boran, john (dr) - mtd group - 2016 cv

08 August 2016 1 CURRICULUM VITAE

CAREER RESUMÉ

Dr. John Boran

Lead Materials Engineer / Consultant Materials Engineer

Personal Statistics Date of Birth: 19th November 1954. Nationality: British. Marital Status Married, one child. Address 39 Salmon Lane, Limehouse, London, E14 7NA. Telephone 020 7790 3864. Mobile 07860 912146. Email [email protected].

Academic and Professional Attainment HNC Metallurgy with Engineering Endorsement, City of London Polytechnic,1975 (Now the London Metropolitan University) (Sir John Cass College, School of Science and Technology). BSc (Hons) Metallurgy (First Class), City of London Polytechnic. 1978 (Sir John Cass School of Science and Technology) Welding Diploma, City of London Polytechnic. 1982 PhD Research, City of London Polytechnic (Sir John Cass College). 1989 European Engineer (Eur Ing) 1995 Chartered Engineer (C Eng) 1985 Member of the Institute of Materials (M I M) 1985 Senior Member of the Welding Institute (Sen M Weld I) 1990 Member of the Institute of Corrosion (M I Corr) 1992

Professional Experience Resumé Metallurgist with thirty (36) years industrial metallurgical experience, twenty four (24) of which have been within the petrochemical and oil and gas exploration industries. During this time I have been involved in the development of materials, fabrication and welding specifications for production platforms, FPSO’s, pipelines, topsides equipment, onshore petrochemical plant including gas treatment plant and LNG plant and sub-sea repairs of offshore platforms and pipelines, including hyperbaric and laybarge welding. I have also been involved in platform and pipeline inspection programmes, corrosion studies, metallurgical research and development and materials selection for oil and gas production equipment, failure investigations and in the materials and corrosion aspects of chemical plant and major water supply projects (nine years). Three years were spent in the metallurgical semi-finished products industry involved in non-ferrous metal casting, extrusion, rod and wire drawing, forging and rolling operations. Full-time education, BSc and PhD (six years).

Boran, John Detailed Professional Experience


August 2016 – To date Minton, Treharne and Davies Group.

Consultant materials engineer specialising in oil and gas failure investigations. April 2016 – July 2016 Independent Design Consultancy.

Institute of Gas engineers. Lecture program for graduate engineers on pipeline materials, metallic and non-metallic, welding and non-metallic joining processes and material defects including welds.

G3 consultancy. Review of fouling mechanisms and corrosion in an onshore glycol gas dehydration plant processing mildly sour gas.

November 2009 – April 2016 British Petroleum.

BP Materials, corrosion and welding Technical Authority (TA) on the Quad 204 project, June 2014 to date - Execute (fabrication) and hook-up phases.

BP’s Project Technical Authority for materials engineering on the fabrication and hook-up phases of the Quad 204 project (Schiehallion FPSO replacement project), including supervision of design contractor and fabricator for the FPSO at Hyundai Heavy Industries (HHI) in Ulsan, South Korea and the extensive subsea facilities designed by Wood Group Kenney and installed and fabricated by Technip.

Supervision includes materials selection, corrosion monitoring, design review including welding, NDT, specifications and data sheets, vendor data review, and supervision of the materials engineering aspects of construction including coating and welding inspectors. The 25 year design life puts a constraint on materials selection and external coating selection for process and utility equipment and structural steel, both topsides and subsea.

Facilities design. To fully exploit the remaining Schiehallion/Loyal reserves the concept for redevelopment of the Quad 204 area involves the installation of a new geo-stationary, turret-moored FPSO at the same location of the existing Schiehallion FPSO (see DP 2 and DP 67). The exploitation of the reservoirs shall be extended via the provision of a total of up to 25 additional subsea production and injection wells across Schiehallion/Loyal fields. This is further described in the project SOR (Ref 1).

The concept for the Quad 204 Project is the selection of a new geo-stationary, turret moored FPSO with tandem oil offloading to shuttle tanker and gas export via the West of Shetland Pipe Line. The concept uses the existing subsea



arrangement of wells, templates and flowlines. Oil offloading shall initially be via an onshore terminal, but the facilities may in the future be able to supply export crude oil of ‘direct to market’ quality which is not expected to be achieved until after 2-3 years after production start-up.

First oil production is scheduled to commence 1Q 2016. The selected design life for the Quad 204 hull structure and topsides facilities is 25 years (DP 92 and DP 53).

Field Suspension and Disconnection of Existing Facilities .

The Quad 204 Project shall require the disconnection and removal of the existing FPSO. It shall be necessary to perform preservation of the wells and subsea systems to ensure no operability or integrity issues when the new FPSO is subsequently connected and production, water injection and gas lift/export are re-started.

The current producing well stock for both Schiehallion and Loyal will be shut in to allow the removal of the FPSO and refurbishment of the subsea infrastructure of the field. The wells will be shut in for 3 years when production ceases in 2013, the FPSO vessel is disconnected in 2014, the new FPSO placed on station in 2015 and first production commenced in 2016.

A well by well risk assessment will be performed to highlight any specific cases that are out with the base case of isolation utilizing valve closure and blind hubs or flanges. The individual well risk assessment will also define any necessary monitoring requirements, such as visual inspections and frequencies, and any other actions required during the extended shut in period. Contingency plans shall be in place should any wells require plugging. The extended shut-in would commence once the flow lines are flushed and tree valves tested and would last until the new FPSO vessel is installed on-station and bleed-off facilities were available to perform the wellhead maintenance routines.

