Dimensional Control Procedure (Pipe Fit Assurance)

Mobil Producing Nigeria Ultd
FACILITY:
PROJECT TITLE:
IDOHO BP RESTORATION PROJECT
DOCUMENT NUMBER : NGBP-WV-NPDIM-00-33187

Company Equipment /
Country Originating Discipline Document Document
Facility / Plant Component Numeric Sequence Number
Code Organization Code Type Sub Type
Code Loc Code
NG BP WV N P DIM 00 33187
DIMENSIONAL CONTROL PROCEDURE
A 09/06/2018 Issued for Review Ajoku Samuel
REV Date Description Prepared by Reviewed By Endorsed by Approved by

IDOHO BP Dimensional Control Procedure Page 2 of 17
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NGBP-WV-NPDIM-00-33187 Rev. B 15.06.2018
AUTHORIZATION PAGE
Prepared by: Ajoku Samuel Date: 09/06/2018
Reviewed by: Date:
Endorsed by: Date:
Endorsed by: Date:
Approved by: Date:

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REVISION MODIFICATION LOG
Revision Section Description
B All Issued for Review

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Table of Contents
1.0 Project overview................................................................................................... 5

1.1 Executive Summary..................................................................................................................... 5
1.2 Project Scope............................................................................................................................... 5
1.3 Abbreviations and Definitions....................................................................................................... 6
1.3.1 Abbreviations................................................................................................................ 6
1.3.2 Definitions...................................................................................................................... 6
1.4 Documents – MPN....................................................................................................................... 6
2.0 Position and Responsibilities.............................................................7

2.1 Project Manager........................................................................................................................... 7
2.2 QAQC Supervisor......................................................................................................................... 7
2.3 Construction Supervisor............................................................................................................... 7
2.4 QAQC Inspector........................................................................................................................... 7
2.5 Dimensional Surveyor/Controller ……………………………………………………………..7
3.0
...............................................................................................................................................................
PROCEDURE....................................................................................................
......................7
3.1 General.......................................................................................................................................... 7
3.2 Dimensional Equipment................................................................................................................ 8
3.3 Dimensional Control Checks.......................................................................................................... 8
3.4 Fabrication Tolerances………………………………………………………………………….8
4.0 Documentation.................................................................................9
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1.0 Project overview
1.1 Executive Summary

The purpose of this document is to provide guidance for the application of epoxy paint
application to be applied during fabrication operations at Sub- Contractor Fabrication yard and
pursued during the installation works for the Idoho BP Restoration project. The Paint
application shall be in accordance with Manufacturers recommendation, Company Global
Practices and Specifications.
1.2 Project Description and Scope
The Idoho field is located approximately 50 km south of Qua lboe Terminal (QIT) at water
depth of approx. 60 - 70 feet. The production (BP) platform is bridge connected to two
platforms (Idoho BA wellhead and Idoho BQ accommodation platform).
The Idoho BP Structural Repairs Project will address SSHE risk to personnel, asset and
environment. Idoho BP Platform is a hub to the following facilities Idoho BA/BQ, Inanga UA
and Iyak SA/SB fields, and JV west leg production from Usari, Ekpe and Asabo.
The project scope includes facility restoration activities to address the continuing escalation of
safety, health and environment, and unscheduled volume loss concerns on Idoho BP platform.
The project scope of work, mostly like-for-like structural and piping replacement, will be
carried out on the main deck, cellar deck and spider deck. This section provides a high level
summary of the scope of work only, for further details refer to the Technical Basis, Issued for
Construction engineering deliverables and the Work Execution Packages.
The current basis is to capitalize on a shutdown of opportunity required by another project.
During this shutdown the project will execute early works, which are aimed at minimizing the
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production impact of a future shutdown and enabling a more effective execution of the balance
of work.
Idoho BP Platform
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1.3 Abbreviations and Definitions

