sow for wire rope inspection and maintenance

SA-SEZZZZ-ME-SOW-9004-000_P01 SHAH DENIZ 2 PROJECT SCOPE OF WORK FOR WIRE ROPE INSPECTION AND MAINTENANCE

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UNCONTROLLED WHEN PRINTED

Revision History and Hold Record Revision History

Date Rev. No.

Detailed Description of Change Ref. Section

18/09/2014 I01 IDC 03/10/2014 A01 Issued for Review 21/10/2014 A02 Issued for Review

Reference to BP-CDZZZZ-CM-PRO-5001 changed to BP-SFSOZZ-CM-PRO-0001

1.2 Added reference to Bos Shelf Lifting Operations Procedure BO-

SEZZZZ-HS-PRO-0203-000 1.2

Added Class and Flag/State Authority requirements 2.1

13/11/2014 P01 Approved for Project Use

Hold Record

Hold Ref. Description / Reason for Hold Ref. Section


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Table of Contents 1 GENERAL ..................................................................................................................................................... 4

1.1 PURPOSE .............................................................................................................................................. 41.2 REFERENCE DOCUMENTS ...................................................................................................................... 41.3 ABBREVIATIONS AND DEFINITIONS .......................................................................................................... 41.4 CONFLICT OF INFORMATION ................................................................................................................... 5

2 SCOPE OF WORK ....................................................................................................................................... 52.1 INSPECTION PERIOD .............................................................................................................................. 52.2 RECORDS OF EXAMINATION .................................................................................................................... 62.3 NDE ..................................................................................................................................................... 62.4 MAINTENANCE AND STORAGE OF WIRE ROPES ........................................................................................ 72.5 LUBRICATION OF WIRE ROPES ................................................................................................................ 72.6 CLEANING ............................................................................................................................................. 82.7 PERSONNEL AND EQUIPMENT ................................................................................................................. 82.8 ITEMS MADE FROM STEEL WIRE ROPE ................................................................................................... 8

3 ATTACHMENTS ........................................................................................................................................... 93.1 CRANE/ WINCH WIRE ROPE RIGGING EXAMINATION .................................................................. 93.2 AHC UTILIZATION REPORT ............................................................................................................ 103.3 WIRE ROPE DETAIL ........................................................................................................................ 12


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1 GENERAL 1.1 Purpose

The purpose of this SOW is to establish a system for the inspection and maintenance of wire ropes used on SD2 Project. In addition, this document will provide a clear understanding of the scope of work associated with each activity to be undertaken and will help to ensure efficient performance.

1.2 Reference Documents

Document Number Document Title

STD-COR-ASST-021-E OFFSHORE LIFTING EQUIPMENT AND OPERATIONS WI-ERS-ASST-018-E WIRE ROPE INSPECTION AND MAINTENANCE

ISO-4309 WIRE ROPE FOR LIFTING APPLIANCE-CODE OF PRACTICE FOR EXAMINATION AND DISCARD ISO-4301 LIFTING APPLIANCES- CLASSIFICATION

IMCA SEL 022,IMCA M194 GUIDANCE ON WIRE ROPE INTEGRITY MANAGEMENT FOR VESSEL IN THE OFFSHORE INDUSTRY SI 1998 No 2307 LIFTING OPERATIONS AND LIFTING EQUIPMENT REGULATION

BP-SFSOZZ-CM-PRO-0001 LIFTING EQUIPMENT CONTROL AND OPERATIONAL PROCEDURE AzSPU-HSSE-DOC-00056-2 PROCEDURE OF LIFTING OPERATIONS

SA-SWZZZZ-HS-PRO-0713-000 LIFTING EQUIPMENTS & OPERATIONS ON BARGE, SHIPS AND YARDS

API 2I IN-SERVICE INSPECTION OF MOORING HARDWARE FOR FLOATING STRUCTURES API 2D OPERATION AND MAINTENANCE OF OFFSHORE CRANES

