OPERATIONS BRIEFING

For

Onshore Double Joint Fabrication

Pipeline Technique Ltd Ref: OSDJ-001 Rev 1 Created: December 2006

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Ref: OSDJ-001 Rev 1

This document has been produced with the intention to show how the process of Double joint fabrication takes place. The facility and equipment was mobilised to cater for the Double Joint Fabrication of the Acergy Statoil Tyrihans Development Project. Which involved making a total of 1,800 Double Joint (DJ) welds on 18 and 20 o/d S.A.W pipe of 23.9mm WT including a 3mm thick 316L Stainless Steel liner The facility is located inside B.L.G. Shed 20 at Bremen port Germany, and was initially in production during the 3rd and 4th quarters of 2006.
Average production was 40 Double Joints per 12hr shift on this lined pipe. Weld reject/repair rate was 0.45% on the whole job. For Carbon Steel pipe welding of the same o/d and wall thickness, production rates of 100+ Double Joints per shift would be expected.

1. Two single joints are lifted by the forklift, using forklift toe stops to stop the single joint moving on the forklift toes. 2. This pipe is then loaded onto rollers. 3. These rollers transported the pipe through door 40 into shed 20 and stop in front of the repositioned MP test rack/ Bevel rack. 4. The pipe was then picked up by pipe buggies and placed on to the MP test rack/Bevel rack. 5. The pipe was then sanded in four sections at both ends of the pipe, and two contact points longitudinally at a distance of 9.5 m. 6. The MP test was then carried out. 7. During this test of the first pipe, the second pipe was loaded on to the MP rack in preparation for testing using the same procedure as detailed above. 8. When the MP test wasn completed and the results recorded the pipe was colour coded prior to being moved from the test rack, by a hempel system, to the bevel station. 9. Pipes within the same MP range were welded together.

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Ref: OSDJ-001 Rev 1

10. One bevel machine was positioned at each end of the bevel rack and used to bevel one end of each alternate pipe. 11. The first pipe was bevelled by bevel machine #1 and then lifted by the forklift (fitted with a pipe clamp and rubber protectors) through the end building columns to front end rack and then moved to one side on the rollers. At this stage the pipe was marked (PIPE 1 STERN), pipe number noted and documented. The next pipe was bevelled by bevel machine #2 and then lifted off the rack by the forklift (fitted with a pipe clamp and rubber protectors) through the end building columns to front end rack. At this stage the pipe number was noted and documented. 12. Two pipe buggies picked up each of these pipes and placed them into station 1, the bead stall. 13. The pipe at the nest end was rollered into to the nest and the ILUC (Internal Line up Clamp) was sent up the pipe and positioned. Dog set 1 was locked onto the clampt. The second pipe was then be moved to the preset height and then moved towards the first pipe. The spacer and panel operator then set up the butt. The argon purge will then be activated and the pipe ends pre heated if necessary. Then the band and bug was fitted. 14. Pass 1 (Root Pass) was then be deposited. 15. Switch off purge 16. The double joint was then rollered back to the nest and the clamp removed. 17. Then the double joint was moved by rollers to station 2 where Pass 2 (hot pass) weld operation took place, with band and bug. 18. The double joint was then moved by rollers to station 3 where X-RAY and internal camera inspection of the root took place.

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Ref: OSDJ-001 Rev 1

19. The double joint was then moved by rollers to station 4 for cooling. This was also a repair station if required. 20. If the X-RAY shoed a defect, the pipe was taken off line by two buggies and landed in VEE blocks, repaired then moved back into line. 21. If there was no repair the pipe continued to station 5 where fill passes 3 & 4 of SAW. (submerged arc welding) were deposited. 22. The double joint was then moved across a hempel system to station 6 where fill passes 5 & 6 of SAW (submerged arc welding) were deposited. 23. The double joint was then moved by rollers to station 7 where it went through a cooling process. 24. The double joint was then moved by rollers to station 8 where the final two passes (7& 8) SAW (submerged arc welding) were deposited. 25. The double joint was then moved by rollers to station 9 where it went through a cooling process. 26. The double joint was then moved by rollers to station 10 where it underwent the final radiography. 27. The completed double joint was then moved by rollers outside to the completion rack. 28. Two pipe buggies then picked up the double jointed pipe and place it on the outbound rack 29. The completed double joint was then lifted from the outbound rack, to either the agreed packing area or on to transport depending on packing requirement. 30. Double Joints were then loaded out on to company transportation vessel.

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