1.3.1 Abbreviations
Abbreviation Meaning
IFC Issued for Construction
ISO Isometric Drawing
MPN Mobil Producing Nigeria
PDF Portable Document Format
GP Global Practice
1.3.2 Definitions
Definition Meaning
QAQC Quality Assurance and Quality Control
NPS Nominal Pipe Size
1.4 Documents – MPN
Reference Title
GP 20-01-04 Upstream Project Quality Assurance - General Requirements
GP 03-19-02 Upstream Piping Fabrication,
Erection, Inspection, Testing, and Cleaning
GP 29-01-11 Upstream Pipeline Fittings and Flanges Onshore/Offshore
GP 29-01-34 Upstream Material Identification and Traceability

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2.0 Position and Responsibilities
2.1 Project Manager

 Shall facilitate the Project delivery from Tombim to MPN and shall support the QAQC as
required especially with the provision of the necessary resources to achieve the
dimensional control checks and documentation.
2.2 QAQC Supervisor

 The QAQC Lead will be responsible for the enforcement of all QAQC control programs
and this Dimensional Control Procedure.
2.3 Construction Supervisor

 The Construction Supervisors will be responsible for the fit up, ensuring that piping and
structural works are fabricated and installed in accordance with approved construction
drawings and also perform the dimensional checks alongside the QAQC Inspector.
2.4 QAQC Inspector

• Ensure that dimensional inspection are performed and reports maintained
2.5 Dimensional Surveyors/Controllers

Responsible for execution of the dimensional control activities utilizing 3D measurement
system (levelness, squareness, plumpness etc.
Perform dimensional inspection and prepare dimensional/inspection/survey reports.
3 PROCEDURE
3.1 GENERAL
The Dimensional Control checks are performed during fabrication and installation by the
responsible Dimensional Controller for the piping and structural fabrication/assembly. The
dimensional checks will be monitored by the QAQC Lead to ensure adherence to the Project
requirements. This control will cover all stage of fabrication, before and after welding, and will
also guarantee that all spools will be checked for dimensions, all flanges and fittings for final
orientation and every activity and output concerning the dimensional control check will be duly
registered and submitted in official final dimensional control report/documentation.
3.2 DIMENSIONAL EQUIPMENT
a) Meter Tape: An equipment to measure the length or size of tubular and others such as any linear
measurement, squareness, height, ovality etc.
b) Theodolite/3D Total Station: An instrument to 3D measurements, straightness and verticality. It

may also measure the length of beam, pipe, tubular etc.
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c) Auto/Dumpy Level: An instrument to determine and measure the level of piping, platform, pipe
rack, and pipe supports, sub-assembly panel etc.
d) Taut String: An instrument to check and measure the bend and straightness, levelness of beam,
pipe and tubular.
e) Try-Square: It is a measuring device used for marking and measure the squareness.
f) Spirit Level/Plumb-Bob: It is a piece of metal which is tied with string to measure the centre line
and alignment.
3.3 DIMENSIONAL CONTROL CHECKS

The Dimensional control shall be carried out using 3D measurement system (Horizontal and
vertical position), angles, levels etc. The setting out and dimensional control shall comply with
AFC drawing, applicable references, codes, standards or Client GP.
The Dimensional checks shall be performed at the following stages:
The Dimensional checks shall be performed at the following stages:
 The Cutting/Preparation of structural and piping materials

 Fit-up (Structural and Piping).
 After welding of spools or structural fabrication.
 Completion of fabrication works.
 The installation work.
At erection and assembly, the following shall be checked:

 Linear tolerances of pipe works
 Orientation of pipe works
 Bend angles of pipe works
 Flange face alignment
 Levels and slopes of pipe works
3.3.1 TIE POINT ANALYSIS & CLASH DETECTION

