DCN Diving

Company Overview

• Family business, established in 1957

• International Diving Company

• With Air and Saturation Diving capability

• ROV and Survey

• Worldwide Contractor Member of IMCA

• Offices in The Netherlands, Germany and Belgium

 Perusahaan Gas Negara

CLIENT REQUIREMENT
• For the contractor to provide a safe, efficient and timely solution to the design,
procurement, fabrication, qualification and installation for the permanent repair
of the pipeline leak location at kp 138-139 on the Labuhan Maringgai to Muara
Bekasi pipeline.

• Restablish the structural integrity of the pipeline at an acceptable level at the

repair location

• Perform the repair with no pipeline shutdown, maintaining a minimum line

pressure of 410 psi

COMPLETION BY DECEMBER 2015

Indonesia: Repair Site

32-inch natural gas pipeline

 Indonesia: Project Work Scope

Circumferential defect Top of Pipe position (20km offshore)

Gas Leak Detected (2013) Temporary PLIDCO Clamp Fitted (2013)

 Indonesia: Project Work Scope

• Permanent repair sought without pipeline shutdown

• To include encapsulation of existing PLIDCO clamp

• To impose no extra physical loading on the pipeline

• To maintain MIGAS certification throughout

• DCN awarded EPIC contract by PGN on December 8th 2014

• Target date for completion – December 2015

• Actual completion date ahead of schedule – October 2015

*** Highly innovative technical solution delivered safely, to

specification and ahead of schedule ***
 Pre-Engineering Survey (Jan/Feb 2015)

Air Diving, Survey and ROV spread - MV Endeavour

Survey Period: 17th January to 20th February 2015

 Pre-Engineering Survey (Jan/Feb 2015)

Multibeam, Side Scan Sonar & Sub-bottom Profiler surveys

 Pre-Engineering Survey (Jan/Feb 2015)

Digiquartz Profiling and ROV Inspection

 Pre-Engineering Survey (Jan/Feb 2015)

Assessment of Pipeline Crossing and Existing Pipeline Supports

 Pre-Engineering Survey (Jan/Feb 2015)

Removal & Recovery of Concrete Coating Adjacent to PLIDCO Clamp

Above: Two sections were removed

Right: Recovered Section

 Pre-Engineering Survey (Jan/Feb 2015)

Measurement and Analysis of Local Curvature using Taut Wire

 Pre-Engineering Survey (Jan/Feb 2015)

Measurement of Local Pipeline Ovality using Purpose Built Jigs

 Pre-Engineering Survey (Jan/Feb 2015)

3D Scanning to Define Pipeline Ovality

3D Laser Scanning Technology employed

 Pre-Engineering Survey (Jan/Feb 2015)

Measurement of Pipeline Wall Thickness and Lamination

Tritex UT-30 Hand Held Scanner Olympus Epoch 4 Flaw A Scanner

 Pre-Engineering Survey (Jan/Feb 2015)

Soil Assessment for Suction Pile Design

Sample Analysis – Fugro (Singapore) Laboratory

Deploying Aquifer Vibrocore
 Pre-Engineering Survey (Jan/Feb 2015)

Temporary Protection (Retrowrap) Installation and Debris Removal

 Engineering / Design / Testing

Pressure Containment Barrier

 Engineering / Design / Testing

Test Fitting Clamp and Sleeve at IK-Norway

Containment Clamp Pressure Tested

to 10 bar using Argon
 Engineering / Design

• Welded Split Sleeve - Final leak prevention

• Restoration of structural integrity of the pipeline

 Engineering Concept

Install Welding Habitat creating a Dry Environment for Final Repair

 Engineering Concept

• Unique approach using

suction piles as Habitat
footings to counteract
soft seabed conditions

• Piles ensure no weight

transfer from Habitat to
Pipeline

• Hydraulic legs allow

for accurate
positioning of Habitat
without risk of impact
to Pipeline
 Hyperbaric Welding Trials
(DCN Netherlands – Bergen Op Zoom)
Hyperbaric Welding Trials
 Hyperbaric Welding Trials

WELDING PROCEDURE
QUALIFICATIONS

DIVER WELDER QUALIFICATIONS

Hyperbaric Welding Trials
Hyperbaric Welding Trials
 Hyperbaric Welding Trials

Removing the Stand Off Sleeve after Welding Trials

Hyperbaric Welding Trials
 Engineering / Design / Testing

Pressure Testing the Stand Off Sleeve to 100 bar

Destructive Testing
 Mobilisation Normand Baltic

Mobilised in Singapore
Type: CSV/ DSV (20th August and 3rd September 2015)
Built: 2010
Design: Aker PSV/ROV 06 CD
LOA/LOB: 94.90 m / 20.00 m
DWT: 4,100 MT
Deck: 1,000 M2
Accomodation: 80
Engine: 8,400 kW

Starboard crane: 5 T@15M

Port crane: 5 T@15M

Offshore crane:
MACGREGOR 100 t AHC
Offshore crane
Vessel Mobilisation - Singapore
 Vessel Mobilisation - Singapore

Survey Equipment Calibrations & Checks

Mobilisation: Normand Baltic
Normand Baltic Passage to Site
Jakarta Support Vessel – “Adventurer I”
 Handover Survey: Explora Nusantara and
Normand Baltic

