Doc No: DBD40024770

Rev: D Page 1 of 36

DESIGN BASIS DOCUMENT, SUBSEA - COMPLETION &

WORKOVER, SHELL GUMUSUT-KAKAP CWOR SYSTEM, 5 YEAR
RECERTIFICATION

Rev ECN No. Date Reviewed By Approved By Status

D PENDING

Summary:

This design basis describes the second recertification to be conducted on the

Completion Workover system first delivered to Shell Gumusut Kakap Phase 1 in
2009/2010. The first recertification for phase 2 including DP upgrade was performed in
2015-2017. Equipment has not been used since then and we plan a condition based for
the current re-certification.
Current re-certification is based on DNV RP-E101.
This document is to be considered as the overall specification and requirement for the
Recertification of the Shell GK CWOR system.

Author rev. D: Roald Berget Nilsen

This document and all the information contained herein are the confidential and exclusive property of TechnipFMC,
and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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Table of Contents
1.0 Applicable Documents.................................................................................. 7
1.1 Order of Precedence.................................................................................. 7
1.2 Client specifications ................................................................................... 7
1.3 Industry standards ..................................................................................... 7
1.4 TechnipFMC Specifications and Documents ............................................. 8
2.0 General Information ...................................................................................... 9
2.1 Purpose ..................................................................................................... 9
2.2 Overview .................................................................................................... 9
2.3 Third party selection and description ....................................................... 10
3.0 System Description ..................................................................................... 11
3.1 Introduction .............................................................................................. 11
3.2 Equipment to be recertified ...................................................................... 11
3.3 General inspection criteria ....................................................................... 17
3.3.1 Fasteners ................................................................................................. 17
3.3.2 Seals ........................................................................................................ 17
3.3.3 Sealing surfaces - inspection ................................................................... 17
3.3.4 Welded surfaces - inspection ................................................................... 17
3.3.5 Hydraulic system ..................................................................................... 18
3.3.6 Coating condition ..................................................................................... 18
3.3.7 Corrosion and wear - findings .................................................................. 18
3.4 Component criticality................................................................................ 19
4.0 Activities - Planning Phase ........................................................................ 19
4.1 Kick-off meeting (with all parties) ............................................................. 19
4.2 Documentation review and evaluation of history by 3rd party .................. 20
4.3 Risk review - project HAZOP ................................................................... 20
4.4 Gap Analysis............................................................................................ 21
4.4.1 Standards and specifications from phase 1 delivery ................................ 21
4.4.2 ECN change history on component PN level ........................................... 22
4.5 Procurement of parts ............................................................................... 22
4.5.1 Create Excel plan for parts to be procured .............................................. 22
4.5.2 Procure parts ........................................................................................... 22
4.6 Vendors and service providers ................................................................ 22
4.6.1 Inspection and NDE ................................................................................. 23
4.6.2 Coating .................................................................................................... 23
4.6.3 Machining and welding repair .................................................................. 23
4.7 Create recertification procedures ............................................................. 24
4.7.1 Overview .................................................................................................. 24
4.7.2 RRP's ....................................................................................................... 24
4.8 Create work packages ............................................................................. 25
4.8.1 WP's- for recertification ............................................................................ 25
4.8.2 WP's - for the Phase 2 Upgrade of EDP/LRP/IWOCS ............................. 26
4.8.3 WP's - Additional tasks ............................................................................ 26
4.9 Set up site for execution phase ................................................................ 27

This document and all the information contained herein are the confidential and exclusive property of TechnipFMC,
and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
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4.9.1 Site organization and responsibilities ....................................................... 27

4.9.2 HSE ......................................................................................................... 27
4.9.3 Quality...................................................................................................... 27
5.0 Activities - Execution Phase ...................................................................... 28
5.1 Disassembly of all equipment .................................................................. 28
5.1.1 Disassembly ............................................................................................ 28
5.1.2 Identification of components, tagging and logistics .................................. 28
5.2 Parts to be replaced ................................................................................. 29
5.2.1 Standard parts ......................................................................................... 29
5.2.2 Major parts to be evaluated for replacement ............................................ 29
5.3 Inspection ................................................................................................ 29
5.3.1 Inspection level ........................................................................................ 29
5.3.2 Acceptance criteria and requirements...................................................... 30
5.3.3 NDT certified vendors .............................................................................. 31
5.3.4 Inspection plan ......................................................................................... 31
5.4 Repair of findings ..................................................................................... 31
5.4.1 General .................................................................................................... 31
5.4.2 Weld repair and heat treatment ............................................................... 31
5.5 Surface treatment and corrosion protection ............................................. 32
5.6 Reassembly ............................................................................................. 32
5.6.1 Equipment to be ' as was' state ............................................................... 32
5.7 Testing ..................................................................................................... 33
5.7.1 Test equipment ........................................................................................ 33
5.7.2 Outline test procedure.............................................................................. 33
5.7.3 Sub assembly testing ............................................................................... 33
5.7.4 FAT .......................................................................................................... 33
6.0 Final Documentation ................................................................................... 34
6.1 5-year COC's ........................................................................................... 34
6.2 MRB's ...................................................................................................... 34
7.0 Project close out and future recommendations ....................................... 35
7.1 Experience transfer and close out ........................................................... 35
7.2 Recertification of spare actuator assemblies ........................................... 35
7.3 Updating relevant PSM's ......................................................................... 36

This document and all the information contained herein are the confidential and exclusive property of TechnipFMC,
and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
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List of Tables
Table 1: Shell Gumusut Phase 1 specifications........................................................................... 7
Table 2: Industry standards ......................................................................................................... 7
Table 3: TFMC specifications and documents ............................................................................. 8
Table 4: Stack components to be recertified ............................................................................. 11
Table 5: ERC Riser and Special joint components to be recertified ........................................... 11
Table 6: Riser and Crossovers involving 3rd party connections ................................................ 14
Table 8: Component criticality ................................................................................................... 19
Table 9: Criticality input ............................................................................................................. 19
Table 10: Gap analysis - relevant Client Specifications ............................................................. 21
Table 11: GAP analysis - relevant Industry Standards .............................................................. 21
Table 12: Inspection categories ................................................................................................ 29
Table 13: NDT Operations ........................................................................................................ 30

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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Abbreviations
The following abbreviations are used throughout this procedure.

Abbreviation Description
API American Petroleum Institute
ASME American Society of Mechanical Engineers
BOP Blowout Preventer
COB Close of Business
COC Certificate of Conformance
CPI Customer Provided Item
CT Coiled Tubing
CWOR Completion Work Over Riser
DBD Design Basis Document
DBI Database Information
DIM Dimensional
DP Dynamically Positioned
ECN Engineering Change Notice
EDP Emergency Disconnect Package
EFAT Extended Factory Acceptance Test
EQD Emergency Quick Disconnect
ERC Enhanced Riser Connection
ET Eddy Current Testing
EVDT Enhanced Vertical Deepwater Tree
FAT Factory Acceptance Test
GV Gate Valve
HPU Hydraulic Power Unit
HSE Health, Safety and Environment
HT Hardness Testing
ISO International Organization for Standardization
IWOCS Installation Work Over Control System
KSI Kilopound per Square Inch
LRP Lower Riser Package
MRB Manufacturing Record Book
MT Magnetic Particle Testing
NACE National Association of Corrosion Engineers
NDT/NDE Non-destructive Testing / Non-destructive Examination
NJ Nusajaya
OEM Original Equipment Manufacturer
PCM Pressure Control Manual
PIV Production Isolation Valve
PMI Positive Material Identification
PO Purchase Order
PRE Product Responsible Engineer
PSM Preservation, Storage and Maintenance
PT Penetrant Testing
PWHT Post weld heat treatment
QA Quality Assurance

