INSPECTION AND TEST PLAN

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RESIDUAL OFFSHORE CONSTRUCTION WORK AT PARADIP CONTRACT NO. PLCC/PHCPL/SPM/0825

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RECORD OF AMMENDMENTS SHEET

Version
A B 0

Purpose
Issued for Inter Disciplinary Check (IDC) Issued for Client Review 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

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TABLE OF CONTENTS

1.0 2.0 3.0 4.0

INTRODUCTION ........................................................................................................................4 REFERENCES ...........................................................................................................................5 TERMS AND DEFINITIONS ......................................................................................................6 INSPECTION AND TEST PLAN................................................................................................7

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Rev. 0 1.0 INTRODUCTION 1.1 General
RESIDUAL OFFSHORE CONSTRUCTION WORK AT PARADIP CONTRACT NO. PLCC/PHCPL/SPM/0825

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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.
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Rev. 0 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 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 Document No. 50037-QA-PLN-001 50037-PM-PLN-001 50037-SI-PRD-001 50037-SI-PRD-002 50037-SI-PRD-003 50037-SU-PRD-001 50037-SU-DOC-001 50037-SU-PRD-002 50037-SU-DOC-002 50037-ME-DOC-001 Project Quality Plan Project Execution Plan CALM Buoy Installation Procedure Anchor Handling and Mooring Procedure Pre-commissioning Procedure Pre-installation Survey Procedure Pre-installation Survey report As-Built Survey Procedure As-Built Survey Report Marine Spread Specifications & Certification Dossier Description
RESIDUAL OFFSHORE CONSTRUCTION WORK AT PARADIP CONTRACT NO. PLCC/PHCPL/SPM/0825

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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 Contractor Company CALM FIM ITP MWS NCR PLEM PQP : : : : : : : : : Approved for Construction by Company Global Industries Asia Pacific Pte. Ltd (GIAP) India Oil Corporation Limited (IOCL) Catenary Anchor Leg Mooring Buoy Free Issued Material Inspection and Test Plan Marine Warranty Surveyor Non Conformance Report Pipeline End Manifold 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. Quality Assurance, Part of quality management, focused on providing confidence that quality requirements will be fulfilled. Quality Control, Part of quality management focused on fulfilling quality requirements. Quality Management System Remote Operated Vehicle Single Buoy Mooring : Personnel nominated by the Company to review, witness and/or approve project activities wherever applicable.

QA QC QMS ROV SBM 3rd Party

: : : :

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REF. NO. 1 1.1 1.2 1.3 1.3 1.4 ACTIVITY DESCRIPTION INSTALLATION PROCEDURES CALM Buoy Installation Anchor Handling and Mooring Pre-commissioning Singapore Singapore Singapore Singapore Singapore 50037-SI-PRD-001: CALM Buoy Installation Procedure 50037-SI-PRD-002: Anchor Handling and Mooring Procedure 50037-SI-PRD-003: Pre-Commissioning Procedure 50037-SU-PRD-001: PreInstallation Survey Procedure 50037-SU-PRD-002: As-Built Survey Procedure 50037-SU-PRD-003: Derrick Barge Survey and Positioning Procedures AFC AFC AFC AFC AFC P/R P/R P/R P/R P/R R/A R/A R/A R/A R/A R/A R/A R/A R/A R/A LOCATION REFERENCE PROCEDURE/ ACCEPTANCE CRITERIA VERIFYING DOCUMENTS SURVEILLANCES BY
GIAP IOCL 3rd PARTY

RESIDUAL OFFSHORE CONSTRUCTION WORK AT PARADIP.

CONTRACT NO. PLCC/PHCPL/SPM/0825

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Pre-installation Survey As-Built Survey

1.5 2

Derrick Barge Survey and Positioning

Singapore

AFC

P/R

R/A

R/A

RECEIPT OF COMPANY FREE ISSUED MATERIALS (FIM)

2.1

Inspect & Receive Companys FIM.

Paradip port

FIM Delivery Notes Shipping documents Materials certificates OSD Check & Visual inspections
NA: NOT APPLICABLE P: PERFORM

Materials Receiving Report

P/H

R/A

R/A

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LEGEND :

A: APPROVE H: HOLD

R: REVIEW W: WITNESS

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REFERENCE PROCEDURE/ ACCEPTANCE CRITERIA VERIFYING DOCUMENTS

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SURVEILLANCES BY
GIAP IOCL 3rd PARTY

REF. NO. 3 3.1 3.2 3.3 3.4

ACTIVITY DESCRIPTION

LOCATION

FABRICATION OF INSTALLATION AIDS (CHAIN TENSIONER & SPREADER BAR) Welding Procedures & Welder Qualification records Visual & dimensions Inspection NDT Load Testing of Chain Tensioner & Spreader Bar Fabrication Documentation 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
LEGEND : 50037-ME-DOC-001: Marine

