Company

The Shell Petroleum Development Company

Of Nigeria Limited (SPDC)
Contractor:

NEMBE CREEK-CAWTHORNE CHANNEL TRUNKLINE

REPLACEMENT PROJECT
Company Contract No.:

Type of document:

PROCEDURE
Company document No.

Revision :

NCT-PRO-D03-00003

COMPANY
DOCUMENT TYPE:

D03

AO1

Document title:

EXISTING PIPELINE & CABLE UNDERCROSSING

ADDENDUM TO PROCEDURE
STATUS CODE
ACCEPTED
A
Do not resubmit unless document is modified
Operation May proceed
ACCEPTED AS NOTED
B
Revise to incorporate comments and resubmit
Operation must not proceed
NOT ACCEPTED
C
Revise to incorporate comments and resubmit
Operation must not proceed
INFORMATION ONLY
D
No impact on construction programme

AO1

02/10/08

AFU

Approved for Use / Design

RO1

27/09/08

IFR

Issued for Client Review /

Comment
Issued for

Rev.

Date

Status

CONTRACTORS DOCUMENT IDENTIFICATION:

JOB CODE:
COMPANY CODE:

TICK

Michael
Nnanna
Michael
Nnanna
Originator

SIGNATURE

M. N.
Graham
Cushion
Checked

V. Lori

Approved

NEMBE CREEK-CAWTHORN CHANNEL

TRUNKLINE REPLACEMENT PROJECT
EXISTING PIPELINE & CABLE UNDERCROSSINGS
NCT-PRO-D03-00003

AO1

CHANGE RECORD PAGE

REV. N

Status

Description of Revision

R01

IFR

Issued for Client Review / Comment

A01

AFU

Incorporated SPDC comments

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NEMBE CREEK-CAWTHORN CHANNEL

TRUNKLINE REPLACEMENT PROJECT
EXISTING PIPELINE & CABLE UNDERCROSSINGS
NCT-PRO-D03-00003

AO1

CONTENTS

1.0

Introduction

2.0

Purpose

3.0

Scope

4.0

References, Standards and Specifications

5.0

Definition and Abbreviations

6.0

Organisation / Responsibilities

7.0

Flowline Undercrossing Method

7.1

Scenario 1 - Undercrossing during string production from lay barge.

7.2

Scenario 2 - Undercrossing during string pulling / Laying.

8.0

Additional Safety Precautions / Considerations

9.0

Appendices

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NEMBE CREEK-CAWTHORN CHANNEL

TRUNKLINE REPLACEMENT PROJECT
EXISTING PIPELINE & CABLE UNDERCROSSINGS
NCT-PRO-D03-00003

1.0

AO1

Introduction
During the installation of the Trunkline and delivery lines for the NCTL Package A, a
number of existing Pipeline undercrossings shall be performed. While the main
procedure for Existing pipeline and cables undercrossing detailed the general procedure
that shall be followed in executing the pipeline undercrossings, flowlines being more
flexible than the more rigid concrete coated trunklines and often of shallow burial, thus
may require an additional consideration or modified undercrossing methodology and
Safety considerations.
Two scenarios of undercrossing of existing flowlines shall be considered thus:

Scenario 1 - Undercrossing during string production from lay barge

Scenario 2 - Undercrossing during pipe pulling and or laying.

The two scenarios appear similar but the processes differ significantly in time (process
duration). This difference can cause very costly consequences if not properly
considered.
While scenario 2 can be timed, as to the period of operation (Low tide or high tide),
scenario 1 can transcend both tidal ranges thus requires consideration for both tidal
ranges during the string production and undercrossing operation.
This addendum thus serves to augment the main procedure for existing pipeline and
cables undercrossing in the area of flowline undercrossings.

2.0

Purpose
This document is for the purpose of supplementing the main procedure for existing
pipelines and cable undercrossing in the area of undercrossing of flowlines.

3.0

Scope
This document shall apply to all the flowline undercrossings that shall be carried out for
the NCTL Package A scope. It must be appreciated, that the methods as detailed herein, may be subject to revision or modification depending upon prevailing conditions and
circumstances encountered on site, however major changes shall be approved by SPDC
prior to implementation.

