SD05wi1 Structural Inspection Workpack

Work Instruction: Structural Inspection Workpack
Document number: SD05wi1
Scope: Global
Date Revision Description Owner Approver
Executive
Contract Services
11 Oct 2018 0 New from Draft Director for
Group Manager
Global Services
General Manager
Updated references to Sparrows Chief Technical
01 Nov 2021 01 – Managed
inspection procedures Officer
Contracts
DELIVERY ASSURED
Structural Inspection Workpack
Table of Contents
1 Purpose ............................................................................................................................................... 3
2 Aim ....................................................................................................................................................... 3
3 References .......................................................................................................................................... 3
4 Example Site Work Instruction ............................................................................................................ 4
SD05wi1 Rev 01 01 Nov 2021 2 of 22

1 Purpose
The below example of a completed Site Work Instruction for a Structural Inspection of a Crane Boom. It
can be used to assist when creating workpacks for Structural Inspections.
It gives an example of the current best practice in complying with the SD05p8 and SD05p9 procedures.
2 Aim
The aim is to ensure that the inspection gathers all the requisite information to ensure a full
understanding of the condition of the crane and that the inspection team undertaking the work have all
the information required.
3 References
Crane Structural Inspection Management

Crane Load Path Guidance
Corrosion Identification Guidance
Pedestal Crane Structural Inspection Management
Crane Structural Thickness Measurement Report
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4 Example Site Work Instruction
Document Number: [Document No.] Frequency: 4Y
Title: [Title]
Client: Sparrows Offshore Services
Site: [Site]
Equipment Details: [Equipment Details] Tag No: A-9800
Revision Control
Rev Revision Status Author Check App Date
[Rev]
Important Points
• It must be ensured that the Daily Defect Report is completed and passed to the onshore team.
• Where there is a critical defect discovered the client must be made aware immediately.
• Inspections must include the areas highlighted by the engineer and any points of corrosion,
damage or previous repair.
• If paint must be removed to complete the examination this must be noted as a defect.
Summary of Task:
Title – East Crane Boom Structural Inspection
Areas of Inspection
The following areas within the East Crane Boom will require inspection during the workscope execution.
• Boom Foot Section

• 1st Mid-Section
• 2nd Mid-Section
• 3rd Mid-Section
• Cathead Section
• Ancillary Equipment
Inspection Requirements
The following inspection techniques will be implemented during the workscope execution.
• Magnetic Particle Inspection (MPI)

• Eddy Current Inspection (ECI)
• Ultrasonic Inspection (UT)
• Close Visual Inspection (CVI)
Visual Inspection
The visual inspection should be used to assess the general condition with attention to areas of corrosion,
damage/indentations, wear and other notable defects. If there is any doubt about the condition of the
component contact Sparrows immediately and refer to INS02g1.
SD05wi1 Rev 01 01 Nov 2021 4 of 22

