Académique Documents
Professionnel Documents
Culture Documents
Rev
Date
Description
Author
Sponsor
09/2008
General Revision
VIMN
MULI
12/2008
September 2008
CWAN
1 of 33
FFS-SU-5218
CONTENTS
1.0
Scope ..........................................................................................................................3
2.0
References ..................................................................................................................3
2.1 ......Purchaser Documents ......................................................................................3
2.2 ......Industry Codes and Standards .........................................................................3
3.0
Acronyms ....................................................................................................................4
4.0
Requirements .............................................................................................................4
4.1 ......Item Definition ..................................................................................................4
4.2 ......General .............................................................................................................4
4.3 ......Materials ...........................................................................................................5
4.4 ......Structural Pipe Fabrication ...............................................................................5
4.5 ......Pile Fabrication .................................................................................................6
4.6 ......Node Fabrication ..............................................................................................6
4.7 ......General Fabrication ..........................................................................................6
4.8 ......Assembly ........................................................................................................11
4.9 ......Workmanship .................................................................................................15
4.10 ....Protective Coatings and Markings ..................................................................15
4.11 ....Vortex Shedding .............................................................................................15
4.12 ....Supplier Engineering ......................................................................................15
4.13 ....Weight Measurement .....................................................................................16
4.14 ....Lift and Rigging Requirements .......................................................................16
4.15 ....Identification, Marking and Platform Signs .....................................................16
5.0
6.0
7.0
8.0
Tables .......................................................................................................................27
9.0
Figures
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....................................................................................................................31
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FFS-SU-5218
SCOPE
1. This specification defines the minimum requirements for shop fabrication, yard fabrication
and offshore fabrication, welding, and bolting assemblies and inspection of fixed offshore
steel platforms and the decks/topside modules of floating platforms.
2. This specification shall be used in conjunction with a Project Particular Specification, if any,
detailing any additional test requirements based on the particular design conditions of steel
structures.
3. No deviations to the requirements stated in the present specification shall be permitted unless
prior written consent has been obtained from the Company.
2.0
REFERENCES
1. The requirements of this specification shall take precedence over the reference codes and
standards.
2. When this specification states no overriding requirements, the reference codes and standards
shall apply.
3. The following documents are referenced herein and are considered part of this specification.
4. Use the edition of each referenced document in effect on the date of the publication of this
specification.
2.1
2.2
Purchaser Documents
FFS-SU-5215
FFS-SU-5216
FFS-SU-5217
COM-SU-2.02
SID-SU-5106
Safety in Designs
Spec 2B
Spec 2H
A 36/A 36 M
A 123/A 123M
A 385
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A 578/A 578M
D 395
D 945
Fiberglass Gratings
U.S. Department of Labor Occupational Safety & Health Administration (US OSHA)
29 CFR PT 1926
3.0
ACRONYMS
CGCenter of Gravity
MWSMarine Warranty Surveyor
4.0
REQUIREMENTS
4.1
Item Definition
Platform fabrication includes project management, labor, quality control, equipment, tools,
machinery, transportation, supplies, materials, and other items required to construct, blast, coat,
store, loadout and tie-down components of the offshore structure.
4.2
General
1. Supplier shall completely fabricate and coat the structures, including the components and
prepare them for transportation to site.
2. Structural welding shall be in accordance with Purchaser Specification FFS-SU-5216.
3. Structural design shall be in accordance with Purchaser Specification FFS-SU-5217.
4. Phases of fabrication shall be performed at Suppliers fabrication yard.
5. Any intention of Supplier to divide the work among various locations, divisions, or to
subcontract portions of work shall be made known to Purchaser at the time of bidding and
Supplier shall proceed with this plan only after review by Purchaser.
6. Shearing, flame cutting and chipping shall be performed by a mechanically guided tool
whenever practical.
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Materials
1. Supplier shall furnish the materials, appurtenances, fixtures, and equipment unless stated
otherwise on the drawings or in the Technical Requirements.
2. Except as stated below, the materials shall be in accordance with Purchaser Specification
FFS-SU-5215.
3. Supplier may submit a material type substitution request in writing to Purchaser for review.
a. The request shall include the nature and extent of the substitution, effect on the schedule,
full specification and physical properties of the proposed substitute and any other pertinent
information requested by Purchaser.
b. Substitutions that have not been accepted in writing by Purchaser will not be accepted and
shall be removed from the work and replaced by the specified materials by the Supplier.
4. Steel shapes, plate and pipe for fabrication shall be new and free from rust and mill scale. If
laminations or split ends exist in plate, pipe or rolled shape, the extent of the defect shall be
determined and repaired in accordance with the appropriate material delivery specification or
replaced if out of specification and repair per specification is not possible.
5. Purchaser furnished material (if any is provided) will be delivered to the quayside at the
fabrication site and shall be unloaded, handled and properly stored in accordance with Project
specification.
6. Supplier is responsible for providing labor and equipment, including slings and spreader bars,
required to unload Purchaser furnished material.
4.4
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Pile Fabrication
1. Piles shall be fabricated to the tolerances of API RP 2A-WSD, API Spec 2B and this
specification.
2. The minimum length of a segment of pipe used in fabricating piles shall be 5 feet (152 cm) or
one pile diameter, whichever is greater.