Other options for well suspension incorporate well plugging or well killing to insure integrity throughout the shut-in period. Part of the shutdown plan for the field considers “dosing” the injection wells to protect the tubulars. Inspection logs could be performed once the field was back on production to provide an update on the status of the tubulars at that time.

Subsea (SURF) system design

Overall the key subsea system requirements are:

1. The primary objective is to ensure that the subsea systems currently serving the Schiehallion and Loyal areas are suitable to continue production to the end of the



design life for the new subsea infrastructure i.e. 20 years, through a combination of: A. Integrity management (e.g. intelligent pigging, remote inspection); B. Operational control (e.g. rate control of wells); and C. Upgrade and repair where necessary (e.g. Riser replacement, production

flowline replacement, SCM replacement & control upgrades). 2. The capacity to handle an additional 25 new wells is a core requirement and the subsea infrastructure requires to be matched to the topsides facility design capacity to ensure no significant bottlenecks are introduced into the overall system. 3. The current FPSO operational efficiency (OE) is a significant problem that will be addressed through refurbishment or replacement. The current subsea system OE of 97.5% shall be the target level for the Quad 204 development.

The new subsea facilities, e.g. trees, wellheads, flowbases, control systems, connection systems, in-field jumpers, manifolds, structures, flowline jumpers, flowlines, riser bases, risers, dynamic umbilicals, static umbilicals, DUTAs, UETs and fly-to-place umbilical jumpers shall be in accordance with BP ETP based specifications.

BP Materials, corrosion and welding Technical Authority (TA) on the Clair Ridge project, January 2010 to date - All project phases, FEED through detailed design, execute (fabrication) and hook-up.

BP’s Project Technical Authority for materials engineering on all phases of the Clair Ridge project, Concept Select, Define (FEED) and Detailed Design and construction, including supervision of design contractor and fabricator for the two substructures, the QU and DP topsides and the pipelines design contractor.

Supervision includes materials selection, corrosion monitoring, design review including welding, NDT, specifications and data sheets, vendor data review, and supervision of the materials engineering aspects of construction including coating and welding inspectors. The 40 year design life puts a severe constraint on materials selection and external coating selection for process and utility equipment and structural steel, both topsides and subsea.

Template and Topsides design was by Amec Foster Wheeler, Jacket design and fabrication was by Kvaerner Verdal in Norway. Topside fabrication was by HHI in Ulsan, South Korea. The subsea oil and gas export pipeline design was by Genesis and fabrication and installation by Subsea7.



The Greater Clair Field, located 75 km west of Shetland, was discovered in 1977 and extends over an area of 220 km2 in water depths of approximately 140 m. The complexity of the field and the difficulty of working in such a harsh environment has meant that this valuable resource was not developed for many years. Clair Phase 1 development was sanctioned in 2001 and consists of a steel jacket supporting drilling and processing facilities. First oil was achieved in February 2005 and production has steadily increased to capacity, 60,000 barrels per day, as new wells have been drilled from the platform. The second phase of the development, Clair Ridge, is targeting the part of the Clair field north of Clair Phase 1. Some key facts about the project.

• Reserves are larger than those on Clair Phase 1.

• The project involves design, construction and installation of a platform consisting of two jackets connected by a bridge with drilling and production facilities on one jacket and utilities and quarters on the second.

• The facilities are being designed for a 40 year life.

• BP proprietary low salinity waterflood (LoSalTM) will be utilised by the project to enhance oil recovery from the reservoir.

Clair Phase 1 was the first fixed jacket installation West of Shetland, the other facilities - Schiehallion and Foinaven - are floating production and storage ships which are also further from the Shetland Islands. During the Clair Ridge project, BP as the operator will be looking to build on the substantial efforts made on Clair Phase 1 to minimise the impact on the environment West of Shetland with its abundant marine and bird life. This effort starts during the earliest stages of design right through to the installation, commissioning and operation of the facilities.

Materials Engineer in the BP Angola Business Unit assigned to the Block 31 FPSO, October 2009 to December 2009.

Materials engineer based in BP Sunbury, on the Angola Block 31 FPSO Project scope reviewing the materials selection, corrosion monitoring, duplex and super duplex stainless steel procurement audits and vendor documentation produced by the detailed design and FPSO construction contractor, MODEC, and other vendors. The BP Angola Programme currently focuses on the development of four projects within the Angolan Offshore Block 31. The strategy employed for each development is to use a centrally located FPSO with subsea 'offline' manifolds and clustered wells located in water depths up to a maximum design of 2500m.



The BP Supplementary Basis of Design addresses a more detailed description for each individual field architecture. The intent of the BP Angola Programme was to develop these assets using common building blocks and repeat engineering wherever possible, to gain maximum benefit from economies of scale and nurturing long term Contractor relationships to maximise reliability through continuous and proactive learning.

September 2009 – October 2009 Independent Design Consultancy.

Saipem UK Ltd, technical review of the FEED design for Total UK Ltd’s Laggan and Tormore subsea field development West of Shetland. Review of the pipeline Materials Selection Report and pipeline specifications for bid purposes.

Saipem UK Ltd, Total UK Ltd, West Franklin Wellhead Platform and pipeline Materials Selection review for bid purposes.

Offshore Design Engineering (ODE) Ltd, Centrica UK Ltd, Baird gas storage project. Concept select corrosion rate assessment for the topsides and pipelines and Material Selection Report.

