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API RP 2SIM Level I Offshore Platform Survey

Overview
Objectives This document describes procedures to conduct offshore above water structural
inspection based on API RP 2SIM Strategy.
This procedure satisfies the requirement for annual above water survey of the platform
per regulation of the Minister of Energy and Mineral Resources No 18/2018
The objective is to detect or verify integrity of critical items as follows:
 Indications of obvious overloading, deteriorating coating systems, excessive
corrosion, and bent, missing, or damaged members of the structure in the
splash zone and above water. Guidance on the grading of coating systems is
provided in NACE SP0108.
 Damage or deterioration to appurtenances and personnel safety, escape, and
evacuation devices.
 The performance of the platform’s under water CP system using dry operator
technique (e.g. a drop cell survey).

Scope The following elements are part of API RP 2SIM Level I Offshore Program:
 General visual survey

Continued 

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Overview, Continued

In this This procedure contains the following information:


procedure
1.0 References............................................................................................................3

2.0 Roles and Responsibilities..................................................................................4

3.0 Requirements.......................................................................................................6

4.0 Safety Considerations.........................................................................................7

5.0 General Procedure..............................................................................................8

6.0 Platform Survey Activities................................................................................10

7.0 Platform Structural Components.....................................................................11

8.0 Riser Above Water and Splash Zone External Inspection..............................14

Riser Above Water and Splash Zone External Inspection, Continued.....................15

9.0 Platform Structural Inspection Criteria..........................................................16

10.0 Survey Checklists and Forms...........................................................................22

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References

Applicable  API RP 2A: Planning, Designing, and Constructing Fixed Offshore Platform
references
 Minister of Mining regulation No 05/P/M/Pertamb/1977: Kewajiban Memiliki
Sertifikat Kelayakan Konstruksi untuk Platform Minyak dan Gas Bumi di
Daerah Lepas Pantai.
 Dirjen Migas regulation No 21.K/38/DJM/1999: Petunjuk Pelaksanaan
Tatacara Pemeriksaan Teknis yan Dipergunakan dalam Usaha Pertambangan
Minyak dan Gas Bumi

Other The following procedures shall be used to support elements of this procedure:
procedures
 6-6-T-029-APO Drop Cell Measurement Procedure for Offshore Submerged
Structure

In addition, refer to the following documents as necessary:


Site-specific standard operation and maintenance procedures
Work management procedures for all appropriate permitting requirements

Manufacturing Refer to the Manufacturer's operating and maintenance instructions for specific tools
manuals/ to be used.
documents

Safety manual Refer to the Pertamina Hulu Energi NSO (PHE NSO) Company Safety Manual, latest
revision, for safety guidelines and best practices.

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Roles and Responsibilities

Survey Team The Survey Team shall conduct an above water inspection of offshore structures. The
team shall assess the condition and corrosion protection system of the platform. The
team shall be composed of the following members:
 Structural Surveyor
 Corrosion Inspection Technician
 Operations Representative

Structural Typically this will be a qualified Engineer but this position could be filled by a
Surveyor qualified Technician or other suitably trained and qualified Operations or Operations
Technical personnel.
Structural Surveyor is responsible for leading the survey and ensuring that all
inspection items are inspected during the survey.

Corrosion Corrosion Engineer shall have the following responsibilities:


Engineer
 Ensure that the inspection is completed on schedule and in accordance with
Company procedures.
 Prepare the Inspection Test Plan (ITP) and procedures for the survey
 Review the survey report
 Identify findings which require additional inspections or more detailed NDT
to characterize condition. Coordinate the additional inspections with the
Inspection Technician.
 Prioritize and rank survey findings.
 Summarize the recommended actions for correcting findings.
 Route the Level 1 Survey report for technical validation by Corrosion
Engineering Specialist.
 Review results and recommendations with the Programmatic Supervisor and
Operations Supervisor.
 Ensure implementation of recommended corrective measures.