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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QC Quality Check
QN Quality Notification
QP Quality Plan
ROV Remotely Operated Vehicle
RP Recommended Practice
RRP Recertification Procedure
RT Radiographic Testing
SAE Society of Automotive Engineers
SFT Surface Flow Tree
SIT Systems Integration Test
SME Subject Matter Expert
SN Service Notification
SSS Subsea Services
TRT Tree Running Tool
TSJ Tapered Stress Joint
UT Ultrasonic Testing
VIS Visual
VO Variation Order
W/O Work Over
WAS Well Access System
WCS Well Completion System
WP Work Package
WP Working Pressure
WPS Weld Procedure Specification
XO Crossover
XT X-mas Tree

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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1.0 Applicable Documents

1.1 Order of Precedence
In the event of a conflict between the content of this document and the content of the
documents referenced herein, the order of precedence is:
• Government Regulations
• Client Specifications
• Industry Standards
• This Document
• TFMC referenced documents and standards

1.2 Client specifications

Table 1: Shell Gumusut Phase 1 specifications
No: Document Number Revision Description
/A1/ DWS 37.80.10.30 2014 Shell - Specification, Deepwater Subsea
Completion/Workover systems
/A2/ DEP 39.01.10.11 2021 Shell - Materials selection
/A3/ DEP 39.01.10.12 2021 Shell - Materials selection
/A4/ DEP 30.48.00.31 2021 Coating of fasteners
/A5/ HSSE.PeS.PR.014 2019 SMEP Lifting and Hoisting Manual rev. 3.0
/A6/ WS 38.80.31.32-Gen 2022 Pressure Control Manual

1.3 Industry standards

Table 2: Industry standards
Document Number Revisi
No: Description
on
/B1/ DNV-RP-E101 2021 Recertification of well control equipment
/B2/ ISO 13628-7 2005 Design and operation of subsea production
systems - Part 7: CWOR systems
/B3/ API 5 CT 2018 Specification for Casing and Tubing
/B4/ API 5L 2018 Specification for Line Pipe
/B5/ API RP 17 G 2006 Recommended Practice for Design and
Operation of Completion/Workover Riser
Systems
/B6/ API SPEC 6A 2010 Specification for Wellhead and XT Equipment
/B7/ API 16D 2018 Specification for Control Systems for Drilling
Well Control Equipment and Control Systems
for Diverter Equipment

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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/B8/ API 53 2018 Blowout Prevention Equipment Systems for

Drilling Wells
/B9/ API 17 D 2021 Design and operations of subsea prod
systems - Wellhead and Tree Equipment
/B10/ NACE MR0175 2015 Standard Material Requirements for Sulfide
Stress Cracking.
/B11/ NORSOK M-503 2016 Cathodic protection
/B12/ NORSOK M-710 2014 Elastomer seals
/B13/ ASME B31.8 2021 Chemical Plant and Petroleum Refinery Piping
/B14/ API 6A / ISO 10423 21 Specification for Wellhead and Tree
Equipment
/B15/ NORSOK M-501 2022 Surface preparation and Protective coating

1.4 TechnipFMC Specifications and Documents

Table 3: TFMC specifications and documents
Document
No: Description
Number
/C1/ SPC10097591 Specification, Subsea - Completion & Workover, Shell Five Year
Recertification Requirements
/C2/ PRD-0000030504 Procedure, Recertification of RLWI Systems
/C3/ MPR60004866 Miscellaneous Procedure, Recertification Of Well Control Equipment
/C4/ DBD40002140 Design Basis Document, Shell Gumusut-Kakap Project
/C5/ DBD40021512 Design Basis Document, Subsea - Completion & Workover, Shell
Gumusut Kakap Phase 2 Modification for DP Rig
/C6/ SPC10015480 Specification, Shell Gumusut Completion And Workover Riser System
/C7/ TST40025550 Outline Test Procedure, Recertification/Upgrade
/C8/ RPT40025617 Gap Analysis, Recertification/Upgrade
/C9/ SPC60181657 Specification, Subsea - Completion & Workover, 5 Years Recertification
Process Philosophy, GK CWOR/IWOCS System
/C10/ SPC60181699 Specification, Subsea - Completion & Workover, Scope of Work for
Gumusut CWOR System, F/ 2022 Recertification
/C11/ SPC60181700 Report, Gap Analysis, Subsea - Completion & Workover, Gumusut CWOR
System, F/ 2022 Recertification
/C12/ SPC60118701 Report, Risk Assessment, Subsea - Completion & Workover, Gumusut
CWOR System, F/ 2022 Recertification
/C13/ SPC60181696 Report, Feed Study, Subsea - Completion & Workover, Operational
History Gumusut CWOR System, F/ 2022 Recertification
/C14/ SPC60181697 Report, Feed Study, Subsea - Completion & Workover, Maintenance
History Gumusut CWOR System, F/ 2022 Recertification
/C15/ SPC60181698 Report, Feed Study, Subsea - Completion & Workover, Repair History
Gumusut CWOR System, F/ 2022 Recertification
/C16/ DBD40024770 Design Basis Document, Subsea - Completion & Workover, Shell
Gumusut-Kakap CWOR System, 5 Year Recertification

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
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2.0 General Information

2.1 Purpose
The purpose of the recertification is to verify that the equipment condition and properties
are within the original design specifications and equipment qualification basis. The
recertification process shall include inspection, overhaul and verification to verify that
the equipment's safety margin is within the original acceptance criteria.
The resulting goal of the recertification is to confirm that the component has completed
the necessary recertification work scope. This validation is made by performing a DNV
recommended recertification according to DNV-RP-E101.
TechnipFMC will issue a COC, valid for 5 years, per assembly, based on a completed
recertification.
This Design basis and the documentation that is created based on it, e.g. RRP's, is
made to be used for future recertification of the Shell GK CWOR System. A revision
update before each future recertification is recommended, to capture changes in
equipment and/or standards/specifications and/or project execution strategy.
Future Recertifications should be planned for execution within every 5 years since last
COC was issued.

2.2 Overview
The following activities shall be included in the recertification process:
• Upfront planning phase

• Gap analysis of all relevant standards/specifications

• Review of original documentation and perform an ECN PN history review

• Review of maintenance history/records and SN/QN history

• Update portfolio of procedures to be used during execution phase

• Create/Update/Review NDE inspection procedures and welding procedures

• Set up execution site, based on a project organization

• Identification of equipment which need to be transported to TFMC's NJ yard

at Johor to complete recertification scope

• Logistics arrangement for equipment identified above

• Create realistic schedule incorporating recertification scope including

contingencies, transportation and procurement of spares, if any

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
Rev: D Page 10 of 36

• Create Recertification Master Equipment List

• Create Recertification Inspection Test Plan

• Create Master Document Register

• Create HSSE & Quality Plans

• Organize a lesson learned workshop

• Manage any interface scope with 3rd party vendors

• Execution 'in workshop' phase

• Stripping/dismantling of equipment

• Visual inspection and dimensional check/review of selected components

• NDE/NDT inspection of critical components

• Change out of all seals/gaskets and wellbore wetted fasteners

• Equipment assembly

• Sub-assembly testing and assembly FAT, including gas testing, if not already
conducted

• Create final documentation, COC and MRB, based on signed procedures

• Shell representative and supervisor's visit to TFMC workshop/recertification

plant/yard for verification/witness during FAT and/or hold/witness points for
QAQC purpose, if required

TFMC should continuously explore optimization opportunities with regards to the

recertification scope and propose to Shell for alignment and approval.