4.0

References, Standards and Specifications

1)
2)
3)
4)

5.0

NCT-NST-PRO-D03-00003 Existing Pipeline and cables undercrossing

SCS Section 35 Contractor Safety
SCS Section 25 Pipeline Construction
DEP 31.40.00.15-Gen. Pipeline Engineering

Definition and Abbreviation

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TRUNKLINE REPLACEMENT PROJECT
EXISTING PIPELINE & CABLE UNDERCROSSINGS
NCT-PRO-D03-00003

6.0

HSE
NCTL
JHA
Over bend

AO1

Health, Safety, Security & Environment

Nembe Creek Trunk Line
Job Hazards Analysis
A curved section of the pipeline allowing it to conform to the dredged
ditch.

Organization / Responsibilities
The organization that shall be responsible for the execution of this document shall be as
described below:
The Project Manager shall have overall responsibility for the successful and safe
execution of all activities in the NCTL Project.
The Construction Manager shall be responsible for the successful and safe
execution of this document. He shall delegate as may be necessary, all or part of this
function to the Field Project Engineer.
The HSE Manager shall be responsible for the monitoring of the HSE aspects of this
document and shall delegate all or part of this function to the Site HSE Officer.
The Field Project Engineer shall in addition to undertaking as directed by the
Construction Manager, have direct Site Management responsibility for a safe and
successful execution of this document.
The HSE Officer shall undertake as directed by the HSE Manager and shall carry out
Site HSE surveillance and ensure HSE compliance
The Tie-in Supervisor shall have direct responsibility for the successful and safe
execution of all pipeline undercrossing operations.
The Tie-in crew shall carry out all field operations for the successful execution of all
pipeline under crossings as directed by the Tie-in Supervisor.

7.0

Flowline undercrossing method.

7.1

Scenario 1 - Undercrossing during string production from lay barge.

String production from the lay barge is a continuous process that can transcend the
2 tidal ranges (high and low tides). Thus when an undercrossing is taking place
concurrently with this operation there is a severe risk of damaging or buckling of
the existing line, due to the uplift force of the floating string under-crossing the
existing flowline. This uplift force is as a result of rising tide.
Thus, in order to prevent this potential hazard, two (2) options are possible.
a) Option 1 Take the existing line out of service and cold cut the crossing
portion to allow for push pull string production to continue un-inhibited, and
thereafter re-instate the cut flowline.
b) Option 2 Suspend the existing flowline at height above HHWS to allow for
un-inhibited push pull string production, and thereafter lower and re-instate the
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NEMBE CREEK-CAWTHORN CHANNEL

TRUNKLINE REPLACEMENT PROJECT
EXISTING PIPELINE & CABLE UNDERCROSSINGS
NCT-PRO-D03-00003

AO1

exposed portions of the existing flow line.

c) Preferred Option
In order to prevent or minimise extended production shut-in as shall be required in
Option 1 above, Option 2 is chosen as the preferred option with limited impact on
production.
7.1.1

Detail methodology for Scenario 1 - Option 1

The methodology to be adopted for this scenario shall be as follows:

7.2

Carry out manual excavation to expose the existing flowline.

Establish the depth of existing flowline.

Establish the required lift height sufficient for undercrossing pipeline with
attached floaters (to be determined on site)

Determine the minimum required length of existing pipe ditch to expose

(refer to attached Pipe lifting analysis chart Appendix 2) to ensure no
restraint during lifting.

Expose the existing pipe as determined above and check the remaining
wall thickness using ultrasonic thickness measuring instrument.

Position the lifting equipment (buggies) at designated intervals

Wrap the lift belt (2 loops) round the pipe and hook to the lifting equipment.
Note that 2lift points shall be utilised at each lift zone in order to distribute
stress and avoid point loading (See Appendix 3).

Lift segment of exposed flowline to designated height and suspend with

timber and or sand bags ensuring that profile of lifted flowline conforms to
the minimum designated profile.

Continue pipe string push-pull from lay barge until all required string makeup is completed.

Pull string to position; lower produced pipe string and install barrier
protection where string is underlying existing flowline(s) as in NCT-NSTPRO-D03-00003, Procedure for Existing Pipeline and Cable Under
Crossing.

Lower suspended flowline(s) and re-instate exposed portions of existing

flowline.