The Pipefit assurance is the starting point for a clash free installation. Prior to the commencement
of the fabrication assurance, the Tie Point and Clash detection will be carried out to achieve the
below;
a. Check for possible clashes between the new lines to be installed and the existing facility by
comparing the 3D model of the new design with the digitized facility (Laser Model) obtained
from the scan data and resolve any hard or soft clashes between the new design and the
existing facility. This includes all isometrics, equipment, structural deck extension, pipe
support and other appurtenances.
b. Carry out other Pipefit assurance exercise such as tie point misalignment checks, fit-up
checks, etc between the new design and the existing facility. This includes all isometrics,
equipment, structural deck extension, pipe support and other appurtenances.
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c. Identify and report any other inconsistency that can negatively affect the overall project
goals.
d. Produce and Issue Pipefit Assurance report showing clash locations, extents, tie point
misalignment and recommendations to evade all clashes, tie point misalignments, and any
other fit up issues.
e. Issue clash free revised IFC Isometrics and Pipe Support drawings.
Items Required for Tie Point Analysis and Clash Detection activities are:
a. Existing Laser scan point cloud data in LFM Format (LFD Dataset). Gmunu understands
that client has a recent point cloud data of Idoho BP
b. Most recent IFC drawings
c. Client PDMS Catalogue
d. Client Piping standards
e. Other necessary documentations such as P&IDs, Client approved materials, Platform

Orientations, etc.
3.3.1.1 Tie Point Check
Tie Point will be checked for misalignments, bolt hole rotation errors, spec errors, etc. All
isometrics connecting to the existing facility will be checked at the connection point and a
report will be issued. This report will include at a minimum the displacement or offset between
the new design tie-point coordinate and the as-built tie point coordinate, Tie point No.,
drawing no, isometric no. Tie point parameters such as flange specs, sizes, connection type,
etc. will be analyzed and reported. Errors will be flagged with snapshots for visual clue and
recommendations will be issued and incorporated on the initial isometrics issued to Gmunu.
Gmunu QAQC procedure will apply for all tie point check.
3.3.1.2 Clash Detection
After the Tie-point coordinates have been checked and corrected, the clash detection exercise
will commence. Areas to be clashed will be cropped and analyzed. All identified clashes will be
reported immediately to the PFA lead who is responsible for clash resolution. Such resolution
will be carried out by the personnel who observed the clash under the full supervision of the
PFA lead. A clash report will be generated with pictures showing where the clash occurred and
the extent of the clashes. Recommendations will be implemented on the 3D model and
incorporated on the Isometrics. Gmunu QAQC procedure will apply for all clash detection
exercise
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3.3.1.3 Preparation of Tie Point And Clash Reports
All reports will be prepared using a suitable office suite such as Microsoft office, Libre Office &
Kingsoft office suite.
Only items having issues will be reported with a suitable picture showing extent of observed
issues / clashes. Microsoft Paint or one note will be used to take snapshots from Truview.
QAQC procedure will apply to the preparation of reports.
3.3.1.4 Isometric Modifications
All isometrics requiring modification will be modified to a clash free status using AutoCAD and
or ProgeCAD. Client CAD standard will be used by default. Modified areas on isometric will be
clouded with revision cloud and a revision triangle. Issue number will be the next revision
number or as stated in client standards. Gmunu QAQC procedure will apply for all clash
detection exercise
3.3.2 FABRICATION ASSURANCE OF FABRICATED SPOOLS
Identification of each spool on site is the starting point for fabrication assurance. A spool tag
system will be established, and each spool will be identified and noted to enable identifying
them in the scan data.
Spools will be arranged on Jigs or on the floor in different sets. This involves proper and timely
planning with the crane operator on site whose job is to lift and place each spool on the jig or
floor. See diagram below for a sample arrangement of a set of 5 spools and scan positions
(Red Balls) to thoroughly digitize these spools.
Each spool will be arranged and scanned in such a way as to capture all details such as olets,
flange bolt holes and faces, etc.
All spools will be laser surveyed as detailed on Gmunu’s laser scanning procedure “GMU-PFA-
PRO-03-0614”.
3.3.2.1. Receipt of Necessary Package from Client
Packages required for fabrication Assurance includes the following;
a. Shop Drawings. This is required to carry out the first level of checks against the approved /
clash free isometrics and to get the tagging system of the spools.
3.3.2.2 3D Modeling of Spools
All Isometrics received from client will be converted to their 3D equivalent. Required software
to be used to generate 3D models will be AutoCAD or PDMS.
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3D modeling will be carried out by a disciplined engineer trained in the use of that software.
Gmunu QAQC procedure will apply for all modeled items. For occasions where a 3D model was
issued to Gmunu by client, Gmunu will verify that all dimensions on the model tally’s with the
IFC Isometric hence forming a first line of check especially if wrong fittings were used.
All models will still be converted to a format compatible with the 3D laser scan data.
3.3.2.3 Summary of Steps for Fabrication Assurance of Idoho BP Structural Repairs

