Cathodic Protection - Quality Control Procedure

Document Number:

CATHODIC PROTECTION SYSTEM Document Type: PRC Contractor Number : SEPOC-ENGG-2009-0002.1

SE-003-QCP-PRC-021

Discipline: QCP

SEPOC/ENG-2009.0002.1: YLNG Upstream Facilities: Phase-II Construction Work

Revision A Status : IFA Rev Date :13-Mar-2010 Page 1 of 7

HAWK BERKSAN Joint Venture

QUALITY CONTROL PROCEDURE CATHODIC PROTECTION SYSTEM

A

IFA

13-Mar-10

Issue For Approval

Prem CP

J.John

S.Jetti

UK Sikdar

Rev.

Status

Date

Revision memo

Issued by HBJV

Checked by HBJV

Approved by HBJV

Approved by SEPOC

This document is the property of COMPANY it must not be stored, reproduced or disclosed to others without written authorization from the Company.

Document Number:

CATHODIC PROTECTION SYSTEM Document Type: PRC Contractor Number : SEPOC-ENGG-2009-0002.1 TABLE OF CONTENTS

Discipline: QCP

SE-003-QCP-PRC-021 Revision A Status : IFA Rev Date :13-Mar-2010 Page 2 of 7 PAGE NO

.1

INTRODUCTION

3

.2

PURPOSE AND SCOPE

3

.3

REFERENCES

.4

DEFINITIONS / ABBREVIATIONS

.5

ORGANIZATIONS AND RESPONSILITIES

4-5

.6

SEQUENCE OF PROCEDURE/METHODS

5-7

.7

DOCUMENT

ITP forms

3-4 4

7 Pages 4


Document Number:


Discipline: QCP

SE-003-QCP-PRC-021 Revision A Status : IFA Rev Date :13-Mar-2010 Page 3 of 7

1. INTRODUCTION

This project Quality Control Procedure is established for the Quality control of the CATHODIC PROTECTION SYSTEM INSTALLATION for YLNG Upstream Facilities – Phase II construction work. This applies to all HBJV employees who are working for these particular activities 2. SCOPE and PURPOSE The Quality Control Procedure explains the minimal requirement of the Quality system for various activities involved in CATHODIC PROTECTION SYSTEM INSTALLATION



Method implemented for these particular activities.  Maintain the workmanship for the entire work period  Closely Monitoring during performance of each activity  Proper documentation is to be maintained upon completion of each activity Within the scope of works at YLNG Upstream Facilities-Phase II Construction Work Contract in accordance with EXHIBIT A: Scope of Work & Services to Company as per project specification The purpose of the procedure is to control the quality requirement, closely monitoring all activities related to CATHODIC PROTECTION SYSTEM INSTALLATION and to ensure that works comply with Project Specifications and Technical Standards related to YLNG Upstream Facilities-Phase-II Construction Work Contract in accordance with EXHIBIT A: Scope of Work & Services to Company. 3. REFERENCES 3.1 PROJECT SPECIFICATIONS 3.2 EXHIBIT A – Scope of Works 3.3 PROJECT REFERENCE DOCUMENTS/DRAWINGS 3.4 METHOD OF STATEMENT 3.5 INSPECTION AND TEST PLAN

4. DEFINITIONS / ABBREVIATIONS


Document Number:

CATHODIC PROTECTION SYSTEM Document Type: PRC Contractor Number : SEPOC-ENGG-2009-0002.1 TERM Method Statement Company Const. Contractor YLNG ITP IFC QA/QC E&I HSE PPE MCT MCC CP QCP

Discipline: QCP


DESCRIPTION A Written document that explains the planned execution method to control the work at various stages and assure quality Safer Exploration & Production Operation Company. (SEPOC) HAWK BERKSAN Joint Venture.(HBJV) Yemen Liquid Natural Gas Inspection Test Plan Issued for Construction Quality Assurance and Quality Control Electrical And Instrumentation Health, Safety and Environment Personal Protection Equipment Mechanical Transit Motor Control Center Cathodic Protection Quality Control Procedure

5. RESONSIBILITIES 

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QA/QC Manager is responsible to organize resources to perform QC systems, QC Supervisors, QC Inspectors to monitor Cathodic Protection System Installation activities including HSE requirements for the particular activity. He will be responsible to monitor and control the activities and report to the Project Manager E&I Construction Manager is responsible to ensure that Cathodic Protection System Installation activities are executed according to the relevant project specifications and in compliance with quality assurance and HSE requirements within his area and discipline. Before starting any activity he is responsible for conducting a toolbox talks with his crews. He will be reporting to Deputy Project Manager regarding detailed activities of each day and co-ordinate with QC documentation E&I QA/QC Superintendent is responsible for all the Quality Control during Cathodic Protection System Installation activities are executed according to the IFC drawings and QCP & ITP with required quality system. He will be reporting to E & I QA/QC Manager regarding the particular activities daily wise. E & I QA/QC Engineers / Inspectors is the overall responsible to ensure that quality requirements of the Cathodic Protection System Installation like are met and record all the activities in the specified form and He will be reporting to E & I QA/QC Superintendent daily wise E & I Supervisor/Foreman will be responsible for the complete E & I crews performing the job at site as per the approved procedure IFC Drwgs. They are also responsible for the Safety of the crews and meet the Quality requirements for the projects and will be reporting E & I Superintendent daily wise E & I Technicians/Electricians will be responsible to ensure that the Cathodic Protection System Installation are carried out as per the instruction of the Supervisor/foreman. They are also responsible to maintain the Quality system and workmanship as per the project requirements. During performing the work all the safety regulation should be followed strictly.