NDT (Non-Destructive Testing) Inspection
Where there are NDT requirements, the coating thickness on the weld or components must be assessed with
locations clearly identified on the drawings. The maximum coating thickness allowable for Eddy Current
Inspection (ECI) is 2.0mm.
Where there is a requirement for protective coatings to be removed, this should be done using suitable
means. Coating removal will only be required where Eddy Current shows a defect (e.g. needle gun, wire brush
etc.)
Note: Where protective coatings have been removed to allow MPI to be carried out, the affected areas must
be recoated to the clients minimum coating standard immediately on completion of NDT or repair of the defect.
If this cannot be completed, the area must be managed as a defect as per SD05p8.
The areas inspected by Eddy Current must adhere to test specification and acceptance to latest Sparrows
eddy current procedure – INS02pBS001E.
NOTE: ANY INDICATIONS FOUND FROM CARRYING OUT AN ECI WILL REQUIRE A FULL MPI CARRIED
OUT.
The areas inspected by MPI must adhere to test specification and Acceptance to latest Sparrows MPI current
procedure - INS02pBS001M.
Wall Thickness UT (Ultrasonic Testing)
Where UT wall thickness checks are required, the inspection should be carried out by a qualified technician
using the appropriate equipment. In particular, areas of evident material loss or corrosion should be targeted
for inspection.
SD05p8 Sparrows Crane Integrity Management Procedure, Section 7.1.1, Defect Categorisation states as
guidance that the maximum limit of wear down and corrosion is <= 10% of the original thickness for non-load
path and <= 8% for load path items.
The areas inspected for Ultrasonic Thickness Measurement must adhere to test specification and Acceptance
to latest Sparrows UT current procedure - INS02pBS02U.
Nominal wall thicknesses have been specified for the boom chords and lattices are:
Boom Foot and Mid-Section Chords: 10.00mm (Minimum allowable thickness – 9mm); Cathead Chords –
11.00mm (Minimum allowable thickness – 9.9mm); Lattices: 5.00mm (Minimum allowable thickness – 4.5mm)
Coating Assessment Criteria
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Coating Assessment – Linear Extent Coating Assessment – Localised Extent
Corrosion Assessment Criteria
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Corrosion Assessment – Linear Extent Corrosion Assessment – Localised Extent
Pitting and Grooving Assessment Criteria
Manpower Required:
• 2-off NDT Inspectors (Rope Access)

• 1-off Level 3 Rope Access Supervisor
Work scope duration: 8 Days

References:
# Document Number Description
1. - Lloyds Code of Lifting - Table 12.3.3
2. 01 to 07 Weld ID Boom Drawings
3. 34/3089/7100 Arrangement of Boom Assembly – SHT 1
4. 34/3089/7101 Arrangement of Boom Assembly – SHT 2
5. INS02pBS01M Magnetic Particle Inspection Procedure
6. INS02pBS02U Ultrasonic Thickness Measurement
7. INS02pBS01E Eddy Current Inspection Procedure
SD05wi1 Rev 01 01 Nov 2021 7 of 22

8. TAQA-TI-009 Addendum E – Paint and Coating Systems

9. SD05p8 ******
10. SD05p9 ******
Safety Precautions:
• Hold and complete the Tool Box Talk form.

• Obtain necessary permits to carry out work scope.
• Ensure barriers are erected where required to prevent unauthorised access to the worksite during
maintenance activities.
• Ensure that the rope access risk assessment is reviewed by all personnel prior to commencing with the
workscope.
• Ensure all additional PPE is worn (Safety Goggles and Face Mask) are worn at all times when using
and preparing all paint and cleaners.
• Ensure Hand Arm Vibration (HAV) guidelines are followed when utilising the Air Drill and Needle Gun.
Platform /Site Services Required:
• Full Access to the East Crane.

• East Crane to be mechanically isolated prior to Inspection.
• Pneumatic Air Supply.
• Platform to provide a water supply for the preparation of the boom.
• All waste (paint and consumables) will require to be disposed of at the end of the workscope – the
platform is expected to facilitate this request.
Parts / Materials Required:
Qty Unit Description Part Number
5 NDT Consumables – (5 x White, 5 x Black)
1 Ultrasonic Couplant
1 Metric Sheave Gauge
1 10L Jotmastic Smart Pack HB (Part A & B) - Red
1 20L Jotun Thinner No. 17
1 5L Panel Wipe Degreaser
1 Various Paint Rollers, Sleeves, Brushes Wire Brushes and Scrapers
1 Plastic Sheet, Masking Tape
1 Mechanical Abrasives (Cup Wire Brush, Flapper Wheel, Spiral Wire Brush)
1 2L, 5L, 10L & 20L Sealable Plastic Pots
1 Safety Goggles - Uvex 9302-245 Ultrasonic
1 Safety Masks - Organic Vapour Half Face Mask - 4255-FFA2P3R
1 Microchem 3000 Yellow Suit
Equipment Required:
Qty Description
1 3 Man Rope Access Kit
1 Eddy Current Kit (Locator 2)
1 Ultrasonic set (A-scan representation)
1 Electromagnet (Y6 Yoke)
1 Tape Measure c/w Lanyard
1 Needle Gun c/w Airline
1 Air Drill
1 Pit Gauge
SD05wi1 Rev 01 01 Nov 2021 8 of 22

