50037-QA-PLN-002 Rev.0

INSPECTION AND TEST PLAN Rev. 0

RESIDUAL OFFSHORE CONSTRUCTION WORK AT PARADIP

Page 2 of 13

CONTRACT NO. PLCC/PHCPL/SPM/0825

RECORD OF AMMENDMENTS SHEET Version

Purpose

A

Issued for Inter Disciplinary Check (IDC)

B

Issued for Client Review

0

Issued for approval for construction

List of updated/modified sections if any IDC comments are incorporated

Intec comments on section 6.1-6.10 have been incorporated and closed out Section 10.5 – Test pressure changed from 20 bar for 4 hours to 225 psig for 3 hours Section 9 – Added “and Mooring Hawser” Section 9 – Added section 9.2, 9.3, and 9.4

50037-QA-PLN-002

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Page 3 of 13


TABLE OF CONTENTS

1.0

INTRODUCTION ........................................................................................................................4

2.0

REFERENCES ...........................................................................................................................5

3.0

TERMS AND DEFINITIONS ......................................................................................................6

4.0

INSPECTION AND TEST PLAN................................................................................................7

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Page 4 of 13


1.0 INTRODUCTION 1.1

General

Indian Oil Corporation Ltd (IOCL) is setting up a crude oil receiving facility having Single Point Mooring terminal about 20 Kms off the coast of Paradip port in the east coast of India. This facility will enable to unload the crude oil from the VLCCs to meet the crude oil requirement of its refineries located in the eastern part of India. Global Industries Asia Pacific Pte Ltd (GIAP) has been contracted by Indian Oil Corporation Ltd to perform the Residual Offshore works at Paradip, Group I project, which involves the below scope of work. 1.2 • • •

• • • • • • • • • • •

Scope of Work Pre-installation and Anchor clearance Survey. Towing of the CALM Buoy (11.5m dia., approx 250 T, SBM-IMODCO Turn Table Type) from Paradip Port jetty to SPM location (approx 20 km). Locating and marking the ends of all the six anchor chains. Each chain is studless apprx 345 m long, weighing 70 T and secured to anchor piles positioned at a radius 316m from the CALM Buoy location, equally spaced at 60 deg. Cross Tensioning of the anchor chains upto 300 T. Positioning the CALM Buoy at the PLEM centre and affixing the chains to the Buoy. Leak test of the Floating Hose String at the jetty before transportation to the CALM Buoy location. Transportation, Assembly and Hydro testing of the Submarine Hose Strings. Affixing the 20” dia Submarine Hoses and Associated Systems. Affixing the 24” dia Floating hoses. Installation of the Hydraulic Umbilical from HPU to the PLEM Actuators. Installation of the Mooring Hawser and associated Mooring Systems. Leak Testing of the CALM Buoy System. Commissioning support. Post Installation Survey.

1.3 Document Purpose The purpose of Inspection and Test Plan is to define the type and level of inspection requirements, which are to be performed during the installation, mechanical completion and pre commissioning phases of the project. It also identifies the reference documents to be allowed/ acceptance criteria and verifying documents which are needed to provide the documentary evidence of the successful completion of the inspection activity and compliance with specified test requirements. This Inspection and test plan also specifies the mutually agreed type and level of inspection, such as witnessing, hold, review and monitoring by all relevant parties before the commencement of quality control activities in the project. 50037-QA-PLN-002

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INSPECTION AND TEST PLAN RESIDUAL OFFSHORE CONSTRUCTION WORK AT PARADIP

Rev. 0

Page 5 of 13


2.0 REFERENCES The below are the key reference documents for this project. All external codes and standards of latest versions are available for project reference in Global intranet and accessible for all employees. Sl. No

Document No.

Description

2.1

50037-QA-PLN-001

Project Quality Plan

2.2

50037-PM-PLN-001

Project Execution Plan

2.3

50037-SI-PRD-001

CALM Buoy Installation Procedure

2.4

50037-SI-PRD-002

Anchor Handling and Mooring Procedure

2.5

50037-SI-PRD-003

Pre-commissioning Procedure

2.6

50037-SU-PRD-001

Pre-installation Survey Procedure

2.7

50037-SU-DOC-001

Pre-installation Survey report

2.8

50037-SU-PRD-002

As-Built Survey Procedure

2.9

50037-SU-DOC-002

As-Built Survey Report

2.10

50037-ME-DOC-001

Marine Spread Specifications & Certification Dossier

50037-QA-PLN-002

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INSPECTION AND TEST PLAN RESIDUAL OFFSHORE CONSTRUCTION WORK AT PARADIP