November 2008 – August 2009 ConocoPhillips.

Client’s Materials Engineer on the Jasmine Project in the J Block area of the UK North Sea, supervising the FEED design contractor for the topsides, substructures and pipeline in all aspects of material selection, corrosion protection and monitoring and specification development. Later stages of the project will include vendor supervision and supervision of fabricators for the three substructures, three topsides decks and pipeline.

The J-Block Area is currently comprised of three producing fields: Judy, Joanne and Jade. The Judy Platform is located 240 km North East of Aberdeen, UK, in the Central North Sea. The Judy platform serves as a hub for petroleum operations in the area, with surrounding developments utilizing the infrastructure. Oil is exported in the Norpipe system to Teesside, UK, and the natural gas is exported in the CATS system to Teesside, UK.

Jasmine is a gas-condensate reservoir which is nominally rated as High Pressure High Temperature (HPHT). The Jasmine Field is located in blocks 30/6 and 30/7a, approximately 9km west of the existing Judy platform in ConocoPhillips’ J-Block operating unit and lies in some 80 meters of water at a depth of 4115 meters below the seabed.

The Jasmine field was discovered in 2006. The core reservoir area (West Limb) contains P50 reserves estimated at 150mmboe and will produce at a peak rate of ca 300mmscfd and 60 kbopd.



The Jasmine development will comprise a wellhead platform tied back to the ConocoPhillips operated Judy platform via a multiphase pipeline and riser platform connected to the existing Judy platform via a linking bridge. The riser platform will contain primary separation facilities for Jasmine. The Jasmine WHP will be supported by a bridge linked accommodation platform.

Greenfield:

·24 slot Wellhead (Drill Centre) Platform

·Accommodation Platform

·Riser platform at Judy end of Jasmine pipeline

Subsea:

·Subsea Pipeline, between the Jasmine WHP and Judy platform

·SSIV skids at the Jasmine and Judy platforms

Brownfield:

·Jasmine Brownfield Modifications (tie-ins)

·Change of Duty Modifications Development wells will be drilled by a separately contracted jack-up drilling facility which will be cantilevered over the wellhead platform during the drilling phase of the development, with 24 well slots will be required on the wellhead platform to accommodate current and future drilling plans.

Produced gas and condensate will be transported from the new wellhead installation via a new multiphase subsea pipeline to a new production riser located on the Judy platform. The new pipeline will incorporate Subsea Isolation Valve (SSIV) skids in the 500 meter zones of both platforms. A High Integrity Pressure Protection System (HIPPS) located on the wellhead platform will allow a conventional design pressure rating for the pipeline to be selected. The pipeline is proposed to be pipe-in-pipe type with insulation in the annulus for heat conservation purposes. The inner pipeline is currently considered to be circa 16 inch diameter.

Reservoir fluids will arrive at the Judy facilities via a HP separator located on the Judy Riser platform and will be processed to meet existing export specifications for both gas and liquids. Gas will be exported to shore via the dense phase CATS pipeline and liquids will be exported to shore via the NORPIPE export line.

The Jasmine development will require significant brownfield modifications to be undertaken on the Judy platform in order to receive and process the Jasmine reservoir fluids. As well as modifications to the primary process and utility systems, these modifications will include a computer based control system and a telecommunications system used to remotely control the Jasmine wellhead platform from the Judy platform.



Aug 2007 – September 2008 BG Group.

Client’s Materials Engineer on the Hasdrubal Project, Offshore Tunisia. The project includes an offshore platform, multiphase subsea export pipeline, onshore gas export pipeline and onshore terminal facilities including the Hasdrubal Terminal oil and gas processing plant and the Gabes LPG storage and export plant. Responsible for the materials engineering aspects of the project, including the supervision of materials engineers employed by four major sub-contractors involved in the design and fabrication of the platform, pipeline and two onshore terminals.

The work undertaken included production of the whole project Corrosion Monitoring Strategy and development of the materials engineering aspects of the operations phase Safety Case for the Onshore Terminal and Offshore Platform. The Safety Cases included development of the material engineering aspects of the Performance Standards and Safety Critical Elements (PS’s and SCE’s), as well as the Written Schemes of Examination (WSE’s).

The Hasdrubal Onshore facilities include slug catcher / surge vessels, and amine plant to remove acid gases, gas export, oil / condensate stabilisation and export and LPG fractionation. The Hasdrubal Onshore facilities are located to the west of the existing Hannibal Plant and common facilities will be made use of as appropriate, i.e. nitrogen, de-mineralized water, acid gas incineration etc.

The new onshore facility will produce Export Gas, Propane, Mixed Butanes and Condensate / Oil Products.

Sour and acid off-gas will be routed to the adjacent Hannibal plant for disposal.

Export of LPG’s will be by road tanker.

The 100 km subsea export pipeline includes a 10 km CRA (alloy 825) clad section to accommodate the high temperatures expected that prevent the use of carbon steels in combination with the CO2 levels present.

The platform and topsides are minimum facilities with producing gas and oil wells exported by a multi-phase pipeline to shore.

The Gabes LPG export terminal comprises propane and butane storage bullets and export facilities to ships and local distribution by road tanker.

Dec 2006 – July 2007 CBI (CHICAGO BRIDGE and IRON. formerly

John Brown Engineering) LTD.

Peru LNG Export Facility – Senior Materials Engineer.