Procedure
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# Instruction completion
or add value
Boom Foot Section
1. Ensure all permits are in place prior to staring the workscope.
Locate the boom in the rest, isolate crane and place a notice of work in operator’s cab.
(Sparrows resident to assist).
2.
Note: Ensure overside cover is available when working along the boom.
A visual inspection of the corrosion and coating present at each section of the boom
should be carried out and assessed as per the assessment criteria contained within the
task summary section of this procedure. Condition to be marked up on copies of the
boom drawings by the following criteria and accompanied with photographs:
a) Good condition – Minor spot rusting (0-2 Score)
b) Fair condition – Local breakdown at weld connectors and/or light rusting over
20 percent or more of areas under consideration (3-4 Score)
3.
c) Poor condition – General breakdown of coating over 20 percent or more of
areas, or hard scale at 10 percent or more at areas under consideration (5-6
Score)
Note: In the event that any defects are found further consultation should be held with
Sparrows onshore personnel.
Note: Refer to Corrosion Identification and Mitigation Procedure contained within the
appendix of this workpack.
Photograph the boom foot section. These are to include stand-off photos of this
4. section, all auxiliary equipment inspected and photos of any anomalies or defects
noted during the inspection.
Carry out Eddy Current inspection of welds detailed within weld ID drawings. Suspect
5. welds (paint flaking, corroded or cracked) should be inspected in addition to these
highlighted areas.
Carry out an Eddy Current inspection on 100% of welds at boom connection flanges
and picture frame lattice welds, noting any defects found.
6.
Note: If any weld defects are found it is important that time be taken to determine the
depth, length and orientation of defects and mark up the appropriate drawing
7. Carry out Eddy Current Inspection (100%) of all plate work to main chord welds.
Any dents or bent sections of lattice or main chords highlighted in (3) above, should
have a full MPI carried out, noting both the location of any defects and their size.
8.
Note: Where any dents or bent sections are found at category 3 or above, consultation
should be held with Sparrows onshore personnel to determine required actions.
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Procedure
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Carry out UT wall thickness check every 1m along the boom chord. The checks should
be carried out on all four main chords at the 12, 3, 6 and 9 o’clock positions, with the
thickness being noted in the inspection report. This is the minimum requirement, if there
are any further areas of corrosion further UT thickness checks must be carried out the
confirm the extent of wall thickness loss.
9. Note: Any areas of corrosion that falls out with the 1m location must also be UT tested.
Note: Ensure all local areas have been prepared properly for UT to allow an accurate
reading.
Note: In the event that any defects are found or more than 10% material loss at any one
location is found further consultation should be held with Sparrows onshore personnel.
Carry out UT wall thickness checks on the 10% of lattices referenced in the weld ID
drawings on each section and 100% of picture frame lattices. In addition to this, any
lattices which show corrosion will require UT thickness measurements to confirm the
10. extent of corrosion.
Note: Ensure reference is made to the lattice numbers detailed on the OS200 Weld ID
Drawings supplied.
Using a pit gauge, complete a pitting and grooving assessment of the boom foot section
making reference to the assessment criteria contained within the task summary section
of this procedure.
11.
Pitting is usually seen on horizontal components while grooving is a linear corrosion
which occurs at structural intersection in welds or heat affected zones.
Visually inspect all boom ancillary equipment noting any defects found. These defects
could include missing bolts, bent, damaged or badly corroded brackets and unsecured
equipment. A close visual inspection (CVI) should also include reports on items in good
serviceable condition.
Equipment to be checked should include but not be exclusive to the following: -
12.
• Walkways: including, grating, handrails stanchions, fasteners, etc.
• Electrical Conduit
• Cable Trays
• Limit Switches
• Light Brackets
• Flange connection bolts
Carry out physical test of the boom foot pins by the crane operator raising / lowering the
13. boom under visual observation. Any anomalies either visual or audible during operation,
consult crane operator.
Carry out 100% NDT of boom foot clevis / connection lugs where accessible.
14. Note: In the event that any defects are found using these inspection methods, further
consultation should be held with Sparrows onshore personnel.
15. Inspect boom flange connection bolts for any visible signs of wear.
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Procedure
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Boom 1st Mid-Section
b) Fair condition – Local breakdown at weld connectors and/or light rusting over 20
percent or more of areas under consideration (3-4 Score)
16.
Score)
Photograph the boom 1st mid-section section. These are to include stand-off photos of
17. this section, all auxiliary equipment inspected and photos of any anomalies or defects
highlighted areas.
Carry out an Eddy Current inspection on 100% of welds at boom connection flanges and
picture frame lattice welds, noting any defects found.
19.
20. Carry out Eddy Current inspection on all butt welds on the main chords.
Any dents or bent sections of lattice or main chord highlighted in (16) above, should have
a full MPI carried out, noting both the location of any defects and their size.
21.
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Procedure
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thickness being noted in the inspection report. This is the minimum requirement, if
there are any further areas of corrosion further UT thickness checks must be carried
out the confirm the extent of wall thickness loss.
Note: Any areas of corrosion that falls out with the 1m location must also be UT tested.
22.
reading.
Note: In the event that any defects are found or more than 10% material loss at any
one location is found further consultation should be held with Sparrows onshore
personnel.
Drawings supplied.
Using a pit gauge, complete a pitting and grooving assessment of the boom 1 st mid-
section making reference to the assessment criteria contained within the task summary
section of this procedure.
24.
25.
• Cable Trays
• Light Brackets
Boom 2nd Mid-Section
SD05wi1 Rev 01 01 Nov 2021 12 of 22

