BHI NSP Final 14_6_12

© 2011 BAKER HUGHES INCORPORATED. ALL RIGHTS RESERVED. TERMS AND CONDITIONS OF USE: BY ACCEPTING THIS DOCUMENT, THE RECIPIENT AGREES THAT THE DOCUMENT TOGETHER WITH ALL INFORMATION
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(COLLECTIVELY "INFORMATION"). BAKER HUGHES RETAINS ALL RIGHTS UNDER COPYRIGHT LAWS AND TRADE SECRET LAWS OF THE UNITED STATES OF AMERICA AND OTHER COUNTRIES. THE RECIPIENT FURTHER
AGREES THAT THE DOCUMENT MAY NOT BE DISTRIBUTED, TRANSMITTED, COPIED OR REPRODUCED IN WHOLE OR IN PART BY ANY MEANS, ELECTRONIC, MECHANICAL, OR OTHERWISE, WITHOUT THE EXPRESS PRIOR
WRITTEN CONSENT OF BAKER HUGHES, AND MAY NOT BE USED DIRECTLY OR INDIRECTLY IN ANY WAY DETRIMENTAL TO BAKER HUGHES’ INTEREST.
NORD STREAM
Pre-commissioning the World’s Largest Offshore Gas Pipeline
Baker Hughes Process & Pipeline Services & Nord Stream AG
Pipetech World Summit, Istanbul, 14 June 2012

INTRODUCTION
© 2011 Baker Hughes Incorporated. All Rights Reserved.2
This presentation will discuss the challenges experienced
during the planning, engineering and preparation for the pre-
commissioning of the first Line and the relevant field experience
collected during its execution, focusing on:
1. THE NORD STREAM PROJECT
2. THE PRE-COMMISSIONING CONCEPT & EXECUTION
3. THE RESULTS
4. CONCLUSIONS
In September 2011 the pre-commissioning of Nord Stream Line 1
was completed. In May 2012 the pressure testing of Line 2 was
completed and remaining pre-commissioning activities are ongoing.

1. THE NORD STREAM PROJECT
Line Details
• Twin 48” x 1,224km
pipelines with transit
capacity of 55 bcm per
year
•3 design pressure zones
• Multiple wall thickness
34.6 / 30.9 / 26.8mm
• Constant ID
•Subsea hyperbaric tie ins
• Internally coated
• Maximum depth 210m
• Free vol = 1,300,000m3
• Entire system certified by
DNV
• World’s longest subsea
pipeline
• New route for Russian
gas to Europe
KP 1,224 KP 675 WD 115m KP 297 WD 80m KP 0
220 bar200 bar177.5 bar
design
pressure:
34.6 mm30.9 mm26.8 mm thickness:
100 bar

1. NORD STREAM AG
51% 15.5% 9%15.5% 9%

1. THE PPS DIVISION OF BAKER HUGHES
Baker Hughes Process & Pipeline Services is the world’s largest specialised pre-
commissioning and commissioning services provider with annual revenues in excess of
US$400M and 1,100 employees, working in over 25 countries.
+

1. PROJECT TIMELINE & STATUS
SaipemSaipem
BJ Services Germany
GmbH
BJ Services Germany
GmbH
BJ Samotlor Services
Vostok
BJ Samotlor Services
Vostok
BJ Services Company
ME
BJ Services Company
ME
BJ PPS Germany GmbHBJ PPS Germany GmbH
Nov 20112008 Apr 2011Aug 2009
Nord Stream
Pre-Com Team
Pre-Com
Contract Award
Pipeline 1 Commence
Pre-Com
Aug 2011
Pipeline 1 Complete
Pre-Com
Pipeline 1 Arrival
of Gas in Germany
Apr 2012
Pipeline 2 Commence
Pre-Com

2. PRE-COMMISSIONING OVERVIEW
Pre-commissioning activities
• Flood, clean & gauge individual sections
• Pressure test sections individually
• Hyperbaric tie-in (by Technip) – pipeline now one section (1224 km)
• Dewatering
• Drying
• Nitrogen purge