Contracted as the CBI Materials Engineer on the Peruvian Camisea LNG export project. Involved in the post-FEED and detail design phases of the project including material selection, equipment and pipework coating, insulation specification development, bid review, vendor welding, NDT, coating and insulation procedure development. The Peru LNG export project is a green field LNG export development of a natural gas treatment and liquefaction facility at Pampa Melchorita on the West Coast of Peru 170 km South of Lima. The feed gas comes from the Camisea gas project via an on-shore pipeline.



The project includes treatment of the incoming gas in an amine plant to remove carbon dioxide, followed by Mercury removal, dehydration, liquefaction and refrigeration LNG storage and loading facilities, marine facilities including breakwater and jetty. Project involvement included material selection for the main process system and all utility systems, welding and NDT procedures, coating and insulation selection.

The design of the liquefaction and refrigeration units is based on the Air Products (APCI) propane pre-cooled MR process and two GE Frame 7 gas turbine drivers with starter/helper motors. The natural gas is liquefied at high pressure and sub-cooled h the main cryogenic heat exchanger (MCHE) to be sent to the storage tank. Storage tanks are designed and built in 9% Nickel steel, by CBI Plainfield.

Chile, Quintero LNG import Facility – Senior Materials Engineer.

Contracted as a CB&I Materials Engineer on a lump-sum contract for Chile's first liquefied natural gas (LNG) re-gasification plant, which will be built by BG Group & partners at Quintero near the capital city of Santiago. Involved in the detail design and construction phases of the project, including material slection, welding and NDT, coating and insulation procedure review for equipment, pipework and structural fabrications.

LNG for the plant is expected to be sourced from Trinidad and Egypt. CB&I's work scope includes the design, engineering, procurement, manufacture, transportation, management, construction, installation, operator training, testing, commissioning and performance testing and demobilisation of the Regas Facilities to be constructed and operated at Quintero. CB&I’s London office will provide design and engineering of the Regas Facilities as well as procurement services for the project.

South Hook LNG import Facility – Senior Materials Engineer.

Contracted as a CBI Materials Engineer on the South Hook UK LNG import project. Involved in the detail design and construction phases of the project, including welding and NDT, coating and insulation procedure review for equipment, pipework and structural fabrications.

LNG for the South Hook Terminal will come from a dedicated LNG train in Qatar owned and run by a Qatar Petroleum / ExxonMobil joint venture, South Hook LNG Limited (SHLNG). This terminal will provide natural gas to the Transco distribution network. The South Hook LNG terminal will be located on the former Esso refinery in Milford Haven, South Wales. The terminal will receive liquefied natural gas (LNG) from Ras Laffan, Qatar. The terminal will be designed for a continuous year-round sendout. The purpose of the LNG terminal is to receive and store LNG unloaded from LNG carriers and deliver this as natural gas product to the UK gas network.

The Phase I terminal facilities design is based on 7.78 million tonnes per annum (MTA) of unloaded LNG. This unloaded rate will increase by a further 7.78 MTA for Phase II. First shipment is targeted for the third quarter of 2007.



The general design philosophy is that three LNG storage tanks will be installed in Phase I with an additional two tanks of the same capacity to be installed during Phase II. The work comprised material selection, coating, insulation, welding and NDT of the process and utility equipment and associated piping The Phase I gas sendout equipment is sized to ensure a peak delivery to the pipeline of 1,110 te/h at a pressure of 94 barg. The sendout rate in Phase II increases to 2,220 te/h delivered to the sendout pipeline.

AGT Pipelines (FSU), AGT, SCP and WERP oil and gas export pipelines, BP Azerbaijan – Georgia – Turkey pipelines. Senior Materials Engineer.

Materials engineer involved in the production of specifications for linepipe procurement for the British Petroleum Azerbaijan – Georgia – Turkey oil and gas export pipelines in the Former Soviet Union (FSU) and the Western Route Extension Pipeline (WREP). Crude oil and gas are both exported from Baku area development projects, ACG 1 & 2 and Kashagan.

QAFCO 5 Ammonia, urea and associated utilities Project The QAFCO 5 site is located approximately 1.5 km west of the existing QAFCO Fertiliser complex. The QAFCO complex forms part of the Mesaieed Industrial City, 40 km south of Doha, on the east coast of the Qatar peninsula. Involved in the FEED phase of the project, including material selection, welding and NDT, coating and insulation procedure review for equipment, pipework and structural fabrications. QAFCO 5 consists of two new 2,200 t/day Ammonia Trains and a 3,500 t/day Urea Plant as an expansion to the existing QAFCO Site in Qatar. The scope is split between ISBL covering the Ammonia and Urea Plants and OSBL covering the Offsites and Utilities. The ISBL scope will be executed by Uhde and the OSBL scope will be executed by CB&I.