Procedure
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27.
Score)
Photograph the boom 2nd mid-section section. These are to include stand-off photos of
28. this section, all auxiliary equipment inspected and photos of any anomalies or defects
highlighted areas.
30.
31. Carry out Eddy Current inspection (100%) on all butt welds on the main chords.
32.
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Procedure
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reading.
34. extent of corrosion
Drawings supplied.
35.
reading.
personnel.
Carry out UT wall thickness checks on a minimum of 10% of lattices (selected prior to
mobilisation and referenced in the weld ID drawings) chosen at random on each section
and 100% of picture frame lattices. All lattices which show corrosion will require UT
thickness measurements to confirm the extent of corrosion.
36. Note: Minimum allowance – 10% = 4.5mm. All Readings of 4.5mm or less will require
further reading to confirm the extent of the area of corrosion/wall loss by means of
corrosion mapping.
Drawings supplied.
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Procedure
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Using a pit gauge, complete a pitting and grooving assessment of the boom 2 nd mid-
section making reference to the assessment criteria contained within the task summary
section of this procedure.
37.
Equipment to be checked should include but not be exclusive to the following:
38.
• Cable Trays
• Light Brackets
Boom 3rd Mid-Section
40.
Score)
Photograph the boom 3rd mid-section. These are to include stand-off photos of this
41. section, all auxiliary equipment inspected and photos of any anomalies or defects noted
during the inspection.
highlighted areas.
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Procedure
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Carry out an Eddy Current inspection on 100% of welds at boom connection flanges and
picture frame lattice welds, noting any defects found.
43.
depth, length and orientation of defects and mark up the appropriate drawing.
44. Carry out Eddy Current inspection (100%) on all butt welds on the main chords.
45.
46.
reading.
personnel.
Drawings supplied.
of this procedure.
48.
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Procedure
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Equipment to be checked should include but not be exclusive to the following:
49.
• Cable Trays
• Light Brackets
Cathead Section
51.
Score)
Photograph the boom cathead section. These are to include stand-off photos of this
52. section, all auxiliary equipment inspected and photos of any anomalies or defects noted
during the inspection.
highlighted areas.
54.
55. Carry out Eddy Current Inspection (100%) of all plate work to main chord welds.
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Procedure
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Any dents or bent sections of lattice or main chord should have a full MPI carried out,
noting both the location of any defects and their size.
56.
reading.
Drawings supplied.
59. Carry out Eddy Current inspection on the sheave shaft mountings on the boom cathead.
of this procedure.
60.
61.
• Sheaves
• Cable Trays
• Light Brackets
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Procedure
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Visually inspect the sheaves & pins on the Boom tip assembly for indications of damage
62. or corrosion noting any defects found. The rope groove of all sheaves should also be
examined around the section of the sheave which are accessible using sheave gauges.
Carry out Eddy Current inspection (100%) on the boom tip termination.
63.
Note: In the event that any defects are found using these inspection methods, further
consultation should be held with Sparrows onshore personnel.
Boom Preparation and Painting
To avoid further deterioration of the boom where paint/scale has been removed, a
solvent degrease, hand prep to ST2 (minimum) and coat with Jotun SmartPack will be
applied.
65.
With reference to the Repair Charts contained within section 4 of the Corrosion
Identification and Mitigation Procedure, the coating breakdown, general corrosion and
pitting and grooving scores for each section will determine the future repair requirements.
Before proceeding, the following conditions must be observed:
66. • Do not apply the coating if the substrate is wet or likely to become wet.
• Do not apply coating if the weather if deteriorating.
• Do not apply coating in high wind conditions.
Where paint/scale has been removed to complete the boom inspection and where any
areas of paint breakdown is evident, complete the following:
With reference to Document No. TAQA-TI-009 (Addendum E – Paint and Coating

