HSTD-PTSCMC-TS-Q-PR-0001 Dimension Control Procedure for TOPSIDE Fabrication

8/10/2019 HSTD-PTSCMC-TS-Q-PR-0001 Dimension Control Procedure for TOPSIDE Fabrication

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THANG LONG JOINT OPERATING COMPANY

HAI SU TRANG FULL FIELD AND HAI SU DEN EARLY

PRODUCTION SYSTEM DEVELOPMENT PROJECT

CONTRACTOR: PTSC MECHANICAL & CONSTRUCTION

DIMENSIONAL CONTROL PROCEDURE

FOR TOPSIDE AND DRILLING DECK FABRICATIONEPCI CONTR

ACT NO: CN3911008

DOCUMENT No.: HSTD-PTSCMC-TS-Q-PR-0001


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PTSC TLJOC


HAI SU TRANG DEN PROJECT

EPCI OF HAI SU TRANG, HAI SU DEN AND PIPELINESDocument No :

HSTD-PTSCMC-TS-

Q-PR-0001.


FOR TOPSIDE AND DRILLING DECK

FABRICATION.

Page 2 of 18

Revision No.: 0Date:

17-Apr-2012

REVISION RECORD SHEET

No. Rev. No. Content of revision Date of Revision

1 A Issued for review 04-Apr-2012.

2 0 Issued for construction 17-Apr-2012


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TABLE OF CONTENTS

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 PURPOSE 5

2.0 SCOPE 5

3.0 REFERENCE 5

4.0 DEFINITION 5

5.0 PROCEDURE 5

5.1 RESPONSIBILITIES 5

5.2 EQUIPMENT 6

5.3 SURVEY CONTROL NETWORK 6

5.4 SETTLEMENT MONITORING. 75.5 METHOD OF DIMENSIONAL & LEVELING SURVEY 7

5.6 DRILLING DECK & TOPSIDE FABRICATION 8

5.7 PIPING 12

6 0 RECORDS 12


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1.0 PURPOSEThis procedure outline the methods of dimensional control survey to ensure specified

dimensional requirements are met in the final fabricated Drilling deck & Topside structures

and appurtenances.

2.0 SCOPE

This procedure is applicable to the following actions:- Material dimensional inspection on receipt.

- Assembly of Drilling deck & Topside and related component items (include: Main legs,

deck-legs, Elevation difference among platforms, conductor guide positions, crane pedestal

bearing surface, deck levelness).

- Final dimensional check the Drilling deck & Topside and Load-out.

3.0 REFERENCE (Latest revision)

API 2B Specification for the Fabrication of Structural Steel Pipe.EEMUA 158(2005) Construction Specification for Fixed Offshore Structures in the

North Sea.

AWS D 1.1 Structural Welding Code-Steel.

API RP 2A Recommended Practice for Planning, Designing, and Constructing Fixed

Offshore Platforms Working Stress Design, 21st Edition, December 2000.

GEN-0-00-S-

SP-0003_F01 Welding & Fabricating Offshore Structures


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5.0PROCEDURE

5.1 RESPONSIBILITIES

Foreman

- Shall be responsible for overall aspects of shift working which includes quality, health

and safety.

- Make recommendation to conduct improvement activities to improve productivity and

quality.

- To be responsibility of production team to liaise with DCS ensuring adequate notice is

given to allow surveys to be performed which meet the obligations of this procedure.

- Train subordinate to meet required standard of quality and output.

Dimensional Control Surveyor.

- The Dimensional Control Surveyorshall be responsible for ensuring that all surveys are

carried out accurately, efficiently and expeditiously, using calibrated equipment and

proven techniques.

- The DCSwill report directly to the Fabrication QAQC Manager. The DCSwill ensure

manning level which adequate service the needs of the production team progressing

fabrication efficiently. In turn, the production team will take account of the knowledge

and experience available, in terms of valid advice for the avoidance of dimensional

problems, when developing assembly and erection method statements.


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- Ensuring that the quality system meets requirements established in this specification.

- Ensuring all reports are correct and acceptably good for TLJOCs QC

acceptance/approved.

- Reviewing and approve all Dimensional reports.

- Monitor/Coordinate quality activities with production team.