2. PROJECT CONSTRAINTS PRE-COMMISSIONING
• Pipeline size & length
• Vessel limitations
• Water flow rates
• Air requirements
• Consumables
Diesel
Chemicals
• Schedule
• Water additives
(residence time)
• Water disposal
• Noise pollution
• Light pollution
• Diesel handling and
storage
• Waste management
• Water disposal
(location / environment
protection)
• Welded subsea test
heads = one shot
operation
• Dewatering distance
• Weather

2. CHOSEN SOLUTION – VESSEL BASED FCGT
Offshore pre-com philosophy:
• 100% equipment contingency
• Oxygen scavenger and water UV
treatment
• 2500 m3/hr flooding from vessel via
twin 6” downlines
• Entire spread function tested prior to
mobilisation in vessel configuration
Benefits:
• Sections 1 & 2 FCGT off the critical
path in parallel with section 3 lay
• All Sections independently FCGT
• Reduced schedule risk
• Optimised pressure and spread
requirements
• Reduced ice risks by eliminating
onshore water winning
• Favourable water temperature for
pressure test

2. THE FAR SAMSON

2. SUBSEA HEADS
© 2011 Baker Hughes Incorporated. All Rights Reserved.
12

2. FCGT PIG TRAIN
FCGT Pig Train (All Sections)
Bi-Di Gauge Pig C/W Magnets
Acoustic Transponder
Bi-Di Smart Gauge Pig
C/W Magnets
Pig Selection and Design
• All FCGT pigs trains are the same configuration
• All pigs have 4 Guide discs, 3 Sealing discs and a
gauge plate
• All pigs have magnets for debris collection and
detection
• Pigs 1, 2 and 4 have transponders for tracking
• Pig 3 has a Smart Gauge for defect detection
• All pigs used “long run” polyurethane
• Trials completed to determine running and flipping
pressures
• PE pigs used for Sections 1 and 2; Rosen pigs used
for Section 3

2. PRESSURE TESTING
Pressure Testing
• Section 1 and 2 from offshore
• Section 3 from onshore Germany
• Maximum pressurisation rate 6m3/min
• Short stabilisation periods
Equipment
• Sound-proofed purpose-built pumps
• Water storage in Germany 15 No 760m3 tanks
Length
(km)
Volume
(m3)
Test Pressure
(barg)
Presurisation
Duration
(hrs)
Volume
Added
(m3)
Stabilisation
Period
(hrs)
Pressure Drop Over
Test Period
(%)
Section 1 297 310,098 248 36:33 4,823 2:32 0.048
Section 2 378 394,670 226 53:16 5,772 4:39 0.035
Section 3 548 572,167 201 40:68 7,596 6:22 0.102

2. DEWATERING, DRYING & N2 PURGING
Solo Seal Tools
Dewatering
Drying
Nitrogen Purge

2. ONSHORE DEWATERING, DRYING & N2
Dewatering & Drying from Germany to Russia
• 40,000 cfm / 68,000 m3/hr capacity
• Maximum pressure 34 bar
• Soundproofed
• Diesel distribution system 100 m3/day
• Dryers producing -70°C dewpoint
• Water storage tanks = 11,400m3
• Diesel storage = 200m3
• Condensate storage = 100m3
• All equipment subject to full FAT
Nitrogen Purging from Germany
• 1,900,000 m3 of N2 injected @ 220m3/min
• More than 100 road tanker deliveries
• Plus 7 rail cars

Russian Site:
• Independent pre-com site at beach
• 6000m3 water storage pond
• 600m 20” Steel onshore water disposal pipeline
• 600m 20” HDPE offshore water disposal pipeline
2. LAND FALL RUSSIA (LFR)