The ISBL scope consists of the following:

• 2,200 t/day Ammonia 5 (A5) • 2,200 t/day Ammonia 6 (A6) • 3,500 t/day Urea 5 (U5) • 99 t/day Urea Formaldehyde Plant (UFC-85B) Utilities and Offsites in the OSBL scope include:

• Natural Gas Metering and Distribution Station, System 96 • Desalination Water, System 90 • Demineralised Water, System 89 • Ammonia Storage & Refrigeration, System 60 • Urea Bulk Storage, System 70 • Urea Bulk Handling and Loading, System 72 • Electrical Power Supply, System 94 • Steam, System 83 • Instrument and Working Air, System 84 • Nitrogen, System 86



• Wastewater Collection and Treatment, System 92 • Potable Water, System 93 • Closed Cooling Water, System 88 • Sea Water Cooling, System 87 • Fire Water, System 91 • Interconnecting Pipework, System 96 • Urea Solution Transfer System, System 96 • Ammonia Ship Loading, System 64

Several stages of site development / expansion are envisaged hence tie-ins and space allocation must be considered in design. Planned future development of the QAFCO 5 site include the following,

o 3,500 t/day Urea 6 (U6) o 900 t/day Sulphuric Acid Plant o 4,900 t/day UAS Plant

The main natural gas feed to A5 / A6 and Cogen 2 on the QAFCO 5 site is taken from the Qatar Petroleum (QP) Metering Station Point S. The gas is transported to site via a new 24 inch pipeline, entering the site from the east. The gas enters the metering and distribution station passing through 2 x 100% filter separators (L9601A/B) and ultrasonic metering before being routed to A5 / A6 and Cogen 2.

June 2003 – Dec 2006 ENCANA UK LTD, later NEXEN PETROLEUM

UK LTD.

Buzzard Field Development, Facilities Engineer for Materials Engineering and Integrity Management.

Contracted as the Nexen (formerly EnCana) Materials Engineer on the Buzzard Field Development Project in the UK Sector of the North Sea. Project activities included detail design supervision, fabrication supervision of the pipelines, three substructures and three decks, on-shore and offshore commissioning and hook-up. The later stages of the Project involved integrity management studies for the facility,

The Buzzard Field Development comprises three jacket structures, three decks, associated oil export, gas export and two water injection pipelines. There are associated sub-sea facilities including water injection trees and a hot tap into the BP Forties pipeline. Onshore plant comprises a mercaptan removal unit at the BP Grangemouth refinery.

Ultimately responsible for the material selection, welding, NDT and corrosion protection of the topsides process and utility systems and equipment, the jacket welding, NDT and corrosion protection, the deck welding, NDT and corrosion protection, project coating and insulation specifications, project cathodic protection design and the pipeline welding and corrosion protection.

Responsible for the supervision of up to 7 detailed design contractor staff and up to 15 site staff with inspection responsibilities.



Buzzard design basis acid gas content was up to 10 mole percent carbon dioxide and 42 ppmw hydrogen sulphide in the oil stream, resulting in uninhibited carbon steel corrosion rates of up to 25 mm/yr. This resulted in the selection of 13 Chromium production and water injection tubing, super duplex stainless steel for the front end process pipework and 904L clad separators. The Process platform employed an amine plant for acid gas removal. The facility also included a Wellhead and a Quarters-Utility platform. Production drilling in the later stages of the project resulted in higher hydrogen sulphide levels in the oil stream, up to 400 ppmw, and this latter stage of the project required a complete re-assessment of the production and water injection tubing and topsides material selection.

The three decks were coated with thermal sprayed aluminium (TSA) on the underdecks and on the sub-structure in the atmospheric zone to give a maintenance free 25 year design life. Close attention was paid to deck structure corrosion protection coatings, passive fire protection and pipework and vessel coating under insulation, where extensive use of TSA under insulation was also made.

The acid gas content of the well fluids resulted in an aggressive produced water which was co-mingled with deaerated seawater for reservoir water injection pressure maintenance. As a result of the corrosivity of the produced water, water injection pipelines were selected in carbon steel clad in high nickel alloy, Inconel 625.

Jan 1993 – May 2003 KBR (KELLOGG BROWN & ROOT).

Senior Materials Engineer, Lead Materials Engineer and Consultant Materials Engineer.

At various times responsible for a department of up to 6 metallurgists/corrosion engineers.

PRIRAZLOMNOYE PROJECT, OFFSHORE OIL PROJECT, SEVMORNEFTEGAZ, FORMER SOVIET UNION.

Materials Engineer responsible for process and utilities material selection and assessment of the re-use of the Hutton TLP deck for use at the revised minimum design temperature (MDT) of – 40 ° C. This includes reassessment of the structural steel and welding impact toughness properties and coordination of a fracture mechanics study into the propensity to brittle fracture of the deck structure under the revised MDT and structural loadings.

BARRACUDA AND CARATINGA OFFSHORE FPSO PROJECT, PETROBRAS, BRAZIL.

Materials Engineer, responsible for topsides and subsea materials selection (umbilicals, in-field flexible flowlines, PLEM and PLET, anchors and umbilical and flexible pipe terminations on the vessel).

Barracuda and Caratinga are FPSO’s designed for installation in the Campos Basin, offshore Brazil, primarily for oil production and export via shuttle tankers.



Gas export is via the PLEM / PLET to an existing pipeline system. Water depth range from 690 to 1150 metres.

MALAMPAYA, OFFSHORE GAS PLATFORM, SHELL, MALAYSIA.

Materials Engineer, responsible for review and acceptance of high pressure gas pipework NDT.

Malampaya Project comprises a gas and gas condensate topsides and concrete gravity base and associated pipelines. The gas is 100 ppm H2S and 4% CO2 and is processed in a single process train for export of 500 mmscfd to an onshore power station. KBR scope was for FEED and EPIC contracts.

SHELL EA, OFFSHORE FPSO PROJECT, SHELL NIGERIA.

Materials Engineer, responsible for review of high pressure gas pipework system materials selection.

Shell EA FPSO is designed to process 140,000 bpd oil and 100 mmscfd gas, with a topside weight of 8,200 tonnes in 27 metres water depth. KBR scope was a lump sum turn key EPIC contract.