DIN EN 12385-3 STEEL WIRE ROPES - SAFETY - PART 3: INFORMATION FOR USE AND MAINTENANCE BO-SEZZZZ-HS-PRO-0203-000 LIFTING OPERATIONS PROCEDURE

1.3 Abbreviations and Definitions Abbreviations

Abbreviation/ Acronym Description

DBA Derrick Barge Azerbaijan DSV Diving Support Vessel (DSV) Academic Tofig Ismayilov LOLER Lifting Operations and Lifting Equipment Regulation LTA Lifting Technical Authority NDT Non-destructive Test RFQ Request for Quotation PLBH Pipe Lay Barge Israfil Huseynov PLN Plan PMT Project Management Team PCWU Production Compression Water Utilities QA Quality Assurance QC Quality Control HSES Health Safety Environmental & Security ROV Remotely Operated Vehicle PPE Personal Protective Equipment RMRS Russian Maritime Register of Shipping


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SOW Scope of Work SOCAR State Oil Company Of Azerbaijan Republic TBA To Be Advised

Definitions

Term Meaning

Company BP Contractor Saipem Contracting Netherlands BV

Competent person

A person with appropriate practical and theoretical knowledge and experience, who may also be hired from an external subcontracted organization. The subcontracted organization will be nominated on the basis of experience in offshore activities related to crane rigging and inspection operations and subject to BP LTA approval.

Sub-Contractor Selected Sub-Contractor to perform the work or provide the required services Responsible / Responsibility Both action and costs are to be account of the referenced party

1.4 Conflict of information In the event of any conflict between descriptions given in this SOW with a documents, specifications and data sheets or with any of the applicable Codes and Standards, Sub-Contractor shall inform Contractor in writing before proceeding with the work.

2 SCOPE OF WORK The scope of this work is to ensure the correct condition of wire ropes by inspection and maintenance. Inspection and maintenance shall be carried out by the Bos Shelf or its subcontractor. The Subcontracted organization must be nominated on the bases of experience in offshore activities related to crane rigging and inspection and need to be approved by BP LTA. Results of all inspections and maintenances to be reported in writing (refer section 3).

List of all required rigging materials attached in Section 3. Note: attached material list is not completed and will be updated with new rigging items.

2.1 Inspection Period

With reference to the corporate Standard Offshore lifting Equipment and Operations STD-COR-ASST-021-E, wire ropes (such as Crane wires, Winch Wires, Mooring Pennants) shall be inspected on regular basis. The frequency of examinations of shall be as follows:

Daily Observation Weekly Observation Periodic examinations Special examinations

Daily and Weekly inspections are to be carried out by Saipem responsible personnel (i.e. Crane Operator, Deck foreman, Deck mechanic etc.). Periodic examinations shall be carried out by Bos Shelf or its subcontractor in accordance with relevant standards/specifications referenced in Section 1.2. Saipem shall confirm to Bos Shelf relevant referenced document, dependent of type of wire.


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Special examinations shall be carried out by Bos Shelf or its subcontractor as per outcome of Daily, Weekly or Periodic inspections. Unscheduled/Unplanned examinations are also to be considered as special. Scope and extent of special examination (destructive tests, NDE etc.) to be confirmed by Saipem. Requirements for such examination need to be based on, but not limited to:

- Manufacturers recommendations, especially for specific types of wires (Dyneema, Euroflex etc.) - Class requirements - Flag/State Authority requirements

Examination may require witnessing by Manufacturers representative, Class, Flag/State Authority.

2.2 Records of examination All periodic and special examinations shall be recorded using the Examination Record form enclosed in Section 4, or will be recorded by the subcontracted Competent Persons own reporting formats. Where the Competent Person recommends that a wire rope should be discarded, the Master/Superintendent will be immediately informed and, having advised Onshore Management, they will take appropriate action to stop all further use of that wire rope, and then instigate the removal and replacement of the rope if deemed necessary. Defect report shall be generated prior to discard of wire rope. The decision for discarding shall be made in consultation with Onshore Asset Management. A Third Party Authorized Certified Person may be appointed for a full assessment of the condemned rope.