Batam Batam Batam Batam

AWS D1.1 AWS D1.1 & 50037-DWG-005 AWS D1.1 , WPS, WQT, ASNT 50037-DWG-005 : Chain Tensioner

Approved documents As-Built Drawing NDT Reports 3rd Party - Load Test/ Functional Test Report

R W R W

NA NA NA NA

NA NA NA NA

3.5 4

Batam

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

NA

NA

Spread Specifications & Certification Dossier Batam

Load-out Drawings & Sea

MPI Report for deck

4.1

welds
Rigging gears

P/W

NA

NA

Fastening Drawings

certificates

4.2

Paradip port

IOCL appointed MWSs approval

Tow Approval Certificate by MWS

R: REVIEW W: WITNESS

P/W

50037-QA-PLN-002

A: APPROVE H: HOLD

NA: NOT APPLICABLE P: PERFORM

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REFERENCE PROCEDURE/ ACCEPTANCE CRITERIA
50037-SU-PRD-003: Derrick

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VERIFYING DOCUMENTS SURVEILLANCES BY
GIAP IOCL 3rd PARTY

REF. NO. 5

ACTIVITY DESCRIPTION SURVEY Pre Installation Survey

LOCATION

5.1

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

CALM Terminal Site

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

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

P/W

W/A

W/A

5.2

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

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

P/W

W/A

W/A

6 6.1

TENSIONING OF ANCHOR CHAINS & INSTALLATION OF SPM Check the calibration status of load cell(s) CALM Terminal Site CALM Terminal Site CALM Terminal Site CALM Terminal Site
A: APPROVE H: HOLD

50037-SI-PRD-001: CALM Buoy Installation Procedure 50037-SI-PRD-001: CALM Buoy Installation Procedure 50037-SI-PRD-001: CALM Buoy Installation Procedure 50037-SI-PRD-001: CALM Buoy Installation Procedure
NA: NOT APPLICABLE P: PERFORM

Calibration Certificate

6.2

Ensure that chain is pulled through the chain hawse/chaser Check that tension load is ~ 150T or Cross tensioning to be ~ 300T for anchors chains tensioning Check that each chains are marked with indelible florescent colour visible in water
LEGEND :

Visual Check Anchor Chains Tensioning Report Visual check

R: REVIEW W: WITNESS

6.3

P/W

W/A

W/A

6.4

P/W

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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 50037-SI-PRD-001: CALM Buoy Installation Procedure 50037-SI-PRD-001: CALM Buoy Installation Procedure 50037-SI-PRD-001: CALM Buoy Installation Procedure 50037-SI-PRD-001: CALM Buoy Installation Procedure 50037-DI-MAN-001 Diving Procedures Manual VERIFYING DOCUMENTS Visual check

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SURVEILLANCES BY
GIAP IOCL 3rd PARTY

REF. NO.

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

LOCATION CALM Terminal Site

6.5

P/W

6.6

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

CALM Terminal Site

Visual check

P/W

6.7

Check the chain numbers are marked to indentify with respect to PLEM ~ CALM Buoy Check the chains are locked off on a reference link by the Chain Stopper Check 2 links remain above the chain stopper after excess chains are cut off.

CALM Terminal Site CALM Terminal Site CALM Terminal Site

Visual Check

P/W

6.8

Visual Check

P/W

6.9

Visual Check
Fugro Survey Report

P/W

6.10

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

CALM Terminal Site

for Anchor Chains Installation Report Diver Survey Report

P/W

W/A

W/A

50037-QA-PLN-002

LEGEND :

A: APPROVE H: HOLD

NA: NOT APPLICABLE P: PERFORM

R: REVIEW W: WITNESS

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RESIDUAL OFFSHORE CONSTRUCTION WORK AT PARADIP.

CONTRACT NO. PLCC/PHCPL/SPM/0825

REFERENCE PROCEDURE/ ACCEPTANCE CRITERIA
50037-SI-PRD-001: CALM Buoy

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VERIFYING DOCUMENTS SURVEILLANCES BY
GIAP IOCL 3rd PARTY

REF. NO.