DISI - AMMAN WATER SUPPLY PROJECT, JORDAN.

Lead Engineer for materials aspects of this water supply project, including pipeline and pipeline coating materials selection, specification and corrosion protection.

VEBA OIL, AMAL FIELD WATER INJECTION PROJECT, LIBYA.

Employed as Lead Engineer for materials aspects of this produced water injection project, responsible for materials selection, materials specification and welding and NDT specifications.

GREAT MAN-MADE RIVER PROJECT, LIBYA.

Contracted on the Great Man-made River Project, the worlds largest civil engineering project to extract water from aquifers under the Sahara desert. The untreated water can contain dissolved CO2 and H S2 and can contain microbiological agents leading to microbiologically induced corrosion, (MIC). Aggressive ground conditions can lead to corrosion of the Prestressed Concrete Cylinder Pipe (PCCP). Metallurgical and corrosion engineering input to the project includes;

(a) PCCP pipeline corrosion control and corrosion failure analysis

including steel in concrete chloride profiling, chloride diffusion in concrete and soils geochemical studies into soil chloride concentration and transport.

(b) An evaluation of austenitic stainless steel failures in deep water well casings and screens. These evaluations included an in-depth study of crevice corrosion in stainless steels, and the effect of



ferrite content in austenitic stainless steel welds on the corrosion behaviour of the weld.

(c) Materials selection of pipe, pump, valve and instrument components for aggressive water exposure.

(d) Studies into the degradation of concrete by CO2 containing water.

(e) Hydrogen embrittlement studies on high strength steel concrete prestressing wire, including FIP ammonium thiocyanate tests, slow strain rate tests and tests of wire buried in concrete, under constant load and cathodic polarisation.

(f) Corrosion monitoring studies including LPR, coupon exposure trials and MIC studies.

(g) Selection of GRP resins for long term service in water environments for well casings and water treatment plant including long term testing of GRP composite to BS 5480. Selection of water reservoir linings and joining processes for these linings.

(h) Failure analysis of failures in Niresist pump and submersible electric motor castings due to stress corrosion cracking.

(i) Corrosion of stainless steels in sodium hypochloride environments for sterilisation purposes.

(j) Technical advice and supervision for Brown & Root and the client of PhD research at Imperial College London, into corrosion and hydrogen embrittlement of concrete pre-stressing wire.

(k) Selection of acid resistant brick for descaling plant (part of the carbon dioxide degassing plant).

Apr 1992 - Dec 1992 RALPH M. PARSONS LTD.

Lead Metallurgist.

Contracted as Lead Metallurgist on the Hamilton Field Development - Operator, the Hamilton Oil Company. Responsible for the Point of Ayre Onshore Terminal Gas Sweetening Plant material selection and all aspects of the terminal materials and fabrication specifications for pressure vessels, heat exchangers, storage tanks, pumps and piping.

The terminal processes sour gas and condensate containing 1600 ppm H S2 , 5800 ppm CO2 and 300 ppm mercaptans. The process system included an amine gas sweetening unit and dew point unit for gas export to National Power. In addition, the terminal process system incorporated a sulphur recovery unit and a tails gas unit along with condensate stabilisation and sweetening units, a methanol recovery unit and all associated utility systems, including a hot oil system, cooling water system, steam generation, flare system, waste water treatment and firewater.



Aug 1991 - Mar 1992 MARATHON OIL COMPANY LTD.

Senior Metallurgist/Welding Engineer.

East Brae Field Development, Metallurgist working on the topsides material selection, detail design and fabrication. The work included corrosion rate analysis, material selection, review of all welding procedures and fabrication support for all topsides vessels, heat exchangers and piping for the oil and gas production system including gas compression and reinjection. The gas contains 6% 2CO plus hydrogen sulphide resulting in extensive use of duplex and super duplex stainless steel piping and Inconel 625 and 316 stainless steel cladding. Electroslag cladding was employed for the separators which were fabricated from 450 grade quenched and tempered steel in order to save weight. Extensive super duplex stainless steel welding trials and stress corrosion testing was undertaken. The seawater cooling system piping employed 6 Mo type super austenitic stainless steels and heat exchangers with C276 tubing and a C276 clad and backface welded tubesheet for the gas reinjection compressor aftercoolers, with Inconel 625 clad shells. The LP compressor aftercoolers ("J/T aftercooler") were fabricated with titanium tubes, a titanium clad shell and Incolloy 825 clad channels.

Feb 1991 - Jul 1991 FOSTER WHEELER PETROLEUM DEVELOPMENT LTD.


Scott Field Development, Amerada Hess Ltd. Metallurgist working on the topsides detail design of the production and utilities decks. The detail design work included the process materials selection for sour service oil and gas production, sea water cooling and water injection systems and the utility systems. Material selection, welding and NDT was also specified for the oil and gas export pipelines, the wellhead flowlines and water injection lines and the deck structural fabrication. The material selection resulted in extensive use of duplex, super duplex and 6% Mo super austenitic stainless steels.

Hamilton Brothers Oil and Gas. Process review and corrosion rate study to determine the material selection for the Liverpool Bay onshore gas processing plant. The work was undertaken as part of a scoping study for the development. The multiphase gas stream contained 0.6 mole percent CO2 and 0.1 mole percent H S2 .

Dansk Olie and Naturgas (DONG). Corrosion study to verify the pipeline design for the DONG Harald West and East, North Arne and Valdemar fields. The 16 inch multiphase gas pipeline was designed to carry wet natural gas and condensate together with injected methanol. The CO2 contents from the various fields exporting into the 16 inch pipeline ranged from 0.5 to 2.6 mole percent.