Rev. 0

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3.0 TERMS AND DEFINITIONS The key terms/ acronyms etc. are defined in the following table or within individual project documents. Terms and definitions shall be as per ISO 9000:2000. AFC

:

‘Approved for Construction’ by Company

Contractor

:

Global Industries Asia Pacific Pte. Ltd (GIAP)

Company

:

India Oil Corporation Limited (IOCL)

CALM

:

Catenary Anchor Leg Mooring Buoy

FIM

:

Free Issued Material

ITP

:

Inspection and Test Plan

MWS

:

Marine Warranty Surveyor

NCR

:

Non Conformance Report Pipeline End Manifold

PLEM PQP

:

Project Quality Plan is a document specifying which procedures and associated resources shall be applied by whom and when to a specific project product, process or contract.

QA

:

Quality Assurance, Part of quality management, focused on providing confidence that quality requirements will be fulfilled.

QC

:

Quality Control, Part of quality management focused on fulfilling quality requirements.

QMS

:

Quality Management System

ROV

:

Remote Operated Vehicle Single Buoy Mooring

SBM 3rd Party

50037-QA-PLN-002

:

Personnel nominated by the Company to review, witness and/or approve project activities wherever applicable.

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INSPECTION AND TEST PLAN RESIDUAL OFFSHORE CONSTRUCTION WORK AT PARADIP.

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Page 7 of 13


4.0 INSPECTION AND TEST PLAN REF. NO. 1

ACTIVITY DESCRIPTION

LOCATION

REFERENCE PROCEDURE/ ACCEPTANCE CRITERIA

VERIFYING DOCUMENTS

SURVEILLANCES BY GIAP

IOCL

3rd PARTY

INSTALLATION PROCEDURES

1.1

CALM Buoy Installation

Singapore

50037-SI-PRD-001: CALM Buoy Installation Procedure

AFC

P/R

R/A

R/A

1.2

Anchor Handling and Mooring

Singapore

50037-SI-PRD-002: Anchor Handling and Mooring Procedure

AFC

P/R

R/A

R/A

1.3

Pre-commissioning

Singapore

50037-SI-PRD-003: Pre-Commissioning Procedure

AFC

P/R

R/A

R/A

1.3

Pre-installation Survey

Singapore

50037-SU-PRD-001: PreInstallation Survey Procedure

AFC

P/R

R/A

R/A

1.4

As-Built Survey

Singapore

50037-SU-PRD-002: As-Built Survey Procedure

AFC

P/R

R/A

R/A

1.5

Derrick Barge Survey and Positioning

Singapore

50037-SU-PRD-003: Derrick Barge Survey and Positioning Procedures

AFC

P/R

R/A

R/A

P/H

R/A

R/A

2

2.1

RECEIPT OF COMPANY FREE ISSUED MATERIALS (FIM)

Inspect & Receive Company’s FIM.

50037-QA-PLN-002

Paradip port

LEGEND :

• • • •

FIM Delivery Notes Shipping documents Materials certificates OSD Check & Visual inspections

Materials Receiving Report

A: APPROVE

NA: NOT APPLICABLE

R: REVIEW

H: HOLD

P: PERFORM

W: WITNESS

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REF. NO. 3

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LOCATION


VERIFYING DOCUMENTS


IOCL

3rd PARTY

FABRICATION OF INSTALLATION AIDS (CHAIN TENSIONER & SPREADER BAR)

3.1

Welding Procedures & Welder Qualification records

Batam

AWS D1.1

Approved documents

R

NA

NA

3.2

Visual & dimensions Inspection

Batam

AWS D1.1 & 50037-DWG-005

As-Built Drawing

W

NA

NA

3.3

NDT

Batam

AWS D1.1 , WPS, WQT, ASNT

NDT Reports

R

NA

NA

3.4

Load Testing of Chain Tensioner & Spreader Bar

Batam

50037-DWG-005 : Chain Tensioner

3rd Party - Load Test/ Functional Test Report

W

NA

NA

3.5

Fabrication Documentation

Batam

WPS, Welder Certs, Electrode Certs, Materials Mill certs, NDT reports, As- As-Built Dossier built drawings, etc

