NEWCROSS Site Survey - Rev1

NEPL OPERATION SAFETY CASE PROJECT
EKULAMA-AWOBA FLOWSTATION PLATFORM

SITE SURVEY REPORT
Prepared for: Prepared by:
Mr Tokunbo Ogunyemi K.Eke
NewCross Petroleum Limited Petrorix Oil and Gas Services

FF Towers 5 Ladipo Latinwo Crescent
Plot 13/14 Ligali Ayorinde Off Admiralty Way, Lekki phase 1
Victoria Island Lagos, Nigeria
Lagos, Nigeria
Telephone: 014540107, 014547556
Website: www.petrorix.com
Confidential: Restricted to NewCross Petroleum Limited
NEPL
OPERATION
SAFETY CASE
Document Title: Ekulama-Awoba Site Survey Report Rev: 01
Document Number: NEPL-PETR-EKAW-SVR-001 Page 2 of 37
REVISION RECORD
DATE REVISION DETAILS
REV 01 15/01/18 First revision of document approved internally and submitted to Newcross.
REPORT APPROVAL
Issue Checked by Approved by Date
1.0 B.Obe A.E 18/01/18
NEPL
OPERATION
SAFETY CASE
TABLE OF CONTENTS
1.0 INTRODUCTION .................................................................................................. 4
1.1 EXECUTIVE SUMMARY ............................................................................................................................. 4
1.2 SITE VISIT TRAVEL INFORMATION........................................................................................................ 4
1.3 DEFINITIONS AND ABBREVIATIONS ..................................................................................................... 5
1.4 SITE SURVEY OBJECTIVES ....................................................................................................................... 6
2.0 BACKGROUND ....................................................................................................... 7
2.1 EKULAMA-1 FLOWSTATION .................................................................................................................... 7
2.2 EKULAMA - 2 FLOWSTATION .................................................................................................................. 8
2.3 AWOBA FLOWSTATION ............................................................................................................................ 8
3.0 SITE SURVEY METHODOLOGY ........................................................................ 10
3.1 CHECKLIST................................................................................................................................................10
3.2 DATA GATHERING..................................................................................................................................18
3.3 OBSERVATION..........................................................................................................................................19
3.4 FINDINGS AND RECOMMENDATION...................................................................................................19
3.4.1 Ekulama-1 Flowstation .................................................................................................. 19
3.4.2 Ekulama-2 Flowstation .................................................................................................. 20
3.4.3 Awoba Flowstation ........................................................................................................ 21
APPENDIX I – PHOTOGRAPH ...........................................................................................................................23

NEPL
OPERATION
SAFETY CASE
1.0 INTRODUCTION
The Newcross Production Limited Operation Safety Case shall include documentation of the
processes and activities carried out at the Ekulama-1, Ekulama-2 and Awoba Flowstations
stating all the studies carried out and the systems in place to ensure safety of personnel,
equipment and environment. Newcross Production Limited (NPEL) has engaged Petrorix to
support in developing an Operational Safety Case for the Ekulama and Awoba Flowstations.
1.1 Executive Summary
A site visit was conducted on the 30th November – 13th December at Ekulama1 and 2
Flowstations as well as Awoba Flowstation. This document presents the Piping, Mechanical,
Process, Instrumentation, Electrical and Structural site visit report which relates to site
investigations base on Scope, Findings (Observations) and Recommendations
1.2 Site Visit Travel Information
Date: 30th November -13th December 2017
Place: Ekulama-Awoba Flowstations
Petrorix Personnel: Kingsley Eke
Newcross Project Rep: Mr Tokunbo
Ekulama HSE Personnel: Mr Olanipekun A.
Awoba HSE Personnel: Mr Benjamin O.

NEPL
OPERATION
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1.3 Definitions and Abbreviations
The following definitions, abbreviations and acronyms are used in this document
LP Low Pressure
HP High Pressure
PPE Personnel Protective Equipment
NEPL Newcross Production Limited
Bbls Barrels of Liquid per day
Mmscfd Million Standard Cubic Feet per day
ESD Emergency Shut Down
HSE Health, Safety and Environment
JHA Job Hazard Analysis
OML Oil Mining Licence
OSDV Operational Shut Down Valve
PSH Pressure Safety High
PSL Pressure Safety Low
SCE Safety Critical Element
NC Normally Closed
PSV Pressure Safety Valve
PDI Pressure Differential Indicator
PTW Permit-To-Work
NEPL
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1.4 Site Survey Objectives
The objectives of the site visit are to carry out the following activities where operational
possible and accessible:
 Inspect physical conditions of the flowstations facilities