5.2 EQUIPMENT( Reference to Appendix I).

- The Dimensional Control Surveyor will be equiped with a suitable supply of survey

instrumentation capable of dealing with complex 3D dimensional geometry. Instruments

will be calibrated regularly in accordance with good survey practice and records kept tothat effect.

- In addition, small tools such as tapes, squares, inclinometers spirit levels, string lines,

plumb bobs etc., all complying with recognized international manufacturing standards,

will be employed.

- Computers can be utilized to facilitate the reduction and computation of some of themore complex best fit solutions.

- Only approved equipments with valid calibration certificate shall be used.

Reference to Appendix I-List of Dimensional Control Equipments.


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- Initial observations around the network will be distilled to produce accurate coordinatesfor each station, and during the life of the project the network will be rigorously

monitored to maintain this accuracy.

- Temporary control stations, in times of peak fabrication activity, may be required to be

established and these will be related to the main control network through conventional

survey techniques such as triangulation, trilateration, braced quad, intersection, resection,

bearing and distance etc.

5.4 SETTLEMENT MONITORING.

- Prior to Lift of the Topside frames, a series of temporary Benchmarks(TBMs) will be

established at convenient location around Drilling deck & Topside erection area. The

height of these TBMs will be obtained using Level model AX 2S from permanent

benchmarks. The level of these TBMs will be obtained at weekly interval to monitor the

settlement.

- The result of the settlement monitoring will be issued as a dimensional survey report

using the initial elevation of each TBM as a datum.

5.5 METHOD OF DIMENSIONAL & LEVELLING SURVEY

The method of dimensional and levelling survey are as follows:

1. Survey of straightness:

The straightness survey shall be accomplished by means of measuring the external

surface of assemblies at two planes, i.e. "X" - "Y" direction with two ends zeroed and

readings at every 3m intervals utilisingpiano wire or thoedolite.


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The work point to work point survey shall be accomplished by measuring the intermediatedimensions (Elevation), overall lengths and squareness survey (cross dimensional) that

have been specified in the approval for construction drawing utilising measuring tape.

5. Survey of level:

The level survey shall be applied to the levelness or flatness of the assemblies i.e. jacket

braces and etc, with two ends at zeroed and reading at every 3m interval ulilising dumpy

level.

5.6DRILLING DECK &TOPSIDE FABRICATION.

5.6.1 CRITICAL ELEMENTS

The following items have been identified as critical elements in terms dimensional control

and will require having particular emphases applied in order to achieve minimum

dimensional deviations.

a. Deck legs and cone spacing.

b. Conductor guide positions.

c. Crane pedestal bearing, surface.

d. Deck levelness.

e. Crane slew bearing flatness and level.

f. Flare Boom.

5.6.2 TUBULAR MAKE UP (e.g. legs, crane pedestal, braces.)

a Single can.

- All single can tubulars shall be 100% dimensionally check. Checks shall be made 100%


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a. Engineering Department shall prepare shop drawing, cutting sheet for every beam.

Dimensional Control Surveyor shall conduct 100% dimensional check on beams based on

approved shop drawing.

b Dimensional surveys should demonstrate correct beam depth, flange width, web

verticality, flange rotation, web to flange eccentricity, beam straightness in two planes and

length of beams.

c If beam is splice in 2 sections, a fit up survey should check the straightness, reading at 3m

intervals and either side of the splice. Both camber and transverse deviations should be

noted.

5.6.4 SUB-CELLAR DECK, CELLAR DECK, DRILLING DECK, MEZZANINE

DECK, MAIN DECK, HELI DECK, FLARE BOOM.

a Basically the cellar/main deck comprises of deck legs attached to star plates. The star

plates are the members holding the main beams on both transverse and longitudinal side.

Pre and post dimensional survey is required for this assembly. See appendix II for

dimensional tolerances.

Interface dimension between mezzanine deck and main deck assembly to be checked for

proper alignment, levelling.

b Drilling deck will be fabricated separately and installed to jacket on offshore. Interface

dimension of conductors between drilling deck and top of jacket leg assembly shall be

dimensionally checked prior to install.

c Heli deck assembly shall be dimensionally checked prior to install into final position. This

is to be done after main deck has been dimensionally checked and installed.