4.6
Node Fabrication
1. The orientation of node cans in deck legs, braces and skirt pile sleeves shall be such that the
longitudinal weld seam does not intersect the welds of braces coming into the joint.
a. In the case of X-joints (intersection of two crossing braces) of approximately the same
diameter, the orientation of the longitudinal seam on the through brace member shall be
approximately midpoint between the crown and the saddle of either of the incoming
braces.
b. The longitudinal seam for other types of node cans shall be oriented to avoid incoming
braces when possible.
c. When unavoidable, the longitudinal seam of the chord seem may be within the incoming
brace footprint but not near its centerline (i.e., within the middle one-third) of incoming
braces.
2. Circumferential (girth) weld seams shall not be permitted to intersect welds to incoming
braces on any type of node can without prior written acceptance by Purchaser. Where there is
no reasonable alternative, permission will be granted to locate girth seams at or near the
centerline (within the middle one-third) of incoming braces.
3. Joints shall be designed and detailed as simple joints per API RP 2A-WSD. Joints are to be
detailed with work point offsets clearly shown.
4. There shall be a minimum 3-inch (7-mm) overlap shall be supplied between adjacent braces
when overlapping is required to keep brace centerline offset dimensions less than D/4. The
overlap shall be measured from the intersection of the overlapping braces radially to surface of
the chord member.
4.7
General Fabrication
1. Structures and equipment shall be grounded (earthed) immediately after being installed.
2. Fuel shall be stored at the Work Site (including temporary facilities sites) only at locations and
in containers accepted by Purchaser. Fueling of construction equipment with nearby hot work
shall comply with US OSHA standards 29 CFR PT 1926 section (c) through (g).
4.7.1
Slotted Members
Where slotted members are required, they shall be slotted to receive gusset plates in
accordance with API RP 2A-WSD and the following:
1. The longitudinal seam shall be at least 90 degrees from the slot when members are to
be slotted unless more than two slots are necessary in which case a 45-degree
separation shall be maintained.
2. No girth weld shall be placed closer than 12 inches (30 cm) from the end of the slot.
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4.7.3
4.7.4
Bolted Connections
1. The bolting surfaces shall be smooth and without burrs.
2. Bolts shall be placed into the holes without damaging the threads.
3. Bolts in bearing shall be threaded to such a length that no more than one thread shall
be within the grip of the structural members. The bolts shall be of a length that will
extend entirely through, but no more than 1/4 inch (6 mm) beyond the nuts. After
having been finally tightened, the nuts shall be locked by tack welding the nut to the
bolt or other locking procedure reviewed by Purchaser.
4. High strength bolts shall be installed in accordance to the AISC Steel Construction
Manual or as specified by the bolt manufacturer.
5. Bolts, studs, nuts, and washers shall be galvanized, unless specified otherwise on the
Supplier drawings or Technical Requirements.
4.7.5
Beam Splices
1. Segments of beams with the same cross-sections may be spliced.
2. The use of the beam shall determine the location and frequency of splicing.
3. Splices shall be in accordance with API RP 2A-WSD and AWS D1.1.
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4. Except for deck stringer beams used to support deck plate or grating, splices shall not
be located within the following locations:
a. Splices in cantilever beam shall not be located in the half length near the support.
b. Splices in beam with supports at both ends shall not be located in the one eighth
length near both supports, nor one quarter length in the middle section.
c. Splices shall not be located closer together than twice the depth of the beam or
3 feet (91 cm), whichever is smaller.
4.7.6
Miscellaneous Splices
1. Splices in ring stiffeners shall be located at 120-degree intervals, unless otherwise
shown on Approved for Construction drawings.
2. Ring stiffeners shall not be located within 6 inches (152 mm) of the circumferential
seams in joint cans, except at conical transitions, where they shall be at least 2 inches
(50 mm) from the transition girth weld.
3. Timber splices shall be staggered a minimum of 5 feet (152 cm).
4.7.7
Deck Plate
1. The continuous seal welds between the deck plate and the deck beams or girders shall
be limited to 3/16-inch (5-mm) fillet weld made in a single pass with no or minimal
preheat.
2. The use of a low heat input welding process is encouraged. The interrupted-arc or
short-arc Gas Metal-Arc Welding (GMAW) process is accepted and encouraged for
the welding of deck plate.
3. Welds between plate sections shall be made directly over structural members.
a. With acceptance by Purchaser, 3-inch (75-mm) channel sections may be added
between deck beams to provide structural backup for the splices.
b. Connections shall develop the full strength of the plate.
4. Welding and inspection of deck beams shall be completed before the plate is installed.
The addition of beam sections for the local support of equipment is to be avoided after
the deck plate is in place.
5. In order to minimize deck plate warpage during weld out, 0.035-inch (0.9-mm)
welding wire spacers may be placed on the deck beams prior to laying the deck plate.
6. If welding wire spacer is used, the deck plate should be in firm contact with the spacer
prior to welding. If no spacer is used, the deck plate is to be in firm contact with the
beams prior to welding.
7. Fabrication procedures for the installation of the deck place, prepared by Supplier,
shall cover weld sequence, control of heat input, control of distortion in supporting
beams, correction procedures, etc.
8. A water ponding test shall be performed on each deck plate prior to painting. Work
will be accepted if the depth of ponding is limited to 1/4 inch (6 mm) or less when the
deck is nominally level.
9. Supplier shall be responsible for adding additional open deck drains where water
ponding is greater than 1/2 inch (13 mm).