Project
The below listed steps will be carried out in a loop until all spools are cleared. Spools will be
surveyed and analyzed after being tacked. Cleared spools will be recommended to proceed for
full weld after which they will be surveyed and analyzed again for final clearance.
Steps
1. Arrangement of Spool in sets on jigs or floor at the fabrication yard.
2. 3D laser scanning of arranged spools (Tacked and Full welded).
3. Registration and processing of each spool set laser scan data.
4. Converting of point clouds to laser models.
5. Alignment of spool in any one axis.
6. Import the digitized spool into Aveva PDMS/E3D.
7. Superimpose the design model derived from the IFC isometric against the digitized spool in
Aveva PDMS.
8. Measure and record all observed errors. Pictures will be taken to clearly communicate
errors to client.
9. Prepare a spool report for each spool.
10. Clear / Hold Spools are required.
3.3.2.4 Software Required
Software to be used for Fabrication Assurance services includes
a. Leica Cyclone Suite
b. Aveva PDMS
c. Microsoft Office Suite

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d. Adobe PDF
3.3.2.5 Analysis Carried out
After the laser scanning activity, each spool will undergo the below analysis and a fabrication
assurance report will be generated. The report will detail all errors/issues observed on each
spool and recommendations to resolve them.
a. Bolt hole rotation analysis
b. Dimensional Analysis
c. Flange / Fitting Specification Deviation Analysis
d. Fitting Orientation Analysis
e. Spool Line Assembly Analysis
f. Flange Skew Analysis
Upon completion of the individual spool analysis, a line system analysis will be carried
out to minimize modification of spools with errors. This analysis will be carried out in
the digitized platform scan data.
3.4 FABRICATION TOLERANCES

Dimensional tolerance shall follow the requirements of GP 03-19-02 section 4.7 Fig 1 and Section
7.1 Fig. 5/table. (See Fig 1 and Fig 2 table below)
-Flange Bolt holes shall align with a 3mm (1/8”) maximum offset before bolt up.
-Before bolt up, the maximum clearance between mating faces shall be equal to the initial gasket
thickness + or – 1.5mm (1/6”)
Tolerances shall be attained after all permanent supports and guides have been installed
between the Equipment and the first anchor point and after all temporary devices, such as chain
blocks and come-a-long have been removed.
-Flange bolt shall be cap able of initial installation by hand.
-All piping shall be installed square and plumb, except where slop is required for drainage.
-Fabrication shall identify optimal locations for field fit welds to facilitate final adjustments of the
piping during installation, such final adjustment serves to accommodate fabrication tolerances
and correct inaccuracies.
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Figure 1: Dimensional Tolerances
Special Services
1
a. Design Temperature
>
– 850°F or Flange Rating >–
ASME Class 900
b. Where plastic or elastomeric

Item Normal Service liner (lapped over the flange
faces) provides the gasket
for the joint.
c. Piping over NPS 3 to be

connected to rotating
3 machinery.
1 ± 1/8 in. maximum from indicated dimensions for face to face, center
to face, location of attachments, etc.
2 Bend flattening tolerance shall be in accordance with the applicable Code.
3 ± 1/8 in. maximum lateral ± 1/16 in. maximum lateral

translation of branches or translation of branches or
connections. connections.
4
4 ± 1/16 in. maximum rotation of flanges from the indicated position,
measured as shown.
± 1/64 in. for piping over NPS 3 to be connected to rotating machinery.
5 Per the applicable Code. ± 1/64 in. maximum out of

alignment of flanges from the
indicated position, measured
across any diameter.
Conversion Equivalents
1 1 1 1 5 in. 1/64 1/16 1/8 850°F NPS 3
mm 0.4 1.5 3 454°C 80