2.3 Third party selection and description

The 3rd party chosen for this recertification is DNV. TFMC initiates DNV as a 3rd party
contractor, and bears all costing related to DNV.
The level of involvement from DNV has to be agreed upon early in the project. They
can/will be involved in the following actions, to be discussed:
• History evaluation of the components (Conducted PSM maintenance &
operation of equipment since delivery or last recertification)
• Involvement in review/approval of critical documents, if any, upfront
• Involvement in the signoff procedures during execution

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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• Involvement in witnessing critical hold points during execution e.g Valve block
inspections, gas testing etc.
• Involvement in review/approval of inspection reports and completed
recertification procedures
• Issue a final recertification report and recertification COC's (RCCs)

3.0 System Description

3.1 Introduction
The Gumusut-Kakap project is located offshore Borneo, Sabah, Malaysia. The host
platform is an FPS located in 1200 meters (3900 feet) water depth. Design water depth
rating is 2886 meters (7,500 feet) with the exception of 6,500 feet for operations with the
completion/workover riser system.
The system consists of a 5'' EVDT and an ERC Riser system with rating of 10 KSI.

3.2 Equipment to be recertified

These tables are based on the scope of supply drawings for the phase 1 Shell GK
project.

Table 4: Stack components to be recertified

Equipment PN SN# Quantity
LRP, ASSY, 5.1/8 X 2.1/16-10K, EVDT RISER P4000015667 2008-12-0509N 1
SYSTEM, SHELL GUMUSUT
EDP, ASSY, 5.1/8X2 1.16-10K, EVDT RISER P4000015666 2008-12-0517N 1
SYSTEM, SHELL GUMUSUT
SURFACE FLOW TREE P1000041484 2008-10-0416N 1

Table 5: ERC Riser and Special joint components to be recertified

Equipment PN SN# Quantity
RISER, MONO BORE STANDARD JOINT P6000047609 2010-01-0081N 94
45FT, 7"OD 5.1/8" NOM BORE ERC BOX X 2010-01-0082N
ERC PIN 2010-01-0083N
2010-01-0084N
2010-01-0085N
2010-01-0086N
2010-01-0087N
2010-01-0123N
2010-01-0124N
2010-01-0125N
2010-01-0126N
2010-01-0127N
2010-01-0180N

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
Rev: D Page 12 of 36

Equipment PN SN# Quantity

2010-01-0181N
2010-01-0182N
2010-01-0183N
2010-01-0184N
2010-01-0191N
2010-01-0192N
2010-01-0193N
2010-01-0194N
2010-01-0195N
2010-01-0196N
2010-01-0197N
2010-01-0208N
2010-01-0209N
2010-01-0210N
2010-01-0211N
2010-01-0212N
2010-01-0219N
2010-01-0220N
2010-01-0221N
2010-01-0222N
2010-01-0224N
2010-01-0225N
2010-01-0226N
2010-01-0227N
2010-01-0228N
2010-01-0229N
2010-01-0230N
2010-01-0231N
2010-01-0232N
2010-01-0233N
2010-01-0234N
2010-01-0235N
2010-01-0236N
2010-01-0237N
2010-01-0238N
2010-01-0239N
2010-01-0240N
2010-01-0241N
2010-01-0242N
2010-01-0243N
2010-01-0244N
2010-01-0245N
2010-01-0246N
2010-01-0247N
2010-01-0248N
2010-01-0249N
2010-01-0250N
2010-01-0251N
2010-01-0252N
2010-01-0253N
2010-01-0254N
2010-01-0255N
2010-01-0256N
2010-01-0257N

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 Doc No: DBD40024770
Rev: D Page 13 of 36

Equipment PN SN# Quantity

2010-01-0258N
2010-01-0260N
2010-01-0261N
2010-01-0262N
2010-01-0263N
2010-01-0264N
2010-01-0265N
2010-01-0266N
2010-01-0267N
2010-01-0268N
2010-01-0269N
2010-01-0270N
2010-01-0271N
2010-01-0272N
2010-01-0273N
2010-01-0274N
2010-01-0275N
2010-01-0276N
2010-01-0277N
2010-01-0278N
2010-01-0279N
2010-01-0280N
2010-01-0281N
2010-01-0282N
2010-01-0283N
2010-01-0284N
2010-01-0285N
RISER, MONO BORE PUP JOINT 20FT, P6000047610 2010-03-0071N 3
ASSY, 5.1/8 IN NOM BORE, 10K ERC BOX 2010-03-0072N
TOP X ERC PIN BTM 2010-03-0073N
RISER, MONO BORE PUP JOINT 10FT, P6000047611 2010-03-0074N 3
ASSY, 5.1/8 IN NOM BORE, 10K ERC BOX 2010-03-0075N
TOP X ERC PIN BTM 2010-03-0076N
RISER, MONO BORE PUP JOINT 8FT, ASSY, P6000047612 2010-03-0077N 4
5.1/8 IN NOM BORE, 10K ERC BOX TOP X 2010-03-0078N
ERC PIN BTM 2010-03-0079N
2010-03-0080N
RISER, MONO BORE, SAVER SUB 5FT-10K, P6000047596 2010-03-0081N 2
ASSY, PIN TOP X PIN BTM, ERC, 5.1/8 IN 2010-03-0082N
NOM BORE
RISER, MONO BORE, SAVER SUB 5FT-10K, P6000047618 2010-03-0083N 2
ASSY, PIN TOP X PIN BTM, ERC, 5.1/8 IN 2010-03-0084N
NOM BORE
RISER MONO BORE, 19.0 OD X 14.5 ID, P1000025342 2009-03-0065N? 2
F/TAPERED TENSION JOINT LOWER BODY 2009-03-0066N
TENSION RING, FOR RISER TENSION P1000050769 9542-1-1 2
JOINT, WELDMENT, 15.62 ID X 45.0 OD, 9542-1-2
VERTICAL LOAD CAPACITY 368 TONS (61
TONS PER PADEYE)
RISER,MONO BORE,5-10K TAPERED P1000041731 2009-04-0127N 2
TENSION JOINT ASSY, W/7.1/16IN CLAMP 2009-04-0128N
HUB TOP X FMC ERC BOX CONNECTOR
BTM, W/5.1/2IN AX GASKET PREP

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 Doc No: DBD40024770
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Equipment PN SN# Quantity

CRA,5.125ID X 277.9LG,397 TON SWL F/2.5
NOM G2140 SHACKLE
RISER STRESS JOINT, ASSY, MONO BORE, P1000041538 2009-04-0123N 2
5-10K, EVDT CWOR TSJ, 45FT LG W/13.5/8- 2009-04-0124N
10K SPEEDLOC 2 BTM W/5.5 IN MC
GASKET PREP CRA X 5.1/8-10K FMC ERC
BOX TOP
RISER, MONO BORE, 5-10K TAPERED P1000025350 2009-04-0002N 2
TRANSITION JOINT ASSY, W/13.5/8-10K 2009-04-0003N
CLAMP HUB TOP X 7.1/16-10K SPEEDLOC 2
BTM W/5.125 AX GASKET, 10K WP, 5.14 ID X
57.47FT LG, U, DD, PSL 3
RISER, MONO BORE, XT MODE, 5-10K P4000023075 2010-04-0109N 1
TAPERED TRANSITION JOINT ASSY,
W/13.5/8-10K CLAMP HUB TOP X 7.1/16-10K
SPEEDLOC 2 BTM W/5.125 AX GASKET, 10K
WP, 5.14 ID X 47FT LG
RISER, MONO BORE, XT MODE 5-10K P4000023076 2010-04-0108N 1
SPACER JOINT ASSY, W/7.1/16-10K CLAMP
HUB TOP X 7.1/16-10K SPEEDLOC 2 BTM
W/5.125 AX GASKET, 10K WP,5.14 ID X 10FT
LG
RISER, MONO BORE 5-10K TAPERED P1000025346 2009-04-0004N 1
TRANSITION JOINT ASSY F/TUBING
HANGER MODE, W/13.5/8-10K CLAMP HUB
TOP X 7.5/8 LDR BOX CONNECTION BTM,
W/5.12 IN AX GASKET PREP CRA, 5.125 ID
X 101.30 LG