2. LAND FALL GERMANY (LFG)

2. DIESEL, WATER & CONDENSATE MANAGEMENT
DIESEL
CONDENSATE
WATER

Compressor Spread
• 23 No. 1,300 scfm 36.8 m3/min at 34 barg
• 3 No. 1,200 scfm 34 m3/min at 34 barg
• 11 No. 900 scfm 25.5 m3/min at 34 barg
• Air delivered 30,000 scfm 850 Nm3/min at
better than -60°C Dewpoint
• Installed power 24,000 hp 18,000 kW
• Diesel consumption 100,000 ltrs/day
• All units silenced less than 76 dBA at 7m
Drying Spread
• 4 No. 10,000 scfm 283 m3/min at 34 barg
• Compressor spread reduced to 60%
• Operated at 24 barg to reduce diesel
consumption
• All units silenced less than 76 dBA at 7m
• Oil in air better than ISO 8573-1 class 2
2. AIR COMPRESSION AND DRYERS

2. DEWATERING PIG TRAIN
Solo-Seal Tool
C/W Acoustic Transponder
Solo-Seal Tool
C/W EM Transmitter
KP 297
Solo-Seal Tool
C/W Acoustic Transponder
Solo-Seal Tool
C/W EM Transmitter
KP 675
Bi-Di Pig
C/W Magnets
Dewatering Train (Desalination)
Bi-Di Pig C/W Magnets
Dewatering Train (Swabbing)
Bi-Di Pig
C/W Magnets
Bi-Di Pig
C/W Magnets
2 No. Solo Seal
Tool at KP297
2 No. Solo Seal
Tool at KP675
4 No. Desalination
Wet Pigs
4 No. Swabbing
Dry Pigs
Bi-Di Pig
C/W Magnets
Bi-Di Pig
C/W Magnets and EM
Transmitter

2. PIG SELECTION
FCGT PIGS – SECTIONS 1 & 2
PIPELINE ENGINEERING
MAXIMUM RUN 375 km
FCGT PIGS – SECTION 3
ROSEN
MAXIMUM RUN 548 km
SOLO SEAL TOOLS
PIPELINE ENGINEERING
MAXIMUM RUN 675 km
1.5 barg SEALING CAPABILITY
DEWATERING PIGS
ROSEN
MAXIMUM RUN 1,224 km
• All pigs of bi-di design
• Manufactured to rigid tolerances < +/- 3mm
• PE solo-seal tool selected early in project
• Solo-seal tools ran up to 675km
• Rosen DW pigs based on Langeled design
• DW pigs designed to run 1,224km

2. PIG TRACKING AND SMART GAUGE
Smart Gauge
• One Smart Gauge located
in the 3rd FCGT pig
• Single-shot use
• Water contact start
• Thru-wall communications
for confirmation of event
• Very accurate location
tracking
• Exceptional battery life
• Multi-pig tracking in the
same train
• Pig position used to
confirm flow meter
readings
Pig Tracking Vessel
• Live tracking of the pig
train
• No ROV required for
Smart Gauge or Acoustic
Transponders
• Magnetic signalers used
subsea and onshore to
count the pigs in and out
of traps

• 1 year + test programme (with Ramboll OY
and VTT) to select most suitable (no
precipitation, minimal pipe corrosion and
environmental impact) water additives :
– Water sampling & analysis
– Full scale testing
– Laboratory testing (Gravimetric, LPR,
MIC, bacteria DNA mapping…
• Selected pre-commissioning medium:
– 50µm filtered sea water with sodium
bisulphite to eliminate dissolved oxygen
– Additional on-line UV treatment to
minimise bacteria load
• Offshore lab to confirm real-time dosage
2. WATER TREATMENT SELECTION

2. WATER TREATMENT OPERATION
Filtration
• 200 µm first stage
• 50 µm second stage
• Automatic flushing for
second stage
• 2600 m3/hr discharge
• Filter differential
pressure monitored in
test cabin
Water Additives
• Used to reduced
oxygen content
• Sodium Bisulphite
• High storage
concentration at 42% to
reduce foot print
• Heating required to
prevent crystalising
UV Treatment
• 99.99% bacterial kill
rate
• Used to reduce
bacterial count only
• 100% contingency
• Designed to be split for
future, smaller projects