 Review periodic testing, inspection and maintenance records of Safety Critical
Elements (SCE)
 Review records of Health Safety and Environment (HSE) activities such as toolbox
meetings, Job Hazard Analysis (JHA), safety briefings, emergency drills, etc
 Review records for Permit To Work (PTW) processes
 Review current drawings against existing conditions and configurations of the
flowstations
 Review site organizational charts, tasks, roles, responsibilities and training records
 Review availability of up-to-date facility operations standards, manuals and
procedures
 Evaluate the compliance to periodic maintenance plans for SCEs
NEPL
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2.0 BACKGROUND
2.1 Ekulama-1 Flowstation

Ekulama-1 flowstation is located on piles on Oil Mining Licence 24 approximately 45km South
West of Port Harcourt. It is bounded by Awoba field to the south, Soku field to the South East
and close to Belema field. The field is accessible by air and by water. A journey from Port
Harcourt by air takes approximately 40 minutes while boat transportation takes 2hours
15minutes.
The flowstation is a single bank with vessels for a two-stage separation. The processed crude is
pumped with gas driven crude oil export reciprocating pumps into the trunkline, while the
separated gas is flared with horizontal flare unit located in a bunded area outside the
flowstation. Ekulama-1 field consists of 11 wells flowing into its flowstation. These wells are
located in swampy area with dredged slot to each well head for easy access during wellhead
activities. Ekulama-1 flowstation is currently producing 17,000bbls/d gross with an average
water cut of 38.85%. It is design to handle a maximum capacity of approximately 30.000bbls/d.
Accommodation for dedicated teams of technical personnel who visit the Ekulama-1
flowstation is provided at the nearest base station on Ekulama-2. Ekulama 1 is normally an
unmanned flowstation however daily visit by means of sea transportation is required to carry
out operational, maintenance activities and troubleshooting of equipment and instruments
failure. Although Ekulama 1 is described as unmanned, a flowstation attendant is on duty
24hours a day to keep vigilance and take bulk line meter readings on 2 hourly basis.
NEPL
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2.2 Ekulama - 2 Flowstation

Ekulama-2 flowstation is located on piles on OML 24 approximately 47km South-West of Port
Harcourt. It is bounded by Awoba field to the south, Soku field to South-East and close to
Belema field. The field is accessible by air and by water. A journey from Port Harcourt to
Ekulama-2 by air takes approximately 45minutes while boat transportation takes 2hours
30minutes.
The flowstation is a double bank with vessels for two stage separations. The processed crude is
pumped with gas driven crude oil reciprocation export pumps into the trunkline, while the
separated gas is flared with two horizontal flare units located in a bunded area outside the
flowstation. The field consists of 12wells flowing into the flowstation. These wells are located
in swampy area with dredged slot to each wellhead for easy access during wellhead activities.
Ekulama-2 flowstation is currently producing 40,000bbls/d gross with an average water cut of
38.71%. It is designed to handle a maximum capacity of approximately 60,000bbls/d.
Ekulama-2 is a base station with full board accommodation unit provided for dedicated teams
of personnel who provide operation and maintenance activities, and troubleshooting of
equipment and instruments failure for Ekulama-1 and 2 flowstations. The accommodation unit
is located a walkable distance from Ekulama-2 flowstation. The flowstation is unmanned.
However, staff work 12hours rotating shift a day while on the field. They work 14days on
14days off basis.
2.3 Awoba Flowstation

Awoba flowstation is built on a piled foundation and bounded by Ekulama field, Soku field and
Belema field. The field is accessible by air and by water. A journey from Port Harcourt to
Awoba by air takes approximately 15minutes while boat transportation takes 1hours. The
facility is a single bank with a three stage, extra high pressure (XHP), high pressure (HP), and
low pressure (LP) two phase liquid-gas separation stations.
The processed crude is pumped with motor driven crude oil centrifugal export pumps into the
trunkline, while the separated gas is flared with horizontal flare units located in a bunded area
NEPL
OPERATION
SAFETY CASE
outside the flowstation. Awoba flowstation is currently producing 23,000bbls/d gross. It