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b As such pre-weld and post-weld survey check shall be conducted to ensure that the positiondeviations of the cone receiving cans are minimized. Weld shrinkage effects should be

anticipated by increasing fit up distances center to center.

5.6.6 CELLAR DECK ASSEMBLY

a The pre- assembly of the cellar deck transverse primary beam East/West in between leg

can to leg can and the cantilever beam will be post weld surveyed for erection. The leg willbe stabbed in to the transportation frame buckets, set at correct theoretical leg spacing.

b Check on the leg cans to conform the verticality and the levelness of the cellar deck. As the

intention is to erect the main deck with the short section of legs, this will ensure the proper-

fit-up of leg splices during the erection.

c Temporary supports shall be set at the correct elevation to attain the flatness of the primary

beams and pre/post weld check of the primary beams straightness, levelness and alignmentshall be checked.

d The North/South longitudinal primary beam in between North/South leg to leg can will be

erected first and follow up with the remaining beam, beams levelness and straightness

should be checked pre/post weld.

e The level of the primary beams shall be surveyed and the relationship of the primarystructural has been set to facilitate the secondary beams fit-up. As the cellar deck is loaded

up with secondary beams settlement should be monitored day to day basis, if the

settlement exceeds an agreed limit of 6mm corrective action shall be taken.

f Since conductor guide are considered critical the center point of the conductor guides


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d The position of any free ends expected to accept cantilever/wing pallets will also be

surveyed.

e As the deck is loaded up the supports should be monitored for settlement and corrective

action taken if the settlement exceeds an agreed limit 6 mm.

5.6.8 INTER DECK BRACING

a The brace between the cellar deck and main deck will be installed after the cellar deck

erection and weld out and as equipment permits.

b Deck bracings are pre profiled and fit up checks shall include verticality and brace landing

surveys.

5.6.9 MAIN DECK ERECTION

a The whole main deck section will be subjected to post weld survey prior to erection. Post

erection check to conform the verticality of the leg and leg to leg spacing, section of the

legs length, deck elevation and deck flatness.

b The whole main deck assembly shall be erected/fitted-up on top of the cellar deck legs. The

full length legs dimension and elevation of the cellar deck to main deck and the main deck

level checks shall be perform to ensure erection fit-up is achieve.

5.6.10CRANE PEDESTAL ERECTION

Si il t th d k l th d t l ill b i t ll d i l i


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a Other miscellaneous structural sub assemblies such as crane boom rest, mud splash walls,

emergency shelter wall, lift pad eyes etc... Should be surveyed on an as-required basis.

b Pipe support, piping vessel and equipment seating should be surveyed on an as requested

basis.

5.6.12LOAD-OUTS

a Load out operation shall be considered as having critical dimension input in term ofmonitoring barge ballast, monitoring lift off and set down operations and hard marking

layout match lines.

b Transverse and lateral derrick barge and transport barge movement shall also be monitored

during load-out, particularly critical for skidded load-out operations.

c Pipe support, piping vessel and equipment seating should be surveyed on an as requested

basis.

5.7 PIPING(Reference to piping fabrication procedure)

6.0 RECORDS

- Dimensional control reports shall generally be A4 sketches of the surveyed item. Each

sketch will have a unique project surveyor number and will reference the revision of the

shop drawing against which the deviations are being reported. Dimensional Controller shall

sign all dimensional inspection reports. Subsequent stages shall be performed if to be sure

that all assembly differentials are within tolerances described in the reports. If necessary,

the survey report will have its own revision status.

- In the reports, dimensions are in "mm"; theoretical dimensions are written in brackets


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-

All original reports will be kept in QA/QC department and will be available for TL JOC atany time. A copy of fit up surveys will be passed to production as evidence of compliance

with the project specification.

- The final as built dimensional report of steel structural part and components shall be

generated and signed by TL JOC representative.

- All original Dimensional Control Reports shall be filed in QAQC Department and the QAEngineer shall be responsible for these documents.

All dimensional control reports shall be submitted to TL JOC for verification.

