Jacket Construction of Oil & Gas Platform
Project Quality Management System on Jacket Construction of Oil and
Gas Platform
Here, Author would like to share about why, what and how to establish, implement,
document, and maintain the Project Quality Management System on Construction
Work of Jackets, as part of Wellhead Platform EPCI Project Contract for Onshore /
Offshore Oil and Gas Field Development.
WHAT IS JACKET OF OIL AND GAS PLATFORM ?
There are several types of oil and gas platforms and drilling rigs in offshore fields.
(see Picture-1, there are: 1, 2) conventional fixed platforms; 3) compliant tower; 4,
5) vertically moored tension leg and mini-tension leg platform; 6) Spar ; 7,8) Semisubmersibles ; 9) Floating production, storage, and offloading facility (FPSO); 10)
sub-sea completion and tie-back to host facility)
Picture Schematic of typical Gulf of Mexico offshore oil or gas platform (Courtesy of
NOAA Fisheries)
Fixed platforms are built on concrete or steel legs, or both, anchored directly onto
the seabed, supporting a deck with space for drilling rigs, production facilities and
crew quarters. Fixed platforms are economically feasible for installation in water
depths up to about 520 m (1,710 ft). Such platforms are, by virtue of their
immobility, designed for very long term use (for instance the Hibernia platform).
Various types of structure are used, steel jacket, concrete caisson, floating steel and
even floating concrete.
Steel jackets are vertical sections made of tubular steel members, and are usually
piled into the seabed.
A jacket is a steel substructure for an offshore installation. It is a complex
construction, and designing one takes several months of engineering, 3D modelling,
computations, design and method work.
Typical Arrangement of Jacket Structure:
Legs and braces
Jacket frame
Mudmat
Anode
Piles
Applicable Codes/ Standards:
STRUCTURAL
API RP-2A, 2B, 5B, AISC etc
AWS D1.1
CATHODIC PROTECTION
Applicable NACE, API, ASTM standards
JACKET AND APPURTENANCES CONSTRUCTION
Processes and Phases in Oil and Gas Fields Development EPCI Projects :
Processes and phases are two different aspects of project. A project may be divided
into interdependent processes and into phases.
Project phases divide the project life cycle into manageable sections, sch as
conception, development. Realization and termination.
Project processes (or Project Works) are those processes that are necessary for
managing the project as well as those that are necessary to realize the projects
product.
Jacket Construction is a project processes/work of an oil and gas field development
phase project.
Why ?
Question
: Why it is necessary to manage project processes within a quality
management system?
Answer
: In order to achieve project objectives.
How to develop Project Management System for Jacket Construction ?
ISO9001:2008 International Standard promotes the adoption of a process approach
when developing, implementing and improving the effectiveness of a quality
management system, to enhance customer satisfaction by meeting customer
requirements.
In addition, the methodology known as Plan-Do-Check-Act (PDCA) can be applied
to all processes.
The project quality management system should be aligned, as far as is possible,
with the quality management system of the originating organization (perennial
quality management system).
For an organization to function effectively in executing Construction Works, it has to
determine and manage numerous linked activities by establish, implement,
document and maintain the Project Quality Management System, such as:
Project Manual / Project Quality Plan (PQP)
Onshore Construction Quality Control Plan (QCP)
Inspection and Test Plan (ITP)
Fabrication Procedures
Control Forms for Project
Quality Records
Project Quality Plan (PQP)
Document setting out the specific quality practices, resources and sequence of
activities relevant to a particular Product, Project or CONTRACT.
Quality Control Plan (QCP)
An Onshore Construction Quality Control Plan (QCP) document setting out the
specific quality practices, resources and sequence of activities relevant to Onshore
Fabrication/Construction activities of a particular Project or CONTRACT.
PQP / QCP is mainly for ensuring and monitoring that the fabrication is carried out
as per contract specifications.
QCP outlines the Quality System for Construction/Fabrication, which will be followed
by Contractor for the fabrication and load out of wellhead platforms infrastucture
comprising of
Jackets,
Decks (Topsides),
Piles,
Conductors, and
Appurtenances
etc
for Oil and Gas FIELD DEVELOPMENT PROJECT in Onshore and Offshore.
Main activities in onshore Fabrication Yard are given as below:
Construction Project Management:includes Project HSE-Q Management
Plan, resource managament, project schedule, project progress, document
control center (DCC), etc.
Fabrication
Engineering:design
and
development,
to
prepare
shop
drawing, welding plan / NDT map drawings, cutting plan, Piping support, E&I
support drawings etc.
Procurement activities:purchasing, inspection, test, supply and delivery of
materials and equipment.
Material Control (includes control of
Customer Property) : Receipt,
acceptance, material identification, handling, storage, preservation, care and
custody of procured items / Customer supplied items.
Material Logistics:follow up with Vendors for inspection , expediting
delivery and shipping.
Pre-fabrication:Materials Preparation (Marking, Cutting, Profiling, Bending &
Others)
Sub assemblies Manufacturing: Fit up and Welding
Calibration
QC Inspection:Visual/Dimensional Control & Inspection (to Check and record
the dimensions of Products at different stages of Fabrication.), Wedling
Inspection, NDE / DE
Final assemblies Manufacturing: Fit up and Welding
Post Welding :PWHT, where ever required.
Testing : Hydrostatic Testing
Coating :Blasting, Painting/Insulation/Fire Proofing
Pre commissioning
Load out
Sea Fastening
Certification :Interfacing with Certifying Authority and Marine Warranty
Surveyor
Quality
Assurance
Feedbacks/Complaints
:NCR
,
control,
Quality
CA/PA,
Audits,
Lesson
learned,
Customer
Project
Quality
System
Manual/Procedures, Quality Records, QA Training and Awareness Program.
MDR / As Built Dossiers :Provision of final documentation as per Customer
specifications.
Jacket Weighing
One of the most important process on jacket fabrication is Jacket Weighing. The
weighing will be conducted at the structure final assembly location before the loadout when all components are being installed in proper position.
The objective of the weighing is to determine:
actual total weight of the structure
determine its plan location of the centre of gravity
Typical Project Documentation consists of:
Fabrication Procedure for the project
Shop drawings
Document Register
Project Schedule
QA/QC Procedures + Certificates (Personnel & Equipment as applicable)
HSE Procedures
WPS/PQR/WQT documents
Inspection & Test Plans for different disciplines
Inspection & Test Records (ITRs)
Material and Welding Traceability Records
Final Documentation refer to CONTRACT Specifications / Requirements.