Files shall be maintained by the Quality Department of all examination records for each sling/wire rope, along with the certification of the ropes. A log of examinations shall be set up and maintained

All files relevant to the slings/wire rope examinations status and certification shall be available for consultation by the Master, Superintendent, Crane Operator, Onshore Management, Inspectors, and Certifying Authorities. A wire rope detail form covering wire ropes under this work instruction shall be kept up-to-date and provide necessary information using the FORM-ERS-ASST-027 Wire Rope Details template (see section 4 as example).

Copies of this documentation will be provided to vessel maintenance engineer and the VAM and shall be kept on file along with the following information:

Wire rope certificates; Wire ropes as-build dossiers; Inspection forms by External Competent Person (always to be filled in on the inspection

format as per this Work Instruction); Internal inspection forms; Lubrication record with date applied, type of lubricant used and method of application; NDE testing reports; Wire rope details form; AHC utilization report to be kept with the data of WRFS to be filed for each operation. 2.3 NDE

NDE of wire ropes shall be carried out as an aid to the visual inspections laid down in the above paragraph for examination of wire ropes. An initial NDE shall be done prior/during installation to provide the baseline for future examinations. This inspection can be avoided if NDE inspection done at manufacturer premises and relevant reports are provided by supplier/manufacturer.


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NDT of speltor sockets for pennants is required during periodic/special inspection.

2.4 Maintenance and Storage of wire ropes Maintenance Steel wire ropes must be serviced regularly to increase reliability and service life. The type of service depends on the utilization and construction of the ropes. Maintenance of wire ropes to be carried out in accordance with Manufacturers recommendations. Storage Wires shall at all times be stored in dedicated areas, preferably off the ground/deck and in such a manner as to avoid mechanical damage, corrosion and chemical exposure and UV exposure ( where applicable). Steel wire ropes should be stored in a clean, cool, dry place indoors. The ropes must not be allowed to rest on the floor. They can be placed on pallets. If outdoor storage cannot be avoided the ropes must be placed on concrete slab and covered in a way that moisture cannot create corrosion problems. Although plastic foil protects the ropes from rain, condensation from beneath might not be able to escape and could damage the ropes permanently. To avoid condensation problems, it is advisable to use breathable water-proof fabric covers readily avail-able from tarpaulin manufacturers. When storing a number of spare ropes, the following rule should be applied: first in - first out. This means, the ropes should be used in the order of delivery. In this way it can be avoided that certain ropes are only put into service after being stored for many years. It is self-evident that the different ropes in stock must be clearly marked to avoid the possibility of confusion (e.g. if similar ropes of different tensile strength are stored.) In addition proper records have to be kept which make it possible to trace the history" of any rope back to the manufacturer on the basis of storing number, specification, date of or-der and date of delivery.

2.5 Lubrication of wire ropes Initial lubrication Initial lubrication is essential and provides a native protection through the life of the wire rope and is applied during manufacturing stage. Re-lubrication Steel wire ropes must be re-lubricated at regular intervals, depending on their use, particularly along the zones subjected to bending. If for operational reasons re-lubrication cannot be carried out, shorter service life is to be expected and the inspection intervals have to be arranged accordingly. When utilized on capstan winches the ropes MUST be greased externally at all times. Non lubricated wire rope working on capstan winches leads to unbalanced load reparation within the capstan winch. Wire ropes shall be re-lubricated when they are becoming dry. The condition shall be assessed during the inspection for the wires and it shall be decided whether lubricating by manual brush application or by means of an automatic lubricator is done. Application of lubricant can be done manually, by brush if there is no other available solution and preferably by means of an automatic lubricating pressurized device. Re-lubricating is preferably done with automatic lubricators as these penetrate the lubricant into the outer parts of the wire. Manual application merely coats the exterior of the rope with a limited penetration of the lubricant. Use of pressure applicators shall be done in accordance to the operating instructions by the manufacturer and with the use of proper PPE. Type of lubricant The following products are recommended lubricants for wire ropes: - Initial lubrication


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NYROSTEN - NYROSTEN T55 - Service dressing - crane and pipe lay equipment wire ropes

BRIDON BRILUBE 70 Wire rope manufacturer recommendation for compatibility to be considered. Other products are available and can be selected in agreement with the Onshore Asset Management. Lubricants for sub-sea wire ropes are under development at the present and changes to specification can be expected shortly.