Table 6: Riser and Crossovers involving 3rd party connections

Equipment PN SN# Quantity
TAPERED STRESS JOINT, ASSY, 5-10K F/ P4000021127 2009-04-0005N 1
WIRE AND DRILL PIPE, F/5-10K DPTRT
SYSTEM, W/ 13 5/8 SPEEDLOC II BTM 7 5/8
VAM LDR BOX
RISER, MONO BORE CROSSOVER ASSY, P4000026517 2010-05-0106N 1
7.5/8 IN VAM, LDR PIN TOP X ERC PIN BTM,
5.1/8 IN NOM. BORE 10K 8FT LG
RISER, MONO BORE CROSSOVER ASSY, P4000027596 2010-05-0108N 2
7.5/8 IN VAM LDR BOX TOP X ERC PIN BTM, 2011-07-0458N
5.1/8IN NOM.BORE 10K, 8FT LG
RISER, MONO BORE CROSSOVER ASSY, P4000026444 2010-05-0104N 2
8.1/4 IN DBL ACME QUICK UNION BOX TOP 2010-05-0105N
X ERC PIN BTM, 5.1/8IN NOM, BORE, 10K,
8FT LG
CROSSOVER JOINT, ERC BOX TOP X 6.5/8 P4000026987 2010-05-0085N 2
TENARIS HW 47.1 LB/FT PIN BTM X 103.9 2010-05-0086N
LG
CROSSOVER JOINT,6.5/8 IN TENARIS HW P4000015944 2009-07-0139N 2
47.1LB/FT BOX TOP X 6.5/8IN TENARIS HW 2009-07-0140N
47.1LB/FT PIN BTM X 100.0 LG

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
Rev: D Page 15 of 36

Equipment PN SN# Quantity

RISER, MONO BORE CROSSOVER ASSY, P4000034815 2011-05-0208N 3
5.1/2 IN GP XT-M57 BOX TOP X ERC PIN 2011-05-0209N
BTM, 4.1/4 IN NOM. BORE 10K 100 IN LG 2011-05-0210N
RISER, MONO BORE CROSSOVER ASSY, 5- P4000028580 2012-03-0198N 1
1/8IN NOM. BORE, ERC BOX TOP, 10K, 8 FT
LG
RISER, MONO BORE CROSSOVER P4000019903 2010-01-0288N 1
COATING 6.5/8 IN GRANT PRIDECO XT-M6
BOX TOP X 7.5/8 IN VAM LDR PIN BTM, 8.53
IN OD X 5.275 ID, 10000PSI WP, 6FT OAL
RISER, MONO BORE CROSSOVER P4000026518 2010-05-0107N 1
ASSY,5.18 IN NOM. BORE, ERC BOX TOP X
7.5/8 IN VAM LDR PIN BTM 10K 8FT LG
RISER, MONO BORE CROSSOVER, P4000019883 2010-01-0286N 2
COATING 7.5/8IN NOM OD, 1.00IN 2010-01-0287N
WALL,7.5/8IN VAM LDR PIN TOP X 6.5/8IN
GRANT PRIDECO XT-M69 PIN BOTTOM,
8.53IN OD X 5.275IN ID,10 KSI WP, 6FT OAL
RISER, MONO BORE CROSSOVER ASSY, P4000028493 2012-03-0199N 1
ERC PIN BTM, 5 1/8 IN NOM. BORE, 10K,
8FTLG

Table 7: Other components to be recertified

Equipment PN SN# Quantity

TREE RUNNING TOOL, ASSY, 5-10K F/WIRE & P1000040814 2009-03-0043N 1
DRILL PIPE, SUPER ASSEMBLY W/13.5/8
SPEEDLOC II TOP PROFILE & 18.3/4-15K
TORUS IV CONNECTOR BOTTOM,
W/ANNULUS ACCESS VALVE
IWOCS HYDRAULIC POWER UNIT P4000016512 45187072-01 1 off
(accumulators only) (5 acc)
OUTLET ADAPTER ASSY, FLANGED X WECO P4000026671 2010-06-0004N 1
UNION FEMALE SUB, 2 1/16-10K X 2 FIG 1502
W/ INCONEL RG INLAY, GASKET AND STUDS
ASSY EE, S-U, PSL 3
OUTLET ADAPTER ASSY, FLANGED X WECO P4000026672 2010-06-0005N 1
UNION FEMALE SUB, 2 1/16-10K X 2 FIG 1502
W/ INCONEL RG INLAY, GASKET AND STUDS
ASSY EE, S-U, PSL 3
SURFACE TREE SWIVEL, SWIVEL, WOR, P7000025751 2015-04-0403B 1
ASSY, 5.1/8-10K FINAL ASSY WITH LIFT/TEST
CAP & SHIPPING SKID
ANNULUS UMBILICAL REELER,1”ID 7,500psi, P4000016538 2010-06-0001N 1
1550m
BODY BLOCK, CVB, WW-VALVE BLOCK P122033-0014 2008-07-0335N 1
SURFACE FLOW TREE ASSY, SKV, SURFACE P122571-1021 2008-10-0023N 1
PRODUCTION WING VALVE WW-3" BARRIER
ELEMENT
SURFACE FLOW TREE HEAD MASTER P1000044673 2008-10-0021N 1
VALVE, SPMV, SURFACE PRODUCTION
MASTER VALVE WW-5" BARRIER ELEMENT

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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SURFACE FLOW TREE SWAB VALVE, SPSV P120042-0003 2008-09-0097N 2

SURFACE PRODUCTION SWAB VALVE WW- 2008-09-0098N
5" BARRIER ELEMENT
SURFACE FLOW TREE SWAB VALVE, SPSV P120177-0012 2008-09-0949N 1
SURFACE PRODUCTION SWAB VALVE WW-
5" BARRIER ELEMENT
SURFACE FLOW TREE HEAD WING VALVE, P122572-1021 2008-10-0048N 1
SPWV, SURFACE PRODUCTION WING VALVE
- WW-3" BARRIER ELEMENT
SEAL STAB, F/ ANY OD, 22.5K WP, F/ USE IN P1000031697 2008-09-0023N 1
6.350 INCH BORE
WORKOVER, RISER CONTROL STATION, P4000016506 45187072-02 1
SHELL GUMUSUT KAKAP PROJECT
IWOCS MAIN UMBILICAL AND REEL, 14-OFF, P4000016537 2010-06-0003N 1
1/4 INCH ID, 15K PSI HYDRAULIC HOSE, 2-
OFF ELECTRICAL QUADS, 1550M
GV SEAT ASSY M130, 2 1/16-10K, STD SVC P144177 2008-09-0691N 1
GV BONNET BODY SURFACE, FINISHED P4000018284 2008-05-2646S 1
MACHINE
EDP, COMPOSITE VALVE BLOCK, ASSY, 5 1/8 P1000025549 2008-10-0414N 1
X 2 1/16-10K
SUBSEA GATE VALVE KIT M3000, 2 1/16-10K, P171706 2008-09-0695N 1
ACTUATED W/ FAIL-CLOSE GATE, W/ M3000
SERIES ACTR ASSY, EE-360, P-X
HYDRAULIC CONNECTOR, ASSY, 18 3/4 P1000002001 2008-10-0393N 1
FLOWLINE/EDP, W/ HYDRAULIC
SECONDARY RELEASE MECHANISM
GV ASSY SUBSEA, M3000, 1-15K, W/ P1000024747 FMCA6919 1
ACTUATOR, HH-360, P-X, PSL 3G, W/ GR 660
BOLTING