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Figure 2: Flange Pair Alignment Tolerances (Excluding Machinery)
1 2
Total Tolerance Per Flanged Joint
Special Services
Item Normal Service

a. Design Temperature –> 850°F (454°C) or Flange Rating –>
ASME Class 900.
b. Where plastic or elastomeric liner (lapped over the flange
faces) provides the gasket for the joint.
1 Per the applicable Code 1/32 in. (1 mm) maximum out of parallel alignment of flanges,
measured across any diameter.
2 Per the applicable Code 1/8 in. (3 mm) maximum translation of branches or
connections.
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NGBP-WV-NPDIM-00-33187 Rev. 0 15.06.2018
4 DOCUMENTATION
Sample Fabrication Assurance Report
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NGBP-WV-NPDIM-00-33187 Rev. 0 15.06.2018

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Mobil Producing Nigeria Ultd

IDOHO BP RESTORATION PROJECT

DOCUMENT NUMBER : NGBP-WV-NPDIM-00-33187

DIMENSIONAL CONTROL PROCEDURE

A 09/06/2018 Issued for Review Ajoku Samuel

REV Date Description Prepared by Reviewed By Endorsed by Approved by

Prepared by: Ajoku Samuel Date: 09/06/2018

Reviewed by: Date:

Endorsed by: Date:

Endorsed by: Date:

Approved by: Date:

REVISION MODIFICATION LOG

Revision Section Description

B All Issued for Review

1.0 Project overview................................................................................................... 5

2.0 Position and Responsibilities.............................................................7

1.0 Project overview

1.1 Executive Summary

1.2 Project Description and Scope

1.3 Abbreviations and Definitions

1.4 Documents – MPN

GP 29-01-34 Upstream Material Identification and Traceability

2.0 Position and Responsibilities

2.1 Project Manager

2.2 QAQC Supervisor

2.3 Construction Supervisor

2.4 QAQC Inspector

2.5 Dimensional Surveyors/Controllers

3.2 DIMENSIONAL EQUIPMENT

b) Theodolite/3D Total Station: An instrument to 3D measurements, straightness and verticality. It

3.3 DIMENSIONAL CONTROL CHECKS

The Dimensional checks shall be performed at the following stages:

 The Cutting/Preparation of structural and piping materials

At erection and assembly, the following shall be checked:

3.3.1 TIE POINT ANALYSIS & CLASH DETECTION

b. Most recent IFC drawings

c. Client PDMS Catalogue

d. Client Piping standards

e. Other necessary documentations such as P&IDs, Client approved materials, Platform

3.3.1.1 Tie Point Check

3.3.1.2 Clash Detection

3.3.1.3 Preparation of Tie Point And Clash Reports

3.3.1.4 Isometric Modifications

3.3.2 FABRICATION ASSURANCE OF FABRICATED SPOOLS

3.3.2.1. Receipt of Necessary Package from Client

Packages required for fabrication Assurance includes the following;

3.3.2.2 3D Modeling of Spools

3.3.2.3 Summary of Steps for Fabrication Assurance of Idoho BP Structural Repairs

1. Arrangement of Spool in sets on jigs or floor at the fabrication yard.

2. 3D laser scanning of arranged spools (Tacked and Full welded).

3. Registration and processing of each spool set laser scan data.

4. Converting of point clouds to laser models.

5. Alignment of spool in any one axis.

6. Import the digitized spool into Aveva PDMS/E3D.

9. Prepare a spool report for each spool.

10. Clear / Hold Spools are required.

3.3.2.4 Software Required

Software to be used for Fabrication Assurance services includes

a. Leica Cyclone Suite

c. Microsoft Office Suite

3.3.2.5 Analysis Carried out

a. Bolt hole rotation analysis

c. Flange / Fitting Specification Deviation Analysis