Systems), prepare the applicable boom section surface using the following equipment to
ST2:
• Minor Areas of Rust – Utilise Sandpaper to remove all signs of mill scale or rust.
Ensure as little of the surrounding painting work is removed. Ensure all paint
edges are chamfered.
67. • Major Areas of Rust – Utilise a combination of the chipping hammer, wire
brushes, air drill c/w cup and spiral wire brush attachments and a needle gun for
areas with limited access.
• Flaked Paint – Utilise scrappers and wire brushes to remove all un-bonded
material back to a firm edge. Ensure the below surface is prepared using
sandpaper and/or air drill c/w flapper wheel.
• Glossy Finishes – Light abrasion to provide a physical key.
Note: When using a wire brush or abrasive attachments, be careful not to polish the
surface as this will reduce adhesion of the coating.
SD05wi1 Rev 01 01 Nov 2021 19 of 22

Procedure
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Once all mill scale, rust and un-bonded material is removed from the boom surface,
degrease the complete surface using Panel Wipe and apply with rags / brush. Ensure all
surfaces are thoroughly cleaned with all dust and debris removed.
68.
Note: Ensure the MSDS for Panel Wipe is reviewed prior to application.
Note: Ensure full PPE including face mask and safety goggles are worn throughout.
On completion ensure all rags are disposed of as per platform requirements. Any
remaining panel wipe should be transferred back into the original container (using the
69.
funnels supplied to minimise any spills) and any plastic containers and brushes used
should be thoroughly cleaned.
Ensure the worksite below the applicable boom section is cleaned of any loose debris
70.
and tidy away all equipment and materials.
Ensure the applicable boom surface is dry with no signs of debris remaining from the
surface preparation stage.
71.
Note: If it has been longer than one full shift since the boom was prepared, clean all
surfaces with a rag / brush as a precaution.
Using the plastic sheeting and tape supplied, fully cover all electrical components,
72.
wiring (including cable trays) to protect against any paint spray or spills.
In order to mix the top coat paint, follow the following steps:
• Mix the base and curing agent inside the dry goods container to prevent any
contamination – it is recommended that the temperature during this process is
18 Degree Celsius or higher.
• Only start mixing paint if a minimum of 1 hour working time is available. Once
mixed the working pot life is 1 hour.
• Locate the paint – Jotmastic Smart Pack HB (A & B) - Red
73.
• Ensure all plastic containers are clear of any dust or debris before used for
mixing / storing paint.
• Measure out equal parts of A & B and empty into either a 20 or 10 Litre plastic
containers. Ensure the measurement is exact.
• Using the air drill and mixing paddle, thoroughly mix Part A then combine the
entire contents with Part B and mix until satisfied with the consistency.
• Once the paint has been thoroughly mixed, split the complete contents between
the 2L paint pots or roller trays.
Ensure the work site directly below the specified boom is barriered off due to potential
for paint spills.
74.
Note: If possible, cover any deck areas and equipment (not operational) with plastic
sheeting or rags to avoid any stains from paint spills.