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10. Containment areas as shown on the drawings, or as required by Purchaser, shall have
perimeter fabricated from half of an 8-inch (20-cm) pipe, or as otherwise noted on
drawings.
a. Containment area shall have an adequate number of drains to permit complete
drainage of the area.
b. Containment perimeter shall be painted Safety Yellow.
4.7.8
Steel Grating
1. Unless specified otherwise, grating shall be standard, hot-dip galvanized type with
1-1/2 x 3/16-inch (38 x 5 mm) serrated bars on 1-3/16 inch (30 mm) centers. Serrated
bearing bar and spacing bar intersections shall be fused or welded.
2. Grating shall be fastened in place. The fasteners shall be installed using the
manufacturers recommended procedures for accepted locations unless specified
otherwise on drawings. The grating should feel secure when walked over
3. Grating shall be trimmed and fitted around equipment supports. Additional support
brackets shall be added as required. Galvanized grating repairs shall be in accordance
with Manufacturers standards.
4. Grating shall be installed after galvanizing and after the support structure has been
painted. Fixed grating shall be attached by welding every fourth bar to each support,
with a 2 x 3/16-inch long (50 x 5 mm) fillet weld on both sides of the bar.
5. Removable grating shall be fastened in place with 316 stainless steel clips.
a. Four clips shall be used to secure sections that are 10 feet (305 cm) or less in
length.
b. Six clips shall be used to secure sections that are longer than 10 feet (305 cm).
6. Pipe penetrations through grating shall be sleeved using Schedule 40 pipe.
Pipe-to-sleeve annulus shall be 2 inches (50 mm). The sleeve shall extend a
minimum of 4 inches (100 mm) above the grating
7. Other penetrations which intersect four or more bearing bars shall be banded on the
sides with pipe or rolled flat bar of the same thickness and projecting 1 inch (25 mm)
above the bearing bars.
8. Banding shall be seal-welded to intersecting bearing and spacing bars. Grating shall
be galvanized after banding.
9. Grating shall be continuously banded around the exposed edges.
10. Steel grating shall be hot-dip galvanized in accordance with ASTM A 123/A 123M,
ASTM A 153 and ASTM A 385 except that the weight of the galvanizing shall be
2.5 oz. per square foot average, and 2.2 oz. per square foot minimum.
11. Steel grating shall be welded and serrated with semicircular serrations formed by
punching as shown in the following:
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Dimension Inches (mm)
Minimum
Maximum
Radius of Punch
1/8 (3)
7/32 (5.6)
Depth of Cutout
3/32 (2.4)
11/64 (4.4)
Punch Center-to-Center
7/16 (11.1)
1/2 (13)
12. Welding of grating should be performed prior to galvanizing to the extent practical.
In-place grating repairs and modifications shall be touched up with accepted cold
galvanizing or equivalent.
4.7.9
Non-Steel Grating
1. Phenolic and/or fiberglass grating may be used on weight sensitive structures subject
to Purchaser review USCG PFM 2-98 rules and Purchasers FFS-SU-5215. Note that
at the time of this publication, there are no Phenolic and/or fiberglass grating rated for
Level 1 application as defined by USCG rules. For Level I areas, metal grating shall
be used.
2. Joints in grating shall occur only at points of support. Joints shall be supported over
their full length.
3. Penetrations through phenolic and fiberglass grating shall be banded with grating
penetration collars by Intrepid Industries, Inc. or Purchaser-accepted equivalent with
stainless steel hardware.
4. Supplier shall provide grating supports locations. Minimum thickness of support
members shall be 5/16 inch (8 mm) to prevent blow-through at the underside of the
support when Hilti studs are used to attach the grating.
5. Complete end support of grating panels is preferred.
a. When impractical to provide end support, cantilever length of grating beyond the
edge of support shall not cause stresses of deflections to exceed allowable limits.
b. There is no acceptable cantilever length for grating cross-bars.
4.7.10 Penetrations
1. Penetrations through structural steel members shall not be permitted without prior
review by Purchaser.
2. Deck, bulkhead and beam penetrations shall be kept to a minimum; alternative piping
and conduit routes shall be explored and reasonable routes selected.
3. Beam and bulkhead penetrations made for piping shall be the next larger Schedule 80
pipe size that provides a minimum of 1-inch (25-mm) clearance on the radius between
the ID of the reinforcement and the OD of the pipe. The reinforcing pipe shall be a
minimum of 6 inches (150 mm) long centered on the web and fillet-welded to both
sides of the web.
4. Supplier shall submit for Purchaser review drawings and calculations for
reinforcement of bulkhead and beam penetrations prior to start of fabrication.
Penetration reinforcement shall be designed to equal or exceed the original strength of
the penetrated member.
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5. Deck penetrations made for piping shall be sleeved with Schedule 40 pipe providing a
minimum of 1-inch (25 mm) clearance on the radius between the ID of the
reinforcement and the OD of the pipe. The sleeve shall be 6 inches (150 mm) long
positioned with the upper end 4 inches (100 mm) above the deck and fillet-welded to
the deck plate on both sides.
6. Deck, beam, and bulkhead penetrations made for conduit shall accommodate the
outside diameter of a coupling for the penetrating conduit. The conduit coupling shall
be positioned with its ends equidistant from the web/plate and shall be fillet-welded to
both sides of the web/plate.