Jan 1990 - Feb 1991 SHELL UK EXPLORATION AND PRODUCTION LTD.

Senior Engineer - Metallurgist/Welding Engineer.



Metallurgist/Welding Engineer for the Shell Expro sub-sea valve installation project. The project involved the supervision of fabrication and inspection of six large (60 to 100 tonne) valve protection frames together with their respective spool pieces containing Neles or Forsac emergency shutdown (ESD) valves, and the supervision of the hyperbaric welding of the spools into the existing pipelines. The hyperbaric welding work involved procedure and welder qualification including CTOD tests and offshore supervision for Shell Expro of the sub-sea tie-ins, which covered a range of diameters (10 and 16 inch in the Brent and Cormorant fields, Northern North Sea, and 30 inch in the Leman and Sean fields in the Southern Sector) and which included developing welding procedures for existing pipelines up to 20 years old.

May 1988 - Dec 1989 JOHN BROWN ENGINEERS AND CONSTRUCTORS LTD.


Hamilton Brothers Oil and Gas, Ravenspurn North Development Project. Lead metallurgist on the detailed design and installation of a 24 inch export pipeline and 14 inch infield pipeline. The project involved the preparation of materials specifications, technical negotiations with suppliers, laybarge pipeline welding procedure qualification including CTOD tests, laybarge welding supervision during pipeline fabrication offshore, hyperbaric tie-in welding procedure qualification and hyperbaric tie-in supervision offshore of the pipeline and ESD valve spools. The export pipeline was designed for sour service and the project included the procurement of three ESD valves for sub-sea installation.

Amoco Arbroath Field Development, Arbroath Field Jacket, development and approval of welding procedures for jacket fabrication at Highland Fabricators, Nigg Bay.

Jan 1986 - May 1988 PLT OFFSHORE LTD.

Senior Metallurgist/Materials Engineer.

Shell UK Exploration and Production - Ethylene pipeline conceptual design:

♦ The conceptual study established the principal design parameters of an offshore and an onshore route for the pipeline and established a plus or minus 25% cost estimate for the various pipeline construction options.

Shell UK Exploration and Production - Sub-Sea Hot Tap:

♦ Preliminary design of a sub-sea welded hot tap connection of a 24 inch

lateral pipeline onto a 36 inch main pipeline in the Northern sector of the North Sea in 110 metres of water. Senior Engineer involved in the welding and metallurgical aspects, in particular the establishment of gas pipeline flowrate reduction to obtain the required preheat levels and the development of costs and construction schedule.

Mobil North Sea - Conceptual Design of a 9.5 Km Infield Pipeline



♦ Involved in the welding, materials selection, internal corrosion and cathodic protection design and review of the welded tie-in design of the pipeline to an existing riser.

QGPC (Offshore) - Emergency Pipeline Repair Procedures:

♦ Senior Engineer and latterly Project Manager for the development of sub-

sea emergency pipeline repair procedures for the QGPC trunk pipeline system. The trunkline system consists of sour NGL gas and liquid and crude oil pipelines. Pipeline repair procedures were based upon hot tap and stopple techniques to isolate damaged sections of pipeline followed by a hyperbaric welded spoolpiece tie-in. Procedures were developed for NDT inspection of the hydrogen induced cracking affected linepipe prior to hyperbaric welding operations, welding procedures including pre-heat analysis, hot tap and stoppling operations, recommissioning of repaired pipelines and diving techniques and sub-sea construction procedures.

IMODCO UK/Petrojet Egypt - Pipe Laybarge Stinger Design:

♦ Materials, fabrication and welding and cathodic protection specifications

for 80 metre articulated pipe laybarge stinger, fabricated in Japan by Hitachi Zosen.

Pennzoil Nederland Company - Sub-sea Hot Tap Detailed Design:

♦ Materials, welding and NDT specifications and procedures for a sub-sea

hot top including hyperbaric welding procedures, pre-heat analysis and prequalification and construction supervision. Additionally development of detailed hot tap fabrication and contingency procedures during sub-sea construction were undertaken.

Aug 1985 - Jan 1986 ATKINS OIL AND GAS ENGINEERING LTD.

Metallurgist.

Conoco (UK) Ltd:

♦ Conoco Southern Basin Gas Development, review of materials, fabrication and welding specifications for Conoco Southern Operations - Mablethorpe.

♦ Materials selection and welding procedures for offshore firewater deluge

system piping.

♦ Lead Engineer in £1M project to evaluate and replace Monel studbolting installed sub-sea on a wellhead platform and associated gas and methanol pipeline flanges and riser clamps.

Project included liaison with Department of Energy Pipelines Inspectorate. Pipeline flange and riser clamp bolt changeout procedures. Offshore supervision of the diving team. Liaison with Harwell Laboratory engaged on studbolt failure analysis. Fabrication and coating specifications for



replacement riser clamps on main complex platforms. Hydrotest procedures and offshore supervision of methanol pipeline hydrotest.

♦ Study of sweet corrosion in wet gas pipelines, including a literature

review, a review of offshore process plant and pipeline corrosion control procedures and corrosion monitoring data as part of a pipeline reliability study and pre-engineering to inform the necessity of intelligent pig inspection.

Mar 1984 - Aug 1985 PETRO-MARINE ENGINEERING LTD.

Metallurgical Engineer.