3. THE RESULTS
8 November 2011

3. SCHEDULE – PIPELINE 1
Durations
• FCGT Spread installed on the Far
Samson in 7 days
• FCGT Sections 1 & 2 - 35 days
• FCG Section 3 - 20.5 days
• Dewater Pipeline 1 - 34 days
• Depressurisation - 3.5 days
• Drying - 18 days
• Nitrogen Purge - 5 days
• Pipeline 1 Pre-Com total 150 days
• All operations were completed
either on or ahead of schedule
• The major schedule gains where
made on the following operations:
• Flooding
• Drying
Drying
• Very dry air injected during
Dewatering and Drying better than -
70°C Dewpoint
• Pig performance
• Rapid depressurisation - 22M m3 in
3.5 days
• Depressurisation direction
• Low pressure drying optimised
using software
Flooding
• Contingency pumps used to achieve
pig speeds of 0.7 m/s / 2600 m3/hr
• Downlines very efficient as they
expand under pressure giving 8”
friction losses on 6” hose
• Stabs designed for very low losses

3. FCGT RESULTS
Flooding, Cleaning and Gauging
• Pig speeds of 0.7m/sec achieved
• No mechanical down time
• Pig tracking assured continuous
control of FCG operation
• Debris in front of last pig <<2kg
• No indications from gauge plates or
Smart Gauge
Pressure Testing
• Ahead of schedule
• No mechanical down time from
pressure testing spread or
downlines
• Short stabilisation period
• Perfect test head and stab integrity
S H

3. DEWATERING, DRYING & N2 RESULTS
Dewatering
• World record for the single longest dewatering run 1224 km
• No air in front of Pig 2
• No water after pig 5
• Low pig wear
• Longest Solo-Seal tool run 675 km
• Best ever results for residual water film thickness of 1 µm (post depressuriation)
Drying
• -35°C dewpoint achieved after soak test
• Drying (including soak test) completed in 18 days
• After completing the pipeline depressurisation the drying phase removed an
additional 4500 ltrs of water to complete the drying operation to better than -35° C
dewpoint which is the equivalent of a 1 micron film thickness
Nitrogen Purging
• Air / N2 interface very short < 1,500m through plug flow control
• 0.0% O2 recorded in Russia
• 1,900,000m3 of N2 delivered, vapourised and injected in 5 days

Dry Pigs
Wet Pigs
3. DEWATERING PIG WEAR
Pig 1 Pig 2 Pig 3 Pig 4
Pig 5 Pig 6 Pig 7 Pig 8

3. WATER DISCHARGE RESULTS
• Water discharge continuously
monitored
- Discouloured water diverted in
to settlement pond
- Clean water discharged directly
to the sea
• Discharged water is clean and
contains no oxygen
• Discharge point located 600m
offshore and fitted with diffuser to
ensure quick oxygenation
• Continuous monitoring from
environmental authorities showed
compliance with local & international
regulations (O2 > 7ppm) within 25m
from diffuser

3. WATER DISCHARGE RESULTS

3. NOISE CONTROL
Noise Control and Monitoring
• Stringent project noise requirements of 65 dB (day) and 55 dB (night) met in
Germany at the nearby marina
• Third party monitoring during the operation to ensure compliance
• All equipment sound proofed to 76 dB at 7 m
• Substantial HSE benefits to local population and work force

4. CONCLUSION
© 2009 Baker Hughes Incorporated. All Rights Reserved.
Nord Stream pre-commissioning – a world
class project that has “moved the needle” in terms of
pre-commissioning engineering, equipment & operations
World’s longest subsea
pipeline, flawless execution, minimal
environmental impact, HSE
Achieved by
experienced people,
thorough planning, &
custom equipment
New
benchmark
has been set

QUESTIONS?

BHI NSP Final 14_6_12

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