4.7.11 Stairways, Ladders and Handrails
1. Stairways, ladders, and handrails shall be fabricated in accordance with SID-SU-5106.
2. Stair treads shall be fabricated from the same type of grating as the landing it serves or
shall be manufactured steel treads with abrasive nosings (e.g., Grip Strut).
a. Each tread and the edge of the landing at the top of the stairs, shall be fitted with a
distinctive nonskid, leading edge nosing, which shall be accepted by Purchaser.
b. The nosing shall be installed after painting and galvanizing.
3. Corners, edges, burrs or rough spots on handrails, guards, etc. shall be ground or filed
smooth.
4. Handrails shall be fabricated such that weep-holes are eliminated (by cutting holes in
the post where midrails intersect).
5. Should weep-holes be cut, Supplier shall plug weepholes by an accepted method.
6. Safety gates shall be manufactured from fiberglass with corrosion resistant hardware.
(Suggested Vendor: Intrepid Industries, Pasadena, Texas.)
4.7.12 Random Arc Strikes
1. Random arc strikes shall not be allowed.
2. Where evidence of such arc strike exists, it shall be ground out, repaired and inspected
using a procedure supplied by the Supplier for Purchaser review.
4.8
Assembly
4.8.1
General
1. Work shall not be performed when the weather does not permit satisfactory
workmanship or conditions prevent required inspection.
2. Supplier shall provide any reinforcement and construction aids required during
erection including padeyes and temporary braces. Stresses in the structure components
and temporary bracing shall be limited to API and AISC basic allowables during
stages of assembly and erection.
3. The site assembly procedures and methods, including details of temporary works,
support points, jacking points and sling points of major components (not minor
subassemblies) shall be submitted to Purchaser for review before assembly.
4. Fabrication procedures and tolerances shall conform to API RP 2A-WSD, AWS D1.1,
project drawings, and this specification.
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5. Access manholes in the tubulars or legs shall not be permitted without prior written
acceptance by Purchaser. The longitudinal seams of windows cut to facilitate fit-up at
the end of braces shall be oriented 90 degrees to the longitudinal pipe seam.
a. The transverse seam shall be located a minimum of two-brace diameters from the
joint.
a. The transitions between longitudinal and transverse seams shall have a minimum
radius of 6 inches (152 mm).
b. Plates covering access manholes and windows shall be flush with the outside
diameter of the brace and joined using full penetration welds.
c. Welds shall be ground smooth and profiled and subjected to the same inspection
as the joint itself.
6. Supplier shall investigate the erection loads imposed on structures from support
jacking and lifting.
a. Calculations shall be submitted to Purchaser for review for the stages of erection
and loadout.
b. Supplier shall make available to Purchaser information necessary to verify
calculations such as crane Manufacturers load/radius curves and rated load
capacity of slings and shackles.
7. Supplier shall also perform calculations to verify the overall stability at any stage of
erection.
a. These calculations shall include the effects of scaffolding, staging, welding,
shelters and environmental loads.
b. Calculations shall be submitted to Purchaser for review.
8. Assembly of structural steel shall proceed on a level and stable surface. Prior to the
start of yard erection, Supplier shall submit to Purchaser details of fabrication site and
loadout path including soils reports and proposed foundations.
9. Checks of blocking and levels shall be made on a monthly (or based on Project
requirement) basis and after each setting of major structural or mechanical assemblies
or if there is evidence of any instability of the supporting working surface.
a. When any portion of the structure settles out of level, the settled section shall be
brought back into level by shimming the blocking under it or by other actions as
required.
b. Frequency level survey reports shall be given to Purchaser.
c. Misalignment shall be corrected at the stages of erection.
10. Fitting of joints shall be restricted to machine or flame cutting and grinding.
a. Any beveled edge that has been damaged shall be restored to the minimum
tolerances.
b. The fit-up of joints shall be inspected by a welding inspector after completion of
fit-up, but prior to any production welding.
c. If the fit-up meets Purchaser requirements, the joint shall be clearly marked for
satisfactory fit-up and initialed by Suppliers welding inspector.
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11. Temporary attachments to the structure, such as scaffolding supports and other
fabrication aids shall be removed prior to loadout without damaging permanent
structures.
a. When removing temporary attachments, the attachment shall be cut off no closer
than 1/8 inch (3 mm) to the permanent member, then ground flush per
API RP 2A-WSD Section 11.1.7.
b. Weld splatter shall be removed and surfaces restored to a smooth, flush finish.
c. Temporary attachments shall not be made to high strength steels (specified
minimum yield strength greater than 36 ksi) without the prior written acceptance
of Purchaser.
12. A 1/2-inch (13-mm) thick neoprene or vulcanized rubber liner shall be installed on
riser clamps.
a. The riser clamp surface shall be abrasive blasted in accordance with SSPC-SP 10/
NACE No. 2, using a 2 to 4 mil (50.8 to 101.6 micron) anchor pattern.
b. The liner shall be attached to the clean surface using a suitable epoxy adhesive
recommended by the liner manufacturer.
c. Where neoprene is used, the clamp shall be trial fit after gluing to ensure a proper
fit and to assist bonding.
d. Supplier shall submit the proposed application procedure for review by Purchaser.
e. The liner shall meet the requirements below:
Condition
Requirement
Design temperature
180F (82C)
60 to 65
2000 lb/in2 (13.8
440%
0 (no cracks)
0 (no cracks)
55%
45%
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bar)
Excellent
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Requirement
4.8.2
Excellent
Dimensional Tolerances
1. Allowable fabrication tolerances shall conform to the following (in order of
precedence):
a. This specification.
b. API RP 2A-WSD, API Spec 2B (for structural steel pipe), AISC Steel
Construction Manual and ASTM A 6/A 6M (for rolled shapes), and AWS D1.1.
c. Tolerances not covered by this specification and the above standards shall be
reviewed by Purchaser.