Engineer in the offshore structures assessment group. Employed as a metallurgist in a principally structural engineering group to input materials, corrosion, welding and inspection specialist knowledge into the group's activities.

The nature of the work involved an appreciation of structural engineering as applied to offshore structures.

Hydrocarbons (UK) Ltd:

♦ Defect assessment and fatigue growth in chevron cracked SAW

longitudinal seam welds of tubular braces on Morecambe Bay platforms. The fatigue crack growth rates and brittle fracture assessments were performed in accordance with B5 PD 6493 (1980).

Conoco (UK) Ltd:

♦ Assessment of the cathodic protection status of Conoco's Viking A and B

complex platforms.

Project Engineer, seconded to Conoco's Southern North Sea Engineering Base to work on the following projects:

♦ Welding specifications and cathodic protection design for a stressed

grouted clamp repair on a Conoco Viking field platform. Onshore support for the project.

♦ Failure investigation on Monel studbolting installed sub-sea and

preparation of an underwater work book for replacement of failed sub-sea bolting on a grouted repair clamp. Monel studbolts were replaced with PTFE coated L7 low alloy studbolts.

♦ Preparation of a structural and inspection computer data base for all

Conoco's Viking field platforms and supervision of six technicians involved in data gathering and collation.

♦ Preparation of specifications for Conoco's Viking field 1985 underwater

inspection programme.



1982 - 1984 ROXBY ENGINEERING INTERNATIONAL LTD.

Cathodic Protection Engineer.

Employed on the design, installation and maintenance of cathodic protection systems, (including main contract and sub-contract negotiations, bid and tender document preparation and materials procurement) for onshore petrochemical, water treatment and general industrial plant.

British Gas:

♦ Cathodic protection monitoring of gas transmission pipelines and the Isle

of Grain LNG plant in the South Eastern Region, including polarised potential surveys, interference testing, pearson surveys and coating and painting inspection.

ADNOC:

♦ Design, installation and commissioning of the Das Island LNG/LPG plant

tankage cathodic protection system.

CEGB:

♦ Monitoring and maintenance of offshore cooing water intake structures, Sizewell Power Station.

South of Scotland Electricity Board:

♦ Internal cooling water plant corrosion survey and monitoring and

maintenance of the internal cathodic protection systems. Longannet power station.

Southern Water:

♦ Design, installation and commissioning of impressed current cathodic

protection system for two, parallel, 3km sub-sea sewage pipelines.

Seal Sands Storage:

♦ Design, installation and commissioning of a sacrificial cathodic protection system for an ethylene pipeline.

1982 - 1983 EDUCATION (PART-TIME).

Welding Diploma (for exemption from the Welding Institute professional examinations), - City of London Polytechnic, The Sir John Cass College..

1979 - 1982 EDUCATION (FULL TIME).

Research Student - City of London Polytechnic, The Sir John Cass School of Science and Technology.

Research for PhD.



Subject: Stress corrosion cracking (hydrogen embrittlement) of AL-Zn-Mg

alloys. Financed by SERC, and in conjunction with ALCAN Atlantic Region Research Laboratory. (Part time study from 1982 to 1989).

Supervisors: Dr. C.A. May, Professor L.L. Shreir.

Courses attended during research: MSc in Corrosion Protection including Aqueous Corrosion, Cathodic Protection, Conjoint Action and Fortran and Basic computer programming.

1978 - 1979 DELTA METAL COMPANY LTD., ENFIELD ROLLING MILLS DIVISION.

Technical Services Metallurgist.

Employed in the Technical Services Department from 1978 - 1979. Duties included works and customer liaison, component failure analysis, product and process development, in particular in the wire drawing and forging shops. Projects included the development of a high strength copper alloy to replace Copper-Beryllium, including continuous slab casting and rolling procedures and the development of a Copper-Silver alloy to be cast on a Southwire continuous casting and rod rolling plant.

1975 - 1978 EDUCATION (FULL TIME).

Sponsored as a Delta Group Management Trainee to read for a BSc degree full-time by the Delta Metal Company Ltd. from 1975 - 1978.

Attended City of London Polytechnic, The Sir John Cass School of Science and Technology, BSc degree course in Metallurgy, First Class Honours.

1973 - 1975 DELTA METAL COMPANY LTD., ROD (EXTRUSION)

DIVISION.

Metallurgical Technician.

Duties included metallurgical analysis of copper base alloys (chemical and metallographic), mechanical testing and foundry control with XRF and UVAQ. (Day release to study for an HNC in metallurgy, City of London Polytechnic, The Sir John Cass College). Projects included commissioning of a Techni-Guss three strand continuous casting plant, and development of a rheocasting process for gunmetals.



Publications “Hydrogen Embrittlement of an A1-4.5Zn-2.5Mg alloy”. International Hydrogen in Metals Conference, Paris, France, 1982. “Sub-sea Hot Tapping: A Technical State of the Art Review”. Pipes, Pipelines and Pipeline Systems International Conference, Utrecht, Holland, 1987. “The Hot Tapping of Sub-Sea Pipelines” Welding Review, November 1987. “Materials Selection, Cathodic Protection and Coating Selection on the Great Man-made River Project”. NDT 99 and UK Corrosion ’99 Conference, Poole, UK, 1999. “Hydrogen Embrittlement Stress Cracking in Prestressing Steel Wires”, Eurocorr 2000 Conference, London, UK, 2000.

boran, john (dr) - mtd group - 2016 cv

Documents