maximum design production capacity is 42,000bbls/d gross liquid and 54Mmscfd gas
Awoba has a house-boat, a few walking distance from the facility, that provide full board
accommodation for dedicated teams of personnel who provide operation and maintenance
activities, and troubleshooting of equipment and instruments failure. The field is unmanned.
However, staff work 12hours rotating shift a day while on the field. They work 14days on
14days off basis.
NEPL
OPERATION
SAFETY CASE
3.0 Site Survey Methodology
3.1 Checklist
A site survey checklist (see tables below) was developed to ensure proper and adequate
implementation of the work scope. The checklist was strictly adhered to during the visit to each
respective flowstations.
Table1-Site Survey Checklist for Ekulama-1 Flowstation
STATUS
S/N DESCRIPTION REMARK
OK NOT OK
A Manifold Area
I Confirm manifold arrangement in operation OK

Confirm the availability of SDVs and their trip functions
II (PSL/PSH) OK
III Confirm the availability of ESD in operation OK
IV Confirm set point of PSV installed OK
B Process Vessel
Confirm the Operating and Design Pressure and
I Temperature of the process vessel OK
II Confirm the availability of OSDVs and their trip functions NOT OK Faulty Rupture Disc
III Confirm drain valves are in NC position NOT OK Faulty Rupture Disc
Confirm all instrumentation tubing are properly arranged to

IV avoid Trip and Fall accident OK
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STATUS
OK NOT OK
V Confirm all check valves are installed in the right direction OK

Wrong connection
VI Confirm all spectacle blind are installed in right position NOT OK of Spectacle blind
VII Confirm all Lines and Valve are properly tagged NOT OK Tag not seen
C EXPORT PUMP
Overhauling
I Confirm pump capacity NOT OK required
Could not access
II Confirm the availability of the pump data sheet NOT OK data
Confirm the availability of Low/High Level Suction trip
III function OK
Confirm the availability of Low/High Pressure Discharged
IV trip function OK
V Confirm the availability of PDI across strainer OK
VI Confirm the availability of recycle line OK
VIII Confirm all check valves are installed in the right direction OK
Confirm the availability of Low pressure suction trip
IX function OK
D Metering System
I Confirm all Meters are properly proved OK

II Confirm all check valves are installed in the right direction OK
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STATUS
OK NOT OK
III Confirm all Lines and Valve are properly tagged NOT OK Tag not seen
E Flare Stack
Confirm the availability of past Technical Safety Studies
conducted (Flare Thermal Radiation Study) to ensure all Information not
I personnel working on the platform are in safe position NOT OK available
D Pig Launcher and Pig Receiver
I Confirm the availability of Pig signaler OK
II Confirm set points of PSVs installed NOT OK Faulty Rupture Disc

No operation more
III Confirm the availability of the pigging operation NOT OK than a year
Confirm all piping are fully rated to handle the maximum
IV source of pressure OK
NEPL
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Table 2-Site Survey Checklist for Ekulama-2 Flowstation
STATUS
OK NOT OK
A Manifold Area

II (PSL/PSH) OK
B Process Vessel
II Confirm the availability of OSDVs and their trip functions NOT OK Faulty Rupture Disc
III Confirm drain valves are in NC position NOT OK Faulty Rupture Disc

VI Confirm all spectacle blind are installed in right position OK
C EXPORT PUMP
Overhauling
I Confirm pump capacity NOT OK required
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STATUS
OK NOT OK
Could not access
III function OK
IV trip function OK
VI Confirm the availability of recycle line NOT OK Valve faulty
IX function OK
D Metering System
E Flare Stack
NEPL
OPERATION
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STATUS
OK NOT OK
II Confirm set points of PSVs installed NOT OK Faulty Rupture Disc
No operation more
NEPL
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SAFETY CASE
Table 3-Site Survey Checklist for Awoba Flowstation
STATUS
OK NOT OK
A Manifold Area

II (PSL/PSH) OK
B Process Vessel
II Confirm the availability of OSDVs and their trip functions OK
III Confirm drain valves are in NC position OK


VI Confirm all spectacle blind are installed in right position OK
C EXPORT PUMP
I Confirm pump capacity OK
Could not access
NEPL
OPERATION
SAFETY CASE
STATUS
OK NOT OK
III function OK
IV trip function OK
VI Confirm the availability of recycle line
IX function OK
D Metering System
E Flare Stack
II Confirm set points of PSVs installed OK
NEPL
OPERATION
SAFETY CASE
STATUS
OK NOT OK
No operation more
3.2 Data Gathering