2. The following lists Purchasers tolerances which supersedes the standards listed
above:
a. Allowable fabrication tolerances are given in Table 1 and Figures 1, 2 and 3.
b. Unless otherwise specified in Table 1 and Figures 1, 2 and 3, fabricated
dimensions shall have a tolerance of 1/2 inch (13 mm) or less.
c. Water-holding ponding areas in excess of 1/4-inch (6-mm) deep shall not be
allowed in the deck plate between any two-deck beams.
d. Handrails shall be fabricated such that, when erected, the top rail shall be level
and the posts plumb.
e. Landing elevations and landing and stairway locations (horizontally) shall be
within 1/2 inch (13 mm) of their accepted dimensions. The vertical rise difference
between stair threads in one flight shall not exceed 1/8-inch (3 mm). Differences
between elevations of grating at seams shall not exceed 1/8-inch (3 mm).
f.
Anodes shall be located within 6-inch of the location shown on the Approved for
Construction drawings.
g. Heliport safety shelf fencing shall be taut between panels. The maximum sag
between panels shall be 1/2 inch (13 mm) under a load of 200 lb (91 kg) at the
panel center.
4.8.3
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Workmanship
1. Fabrication techniques shall be in accordance with accepted, current good practices of the
trades involved and the requirements of this specification.
2. Steel work shall be well formed to shape and size with true lines and smooth surfaces.
3. Members shall be accurately fabricated and assembled plumb, square and level in accordance
with the tolerances set forth in this specification.
4.10
4.11
Vortex Shedding
1. Supplier shall be responsible for and take measures to protect members and appurtenances that
are susceptible to vibration due to wind-induced vortex shedding.
2. Such measures may consist of hanging weights from or wrapping chain or wire around the
susceptible members.
3. Supplier shall provide a reliable method of determining wind speed, such as an anemometer, at
the fabrication site.
4.12
Supplier Engineering
1. Supplier shall provide required engineering including the following:
a. Materials procurement, handling and storage
b. Project schedules
c. Monthly project reports
d. Fabrication and shop drawings
e. As-built drawings
f.
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Tubular joint details including can and stub lengths and work points
j.
k. Welding engineering
l.
Weight Measurement
1. Topside equipment items shall not be installed without certified weight documentation. If
vendor certification for an item is not available, Supplier shall weigh and provide certified
documentation. Purchaser will furnish vendor weights for Purchaser-furnished equipment.
2. Deck modules and appurtenances requiring weighing prior to loading-out and lifting offshore
shall be weighed at frequency as described in the Coordination Procedure.
3. A weight control plan shall include a dead weight survey prior to weighing, the weighing
procedure, and the monitoring of additional weight placed between weighing and load-out.
The plan shall follow Purchasers Weight Management Philosophy and Weight Estimating,
Reporting, and Weighing listed in project specification.
4.14
4.15
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2. Pipes from other than ASTM A 36/A 36M material shall be painted in accordance with the
general provisions of ASTM A 6/A 6M. Supplier shall not exceed Manufacturers working
load limit rating for slings.
3. Each length of structural beam, pipe, plate, or tubular can be rolled from plate shall be marked
on one end by paint in 1-inch minimum high letters. Paint identification will include the
following:
a. Metal grade
b. Heat number(s)
c. Plate or Can number (Can numbers traceable back to Plate numbers)
d. Can dimensions (diameter, wall thickness, length of can)
e. Manufacturers name
f.
Inspecting Purchaser
DOCUMENTATION REQUIREMENTS
5.1
General
1. Supplier responsibilities are to review the documentation provided by Purchaser, including
noting any discrepancies and/or omissions as described in the Coordination Procedures.
2. Supplier is also responsible to provide Purchaser with the following:
a. Fabrication and erection plans, including sketches, estimated weight of each major lift and
roll-up, and erection sequence/procedure.
b. Major lift plans, including detail analysis and procedures.
c. Loadout plan, including detailed analysis and procedures.
d. Material traceability, including mill certificates and construction drawings with the associated mill certificate tag for each component or segment of the component.
5.2
Weight Report
1. Supplier shall compile and maintain an accurate weight report of the jacket, deck, modules,
piles and appurtenances.
2. The weight report shall be of sufficient detail to identify the weight and Center-of-Gravity
(CG) of individual primary and secondary structural members, equipment and appurtenances.
3. The weight report shall include a summary of the following:
a. Jacket total loadout weight and CG,
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g. Major lift weights and CG for any lift greater than 50 s. tons.
4. Supplier shall prepare and submit to Purchaser, at least 120 days prior to the scheduled date for
the beginning of the weighing operation, a detailed procedure for the weighing of each
structure.
5. Supplier shall submit a detailed monthly (or based on Project requirement) construction report
to Purchaser along with the look-ahead schedule.
5.3
Fabrication Drawings
1. Supplier shall prepare fabrication drawings for fabrication work and submit these to Purchaser
for review.
2. Drawings shall be complete and shall include connections, holes and bolts, piece numbers in
accordance with the contract drawings.
3. Welds including longitudinal pipe seams, both shop and field, shall be indicated on the shop
drawings by standard welding symbols in accordance with AWS D1.1.