Note: As the THRA's (2 off) for phase 2 gas injector wells were modified from phase 1
and recertified in September 2014, both THRA's have been purposely left out of the 5-
year recertification work scope. The THRA is currently one of Shell's optional methods
to gain access to the well via BOP on Tree for intervention works, while the CWOR
system is out of service. The THRA's should be considered to be included in the next 5-
year recertification, or perhaps 1 year in advance.

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
Rev: D Page 17 of 36

3.3 General inspection criteria

3.3.1 Fasteners

All fasteners shall be visually inspected for wear, corrosion and degradation.
All wellbore pressure containing fasteners should be replaced in accordance with the
equipment's original design specification and DGL10000290.
All critically load bearing fasteners should either be thoroughly inspected or procured
new.

3.3.2 Seals

All elastomer seals, both exposed and non-exposed to wellbore fluids shall be replaced.
This scope is to be agreed upon upfront, based on criticality and result from RIT.
All metal seals exposed to wellbore fluids shall be replaced.
Seals that are replaced should be visually inspected for damage and deformation so
that the PSM's potentially can be improved for the future.

3.3.3 Sealing surfaces - inspection

All sealing surfaces exposed to wellbore fluids shall be NDT inspected as per
DBI/design requirements.
All sealing surfaces not exposed to wellbore fluids shall be visually inspected and
potentially NDT inspected as per TFMC and 3rd party recommendations, to be
evaluated upfront.

3.3.4 Welded surfaces - inspection

All welded surfaces exposed to wellbore fluids, e.g., joining riser joint flange to pipe,
shall be NDT inspected as per RRP, based on DBI requirements and an agreement
between TFMC/Shell/DNV.
Load bearing welds/welded surfaces not exposed to wellbore fluids, e.g., EDP
protection structure, shall be visually inspected and potentially NDT inspected as per
RRP, based on DBI requirements and an agreement between TFMC/Shell/DNV. This
scope is to be agreed upon upfront, based on criticality.
For potential repairs, see section 5.4.

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
Rev: D Page 18 of 36

3.3.5 Hydraulic system

All hydraulic components shall be visually inspected for damage.

All accumulators shall be recertified by OEM, usually meaning redressing of seals,
volumetric and pressure testing. Some accumulators should be replaced directly. This
scope is to be agreed upon upfront, based on criticality and result from RIT.
All hydraulic lines shall be tagged and capped off if being disassembled during
disassembly of stack components, to ensure and maintain hydraulic cleanliness. Plenty
of pictures are to be taken before and during any disassembly. All hydraulic lines shall
be flushed, and leak tested as per FAT, either separately or installed in assembly.
The hydraulic system shall be walked down during re-assembly to ensure accuracy
between the equipment and the hydraulic schematic. Discrepancies between schematic
and equipment shall be corrected to the extent possible, either by updating the hydraulic
schematic or replacing components on the equipment (pending size and cost of item).

3.3.6 Coating condition

Coated surfaces that are visually inspected and found to be in poor condition, shall be
stripped and recoated as per design specification. It is important that available vendors
for all types of relevant coating application are to be set up and prepared relative to the
execution site.
Coatings on pressure containing and load bearing components requiring NDT
inspection shall be stripped to allow for inspection. Stripping of coating shall only be
performed to the extent necessary to complete the required NDT inspection.

3.3.7 Corrosion and wear - findings

Load bearing and pressure containing: Visible corrosion shall require NDE and/or
dimensional verification to determine the extent and severity of the corrosion. Tubular
components shall be inspected using a borescope.
Corrosion repair will be performed after direction by relevant product responsible and/or
SME's on the matter. Using Teams, findings will be reported, and a separate work
package (see section 4.8.3) is to be made on site by responsible engineer for approval
by relevant parties. This is to be turned around quickly enough, so that corrective
measures can be taken within the planned schedule.
Note: An inspection of all equipment in Nusajaya/Labuan shall be conducted as early as
possible in the project. To mitigate risk of findings and to plan for corrective measures
within the Execution phase.
Cathodic protection: Shall be visually inspected and only replaced if found necessary.

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
Rev: D Page 19 of 36

3.4 Component criticality

Each component and/or group of components will be assigned a component criticality.
The classification of the component will be made based on TFMC design experience,
previous recertification experience and a review with product responsible.
Component criticality is directly linked into the RRP, as to explain why a certain
component inside an assembly is inspected.
Table 8: Component criticality
CC Label Component Criticality
BARR Barrier
MLB Major Load Bearing
SL Sealing
FC Function Critical
STRL Structural lifting
NC Non Critical
HSE HSE Critical

The table below defines the minimum requirements to be performed for used
equipment. It is to be implemented for each assembly in each recertification procedure.
Table 9: Criticality input
Criticality Required inspection Witness/Hold points*
BARR VIS, DIM, NDT Required
MLB VIS, DIM, NDT Required
SL VIS, DIM, NDT Required
FC VIS, TEST Required
STRL VIS Required
NC VIS N/A
HSE VIS N/A
* Usually, TFMC and TFMC 3rd party inspector, but can also be Shell or Shell 3rd party.

4.0 Activities - Planning Phase

4.1 Kick-off meeting (with all parties)
This list is to be considered as a template for the kick-off meeting, as there will be
additions and reductions to this list in the actual meeting.
• Review the scope of tools to be Recertified

• Equipment history since delivery to client

• Governing QA/QC documentation

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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• Introduction to HSE regulations

• Agreement on standards/codes applicable for the recertification, including

revisions, to form the basis for gap analysis.

• Review of original documentation by 3rd party

• Review of updated design and documentation since delivery, if any.

• Final documentation requirements

• Labuan & Joho execution site introduction

• Delivery schedule

• Involvement from owner (Shell), 3rd party (DNV), TFMC 3rd party inspector and
main contact points within TFMC

• Project Management Team and administration (Organization of work scope,

schedule, purchasing, invoicing, KPIs etc.)

• Handling of non-conformances before/during project

4.2 Documentation review and evaluation of history by 3rd party

TFMC shall conduct Engineering review to generate requirements during tender before
execution to algin all stakeholders including Shell and DNV.
Evaluation of history involves the conducted maintenance and operation of the
equipment since delivery, or last recertification. This is to verify that the equipment has
been used correctly and to evaluate the PSM history of the components.

4.3 Risk review - project HAZOP

A risk review shall be planned and executed with all parties present. Topics include
risks related to schedule, critical findings and repair, resources, site, quality and HSE.
All critical risks identified in the review shall be listed, and mitigating actions shall be
listed and reviewed upfront before the execution phase. The following topics shall as a
minimum be included:
• Schedule

• Critical Findings and Repair

• Subcontractor Management e.g Welding, Inspection, Repair etc.