Corrosion The Corrosion Inspection Technician shall have completed fundamental corrosion and

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Inspection inspection training and shall demonstrate competency in the work performed. The
Technician Corrosion Inspection Technician shall facilitate execution of all elements of the
General Visual Survey. Responsibilities include:
 Review the Inspection Test Plan (ITP) and inspection history prior to the
scheduled survey.
 Ensure that necessary drawing(s), design, and materials of construction data
are available for on-site reference during inspection activities.
 Arrange for all appropriate tools needed for inspection and measurement,
including those tools and equipment needed for personnel safety, to be
available on-site. Ensure calibration and proper working condition prior to
the inspection.
 Obtain proper site permits for all work to be performed.
 Perform drop cell potential measurement during the inspection.
 Complete the checklists for each element of the API RP 2A Level 1 Platform
Survey and drop cell data sheets survey.

Senior The Senior Operations Supervisor shall:


Operations
Supervisor  Assign an Operations Representative from each Operations Area to participate in
the inspection.
 Review the survey report and recommended corrective actions.

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Requirements

The timing The above water structural inspection of offshore platforms should be carried out
annually or as part of special inspection after direct exposure to the design event or to
any accidental overloading (e.g storm, tsunami, hurricane, earthquake, or any incident)

Equipment This inspection involves general visual assessment and cathodic potential
and tools measurement. The following equipment is required to support the above water
structural inspection:
General Visual Assessment Equipment:
 Pit Depth Gauge
 Measuring Tape
 Calipers and Micrometers
 Scraper
 Digital Camera (safe for hazardous area)
 Binoculars (for inspection high elevations and some difficult to access areas)
 Air Gap Measurement Kit

Drop Cell Potential Measurement Equipment:


 As defined in 6-6-T-029-APO (Drop Cell Measurement Procedure for Offshore
Submerged Structure)

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Safety Considerations

Personal Maintenance personnel are required to wear the appropriate Personnel Protective
Protective Equipment (PPE) in designated areas. The minimum PPE required for this procedure
Equipment includes:
(PPE)
 Safety shoes
 Safety helmet
 Safety glasses (when appropriate)
 Safety harness (when working on elevated area)
 Fire retardant coverall.
 Double hearing protection must be carried at all times and used in designated
areas.
 Suitable gloves should be worn when handling hazardous materials or contacting
a cold or hot surface.
 Personal protective H2S detector must be worn all the time.
▲Caution: Follow the required precautions when working around H2S and
toxic gas.

Special safety The following activities are essential to conducting the work safely.
considerations
 Complete a Job Safety Analysis (JSA) prior to starting the work.
 Obtain an approved work permit.
 Carried valid H2S certificate
 Ensure all safety systems are operational and working properly.
 Follow good housekeeping practices.
 Be aware of hazards when working at elevations requiring safety harnesses.
 Ensure good health and fit to work at offshore environment

Environmental Operations are conducted in accordance with governmental requirements


Precautions (MIGAS) for protection of the environment (GOI emission limit of H 2S 400
ppm and overboard water 50 ppm).

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General Procedure

Preparation Follow these tasks to prepare a API RP 2A Level 1 Platform Survey


..

Task Action
1. Understand the Inspection Test Plan (ITP) for the survey
2. Understand the observation criteria for the inspection
3. Understand Level 1 platform survey and drop cell checklist forms
4. Understand platform structural components in the scope of the survey
5. Prepare copies of the survey forms.
6. Obtain all the necessary inspection equipment and tools required for the
survey
7. Obtain a copy of the survey schedule

Survey Follow these tasks to perform a API RP 2A Level 1 Platform Survey


..

Task Action
1. Inspect for indications of or susceptibility to the relevant corrosion or failure
modes.
2. Document all findings on the relevant survey form including :
 Location (include the elevation)
 Structural condition rating
 Clear description of area or equipment surveyed, include tag/line
number where available
 Detailed description of anomalies and other findings
 Photograph of all significant findings and areas of concerns
 Actions recommended (e.g. NDT, replacement, more extensive
close visual survey inspection)
3. Attach hand sketch to adequately describe finding
4. Document additional relevant information (e.g. leaking history, fluid service,
etc) in the comments section

Reporting After the survey is conducted, an inspection report shall be generated including the
following items:

 General survey information (Inspection date and Inspector name)

 Summary of survey

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 Anomaly sheets: present an index of anomalies found include relevant
photographs and the recommended actions.