As part of document collation, the following documents were required from NEPL to serve as
inputs into the development of the NEPL Operation Safety Case;
 List of past risk assessment studies

 Fire and Gas detection system
 Leak detection System
 Sand monitoring system
 Corrosion management System
 Logistics and transportation (Journey Management Plan)
 Periodic maintenance system
 Standard operating procedures
 Spares Philosophy
 Security management system
 Health and safety management system
 Past incidents reports
 Evidence of JHAs, PTWs
 Escape, Evacuation and Rescue (EER)
 Fire drill
 Emergence drill
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 Hazardous area classification layout drawing

 Evidence of pigging operation
 Chemical injection system
 Fire protection system
From the above list, the following documents were made available; Standard operating
procedures, PTW, and Past incident reports
3.3 Observation
The facilities (Ekulama 1, Ekulama 2 and Awoba) were inspected and the following
observations were made:
1. Safety briefing was carried out at the briefing room on arrival to the facility.
2. Tool box meetings were effectively implemented prior to the commencement of all
daily activities.
3. Use of minimum required PPE was adhered to strictly prior to platforms visit.
4. Stop cards were placed at strategic points and issued to personnel to encourage
reporting of unsafe acts and unsafe conditions.
5. The job hazard analysis, fire drill and emergency drill were found to be progressing
appropriately.
6. No Knockout Drum installed at Ekulama-2 flowstation and Awoba flowstation
3.4 Findings and Recommendation
The following findings were noted to constitute a major hazard.
3.4.1 Ekulama-1 Flowstation
1. The Platform Structures Damaged due to corrosion (Handrails, Man way Davit etc)
2. The Inlet manifold, valves, flanges and piping are severely corroded
3. Frequent breakdown of reciprocating pumps
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4. No Fire and Gas detecting system

5. No pigging operation for more than a year
6. Frequent theft at the wellheads
7. Flare header in poor condition
8. OSDV faulty in auto-mode
9. Wrong connection of spectacle blind on drain line
10. No readily available spares
(See Appendix 1 for pictures)
Recommendation:
1. All corroded valve, flanges be replaced

2. Cathodic protection system be installed and working effectively
3. Overhauling of reciprocation pump should be implemented and establish a
scheduled periodic maintenance
4. A documented Pigging Operation should be implemented
5. Improve security system around the wellheads to prevent further theft of parts at
the wellheads
6. Check the connection of valves and fitting immediately after maintenance operation
7. Install a Fire and Gas system
8. Replace faulty rupture disc in OSDV, PSV, and LCV
3.4.2 Ekulama-2 Flowstation
1. Valves, Hydrant line, flanges and piping are severely corroded

2. The reciprocating pumps are weak
3. Damaged pump oil seal
4. No Fire and Gas detecting system
5. No pigging operation for more than a year
6. Faulty recirculation valve
7. The relief valve on Test, HP and LP Separators depressurized to the atmosphere
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8. OSDV, LCV, PSV faulty in auto-mode

9. Saver pit is small
10. Water ingress in gas driven reciprocating pumps
(See Appendix 1 for pictures)
Recommendations:
1. All corroded valve, flanges be replaced

2. Cathodic protection system be installed and working effectively
3. Overhauling of reciprocation pump should be implemented and establish a scheduled
periodic maintenance
4. A documented Pigging Operation should be implemented
5. Replace faulty rupture disc in OSDV, PSV, and LCV
6. Modification required on mode of depressurization
7. Install a Fire and Gas system
8. Modification of pump house to prevent water ingress especially during rainy season
9. Replace saver pit with a larger size.
3.4.3 Awoba Flowstation

1. Breakdown of gas generators. The generators are weak
2. Centrifugal Pump strainer clogged with sand deposit
3. Inadequate appropriate working tools for the electrical and mechanical department
4. Incomplete combustion as a result of Liquid-carryover at the flare stack
5. Fire and Gas systems faulty
(See Appendix I for pictures )
Recommendations:
1. Overhaul required on gas generators

2. Repair the Fire and Gas detector
3. Provision of appropriate workings tools
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4. Install or replace process vessels demystifier