4. Each fabrication drawing will be identified as having received such acceptance by being so
stamped and dated. No fabrication work shall begin before the relevant shop drawings have
been reviewed by Purchaser.
5. The review of shop drawings by Purchaser will not be construed as a complete check, but will
indicate only that the general methods of construction and detailing are satisfactory.
6. Supplier shall prepare drawings which define the extent and type of nondestructive
examination for each weld joint for review by Purchaser.
5.4
5.5
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3. These drawings shall detail the proposed sequence methods provided in Suppliers Project
Execution Plan.
5.6
As-Built Drawings
1. Supplier shall prepare as-built drawings as the work progresses incorporating the significant
changes that occur before or during construction.
2. Upon completion of the work, Supplier shall furnish Purchaser one set of editable as-built
CAD drawing files.
5.7
Submittal Requirements
The following documents shall be prepared or obtained and submitted to Purchaser:
1. Status reports on Purchase Orders for material and equipment ordered by Supplier for
incorporation into the structure and appurtenances.
2. Purchase Orders, Manufacturers certified mill certificates and inspection reports, relating to
the materials and equipment ordered by Supplier for incorporation in the structure and
appurtenances.
3. The weld procedures.
4. The material trace records.
5. The drawings required.
6. The calculations.
7. Nondestructive testing and inspection reports. Supplier shall compile the records and submit
for acceptance after completion of loadout.
6.0
6.1
General
1. For areas not clearly defined by project drawings, specs and codes, Purchaser will be the final
judge for acceptability of Supplier materials and workmanship.
2. Supplier shall be solely responsible for thorough craft inspection during construction and for
the quality of the work.
3. Supplier shall provide the inspection specified herein, using properly qualified inspectors.
4. Purchaser will make inspections in order to check the progress and the quality of the work, and
to verify that Suppliers employees are properly qualified in their respective crafts, that
workmanship is of an acceptable grade, and that the requirements of the specifications are
being met.
5. Third party personnel responsible for verification (if required) and Purchasers inspectors shall
have free and safe access to fabrication and erection areas during the progress of the work to
ensure that the required quality of workmanship is attained.
6. Supplier shall compile, retain and submit to Purchaser the following construction records:
a. Mill certificates
b. Material trace records
c. Tubular fabrication records
d. Weld procedure qualification records
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j.
Tests
6.2.1
Jacket Members
1. The internal clearance of the pile spacers or centralizers provided inside the jacket
legs and skirt sleeves shall be checked with a hand-held circular drift to ensure free
passage of the piles.
2. Drift shall be cylindrical.
3. Supplier shall submit details of the drifting tool and procedure to Purchaser for review.
4. The legs and skirt pile sleeves shall be drifted at the following stages of fabrication:
a. after welding pile guides inside legs,
b. after welding braces to legs at panel (bent) assembly stage,
c. after welding tie-in braces to legs after roll-ups, and
d. launch legs after loadout.
5. Each pile section shall be drifted to ensure straightness and that internal diameters are
not excessively oval, obstructed or in any way present a hindrance to the installation
of piles.
6. When permanent buoyancy or temporary buoyancy for transportation or installation
(launch/upending) is required for installation, jacket legs shall be pneumatically tested
prior to loadout to ensure their water-tightness.
a. Jacket legs (including the closures) shall be individually and independently tested
with compressed air to a pressure of expected (dive) depth plus 10 percent or
15 psig (10.3 bar g) or recommended test pressure by the closure manufacturer,
whichever is larger. This pressure shall be maintained for a period of 24 hours
without further addition of air or loss of pressure, making due allowance for
ambient temperature changes.
b. The Supplier shall examine joints for tightness using soap solution or other
indicator accepted by Purchaser. Leaks or other defects discovered by the testing
and caused by faulty workmanship shall be repaired by the Supplier.
6.2.2
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2. In-place tests of diaphragms and wiper plugs, if any, must be performed in accordance
with Manufacturers recommendations. Manufacturer shall monitor and assist
Supplier during installation of these diaphragms and wiper plugs.
3. Supplier shall provide yard space and any necessary labor or equipment to assist
Manufacturer in assembling the diaphragm and wiper plugs.
4. Supplier shall prepare a plan for testing and pressure monitoring of the grout system
as the following:
a. Grout lines shall be pressure tested, at a pressure of 1.5 times the working
pressure, for not less than 30 minutes. Leaks shall be repaired.
b. Grout lines shall be internally cleaned prior to testing and loadout to remove weld
slag and other debris.
c. Grouting valves shall be lubricated and test operated before loadout to ensure that
the valve control risers and valves operate smoothly and freely.
d. Grout packers shall be tested in accordance with Manufacturers specifications.
Packers shall be tested after weld out of leg cans and before roll up of jacket bents.
6.2.3
6.2.4
Flooding System
1. Flood lines shall be pressure tested, at 1.5 times the working pressure, for not less than
30 minutes.
a. For small jackets with the flooding system consisting solely of a nipple and flood
valve, the test shall be performed at the jacket leg test pressure of 15 psig
(10.3 bar g).
b. Leaks shall be repaired in accordance with an accepted repair procedure.
2. Flood lines shall be internally cleaned prior to testing and loadout to remove weld slag
and other debris.
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3. Flooding valves shall be lubricated and test operated before loadout to ensure that the
valve control risers and valves operate smoothly and freely.
a. After testing, the valves shall be checked to ensure that they are properly oriented
according to the flooding plan.
b. Valves shall be checked to ensure that the protective caps and other obstructions
that may hinder proper operation are not present.