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Procedure
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Apply the paint to the boom surfaces using a paint brush (utilise the synthetic bristle
brushes supplied). Please note that all brush marks will flatten within 5-10 minutes after
application.
75.
Ensure a smooth coat is applied with uniform thickness (if possible) with no detrimental
bush marks. Paint must be worked into all corners and crevices.
Note: The surface will be touch dry within 7-10 hours (at 5 to 10 Degrees Celcuis).
Once all painting has been completed, complete the following:
76. • Dispose of any mixed paint in accordance with the platform procedure.
• Wash surfaces (where spills have occurred) with Jotun Thinner No. 17. Ensure
reference is made to the MSDS before using.
• Dispose of all rags, equipment (brushes or rollers) and used plastic containers.
Ensure all items - painting and NDT equipment have been removed from the worksite
77.
and prepared for backload.
SD05wi1 Rev 01 01 Nov 2021 21 of 22

On Completion of this Procedure please certify below. Date
I have carried out all of the steps as listed above Print Name
1 and have ticked or added a value to each step as
required Sign
Any anomalies that were found during Print Name

2 completion of the procedure steps are listed in
the Comments Section below Sign
Comments:
SD05wi1 Rev 01 01 Nov 2021 22 of 22

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Work Instruction: Structural Inspection Workpack

Document number: SD05wi1

Date Revision Description Owner Approver

SD05wi1 Rev 01 01 Nov 2021 2 of 22

Crane Structural Inspection Management

SD05wi1 Rev 01 01 Nov 2021 3 of 22

4 Example Site Work Instruction

Document Number: [Document No.] Frequency: 4Y

Client: Sparrows Offshore Services

Equipment Details: [Equipment Details] Tag No: A-9800

• Boom Foot Section

• Magnetic Particle Inspection (MPI)

SD05wi1 Rev 01 01 Nov 2021 4 of 22

NDT (Non-Destructive Testing) Inspection

Wall Thickness UT (Ultrasonic Testing)

Coating Assessment Criteria

SD05wi1 Rev 01 01 Nov 2021 5 of 22

Coating Assessment – Linear Extent Coating Assessment – Localised Extent

Corrosion Assessment Criteria

SD05wi1 Rev 01 01 Nov 2021 6 of 22

Corrosion Assessment – Linear Extent Corrosion Assessment – Localised Extent

Pitting and Grooving Assessment Criteria

• 2-off NDT Inspectors (Rope Access)

Work scope duration: 8 Days

SD05wi1 Rev 01 01 Nov 2021 7 of 22

8. TAQA-TI-009 Addendum E – Paint and Coating Systems

• Hold and complete the Tool Box Talk form.

• Full Access to the East Crane.

SD05wi1 Rev 01 01 Nov 2021 8 of 22

Boom Foot Section

1. Ensure all permits are in place prior to staring the workscope.

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Boom 1st Mid-Section

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Boom 2nd Mid-Section

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Boom 3rd Mid-Section

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Boom Preparation and Painting

Before proceeding, the following conditions must be observed:

With reference to Document No. TAQA-TI-009 (Addendum E – Paint and Coating

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SD05wi1 Rev 01 01 Nov 2021 21 of 22

On Completion of this Procedure please certify below. Date

Any anomalies that were found during Print Name

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