ACTIVITY DESCRIPTION

LOCATION

6.11

Verify the CALM Buoy system has been CALM Terminal installed in specified positions and coordinates Site INSTALLATION OF UNDER BUOY HOSES Ensure the hose identifications with respect to CALM Terminal SPM / PLEM inlets/ manifolds Site Bolts types/ spec are correct for the flanges and hoses Ensure the tightening of flange bolts to the required torque values Ensure the configuration of Under buoy houses installation is as per AFC drawings INSTALLATION OF FLOATING HOSES Ensure the hose identifications with respect to CALM Terminal SPM / PLEM inlets/ manifolds Site Bolts types/ spec are correct for the flanges and hoses CALM Terminal Site CALM Terminal Site CALM Terminal Site CALM Terminal Site

Installation Procedure

Fugro Survey Report for CALM Buoy Installation

P/W

W/A

W/A

7 7.1

50037-SI-PRD-002: CALM Buoy Installation Procedure 50037-SI-PRD-002: CALM Buoy Installation Procedure 50037-SI-PRD-002: CALM Buoy Installation Procedure 50037-SI-PRD-002: CALM Buoy Installation Procedure

AFC SBM Assembly Drawings AFC SBM Assembly Drawings Bolt Tensioning/ Tightening Reports Fugro Under Buoy Hoses Configuration Survey Report

7.2

7.3

P/W

R/A

R/A

7.4 8 8.1 8.2

P/W

R/A

R/A

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

AFC SBM Assembly Drawings AFC SBM Assembly Drawings

P P

W W

W W

50037-QA-PLN-002

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A: APPROVE H: HOLD

NA: NOT APPLICABLE P: PERFORM

R: REVIEW W: WITNESS

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CONTRACT NO. PLCC/PHCPL/SPM/0825

REFERENCE PROCEDURE/ ACCEPTANCE CRITERIA 50037-SI-PRD-001: CALM Buoy Installation Procedure 50037-SI-PRD-001: CALM Buoy Installation Procedure VERIFYING DOCUMENTS Bolt Tensioning/ Tightening Reports Fugro - Floating Hoses Configuration Survey Report Fugro - Umbilical Hoses Configuration Survey Report AFC Mooring Hawser drawing AFC Mooring Hawser drawing AFC Mooring Hawser drawing

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SURVEILLANCES BY
GIAP IOCL 3rd PARTY

REF. NO. 8.3

ACTIVITY DESCRIPTION Ensure the tightening of flange bolts to the required torque values Ensure the configuration of Floating houses installation is as per AFC drawings

LOCATION CALM Terminal Site CALM Terminal Site

P/W

R/A

R/A

8.4 9 9.1

P/W

R/A

R/A

INSTALLATION OF UMBILICAL and MOORING HAWSER Ensure umbilical identification with respect to PLEM ~ HPU inlets/outlets. Ensure mooring hawser has been preassembled as per AFC drawings Check all shackles and chain support buoys have split pins or other retaining pin to prevent from backing loose. Ensure mooring hawser has been securely installed to the mooring arm structure CALM Terminal S50037-SI-PRD-001: CALM Buoy Site Installation Procedure 50037-SI-PRD-001: CALM Buoy CALM Terminal Installation Procedure Site Drawing No. MR.00.002.7700 50037-SI-PRD-001: CALM Buoy CALM Terminal Installation Procedure Site Drawing No. MR.00.002.7700 50037-SI-PRD-001: CALM Buoy CALM Terminal Installation Procedure Site Drawing No. MR.00.002.7700 50037-SI-PRD-003: PreCommissioning Procedure 50037-SI-PRD-003: PreCommissioning Procedure
NA: NOT APPLICABLE P: PERFORM R: REVIEW W: WITNESS

P/W

9.2

A/W

9.3

A/W

9.4 10 10.1 10.2

A/W

LEAK TESTS (HOSES & CALM BUOY SYSTEM) Ensure pressure gauges are calibrated and CALM Terminal used within specific test range Site Check the bleed-off air prior to pressurising CALM Terminal Site
A: APPROVE H: HOLD

AFC AFC

P P

R R

R R

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REFERENCE PROCEDURE/ ACCEPTANCE CRITERIA 50037-SI-PRD-003: PreCommissioning Procedure 50037-SI-PRD-003: PreCommissioning Procedure @ 225 psig for 3 hours VERIFYING DOCUMENTS AFC Floating and Under Buoy Hoses Leak Test Report CALM Buoy System Leak Test Report Company approved installation & survey records, & reports AFC

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SURVEILLANCES BY
GIAP IOCL 3rd PARTY

REF. NO. 10.3 10.4 10.5 11 11.1

ACTIVITY DESCRIPTION Check the bleed-off air prior to pressurising Leak test for Floating and Under buoy hoses. Leak Test of CALM Buoy System. (PLEM Valve ~ Blind of Floating Hoses) AS BUILT DOCUMENTATION Ensure that all as-built documentations/ records are reviewed and approved/signed by relevant parties onboard. Submission of As built for Company approval.

LOCATION CALM Terminal Site Paradip port CALM Terminal Site

P P/W P/W

R W/A W/A

R W/A W/A

Singapore

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

P/R

R/A

R/A

11.2

Singapore

P/R

R/A

R/A

50037-QA-PLN-002

LEGEND :

A: APPROVE H: HOLD

NA: NOT APPLICABLE P: PERFORM

R: REVIEW W: WITNESS

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