R

NA

NA

P/W

NA

NA

P/W

R

R

4

4.1

4.2

MOBILIZATION & TOWING Ensure the following are secured, lashed, seafastened and preserved properly as per drawings • Diving Spread • Installation Aids • Free Issued Materials Ensure "Tow Approval" issued by Marine Warranty Surveyor

50037-QA-PLN-002

LEGEND :

• 50037-ME-DOC-001: Marine

Spread Specifications & Certification Dossier Batam

• Load-out Drawings & Sea

Fastening Drawings

Paradip port

IOCL appointed MWS’s approval

• MPI Report for deck

welds • Rigging gears

certificates

Tow Approval Certificate by MWS

A: APPROVE

NA: NOT APPLICABLE

R: REVIEW

H: HOLD

P: PERFORM

W: WITNESS

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Rev. 0

REF. NO. 5


6

VERIFYING DOCUMENTS


IOCL

3rd PARTY

P/W

W/A

W/A

P/W

W/A

W/A

SURVEY • 50037-SU-PRD-003: Derrick

(Locating Anchor Chains & Report any significant seabed debris for resolution) Post Installation As Built Survey.

5.2


LOCATION

Pre Installation Survey 5.1

Page 9 of 13


(SPM position, positions and angles of anchor chains, positions of Under buoy house , floating hoses, coordinates of PLEM, etc)

CALM Terminal Site

Barge Survey and Positioning Procedures • 50037-SU-PRD-001: PreInstallation Survey Procedure

50037-SU-DOC-001: Pre- Installation Survey Report

50037-SU-PRD-002: As-Built Survey 50037-SU-DOC-002: CALM Terminal As-Built Survey Procedure Site Reports

TENSIONING OF ANCHOR CHAINS & INSTALLATION OF SPM

6.1

Check the calibration status of load cell(s)

CALM Terminal Site


Calibration Certificate

R

R

R

6.2

Ensure that chain is pulled through the chain hawse/chaser

CALM Terminal Site


Visual Check

P

W

W

6.3

Check that tension load is ~ 150T or Cross tensioning to be ~ 300T for anchors chains tensioning

CALM Terminal Site


Anchor Chains Tensioning Report

P/W

W/A

W/A

6.4

Check that each chains are marked with indelible florescent colour visible in water

CALM Terminal Site


Visual check

P/W

W

W

50037-QA-PLN-002

LEGEND :

A: APPROVE

NA: NOT APPLICABLE

R: REVIEW

H: HOLD

P: PERFORM

W: WITNESS

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Rev. 0

REF. NO.

Page 10 of 13



LOCATION

REFERENCE PROCEDURE/ ACCEPTANCE CRITERIA 50037-SI-PRD-001: CALM Buoy Installation Procedure 50037-DI-MAN-001 Diving Procedures Manual 50037-SI-PRD-001: CALM Buoy Installation Procedure 50037-DI-MAN-001 Diving Procedures Manual

VERIFYING DOCUMENTS


IOCL

3rd PARTY

Visual check

P/W

W

W

Visual check

P/W

W

W

6.5

Check the ends of all six chains are fixed to submerged marker buoy

CALM Terminal Site

6.6

Check that each chains are straight line from anchor piles to SPM

CALM Terminal Site

6.7

Check the chain numbers are marked to indentify with respect to PLEM ~ CALM Buoy

CALM Terminal Site


Visual Check

P/W

W

W

6.8

Check the chains are locked off on a reference link by the Chain Stopper

CALM Terminal Site


Visual Check

P/W

W

W

CALM Terminal Site


Visual Check

P/W

W

W

CALM Terminal Site

50037-SI-PRD-001: CALM Buoy Installation Procedure 50037-DI-MAN-001 Diving Procedures Manual

P/W

W/A

W/A

6.9

Check 2 links remain above the chain stopper after excess chains are cut off.

6.10

Ensure the anchor chains have been installed and connected per procedures / drawings.

50037-QA-PLN-002

LEGEND :

• Fugro Survey Report

for Anchor Chains Installation Report • Diver Survey Report

A: APPROVE

NA: NOT APPLICABLE

R: REVIEW

H: HOLD

P: PERFORM

W: WITNESS

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Rev. 0

REF. NO.