5. Establish sand monitoring system
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Appendix I – Photograph
Location Ekulama-1
Corroded flanges on the manifold
NEPL
OPERATION
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Location Ekulama-1
Corroded flanges fitting
NEPL
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Location Ekulama-1
Damaged Structural Platform
NEPL
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Location Ekulama-1
NEPL
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Location Ekulama-1
NEPL
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Location Ekulama-1
Poor Condition of FlareHeader
NEPL
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Location Ekulama-1
Wrong connection of Spectacle blind
NEPL
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SAFETY CASE
Location Ekulama-2
Corroded fittings
NEPL
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Location Ekulama-2
Corroded fittings
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Location Ekulama-2
Corroded Hydrant Line
NEPL
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Location Ekulama-2
Relief Valve in HP, LP, Test Separator depressurized to the atmosphere
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Location Awoba
Liquid-Carry-Over on the flare stack
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Location Awoba
Vessel due for test
NEPL
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SAFETY CASE
Location Awoba
Vessel due for test
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Location Awoba
Fire and Gas Detector faulty

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NEPL OPERATION SAFETY CASE PROJECT

EKULAMA-AWOBA FLOWSTATION PLATFORM

Prepared for: Prepared by:

Mr Tokunbo Ogunyemi K.Eke

NewCross Petroleum Limited Petrorix Oil and Gas Services

Document Number: NEPL-PETR-EKAW-SVR-001 Page 2 of 37

DATE REVISION DETAILS

Document Number: NEPL-PETR-EKAW-SVR-001 Page 3 of 37

1.0 INTRODUCTION .................................................................................................. 4

1.1 EXECUTIVE SUMMARY ............................................................................................................................. 4

1.2 SITE VISIT TRAVEL INFORMATION........................................................................................................ 4

1.3 DEFINITIONS AND ABBREVIATIONS ..................................................................................................... 5

1.4 SITE SURVEY OBJECTIVES ....................................................................................................................... 6

2.0 BACKGROUND ....................................................................................................... 7

2.1 EKULAMA-1 FLOWSTATION .................................................................................................................... 7

2.2 EKULAMA - 2 FLOWSTATION .................................................................................................................. 8

2.3 AWOBA FLOWSTATION ............................................................................................................................ 8

3.0 SITE SURVEY METHODOLOGY ........................................................................ 10

3.2 DATA GATHERING..................................................................................................................................18

3.4 FINDINGS AND RECOMMENDATION...................................................................................................19

3.4.1 Ekulama-1 Flowstation .................................................................................................. 19

3.4.2 Ekulama-2 Flowstation .................................................................................................. 20

3.4.3 Awoba Flowstation ........................................................................................................ 21

APPENDIX I – PHOTOGRAPH ...........................................................................................................................23

Document Number: NEPL-PETR-EKAW-SVR-001 Page 4 of 37

1.1 Executive Summary

investigations base on Scope, Findings (Observations) and Recommendations

1.2 Site Visit Travel Information

Date: 30th November -13th December 2017

Place: Ekulama-Awoba Flowstations

Petrorix Personnel: Kingsley Eke

Newcross Project Rep: Mr Tokunbo

Ekulama HSE Personnel: Mr Olanipekun A.

Awoba HSE Personnel: Mr Benjamin O.

Document Number: NEPL-PETR-EKAW-SVR-001 Page 5 of 37

1.3 Definitions and Abbreviations

PPE Personnel Protective Equipment

NEPL Newcross Production Limited

Bbls Barrels of Liquid per day

Mmscfd Million Standard Cubic Feet per day

ESD Emergency Shut Down

HSE Health, Safety and Environment

JHA Job Hazard Analysis

OML Oil Mining Licence

OSDV Operational Shut Down Valve

PSH Pressure Safety High

PSL Pressure Safety Low

SCE Safety Critical Element

PSV Pressure Safety Valve

PDI Pressure Differential Indicator

Document Number: NEPL-PETR-EKAW-SVR-001 Page 6 of 37

1.4 Site Survey Objectives

 Inspect physical conditions of the flowstations facilities

Document Number: NEPL-PETR-EKAW-SVR-001 Page 7 of 37

2.1 Ekulama-1 Flowstation

Document Number: NEPL-PETR-EKAW-SVR-001 Page 8 of 37

2.2 Ekulama - 2 Flowstation

2.3 Awoba Flowstation

Document Number: NEPL-PETR-EKAW-SVR-001 Page 9 of 37

outside the flowstation. Awoba flowstation is currently producing 23,000bbls/d gross. It

Document Number: NEPL-PETR-EKAW-SVR-001 Page 10 of 37

3.0 Site Survey Methodology

Table1-Site Survey Checklist for Ekulama-1 Flowstation