• Resources

• Sites

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
Rev: D Page 21 of 36

• Quality

• HSSE

4.4 Gap Analysis

4.4.1 Standards and specifications from phase 1 delivery

Gap Analysis - RPT40025617, will be revised in order to investigate the revision

changes of all applicable standards since last re-certification.
The tables below list all standards from two levels:
1. Gumusut Completion and Workover Riser system specification SPC10015480
2. Product specifications, e.g., riser SPC60027837
The standards and specifications not listed here are found to be N/A for the gap
analysis. The complete list can be found in the RPT40025617 itself.

Table 10: Gap analysis - relevant Client Specifications

Ref Description Rev Rev Rev Where
Doc Nr
# as built 1.10.14 1.1.23 referenced
A1 DWS 37.80.10.30 CWOR Spec 2005 2014 2014 CWOR SPC
A2 DEP 39.01.10.11 Materials 2009 2013 2021 CWOR SPC
(old 37.81.20.32)
A3 DEP 39.01.10.12 Materials 2009 2014 2021 CWOR SPC
(old 37.81.20.32)
A4 DEP 37.80.00.36 EVDT System Spec - 2013 2013 CWOR SPC
A5 DEP 30.48.00.32 Coating of fasteners 2006 2012 2012 CWOR SPC

Table 11: GAP analysis - relevant Industry Standards

Ref Description Rev Rev Rev Where
Doc Nr
# as built 1.10.14 1.1.23 referenced
B6 API SPEC 6A Wellhead and XT 19th,2004 20th 2018 CWOR
2010 SPC
B8 API 53 BOP equipment 3rd, 1997 4th 2018 CWOR
2012 SPC
B3 API 5 CT Casing and tubing 7th, 2001 9th 2018 CWOR
2011 SPC
B4 API 5L Line pipe 44th,2005 45th 2018 CWOR
2012 SPC
B9 API 17 D Subsea WH and XT 1st, 1992 2nd 2021 CWOR
2011 SPC

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 Doc No: DBD40024770
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Ref Description Rev Rev Rev Where

Doc Nr
# as built 1.10.14 1.1.23 referenced
B10 NACE MR0175 Materials for H2S 2003 2010 2015 CWOR
SPC
B11 NORSOK Cathodic protection 5th, 2004 6th 2016 Riser SPC
M-503 2012
B12 NORSOK Elastomer seals 2nd, 2001 3rd 3rd, Riser SPC
M-710 2014 2014
B13 ASME B31.8 Piping systems 2007 2012 2021 CWOR
(10) SPC

4.4.2 ECN change history on component PN level

All class 1 and class 2 changes to all PNs in the CWOR system since delivery shall be
established and documented in gap analysis report RPT40025617. This can be done in
a table format, in conjunction with the procurements of parts listed in the next section.
Class 1 change that has not been performed through PSM work already should be
performed during the Recertification if possible or justified through this gap analysis.
Class 2 changes usually involve smaller changes and will usually be justified in the gap
analysis.

4.5 Procurement of parts

4.5.1 Create Excel plan for parts to be procured

A plan for procuring all parts to be changed out is to be made. This needs to be detailed
out for each assembly, and when a PO is set this need to be linked into the plan. This
will ease the follow-up during the execution phase between the project
planner/purchaser and procurement team.

4.5.2 Procure parts

Parts are to be purchased by the purchaser in the project via the proper channels in the
line organization. KL / Nusajaya, being the project executioner, will procure parts as
necessary, thereby receiving products with the required quality control.

4.6 Vendors and service providers

TFMC should plan meetings upfront with the vendors involved in recertification e.g.
TOT, Hitec, Tobul etc. to discuss the recertification scope and potential improvements.
TFMC shall identify interface work upfront with vendors and service providers and plan
to avoid potential delays.

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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4.6.1 Inspection and NDE

TFMC shall choose a third-party inspector as an independent inspector.

Inspection and NDE procedures are to be made by the service provider. These
procedures should detail the acceptance criteria, guidelines, and steps for each
inspection method. They can either be made based on TFMC Q-specs, or as the
service provider prefers to make it.
All procedures are to be approved by TFMC level 3 NDT specialists before client Shell
and DNV reviews and approve them.

4.6.2 Coating

Vendors for performing various types of coating are to be set up in the local area of the
execution phase, if not already present. If certain coating applications are unavailable,
components will potentially be shipped to NJ, Malaysia.
All coating types and applications are to be outlined upfront before the execution phase,
so that the components that need to be sent out of Labuan are identified upfront.

4.6.3 Machining and welding repair

Vendors for performing machining and welding are to be set up in the local area of the
execution phase. They should be able to do a variety of 'ad hoc' repair.
For potential major findings resulting in major repairs, a contingency plan shall be made
upfront. This might call for a shipping of components to other sites and countries. The
most critical example to be made is the composite valve block of the LRP, where a
major repair might result in the transportation of the block back to manufacture site -
TFMC Dunfermline, Scotland. This example is also subject to the upfront risk review.
Relevant welding procedures need to be prepared upfront from the relevant workshops
and reviewed/approved by TFMC Welding Engineers. The relevant procedures, related
to material and application, should be outlined during the writing of the recertification
procedures.
Any alteration, modification from the component's initial design, potential findings
resulting in repair during disassembly of the equipment or during NDE inspections, shall
be captured using management of change process and the rectification method
proposed is subjected to Shell approval.

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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4.7 Create recertification procedures

4.7.1 Overview

Two different types of procedures will be made for essentially all components: RRP's,
recertification procedures, and WP's, work packages

4.7.2 RRP's

RRP's are to be made based on best practices from last recertification. They are made
per assembly as shown in the figure above. They will include high-level steps for
disassembly, inspection, assembly and test, and function as a top-level document
whereas for details they will refer to the relevant assembly and test procedures via the
work packages.
The RRP's will include inspection tables for existing equipment and serialization tables
for new equipment that is to be installed. They will be released after the Receive
Inspection Test that is performed in the planning phase and should be
reviewed/approved by both Shell and DNV.

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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On site in the execution phase they will be filled out continuously, and signed off by
TFMC and TFMC 3rd party, Shell or Shell 3rd Party and DNV.
The RRP's, completed and signed off, forms the main requirements for TFMC to make
and issue a 5-year COC per assembly to Shell. They are also treated as the basis for
the Recertification Upgrade MRB's to be compiled.
Any deviations/changes from the planned work scope will be captured through TFMC's
management of change process or a customized solution to meet our project needs.
The change, depending on criticality, should be subject to a risk review and be signed
off by TFMC, Shell and DNV.
The RRP's should be updated and revised after the execution phase is completed to
incorporate experience from the project.

4.8 Create work packages

Work packages will be made based on the recertification procedures. Every RRP
constitutes of small work packages. The main reasons for splitting up the RRP are
increased procedure detail level, increased control and quality, increased engineer to
workshop-personnel interaction, less risk of missing out important activities, easier to
plan and easier to report to client.
Work packages will usually only be signed off by TFMC internally, as the important
signing fields and information from these will be transferred over to the RRPs which
function as the governing procedures. The transferring of information will be captured in
the WP's.
Work packages will be generated after each RRP is approved by all parties.

4.8.1 WP's- for recertification

Work packages will, when needed, be made based on splitting up the RRP's into more
practical procedures. E.g., Disassembly/Assembly and Testing Procedures for Torus
connector, TOT rams, 5'' gate valves etc. They will include more detailed steps for the
workshop personnel and refer to relevant procedures and drawings released in the
system. They will be created and approved by TFMC in the planning phase, but do not
require review/approval by Shell/DNV as the RRP's are the main procedures basing the
COC's and MRB's.
The procedure steps will be filled out by the personnel performing the actual execution
at site, and important information will be transferred from the work packages to the
RRP's by the engineers on site. This transfer should be done daily at COB, so that the
RRP's are kept updated at all times.