4. Where applicable, functional operation of the pneumatic flooding control panel shall
be performed to ensure proper operation.
6.2.5
6.2.6
J-Tubes
1. Supplier shall pig J-tubes with a cleaning pig to remove mill scale and hard deposits.
2. Supplier shall also pig J-tubes with a gauging pig.
3. Final J-tubes inside diameter shall not be less than 95 percent of the original inside
diameter.
4. Pig types and procedures shall be submitted to Purchaser prior to pigging.
6.3
Inspections
6.3.1
General
1. Purchaser may use any method of inspection necessary to establish quality control and
ensure adherence to specific offshore platform fabrication procedures.
2. Materials and workmanship shall be subject to inspection at any time by Purchaser.
3. When, in the judgment of Purchaser, any work area or section should be inspected,
Supplier shall thoroughly clean it of excess and waste materials, such as sand, slag,
weld spatter, used electrodes, etc. and allow sufficient time for it to be properly
inspected. Supplier shall furnish, install and maintain in a safe operating condition the
necessary scaffolding, ladders, walkways, adequate lighting, etc. for a safe and
thorough inspection by Purchaser.
4. Purchaser will review changes in plans, material purchases and services not included
in the specifications, and will inspect work performed by Supplier.
6.3.2
Inspection Requirements
1. Minimum inspection points shall be in accordance with Table 2. At a minimum,
Supplier shall provide the inspections listed in Table 2.
2. Inspection of welds shall be in accordance with Purchaser specification FFS-SU-5216.
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7.0
7.1
General
1. Purchaser shall interface with Marine Warranty Surveyor (MWS) and seek MWSs consent in
performing the following works:
a. Review loadout plan.
b. Review seafastening and tiedown, including internal seafastening.
c. Perform inspection of the vessel and all vessel related operations prior to loadout.
d. Perform inspection of the loadout related areas (fabrication yard bulkhead, skidding system and foundation, and loadout/lifting equipment), and the structure itself prior to loadout.
e. Perform final inspection of the structure after loadout but prior to transport for damages
due to loadout.
f.
2. Supplier shall provide the Warranty Surveyor the required information and inspection access.
3. Supplier shall repair damage to the structures, equipment, and protective coatings that occurs
during the loadout or tie-down. This work shall be completed to the satisfaction of Purchaser
prior to transport to the installation site.
4. Supplier shall provide items associated with loadout and seafastening including:
a. Overall loadout plan, including soil stability calculations.
b. Appropriate support and/or equipment to move the fabricated component from the erection locations to the designated vessel by way of an acceptable loadout methods (skidding,
rolling, transporting, or lifting), which are suitable for the platform and components loadout onto the required cargo vessels.
c. Platform and components seafastening.
d. Labor, materials and equipment required for the loadout and seafastening operation.
5. Supplier shall interface with Transportation Supplier for issues associated with loadout
planning and execution.
7.2
Loadout Plan
Supplier shall prepare and submit to Purchaser, at least 120 days prior to the scheduled date for the
loadout, a detailed plan including the minimum requirements shown in Table 3.
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Loadout Analysis
1. Loadout of the platform and components shall be the sole responsibility of Supplier.
2. Supplier shall be responsible for developing a loadout plan, performing a detailed
loadout analysis, and ensuring that structure member stresses do not exceed API and
AISC basic allowables during any stage of loadout.
3. The loadout plan shall include performing detailed 3D computer stress analysis
including structural force and deformation calculation of the structure and cargo as per
basis of design.
4. The loadout analyses shall include studies to determine the allowable differential
deflections at the structure support points which shall become the basis for deflection
tolerances during loadout.
5. A detailed ballasting plan shall be furnished to the Owner and MWS for review.
6. Due to wide range of loadout methods, it is not possible to cover all aspects of every
loadout scheme. Therefore, it is the responsibility of the Supplier to propose a project
specific loadout method and demonstrate to the Purchasers satisfaction that it can be
done safely and in a controlled manner.
7.3.2
Modifications
1. Supplier shall provide for the dock and dockside modifications necessary for loadout
of the jacket onto the launch barge. Modifications shall include providing necessary
reaction and mooring points for the barge and performing any dredging required for
the barge, strengthening the quayside, etc.
2. Supplier shall protect the barges from excessive motions due to environmental loading
or wave action from other vessels on the waterway during loadout.
7.3.3
7.3.4
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2. Supplier shall submit detailed drawings and calculations to Purchaser for review prior
to commencing fabrication.
3. Supplier shall provide redundancy for any potential system failure that will endanger
the safety of the jacket and Topsides facilities because of fluctuating tides or other
prevailing conditions.
4. If Supplier elects to utilize systems on the launch barge to assist in the loadout,
Supplier shall be responsible for providing backup for these systems when warranted.
7.4
Loadout by Lifting
1. The following is applicable to loadout by lifting method only.
2. Additional movement by skidding, rolling, or transporting to the lifting location shall meet the
requirements specified in the previous section.
3. Lift Analysis
a. Supplier shall perform a three dimensional computer stress analyses of the structure to be
lifted off the transport barge as per design basis and demonstrate to the Purchasers satisfaction that it can be done safely and in a controlled manner.
b. Member and joint stresses shall not exceed API and AISC basic allowable stresses during
any stage of loadout.