6.11

7

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LOCATION

Verify the CALM Buoy system has been CALM Terminal installed in specified positions and coordinates Site


VERIFYING DOCUMENTS


IOCL

3rd PARTY

Installation Procedure

Fugro Survey Report for CALM Buoy Installation

P/W

W/A

W/A

• 50037-SI-PRD-001: CALM Buoy

INSTALLATION OF UNDER BUOY HOSES

7.1

Ensure the hose identifications with respect to CALM Terminal SPM / PLEM inlets/ manifolds Site


AFC SBM Assembly Drawings

P

W

W

7.2

Bolts types/ spec are correct for the flanges and hoses

CALM Terminal Site



P

W

W

7.3

Ensure the tightening of flange bolts to the required torque values

CALM Terminal Site


Bolt Tensioning/ Tightening Reports

P/W

R/A

R/A

7.4

Ensure the configuration of Under buoy houses installation is as per AFC drawings

CALM Terminal Site


Fugro – Under Buoy Hoses Configuration Survey Report

P/W

R/A

R/A

8.1

Ensure the hose identifications with respect to CALM Terminal SPM / PLEM inlets/ manifolds Site



P

W

W

8.2

Bolts types/ spec are correct for the flanges and hoses



P

W

W

8

INSTALLATION OF FLOATING HOSES

50037-QA-PLN-002

LEGEND :

CALM Terminal Site

A: APPROVE

NA: NOT APPLICABLE

R: REVIEW

H: HOLD

P: PERFORM

W: WITNESS

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Rev. 0

REF. NO.

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LOCATION


VERIFYING DOCUMENTS


IOCL

3rd PARTY

8.3

Ensure the tightening of flange bolts to the required torque values

CALM Terminal Site


Bolt Tensioning/ Tightening Reports

P/W

R/A

R/A

8.4

Ensure the configuration of Floating houses installation is as per AFC drawings

CALM Terminal Site


Fugro - Floating Hoses Configuration Survey Report

P/W

R/A

R/A

9

INSTALLATION OF UMBILICAL and MOORING HAWSER

9.1

Ensure umbilical identification with respect to PLEM ~ HPU inlets/outlets.

CALM Terminal S50037-SI-PRD-001: CALM Buoy Site Installation Procedure

Fugro - Umbilical Hoses Configuration Survey Report

P/W

A

A

9.2

Ensure mooring hawser has been preassembled as per AFC drawings

50037-SI-PRD-001: CALM Buoy CALM Terminal Installation Procedure Site Drawing No. MR.00.002.7700

AFC Mooring Hawser drawing

P

A/W

A

9.3

Check all shackles and chain support buoys have split pins or other retaining pin to prevent from backing loose.



P

A/W

A

9.4

Ensure mooring hawser has been securely installed to the mooring arm structure



P

A/W

A

10 10.1 10.2

LEAK TESTS (HOSES & CALM BUOY SYSTEM) Ensure pressure gauges are calibrated and CALM Terminal used within specific test range Site

50037-SI-PRD-003: PreCommissioning Procedure

AFC

P

R

R

CALM Terminal Site


AFC

P

R

R

Check the bleed-off air prior to pressurising

50037-QA-PLN-002

LEGEND :

A: APPROVE

NA: NOT APPLICABLE

R: REVIEW

H: HOLD

P: PERFORM

W: WITNESS

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Rev. 0

REF. NO.


LOCATION

10.3

Check the bleed-off air prior to pressurising

10.4

Leak test for Floating and Under buoy hoses.

10.5

Leak Test of CALM Buoy System. (PLEM Valve ~ Blind of Floating Hoses)

11

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CONTRACT NO. PLCC/PHCPL/SPM/0825 REFERENCE PROCEDURE/ ACCEPTANCE CRITERIA

VERIFYING DOCUMENTS


IOCL

3rd PARTY

P

R

R

CALM Terminal Site


Paradip port


Floating and Under Buoy Hoses Leak Test Report

P/W

W/A

W/A

@ 225 psig for 3 hours

CALM Buoy System Leak Test Report

P/W

W/A

W/A

Company approved installation & survey records, & reports

P/R

R/A

R/A

P/R

R/A

R/A

CALM Terminal Site

AFC

AS BUILT DOCUMENTATION

11.1

Ensure that all as-built documentations/ records are reviewed and approved/signed by relevant parties onboard.

Singapore

50037-AB-DOC-001: As-Built Documents

11.2

Submission of As built for Company approval.

Singapore

50037-AB-DOC-001: As-Built Documents

50037-QA-PLN-002

LEGEND :

AFC

A: APPROVE

NA: NOT APPLICABLE

R: REVIEW

H: HOLD

P: PERFORM

W: WITNESS

25-11-2008

50037-QA-PLN-002 Rev.0

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