 Survey results: this section contains copies of the checklist data, sketches
and pictures.

 Photographic Logs

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Platform Survey Activities

API RP 2A An API RP 2A Level 1 Platform Survey shall be conducted per Section 14 of API RP
Level 1 2A. This Platform Survey includes the following elements:
Platform
Survey

Activity Scope of Work Commentary


Structural Perform a topsides structural Look for obvious signs of damage or distress, such
Components component survey to assess the as missing members, failed joints, failed welds,
condition of primary, secondary, impact damage, loose or missing appurtenances and
and tertiary steelwork. Visually other obvious deterioration, such as coating system
survey all members, joints and loss and corrosion condition. Any damage or
appurtenances as defined in corrosion is to be documented with photographic
section 7.0. evidence.
Survey shall conducted using standard checklist
(attachment 1-5)
Conductor Visually survey all conductors from Perform a conductor survey to assess the condition
Visual splash zone area upward of the conductors. Any damage or corrosion is to be
Survey documented with photographic evidence
Dropped Cell Assess the adequacy of the Measurements are normally made following 6-6-T-
Cathodic underwater CP system for the 029-APO procedure.
Protection structure and risers
Survey
Air Gap Measure the distance from At least three measurements should be taken from
underside of the sub-cellar deck to different location on the platform, and the exact date
mean water surface and time of each measurement recorded to allow for
tidal/ surge correction at a later day.
Measurement shall conducted using standard
checklist (attachment 7)

Seismic and A walk-down should be carried out The visual survey should look for signs of lateral
hurricane as part of the above water movement of items such as modules, equipment,
walk-down inspection for platforms located in piping, and so forth due to failure of tie-
areas of known seismic and downs/attachments.
hurricane activity. The walk-down
primarily should cover the Findings should be ranked in accordance with the
anchorage of equipment, pipe priority ranking. Findings also should be categorized
system flexibilities to according to safety or operational concerns.
accommodate lateral load, and
status/location of items that may Note: This inspection is event-triggered. The
move or fall, ultimately causing triggering event should be set at 80% of the
interaction with other systems. design event, unless a higher level is
justified by risk analysis (RA).

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Platform Structural Components

Primary Primary structures are structural components that carrying the major loads to support
Structures the platform and/ or critical to safety during an emergency situation. Below is the list
of primary structures:

 Deck Legs
 Primary Deck/Module Trusses
 Plate Girders
 Girders in two-way floor systems
 Girders/Beams supporting cantilevered lay down areas
 Nodes/Joint Cans
 Lifting Points (Lifting Padeyes, Trunnions, Padears)
 Primary trusses of living quarters or load carrying elements of living quarter
stress skin design
 Helideck trusses/girders
 Crane Pedestals
 Crane foundation
 Flareboom and its Support Structure
 Atmospheric vent structure
 Lifeboat and fast rescue craft platform supports
 Fire/Blast Walls
 Sea Fastening of deck structure
 Communication & navigation tower

Secondary Secondary structures are structural components that support primary structures to
Structures support the platform. Example of secondary structures mentioned as following:

 Deck Beams/stringers
 Deck Plate
 Local Stiffening of Deck
 Crane Boom Rests
 ROV Porch
 Equipment supports and Skids

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 Monorails, bridge cranes, maintenance padeyes
 Living quarter load bearing walls (but not part of main trusses or stress skin
design)
 Pipe Racks and Riser Racks
 Installation Aids/Bumpers
 Mezzanines and Misc. Platforms that are equipment bearing
 Grillage

Tertiary Tertiary structures are structural components that support secondary structures to
Structures support the platform. Some of tertiary structures are designed to provide access for
personnel in platform during operations.

 Access Platforms that are not equipment bearing


 Walkways
 Grating
 Handrails
 Stairs/Stair Tower
 Pipe and Electrical Supports
 Deck Coaming
 Ladder and Ladder Cages
 Non-load bearing walls

Equipment Equipment structural supports carry load from equipment and have significant
supports influence on equipment integrity. Piping supports, vessel skirts, and saddles are
examples of equipment support.