Document Number:

CATHODIC PROTECTION SYSTEM Document Type: PRC Contractor Number : SEPOC-ENGG-2009-0002.1 

Discipline: QCP


HSE will responsible to ensure that all the works are performed safely as per the HSE requirements. E&I Supervisor/Foremen must make sure proper works permits are issued for the particular activities and works permit should be kept at work area. It is the duty of the HSE officer’s to monitor any unsafe activities of the crew during site performance of the crews under him and house keeping is mandatory every end of working days. Job Description of HSE Officer is attached.

6. SEQUENCE OF PROCEDURE AND METHODS 6.1 MANPOWER The Electrical & Instrumentation QA/QC Inspectors will control the Inspection and Testing activities and he will be directly reporting to the E & I QA/QC Superintendent. The E & I Supervisor will perform the test and E & I QA/QC Representative from HBJV and SEPOC will witness the test. The basic manpower under E & I Supervisor will consist of the following

5.1 E & I Foreman 5.2 E & I Technician 5.3 E & I Helpers 5.4 Safety Officer/Safety Watcher

6.2 TOOLS AND EQUIPMENT Tools and Equipment should be in good condition and must be checked by E & I supervisor prior to use. The E & I QA/QC representative from HBJV and SEPOC will check the Third party calibration certificate, Date of Validity and Due date of all the Test equipment of These includes but not limited to: 6.2.1 EXECUTION 

Hand Tools

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Transformer Oil tester

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Torque wrench



Multi Meter with test leads

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Mega Ohm Meter with test leads

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Insulation flange tester

6.2.2 HSE 

Safety Coverall

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Safety Helmet

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Safety Boot

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Safety Goggles

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Safety Gloves

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Full body Harness (If required)

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Dust Mask (If required)


Document Number:

CATHODIC PROTECTION SYSTEM Document Type: PRC Contractor Number : SEPOC-ENGG-2009-0002.1  6.3

Discipline: QCP


Ear Protection (If Required) INITIAL SET UP:

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6.4

Work shall be started only after getting a valid work permit as applicable Safety line should be used when working at height as required. All personnel performing works should wear basic PPE such as Safety Shoes, goggles, hand gloves, hard-hat and cover all. Toolbox talk shall be conducted to keep all the personnel aware of job activity involved. Make sure all the elevated scaffolds are inspected and tagged green. Before wearing the safety harness a thorough check-up should be carried out for the worn out parts and satisfy. CATHODIC PROTECTION SYSTEM

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Verify the Method of Statement /Procedure preparation and it meeting the project specification, Project standards and IFC drawings Verify all the Test Equipment third party calibration certificate, Date of validity, Calibration Due date and the working condition of the equipments prior to start the activity Verify the material test certificate against the data sheets and confirm it is meeting the project specification and requirements Verify the construction is following the steps which have mentioned in approved procedure during Cathodic Protection system installation During the inspection of the Transformer-Rectifier installation, check the location as per the IFC layout drawing, Civil foundation is installed as per the IFC drawing and project standards, civil is provided enough conduit sleeves for cabling as per the electrical standard installation details and completed the QC documentation, approved by the COMPANY Check the fabrication of the base frame (If applicable) for good workmanship, painting and installation methods are matching with the standard installation details drawing After installation of the Transformer-Rectifier check the orientation, alignment, fixing methods etc... Check the transformer for the internal damages, Breaker/Fuse rating, internal wiring, marking, tightness of the connections etc.... Check for the external damages, oil level, oil leakages, breather installation, indicators etc... After the visual inspection carry out the winding continuity, resistance test and insulation resistance test and record all the test results in the respective ITP forms. Check the transformer-rectifier for the gland plate penetrations as per the cable schedule and all the spare entries are plugged with certified plugs as per the area classification, ready for cabling, glanding and termination After the installation of the Reference anode and reference electrode junction box check the Support fabrication, painting and installation as per the standard installation details drawing. And Junction box installation, bolting as per the standard drawing Reference Anode and reference electrode Junction box check for the internal and external damages, internal wiring, marking, tightness of the connections etc... Reference Anode and reference electrode Junction Box check for gland plate penetrations as per the cable schedule and all the spare entries are plugged with certified plugs as per the area classification, Ready for glanding and termination.


Document Number:


Discipline: QCP


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After the installation of the Anode/electrode, check Installed as per the standard installation details, Anode/Electrode main cable to anode JB and anode/electrode cable splicing /jointing with approved splice/joint kit and protected well

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Check the number of anodes, anode loop resistance and record as per the respective ITP form Check the anode ribbon to conductor bar installation and connection as per standard installation drawing with proper spot welding Check the test posts were installed as per the IFC layout drawings and it is matching the typical installation detail drawings. Check for the alignment, verticality, terminal box and terminal damages and missing bolts, nuts and washers and ready for cabling and termination After the completion of the termination, check the termination standards, marking and tightness. Carry out the soil potential reference cell test with portable copper/copper sulphate electrode and the record the results as per the respective ITP forms. Check the insulating flanges installed as per the piping layout drawing complete the insulating flange test with insulating flange tester or Megger tester Carry out the final Inspection, area and internal cleanliness, Document review and ready for energize The following are the Inspection and test forms to be followed during the Inspection of the Cathodic Protection system Inspection 1. QCP-701-CS-20 – Cathodic Protection system Transformer-Rectifier 2. QCP-701-CS-21 – Cathodic Protection System 3. QCP-701-TS-20 – Cathodic Protection system Transformer-Rectifier 4. QCP-701-TS-21 – Cathodic Protection System

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7. DOCUMENT 

ITP forms-

4 Pages


Cathodic Protection - Quality Control Procedure

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