MBES survey 300m x 200m

Check PLIDCO clamp integrity (Explora Nusantara 3rd
visually by ROV September 2015)

• ROV survey, assessment of supports and 3rd party Pipeline

• Site Handover from Client before commencing Repair Works
 Handover Survey: Normand Baltic

Grout Bag Support # 1 Sleeper Support # 6

 Suction Pile Installation

Support foundation for the Welding Habitat

 Suction Pile Installation

• 5 x 6.5m long piles installed

• 1 x test pile and 4 x Habitat foundation piles

• Intended Pile penetration 5.5m to 6.0m

 Suction Pile Installation

SPT Suction Pump Test Fitted to Pile

 Suction Pile Installation

SPT provided Suction System Spread and Operator

 Suction Pile Installation

Accurate Position, Height and Verticality for each Pile

MS1000 Sonar, Digiquartz and Mini-Tilt used

 Suction Pile Installation

Accurate Pile Positioning using Pipeline Mounted MS1000 Sonar

 Suction Pile Installation

INSTALLATION TOLERANCES:

RELATIVE XY POSITION +/- 0.3m

RELATIVE HEIGHT +/- 0.2m

PILE VERTICALITY +/- 2°

 Suction Pile Installation

ALL PILES WERE INSTALLED WITHIN TOLERANCE:

POSITION >>

HEIGHT >> >> (All within tolerance)

VERTICALITY >>
 Suction Pile Installation

CDL Mini-Tilt for Inclination

Digiquartz and Mini-Tilt

bracket-mounted on top of pile
 Suction Pile Installation

Pile Top Plates Landed Subsea on Installed Piles

Offshore, ready to deploy

Onshore – Test Fitting
 Habitat Installation

Habitat Legs & Rams pre-marked for known Pile positions & heights
 Habitat Installation

Below: Gas Containment Barrier

(white half shells, sides of Habitat)

Right: Top half of Split Stand Off

Sleeve being installed into Habitat
 Methodology

Gas containment barrier

and Stand Off Sleeve
stored in roof of Habitat
(dry space) throughout
deployment
 Habitat Installation

Steel doors pre-installed (Equipment Remains Dry)

From Inside Habitat From Outside Habitat

 Habitat Installation

• Habitat legs extended fully by diver (vertically)

• Habitat legs extended by diver to pre-set marks on Rams (laterally)

• Centre line marked and plumb lines attached High and Low ends
 Habitat Installation

Habitat with Safe Haven attached to Offshore Crane – 4 point lift

Over boarded 40m from seabed assets and wet tested for leaks
 Habitat Installation

Habitat Weights and Buoyancy Landed on Piles

 Habitat Installation

Habitat Weights and Buoyancy after Removal of Temporary Doors

 Habitat Installation

Habitat Weights and Buoyancy – Operating Phase

 Habitat Installation & Positioning

Habitat lowered onto Pile Top Plates and Habitat centred over Pipeline

USBL mini-beacons attached to Habitat legs for position monitoring

 Habitat Installation

• Steel doors removed in stages

• Habitat lowered to pre-defined height
Habitat Installation

Installation of door seals around

concrete / pipeline and de-watering
of Habitat
 Install Gas Containment Clamp

• Gas containment clamp positioned using chain hoists

• Packers and bolts inserted

• Lateral Bolts and Compression Flange Bolts Hytorc’d

• Pressure tested to 120 bar with Argon
• Pressurise void to 10 Bar Leak Test 5 minute hold
Stand Off Sleeve Fit Up
 Pre-Heat Setup

• Induction heating - Miller Pro Heat 35

• Fit Pre heat coils

• Monitor pre heat temperature

 Longitudinal Welding

Real Time Welding Data Recording – AMV 3500

 TOFD / MUT

Test Standard: DNV OS F101 (ISO17640-2010)

Acceptance Criteria: DNV OS F101-Appendix D Table D6 and ECA
Any indications during TOFD characterised and sized by Manual Shear Wave UT
 Circumferential Weld

Gap Survey and Pre-Heat Application

 Circumferential Welds

The weld consisted of Buttering Runs, Root Pass, Hot Pass,

Layers and Temper Bead
 Corrosion Protection

Application of STOPAQ
(3-layer system)
Anode Attachment
Flood Habitat for Removal
 Remove Habitat

• Disconnect bolts between doors and Habitat

• Remove cargo straps from legs to pile tops
• Attach vessel crane – 4 point lift arrangement
• Lift flooded Habitat clear of pipeline
• Move vessel 40m to safe recovery location
• Lift Habitat back onboard and secure
 Remove Suction Piles

• Remove pile top plates

• Attach suction pump to pile top
• Reverse suction and apply lift with vessel crane
• Remove pile and move vessel 40m to safe recovery location
• Recover pile to vessel
Final Inspection (Diver & ROV)
 Handover Survey & De-mobilisation

• Handover of site back to Client on completion of Subsea Works

• MBES survey 300m x 200m & water samples (Explora Nusantara)

• ROV survey & assessment of supports and 3rd party pipeline

(Normand Baltic)

• Ensure site cleared of all project debris

• Explora Nusantara de-mobilised in Jakarta on 15th October

• Normand Baltic arrived Singapore on 19th October

• Normand Baltic de-mobilisation was completed by 22nd October

Certificate of Great Achievement