2.6 Cleaning Wire ropes are shall be cleaned prior to re-lubricating. Cleaning devices shall be available on board and used for this purpose. Sub-sea wire ropes shall be flushed with fresh water immediately after recovery from sea and dedicated flushing devices shall be made available on board

2.7 Personnel and Equipment Personnel (riggers, hot work team, cranes/forklifts operators etc. ), equipment (cranes, forklifts, compressors, generators etc.) and materials/consumables (tarpaulin, wooden/concrete slabs/block, lubricants etc.) required for Maintenance, Storage, Periodic and Special examinations to be provided by Bos Shelf. Personnel to be qualified as per job role in accordance with Project and Statutory requirements. Equipment to be certified and current certification/calibration/test records to be provided.

2.8 Items Made From Steel Wire Rope Items made from steel wire ropes (such as pennants, slings, grommets etc.) may be a subject for the Inspections and Maintenance as well. Scope of inspection, maintenance and storage are the same as described in relevant section of current SOW.


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3 ATTACHMENTS 3.1 CRANE/ WINCH WIRE ROPE RIGGING EXAMINATION

Vessel :

Crane Location :

Date :

Crane No./Identification :

Rope Location :

Rope No. :

Reference: Boom down on rest. Looking from stern to bow, other specify :

Rigging RINA

Certification LLOYDS

Nos. OTHERS

Nominal Diameter : Date Fitted :

Length : Direction of Rope Lay :

Measured Diameter Minimum Breaking Load :

Under a Load of : Working Load :

Types of Termination : Date Previous Inspection Date This Inspections

Visible Wire Breaks

Abrasion of Outer Wires Corrosion Measured Rope

Positions Measured

Overall Assessment

Damage a Deformation

s

Number in Length of 6d

Degree of Deterioration*


Diameter

(mm)

Lay length (mm)

(Ref. Drum, Layer Coil)


Degree of Deterioratio

n*

Remarks/Other Observations :

* = Describe as : Slight, Medium, High, Very High, Discard = Delete as Applicable

Examined by

1.1.

Reason for Recommending Discard

Name : Signed : Date :

Name : Signed : Date :


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3.2 AHC UTILIZATION REPORT

Site: 500 Tons wire rope . 750Tons wire rope.

Winch Model.: Rope No.:

Test Certificate Details: Date Fitted:

Delivery condition

Maker : Actual Diameter : Length : Construction : Type of Core : Rope Lay : Surface Finish : Rope Grade : Mass : Actual Min BL :

Rope diameter survey

wireposition measurement


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Rope Utilization

Project (name- phase ) Operational depth Operational load

Temperature recorded Approx duration of AHC session

Termination details

Types of Termination: Date Previous Inspection Date of previous cut back and/or re-socketing

Inspection results

Visible Wire

Breaks

Abrasion of Outer Wires Corrosion Measured Rope

Positions Measured

Overall Assessmen

t

Damage and Deformations

Number in Length of 6d

Degree of Deterioration**


Diameter (mm)

Lay length (mm)

(Ref. Drum, Layer, Coil)



** = Describe as : - Slight, Medium, High, Very High, Discard. * = Delete as applicable.

Reason for Recommendation discard / other remarks

Prepared by Examined by Approved by

Name: Name: Name:

Signed: Signed: Signed:

Date: Date: Date:


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3.3 WIRE ROPE DETAIL