline Repairs for Oil

and Condensate Pipelines 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6

Planned Repairs and Upgrade for

Oil and Condensate Pipelines 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6

Composites Repairs / Upgrades 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6

Decommissioning/Abandonment of
disused pipelines and manifolds
3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 6

CP Systems Upgrade / Repairs 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 6

Coating Survey and repairs 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 6

6 6 6 6 6 6 6 6 6 7 7 7 7 6 6 6 7 7 7 6 6 6 7 9
Total Manpower day 8 8 8 9 7 7 0 9 9 9 3 3 73 0 3 1 9 9 7 1 0 3 73 3 9 9 9 0 0 2

Q
t
Personnel y
Pipe Fitters 4
Welders 5
Corrossion Technicians 4
 PIPELINE REPAIRS AND MAINTENANCE
Document Status

PROVISION OF INTEGRATED PIPELINE REPAIR AND

Project Title JV
MAINTENANCE SERVICES

Engineers 4
Mechanical Technicians 6
Electricians 6
Mason 4
Drivers 6
Cathodic Protection Engineer 4
1
Helpers 2

35

Activity
Series2
30 Manifold piping works
Civil & Structural Works
Manifolds Protection Systems
25
Valve replacements
Valve maintenance
Gas lines Repairs
20
Major sectional replacements of oil
lines including welded valves
Riser burials

15 River crossings
Road crossings
Emergency Pipeline Repairs for Oil
and Condensate Pipelines
10
Planned Repairs and Upgrade for
Oil and Condensate Pipelines
Composites Repairs / Upgrades

5 Decommissioning/Abandonment of
disused pipelines and manifolds
CP Systems Upgrade / Repairs
Coating Survey and repairs
0
1