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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4.8.2 WP's - for the Phase 2 Upgrade of EDP/LRP/IWOCS

During the Gumusut CWOR recertification in 2015, engineering and delivery of the
Phase 2 Upgrade was performed in parallel. The Upgrades involve changes to the EDP,
LRP and IWOCS.
DBD40021512 describes the modifications that were performed.

4.8.3 WP's - Additional tasks

There are several additional tasks that can be created:

1) ECN change history since delivery of component, see section 4.4.2. There
might be class 1 or 2 changes within a component that should be implemented
during a recertification, if possible. Usually, these changes are implemented
during a PSM level 2 or similar, but sometimes this is not possible due to
component not being disassembled. Note that no major changes are discovered
during the preliminary check.
2) Potential small improvement suggestions discovered during disassembly of
the components. These shall be captured using the same management of
change process described in 4.7.2, before a work package is potentially created.
Level of task and deliverables will decide whether it is feasible for inclusion into
project, or if it should be saved for later implementation, e.g., in next PSM level 2
or similar.
3) Potential findings resulting in repair. Either discovered during disassembly of
the equipment in Labuan or found during NDE inspections. These shall first be
captured using the same management of change process as described in 4.7.2,
before a work package is potentially created. See more info in section 4.6.3.

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 Doc No: DBD40024770
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4.9 Set up site for execution phase

4.9.1 Site organization and responsibilities

A separate organization chart for the execution phase is to be made. Responsibilities on

site should be clearly defined. Contact information to relevant personnel on site, off site,
vendor hotlines and TFMC global product responsible is to be established. Also see
Quality below.

4.9.2 HSE

An HSE plan is to be made, based on the site of execution and the type of work to be
conducted. If a current plan for the site is in place, the project related HSE should
review this in terms of project relevance and Client relevance.

4.9.3 Quality

A quality plan is to be made for the execution phase on site.

It shall include process flow charts detailing the responsibilities and tasks of all
personnel related to various scenarios on site. This is to mitigate potential standstill
during any arising scenario, both planned and not planned for in advance.

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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5.0 Activities - Execution Phase

5.1 Disassembly of all equipment

5.1.1 Disassembly

Disassembly will be based on best workshop practices. Separate disassembly

procedures will not be made, and the recertification procedures will refer to the
assembly procedures.
This calls for a relatively experienced group of workshop personnel in terms of product
knowledge. The workshop supervisor, and the main workshop personnel, should be
highly experienced in terms of EDP, LRP and XT assemblies and how they are
assembled.

5.1.2 Identification of components, tagging and logistics

The components to be verified, with part and serial number towards original
documentation, shall be specified in the recertification procedures. The work packages
will then incorporate checklists for identifying these components.
Components shall be tagged during disassembly, so that they are logged properly into
the logistic/warehouse system on the site. It will then be the logistic engineer that has
100% control over where the parts that was disassembled are located. This should be
done by implementing a known marking/tagging system, and by the logistic engineer to
have a logistic log (Excel sheet) that is updated daily and placed on Teams so that it is
available to all.
Some parts might need to go out for coating, machining etc., and it is then important
that the tagging at disassembly is done properly containing this information. It is
furthermore the logistic engineer and delivery coordinator on site to make sure that the
item e.g., bracket, leaves the site and comes back again. It is important that the logistic
log is updated continuously for knowing where this component is at all times. And it is
important that the delivery coordinator makes sure that the e.g., the coating vendor has
the required procedures in place and returns the required reports/COC's for the job.
Note: For critical components that cannot be identified, e.g., even heat number is worn
away; alternative solutions should be presented in the recertification procedures.

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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5.2 Parts to be replaced

Since the equipment has not been used since last re-certification and that we plan to
have a condition-based approach it may not be a need to replace some parts. This will
be based on the RIT performed to get an overview of condition.

5.2.1 Standard parts

• Metal gaskets and Elastomeric seals.

• Load bearing / wellbore wetted Fasteners.

5.2.2 Major parts to be evaluated for replacement

• Bladder Accumulators / Piston Accumulators

• Other parts based on experience and usage, e.g., GV seats, gates, and bearings.

5.3 Inspection

5.3.1 Inspection level

All components will be subjected to a visual inspection when arriving at recertification

site, prior to starting dismantling. Thereafter the load case along with its functional use
determines the next level of inspection.
If visual inspection is specified at inspection level, 3rd party shall attend this inspection.
The type of NDT to be performed will be based on DBI requirements, except where
other solutions are agreed between all parties to be feasible. NDT will be performed on
all sealing areas that are exposed to well pressure, and on all welds that are exposed to
well pressure and/or are critical load bearing.
Exceptions can be made on equipment that have been stored and preserved since last
NDT inspection, to be agreed upon by all parties.
Generally, all load bearing components will be subject to a dimensional check at critical
locations. This will be detailed out in the recertification procedures.

Table 12: Inspection categories

Level Inspection Categories
VIS Visual:
Inspection of item for damage, wear and tear.

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 Doc No: DBD40024770
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DIM Dimensional:
Dimensional check of critical dimensions on dynamic parts.
PMI Positive Material Identification:
Identifying chemical composition in material.
NDT Non Destructive Testing:
Type of NDT operation to be selected

Table 13: NDT Operations

Level NDT-Operations
Penetrant Testing:
PT
Check welds and machined areas for defects on materials/non-porous surfaces.
Fluorescent Fluorescent Penetrant Testing:
PT Check machined and fine surfaces.
Magnetic Particle Testing:
MT
Check welds and machined areas for defects on ferromagnetic materials.
Fluorescent Magnetic Testing:
Fluorescent
Check welds and machined areas for defects on ferromagnetic materials. This
MT
is the preferred method for inspection of threads.
Ultra Sonic Testing:
Check welds and parts for internal linear and volumetric defects.
UT
This is the preferred method for detecting linear defects such as Lack of fusion,
laminations. Also used for thickness measurements.
Radiographic Testing:
RT Check welds and parts for internal volumetric and linear defects. Preferred
method for detecting volumetric defects such as porosity, slag inclusions etc.
Eddy Current Testing:
ET
Check welds and machined areas for defects. Can be used on coated surfaces.
Hardness testing
HT
Check hardness of surface or welded regions.

5.3.2 Acceptance criteria and requirements

Critical dimensions shall be confirmed to be within approved design-drawing tolerances

on original manufacturing drawings. These critical dimensions and their acceptance
criteria will be presented as part of the recertification procedures. Inspection points are
to be shown on machining level drawings.
Acceptance criteria for all types of NDT on various applications (seal surfaces, welds
etc.) shall be detailed in the 3rd party inspectors' procedures to be approved by all
parties (see Section 4).
If initial documentation does not clearly define the acceptance criteria to be used, new
acceptance criteria will need to be defined based on:
• Standards and codes at time of original manufacture

• Design Specifications

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5.3.3 NDT certified vendors

A 3rd party inspector will be chosen in the planning phase, see chapter 4.
They will prepare all procedures as already mentioned. They will also prepare
inspection equipment and certified inspectors to the site.

5.3.4 Inspection plan

The Inspection Plan will be an Excel sheet describing the inspections to be performed
during the recertification. It will be a summarizing table of all inspections points in the
recertification procedures (RRP's) and includes:
• Component PN and material type for relevant part

• Drawings showing where inspections shall be performed

• NDT method to be used and procedures with acceptance criteria

• Witness / hold points for DNV and Client.