Structural Structural appurtenances are those structural components that, while not carrying the
Appurtenances primary loads to support the platform, do serve to provide operationally significant
support. These structural components are described below.

Boat landing A boat landing is an embarkation/debarkation structure


attached to the jacket near the water level to allow
personnel to arrive or depart the platform by boat.

Conductor The conductor is the external pipe casing that contains the

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drilling pipes to extract the hydrocarbons from the
reservoir. The conductor also acts as a foundation pile that
can extend 100 ft into the seafloor. The conductor
terminates at the cellar deck of the platform topsides.
Guide frames attached to the substructure may be provided
to laterally support the conductor through the water
column; depending on water depth.

Caisson For the purposes of this section, caisson refers to the


suction or discharge casings from fire main system pumps
or other equipment. These caissons run vertically
downward to an elevation below the mean low water
(MLW) level.

Risers Risers are the sections of the pipeline that rise from the
seafloor through the substructure and terminate at the
pipeline isolation valve or pig launcher or receiver.

Riser guard The riser guard is a protective fendering system that


protects risers from impacts near the water-line.

Boat fendering Structural appurtenances are those structural components


that, while not carrying the primary loads to support the
platform, do serve to provide operationally significant
support. These structural components are described below.

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Riser Above Water and Splash Zone External Inspection

Riser This section describes corrosion inspection of the external surface of subsea risers
Inspection above water and in the splash zone. The purpose of this inspection is to visually
Scope inspect the external condition of risers for evaluating and prioritizing follow-up
actions such as Close Visual Inspection or Non- Destructive Testing.
The splash zone is the region of the riser that is periodically wetted from the action
of waves and tides. Unprotected and poorly protected carbon steel corrodes rapidly
in the splash zone environments. Scope of this inspection shall extend from the water
line in the splash zone to the pig launcher valve.
The survey includes examination of the coating condition and observation of rust
staining at all sections that can be observed without erecting scaffolding and without
opening the riser clamp.

Inspection Special attention shall be directed toward the potential problem area and the riser
Requirements inspection performed as the following requirements :

Riser Clamp

 Detect rust staining underneath the riser clamp area.


 Determine whether or not the rust staining source is the clamp or the riser
pipe.
 Note whether or not the riser clamp has been modified with a break-away
flange or other modification.
 Visibly inspect the clamp condition for indication of loose bolting, damaged
shims, coating breakdown, movement evidence, etc.

Riser Contact Area

 Visibly check whether or not the riser has moved and is in contact with the
floor grating or any of the structural members. If a riser is observed to be
moving, measure the distance between the riser and the structure for future
reference.

Hanger (Anchor) Flanges

 Check for possible rust staining in the area below the hanger flange and in the
gaps between the two halves of the flange.

Continued 

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Riser Above Water and Splash Zone External Inspection, Continued

Inspection Coated Riser


Requirement
 Identify the type of coating system used.
 Determine the condition of coating and the presence of any rust staining.
 Examine areas for possible mechanical damage.

Riser Guards

 Observe and document the condition of the riser guard and overall general
condition of paint.

Riser Bend up to Pig Trap


 Visibly check for the presence of rust staining from the pipe supports.
 Inspect the flange connection for possibly leakage.

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Platform Structural Inspection Criteria

Inspection Inspection criteria were developed to classify the damage in term of the urgency of
Criteria mitigation action. The assessment is based on visual inspection and is used to
highlight those areas that require remedial action or more detailed inspection work to
determine the risk level of the structure / element in question.

General Following are the ratings for the structural inspection. A higher rating means high
Ratings risk to structural integrity and required faster mitigation actions.

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RATING DETERIORATION SCOPE CONDITION ACTION
No Deterioration with Structural  Coating system generally intact with no signs of None
Adequate Protective Surface corrosion.
Measures in Place  No damaged on surface due to impact/ overloading.
Element is in near original, Weld No crack or damage on weld area.
as-constructed condition. Bolts/Nuts Connection bolts/nuts in good condition with no corrosion
Minor non-structural defects Fire Fireproofing in good condition with no cracks or rust
may be present. proofing stains
Alignment No misalignment and distortion.