7.5
7.6
Inventory List
Supplier shall be responsible for providing Purchaser with an inventory list of shipped loose items
which will be loaded out onto the cargo barges.
7.7
7.8
General
1. Supplier shall provide the labor, equipment, supervision and materials necessary to
tie-down, seafasten or otherwise secure the platform components to the barge(s).
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2. The fabrication and installation of the seafastening and tie-down to suit the cargo/
launch barge shall be the responsibility of Supplier.
3. Supplier shall design the tie-down and seafastening as per design basis and
demonstrate to the Purchasers satisfaction that the tie-down and seafasting is
adequate for transportation of the cargo for the selected vessel and route.
4. Supplier shall rig the jacket for launch by resetting jacks or winches and Supplier
required rigging gear.
5. Supplier shall also load and secure the items required for seafastening removal as
supplied by the platform installer.
6. Supplier shall verify to the satisfaction of Purchaser that consoles, equipment, etc., are
properly secured for transport. When required, Supplier shall design, procure,
fabricate and install additional seafastening components.
7. Vessel or cargo barge ballasting shall be brought to seagoing condition prior to
seafastening the cargo/module to avoid additional locked-in loads and stresses in the
vessel, seafastening components and grillage, and cargo/module itself.
8. Review sea fastening design provided by Transportation supplier.
7.8.2
Certification
1. Supplier shall receive certification of the adequacy of the seafasterning and barge
preparation by an independent licensed marine surveyor prior to each structure
leaving the dock.
2. In addition, certification from local government inspector may also need to be
obtained.
7.8.3
Navigational Aids
Supplier shall install navigational aids on the superstructure ready for use during
transportation.
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TABLES
Table 1: Tolerances (1 of 2)
Item
Tolerance
Horizontal distance from the centerline of any leg to the centerline of an adjacent
leg at each horizontal framing level
1/4" (6 mm)
2.
1/4"(6 mm)
3.
Angle between transverse column lines and longitudinal platform faces at each
horizontal framing level
4.
5.
6.
7.
Distance between actual centerlines of bracing girth weld and the outside of the
closest intersecting brace weld
8.
Distance between the thickened joint can girth weld and the outside of the closest
intersecting brace weld
9.
10.
Distance between skid beams on top of main girders at any point along length
11.
1 minute
a. Overall
b. At adjacent legs
1/4" (6 mm)
12.
1/8" (3 mm)
13.
2.
1/8" (3 mm)
Boat Landings
1.
1/8" (3 mm)
2.
1/4" (6 mm)
Conductor Guides
1.
2.
Distance between conductor guides at one framing level for one well bay
1/4" (6 mm)
3.
2.
Batter of guides, center point location of top of guide with respect to bottom of
guide
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1/4" (6 mm)
1/8" (3 mm)
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Table 1: Tolerances (2 of 2)
Item
Tolerance
Launch Rail
1.
2.
1/8" (3 mm)
3.
1/4" (6 mm)
4.
Dimensions on cradle drawings that locate the closely spaced stiffeners with
respect to the horizontal levels of jacket framing
5.
Piles
1.
2.
1/4" (6 mm)
2.
3.
4.
1/4" (6 mm)
5.
1/4" (6 mm)
6.
7.
8.
1/4"/10'(6 mm/
250 mm)
9.
1/8" (3 mm)
10.
1/8"/10'(3 mm/
250 mm)
11.
12.
1/8" (3 mm)
13.
1/8" (3 mm)
14.
15.
1 minute
1/8" (3 mm)
1/4" (6 mm)
1/4" (6 mm)
2.
Note (1):Deck beams shall be erected with the top flanges level or to the specified slope. Deck beams
shall be erected with the webs plumb. Distortion of deck beams from welding shall be corrected
or otherwise compensated so that the tolerances of this Table are met.
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Item
W
Supplier (1)
G
Fit-up inspection
Gauge inspection
Dimensional
Pressure test
Final inspection
Seafastening inspection
Notes:
(1) Definitions:
W = Witness
R = Record review
S = Spot check
G = General surveillance
(2) Inspection stages (hold points) shall be shown in a Fabrication Sequence Diagram (FSD) prepared
by Supplier.
(3) Purchaser Representative to witness 100% of activity shown for primary members and make
inspections required at hold points shown in FSD.
(4) S includes UT calibration, procedure and field work check; R includes 100% review of
radiographs and reader sheets, UT and MT reports, and weld map review.
(5) Material traceability.
(6) Primary to primary member T,K,Y joints and erection stage tubular butt joints. Primary members
are defined as members manufactured from Type A through D material.
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2.
Description of the component to be loaded out, including estimated weights and center-of-gravity
locations.
3.
Details of site preparations required prior to the initiation of the loadout operations.
4.
Details of vessel preparations required prior to and after the initiation of the loadout operations.
5.
Detailed step by step listing of operational procedures, including engineering drawings that are
necessary to explain the operations.
6.
Description of the surveying scheme to be used to monitor the load and/or deflection tolerances for
component and loadout equipment.
7.
8.
Engineering information on the loadout equipment (including slings), preferably current certification or
inspection certificates.
9.
Tidal data along with an explanation of how the tidal conditions will influence loadout operations.
10.
11.
12.
13.
14.
15.
Contingency and recovery plans detailing the actions to be taken in the event of equipment failures,
deterioration of weather conditions or other considerations.
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FIGURES
Figure 1:
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