5.4 Repair of findings

5.4.1 General

Repair of potential findings shall be in accordance with the original procedures and
potential findings during inspection shall be reported. Any repairs done to the equipment
shall be documented and traceable. Depending on the size of repair, it may be
advantageous to make an additional work package (see section 4.7.3) for control and
quality of the repair job.

5.4.2 Weld repair and heat treatment

Shall be performed per approved WPS procedures, see section 4.6.

Prior to welding, the specified PWHT shall be verified and evaluated against the
tempering temperature described in the original material certificate.
Any component exposed to hot work (welding, hot forming), followed by heat treatment,
should, if possible, be exposed to an isolated Hydrostatic Body Test prior to
reassembly. This test will then be at test pressure = 1,5 x WP.

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 Doc No: DBD40024770
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5.5 Surface treatment and corrosion protection

Depending on the condition of the surface coating, and the level of NDT (certain NDT
methods requires stripping), a new application of surface coating is to be performed.
A plan for coating shall be made before execution phase and agreed upon with Shell.
This is to be based on an inspection of the physical state of the components. The plan
should include type of coating and corresponding TFMC C-spec, found in the DBI's.

5.6 Reassembly

5.6.1 Equipment to be ' as was' state

All equipment listed in section 3.2, except the ones described in the section below, are
generally to be assembled the way they were before the recertification process started.
The only differences might come from the additional tasks listed in section 4.8.3, but
these should not result in any changes in functionality or design.
Assembly procedures and drawings will be referred to in the work packages, and should
be printed out by engineers on site, and reviewed together with the workshop personnel
accordingly while performing the work packages.
Assembly procedures and drawings will be referred to in the work packages, and should
be printed out by engineers on site, and reviewed together with the workshop personnel
accordingly while performing the work packages.

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and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.
 Doc No: DBD40024770
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5.7 Testing

5.7.1 Test equipment

All test equipment will be listed in a separate document early in the planning phase.
Most of the components should be CPI from Gumusut Phase 1, but items such as seals
(for test only) should be procured if needed. If any required test equipment is missing,
this needs to be either rented or procured from the Labuan base or Shell to be ready for
the execution phase.
A contingency plan for potential hot work repairs, see section 5.4, should be made.

5.7.2 Outline test procedure

Test procedure, TST40025550 will be updated. This will give an overview of testing to
be performed on equipment from section 3.2, and the order of how to perform them.
Testing will be conducted during RIT, any re-work, and the FAT to get the re-
certification.

5.7.3 Sub assembly testing

During reassembly of the stack components, there is a huge benefit to performing sub
assembly leak testing at certain stages of assembly. For instance, a 10k hydrostatic
leak test of the LRP valve block assembled, thereby eliminating leakage at an early
stage. This can potentially save a lot of time at a later stage with regards to not having
to disassemble the entire piping/structural package to fix the problem.
Sub assembly testing will be performed as separate work packages, and will be brought
into the flowchart/schedule so that it is performed at the right time. The necessary
procedures are already in place, as per DBI's.
Witness/hold points for sub assembly testing is not required as it will be repeated during
the FAT at a later stage, but this can be discussed upfront with all relevant parties.
Any 10k psi well pressure exposed components that undergo repair or modification
during the project, will need to undergo a new 1.5 x WP = 15 KSI hydrostatic test. See
section 5.4.2 for more information.

5.7.4 FAT

Separate work packages will be made for the FAT's. These will refer to relevant
chapters of the already released TST test procedures.
Some changes to the TST's might also be required to accommodate the appropriate
leak testing criteria (not always in the TST procedures from original assembly).

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Relevant chapters of the FAT procedures include, but are not limited to: hydraulic
system flushing and leak testing, functional testing of connectors/valves, interface
testing, 1.1 x WP hydrostatic leak testing and 1 x WP gas test (EDP, LRP, SFT only).

6.0 Final Documentation

Final documentation, and especially the COC's, is required by the client in timely
manner after the execution phase has been completed. It is therefore vital that the work
related to preparing these is initiated during the execution phase.

6.1 5-year COC's

These will function as Shell's renewed licenses for operating the components of the
CWOR system for 5 new years, as per Shell PCM, API 17G and API 53. DNV will make
an RCC, validating TFMC's COC from a 3rd party perspective.
The starting date in the COC shall be the day the COC is issued, and preferably within 1
month after the execution phase is completed.
One COC is to be made per assembly level PN, e.g. LRP or ERC riser joints, and there
can be several equipment numbers (serial numbers) displayed on each COC. Assembly
components like the EDP require separate chapters for each barrier element, e.g. PIV,
in the COC.
The main documentation underlying the COC's is the completed MRB, though the COC
can be issued before the MRB is reviewed and approved by Shell.
The COC's shall also include any non-conformances, if any.

6.2 MRB's
These will be compiled continuously in the execution phase. There will be one MRB per
assembly PN. The recertification is covered in this MRB. The MRB mainly constitutes
signed RRPs, RIT and ITPs which gives proof that all inspections have been performed
accordingly. The RRPs will also include BOM tables for the entire assembly, where
existing parts and replaced parts will have a column for serialization. They also contain
the approved FAT (with gas test if relevant) stating that the equipment is ready to go
offshore or to SIT.
Based on this, Recertification MRB's 2023 shall be considered as the main MRB going
forward after the Recertification. Old MRB´s (from phase 1 and 2 delivery) will be
available in the system but will be superseded by the new MRB. Similarly, the next
Recertification with corresponding MRB's based on new RRP's will be superseding
again.
The time required to compile MRB's results in them being completed after the execution
phase is completed, though the compilation of them shall start early in the execution
phase and run continuously through the project.

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 Doc No: DBD40024770
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The MRB's shall include the following, but are not only restricted to:
• Signed off and completed RRP's

• Signed off assembly procedures (where applicable)

• Signed off FAT procedures, reports and pressure charts

• MRB's on Parts that are replaced, including serialization/batch

• History of repair (if applicable)

• Documentation of the recertification process

7.0 Project close out and future recommendations

7.1 Experience transfer and close out
After the execution phase is completed, a gathering of all experiences throughout the
project is to be made. This can be of great benefit for the next recertification of Shell GK
CWOR.
A closeout meeting with all parties should be held, to gather all experiences made and
to present the client with recommendations for improvements towards the next
recertification.
Based on these findings, errors and positive/negative experiences during and after the
recertification, the necessary documentation shall be revised to incorporate this
experience. This should be done in order to ensure that the next recertification project
avoids the negative experiences and implements the positive findings.

7.2 Recertification of spare actuator assemblies

Any actuators that need to be changed out with new ones, should be preserved and
stored until future recertification. This should be performed as close as possible to the
next Recertification project. That means that once the Actuators are recertified, their
COC clock starts running at the same time as the rest of the stack is.
Measures for implementing a future plan to perform this recertification of spare
actuators should be detailed after the Recertification project is completed.
This is not included in this DBD and corresponding tender.

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 Doc No: DBD40024770
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7.3 Updating relevant PSM's

It is recommended to revise all relevant PSM's after the Recertification project is
completed. They should be revised both due to operational experience since phase 1
delivery, in addition to experience from the Recertification/Upgrade project described in
this DBD.
This is not included in this DBD and corresponding tender.

This document and all the information contained herein are the confidential and exclusive property of TechnipFMC,
and may not be reproduced, disclosed, or made public in any manner prior to express written authorization by TechnipFMC.