Visualization Example:

Galvanized steel and fireproofed members in good condition Steel pipe supports in good condition

RATING DETERIORATION SCOPE CONDITION ACTION

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Active Deterioration Structural  Coating system failure over more than 10% of area. Arrest deterioration or
Deterioration is active with Surface  Heavy rust scale. correct defect to assure
loss of section / capacity  Deep pits future durability /
not exceeding 10% or  Less than 10% corrosion loss of cross section performance. Risk
minor structural defect assessment / cost-benefit
identified. Weld Hairline crack observed on weld area. appraisal may allow
Bolts/Nuts Connection bolts / nuts and anchor bolts / nuts corroded deferral of remedial
but still defined threads and flats measures.
Fire proofing Fireproofing cracks <0.25” (<6mm) wide
Alignment No evidence of other misalignment or distortion of
members

Steel showing loss of paint and local minor Severe loss of paint but corrosion loss of The misalignment is less
corrosion steel is <10% than half the column depth
and the degree of
deformation does not
significantly reduce the
load capacity

RATING DETERIORATION SCOPE CONDITION ACTION

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Significant Deterioration Structural  Corrosion loss of cross section between 10% and Remedy the fault or
Structural loss between Surface 25% investigate further with a
10% and 25% of section /  Holing of member civil / structural engineer
capacity, or a defect Weld  Cracked or severely corroded weld or heat affected or suitably trained and
identified which has the zone area qualified individual and
potential to impair the conduct a risk
Bolts/Nuts  Connection deficient, such as missing bolt or nut
structure's fitness for assessment to determine
 Severely corroded on connection bolts
purpose or forms a required mitigation.
potential safety risk.
Fire proofing Extensive cracking of fireproofing with cracks >0.25”
(>6mm) wide
Alignment  Noticeable deflections or misalignment of members
 Impact damage resulting in member being distorted
or bent greater than half the depth of the member

Corrosion is evident but loss of section appears to be Cracks to fireproofing are >6 mm wide indicative
less than 10% which would be condition category #2. of potential corrosion loss of underlying steel
However because the base detail forms a water/debris exceeding 10%. Follow up by removal of
trap and could hide more significant corrosion then #3 fireproofing required to determine
condition category should be assigned

RATING DETERIORATION SCOPE CONDITION ACTION

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Advanced Deterioration ALL As mentioned in rating 3 but have a significant Early action required.
Structural loss exceeds impact to safety Measures may comprise
25% of section / capacity, repair, strengthening or
or a defect identified such Structural Corrosion loss of cross section greater than 25% replacement. Barricading
Surface
that the structure has been the area and / or
Weld Failed welded connection
significantly compromised. providing temporary
The structure may have shoring to support
Bolts/Nuts Two or more of the bolts or nuts broken or missing in a
failed or be in danger of members could be
connection
failure under design loads / necessary. A civil /
Fire proofing Extensive cracking of fireproofing with cracks >0.25”
conditions. structural engineer or
(>6mm) wide but gives cause for serious concern
suitably trained and
Alignment  Failure of connection or gross distortion such as bent
out of line greater than 2 times the depth of member qualified individual should
 Gross deflections or misalignment of members be consulted
 Member missing

Severe corrosion leading to holing of the web Severe corrosion (>25%) of staircase Pipe support incorrectly
and thinning of the flange of the floor beam stringer. installed.
judged to be >25%.

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Survey Checklists and Forms

Survey Checklist and forms required for this survey are included in the following
Checklist and attachment:
Forms
 Attachment 1: Below Sub-Cellar Deck Inspection

 Attachment 2: Sub-Cellar Deck Inspection

 Attachment 3: Cellar Deck Inspection

 Attachment 4: Main Deck Inspection

 Attachment 5: Helideck Inspection

 Attachment 6: Riser Inspection

 Attachment 7: Air Gap Measurement

Drop cell potential measurement checklist that required for conducting API level 1
Survey is available in separate procedure, 6-6-T-29-APO (Drop Cell Measurement
Procedure for Offshore Submerged Structure).

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