Scenario 2 - Undercrossing during string pulling / Laying.

During pipe laying, a number of strings may be produced in the floatation ditch and
pulled/floated down the flotation ditch to their respective positions for laying.
Pulling of these strings to their locations may involve undercrossing of existing
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NEMBE CREEK-CAWTHORN CHANNEL

TRUNKLINE REPLACEMENT PROJECT
EXISTING PIPELINE & CABLE UNDERCROSSINGS
NCT-PRO-D03-00003

AO1

pipelines and flowlines.

Two options are also possible thus:
a) Option 1 Bottom pull of undercrossing by means of buoyancy control as in
river crossing refer to undercrossing of trunk lines in document NCT-NST-PROD03-00003.
b) Option 2 Slight lifting and suspension of existing line with sand bags and / or
timber, in order to allow for pulling/floating of undercrossing pipe strings into their
respective ditches for laying (most preferably for shallow buried flowlines).
c) Preferred Option
For the undercrossing of rigid concrete coated pipelines (trunklines), which are
often of deeper burial, Option 1 above is chosen as the preferred option; refer to
document NCT-NST-PRO-D03-00003.
However for flowlines, which are more flexible and often of shallow burial, Option 2
above is chosen as the preferred option aside from its advantage of good timeefficiency, thus reduced exposure of existing facility.
7.2.1

Detail Methodology for Scenario 2 - Option 2

Unlike scenario 1 above, this activity can be timed in order to exploit the favourable
tide level (low tide).
The detail methodology shall be as follows:
Carry out manual excavation to expose the existing flowline.

Carry out manual excavation to expose the existing flowline.

Establish the depth of existing pipe wrt. LLWS

Establish the required lift height sufficient for undercrossing pipeline with
attached floaters (to be determined on site)

Determine the minimum required length of existing pipe ditch to expose

((refer to attached Pipe lifting analysis chart Appendix 2), to ensure no
restraint during lifting.

Expose the existing pipe as determined above and check the remaining
wall thickness using ultrasonic thickness measuring instrument.

Position the lifting equipment (buggies) at designated intervals

Wrap the lift belt (2 loops) round the pipe and hook to the lifting equipment.
Note that 2lift points shall be utilised at each lift location in order to
distribute stress and avoid point loading. See attachment 3.

Lift segment of exposed flowline to designated height and suspend with

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NEMBE CREEK-CAWTHORN CHANNEL

TRUNKLINE REPLACEMENT PROJECT
EXISTING PIPELINE & CABLE UNDERCROSSINGS
NCT-PRO-D03-00003

AO1

timber and or sand bags ensuring that profile of lifted flowline conforms to
the minimum designated profile.

8.0

Continue pipe string pulling to float pipe string under the existing flowline.

Pull pipe string to its position and lower string.

Where string is to be pulled and laid directly below suspended

undercrossed flowline, lower produced pipe string and install barrier
protection as in NCT-NST-PRO-D03-00003, Procedure for Existing Pipeline
and Cable Under Crossing.

Lower suspended flowline(s) and re-instate exposed portions of existing

flowline.

Additional Safety Precautions / Considerations.

In order to ensure a safe and successful execution of this document, additional safety
considerations were made in the area of possible corrosion or reduced pipeline integrity as
follows:
1) Integrity checks will be performed on the exposed pipeline in the form of wall thickness
measurements (probes), to confirm the integrity of the pipeline prior to carrying out any
lifting. Where the measured thickness is less by more than 25% of the original pipe
wall thickness, then the lifting shall be suspended to allow for further considerations.
2) An additional factor of safety of 2.5 was considered in calculating the minimum elastic
bend radius for the respective pipe sizes to augment for possible reduction in integrity
due to corrosion.
3) 2point lifting was adopted to minimise point loading and enhance stress distribution
around the lift area (stress zone).
4) All pipe lifting shall be by appropriate rated and certified belts. On no account should
sling wire or shackle be used on pipe.
5) PTW shall be ensured prior to commencement of works.

9.0

Appendices
9.1

Appendix 1 Flowlines undercrossing procedure drawings

9.2

Appendix 1 Pipe lifting analysis chart

9.3

Appendix 1 2-point lifting diagram

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