List of asbuilt dimensional control Inspection reports as follows:

I. WHP HSD -TOPSIDE Before welding After welding

HSD Main Deck framing Plan X X

HSD Helideck framing Plan X X

HSD Elevation Grid Row B X X

HSD Elevation Grid Row 1 X X

HSD Elevation Grid Row 2 X X

HSD Drill Deck Framing plan and

Elevations

X X

HSD Drill Deck Stabbing Guide Post X XHSD Drill Deck Lifting Trunnion X X

HSD Crane Boom Rest X

HSD Crane Pedestal/Diesel Storage tank X X

HSD Lifting Padeye. X X


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7.0 APPENDICES

APPENDIX I

LIST OF DIMENSIONAL CONTROL EQUIPMENTS

No.Type of

EquipmentsSerial no. Purpose Remarks

01Total Station Leica

TS09-power 11315978

All dimension

checking

02Total Station Leica

TS09-Power 11300805

All dimension

checking

03Theodolite Model

NE-20H

055921

To ensure angle,

trigon metric

leveling and definestraight lines

04 Level Model AE-7C 277233 Check leveling

05 LevelCheck leveling,

plumpness.

06 Measuring Tape,Rule

Linear measurementand it apparatus

5m, 30m,50m

07 SquareTo ensure the angle

is square0.3m, 0.6m ..


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7.1 TOLERANCESSources: 1. Structural Welding and Fabrication Specification.

2. API-RP2A-WSD-Section 11.1.5.

3. API spec 2B: Specification for the fabrication of structural steel pipe.

4. AWS D1.1(2008). Section 5.23: Dimensional tolerance of welded structural

members.

5. EEMUA 158(2005) Construction Specification for Fixed Offshore Structures

in the North Sea.

APPENDIX II: TABLE OF DIMENSIONAL TOLERANCES

NO. DESCRIPTIONDIMENSIONAL

TOLERANCE

1

Top of the jacket and the bottom of the deck

columns, the horizontal distance from the

centerline of any column to the centerline of thecolumn adjacent in any direction.(Refer to

Section 11.1.5b-API RP2A).

10mm (3/8 inch) of the net

drawing dimension

2

At all deck levels, the horizontal distance from

the centerline of any column to the centerline of

the column adjacent in any direction.(Refer to

Section 11.1.5b-API RP2A).

13mm (1/2 inch) of the net

drawing dimension

3

Diagonals of rectangular plan layout between the

deck leg punch mark shall be

(Refer to Section 11.1.5b-API RP2A).

19mm from the design

dimensions

4

The centerline of deck beams/cap beams at their

ends should be within reference to section

11.1.5d API RP 2A.

13mm of the drawing

location.


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(refer to Section 6.4.1-EEMUA 158).

9

Walkways, stairways and landings shall be

positioned within the tolerance in relation to the

theoretical position (refer to Section 6.4.2-

EEMUA 158).

Deck plating level

Plate or grating joints shall be flat without

visible warping

12mm in elevation.

6mm in any 3m length.

12mm in horizontal position.

6mm in 3m.

Mismatch >2mm grating joints

shall be ground out and recoated.

10

Padeyes, padears and lifting trunnions location

and final orientation, work points shall be

located within the design radius sphere.(refer to

Section 6.3.4-EEMUA 158).

0.5 of final orientation.

15mm error on radius sphere.

11

The best-fit cente line for conductor guides of

the adjacent or nearest leg at the jacket-deck

interface level

At all other levels this tolerance

(refer to section 6.3.3 EEMUA).

10mm.

25mm

Tubular

Circumference (at joints or within 610 mm

from the joint).

Circumference ( he remaining length of thetubular). Reference to section 6.2.1.1 of

EEMUA 158.

Ovality (Dn 610)

Tubular

30% of tn or 10mm

(whichever is smaller)

45% of tn or 15mm(whichever is smaller)

Not exceed 1% Dn.


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Abbreviation:tn : Nominal wall thickness

Dn : Nominal externaldiameter

Cn : Nominal circumference

OD: Outer diameter

c : Circumference tolerance


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APPENDIX III: DIMENSIONAL CONTROL INSPECTION REPORT.


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HSTD-PTSCMC-TS-Q-PR-0001 Dimension Control Procedure for TOPSIDE Fabrication