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FFS-SU-5219-A

INSTALLATION OF PLATFORM STRUCTURES


FOR FIXED OFFSHORE PLATFORMS

APPLICATION: FLOATING AND FIXED PLATFORMS

This document is the confidential property of Chevron U.S.A. Inc. Neither


the whole nor any part of this document may be disclosed to any third
party without the prior written consent of Chevron U.S.A. Inc. Neither the
whole nor any part of this document may be reproduced, stored in any
retrieval system or transmitted in any form or by any means (electronic,
mechanical, reprographic, recording or otherwise) without the prior
written consent of Chevron U.S.A. Inc.

June 2010

Rev

Date

12/2008

Document number change only.


Formerly CIV-SU-1.27-A

Description

06/2010

General revision

Author

Sponsor
CWAN

GNBE

20072010 Chevron U.S.A. Inc. All rights reserved.

CWAN

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CONTENTS

1.0

Scope ..........................................................................................................................3

2.0

References ..................................................................................................................3
2.1 ......Purchaser Documents ......................................................................................3
2.2 ......Industry Codes and Standards .........................................................................3

3.0

Terminology ................................................................................................................3
3.1 ......Acronyms .........................................................................................................3
3.2 ......Definitions .........................................................................................................4

4.0

General Conditions ....................................................................................................4

5.0

Installation ..................................................................................................................5
5.1 ......General .............................................................................................................5
5.2 ......Weather Forecasting ........................................................................................6
5.3 ......Anchorage ........................................................................................................6
5.4 ......Jacket Installation .............................................................................................7
5.5 ......Pile and Conductor Installation .........................................................................8
5.6 ......Grouting ..........................................................................................................12
5.7 ......Superstructure Installation ..............................................................................14
5.8 ......Accessories ....................................................................................................17
5.9 ......Tolerances ......................................................................................................19
5.10 ....Pollution Prevention .......................................................................................20
5.11 ....Workmanship .................................................................................................21

6.0

Supplier Requirements ............................................................................................21


6.1 ......General ...........................................................................................................21
6.2 ......Damage Repair ..............................................................................................21
6.3 ......Scrap Material ................................................................................................22
6.4 ......Cleanup ..........................................................................................................22

7.0

Documentation Requirements ................................................................................22


7.1 ......Installation Manual .........................................................................................22
7.2 ......Drawings, Calculations, and Records ............................................................23
7.3 ......Lift Vessel Certification ...................................................................................24

8.0

Quality Assurance Provisions ................................................................................24


8.1 ......Tests ...............................................................................................................24
8.2 ......Inspections .....................................................................................................24

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1.0

FFS-SU-5219-A

SCOPE
1. This specification establishes requirements for the installation of bottom-founded platform
structures and platform topsides.
2. Offshore platform installation includes the engineering, equipment, supervision, quality
assurance/quality control, material, supplies, crane vessels, and marine support necessary to
install the jacket, deck, piling, modules, skids, and other items associated with an offshore
facility.

2.0

REFERENCES
1. The following documents are referenced herein and are considered part of this specification.
2. Use the latest edition of each document referenced below unless otherwise specified.

2.1

Purchaser Documents
None.

2.2

Industry Codes and Standards


American Petroleum Institute (API)
RP 2A-WSD

Recommended Practice for Planning, Designing and Constructing Fixed


Offshore PlatformsWorking Stress Design

Spec 10A

Specification for Cements and Materials for Well Cementing

American Society of Testing and Materials (ASTM)


C109

Standard Test Method for Compressive Strength of Hydraulic Cement


Mortars (Using 2-in. or [50-mm] Cube Specimens)

D4945

Standard Test Method for High-Strain Dynamic Testing of Deep


Foundations

International Marine Contractors Association (IMCA)


M 179

Guidance on the Use of Cable Laid Slings and Grommets

International Organization for Standardization (ISO)


7531

Wire rope slings for general purposesCharacteristics and specifications

2408

Steel wire ropes for general purposesMinimum requirements

United States Coast Guard (USCG)


33 CFR 67

Aids to Navigation on Artificial Islands and Fixed Structures

3.0

TERMINOLOGY

3.1

Acronyms
AWSAmerican Welding Society
ELTExternal Lifting Tool
ILTInternal Lifting Tool
MARPOLMarine Pollution
MLWMean Low Water

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NDENondestructive Examination
ROVRemotely Operated Vehicle
SRDSoil Resistance to Driving
SWLSafe Working Load
3.2

Definitions
Pile Driving RefusalThe point at which pile driving resistance exceeds either 200 blows per
foot for five consecutive feet (165 blows per 25 cm), or 300 blows for one foot or less (250 blows
per 25 cm), of penetration with the hammer working at or above design operating efficiency. Also
defined as the point at which the combined stresses in the pile due to driving and the weight of the
hammer reach the maximum allowable stress, based on pile monitoring instrumentation (strain
gauges mounted on the pile near the top of the add-on section being driven) or drivability analysis
performed for pile-hammer-soil conditions.

4.0

GENERAL CONDITIONS
1. Materials and equipment shall be installed by Supplier in accordance with drawings and
specifications.
2. Any work or material that is necessary for the performance of work in accordance with the
contract, but which is not indicated on drawings or called for in specifications, shall be
provided.
3. Any exceptions to the requirements of this specification shall be submitted in writing for
resolution by Purchaser.
4. Should any error, omission, or discrepancy appear in drawings, specifications, instructions, or
work done by others, Supplier shall notify Purchaser at once, and Purchaser shall issue
instructions to be followed.
5. Supplier shall designate one person to serve as contact with Purchaser for questions, errors,
omissions, changes in work, and progress of work.
6. Supplier shall furnish marine equipment and associated specifications necessary to complete
these installations.
7. Cargo barges provided by Supplier shall have decks that are clean and level (to the extent
possible), and shall have full class certification.
a. Purchaser reserves the right to inspect and accept or reject barges provided by Supplier.
b. Purchaser shall be provided with a copy of Suppliers on-hire survey within six months of
Purchasers proposed on-hire period.
c. Recommendations identified in subject report must be resolved to the satisfaction of the
warranty surveyor prior to commencement of the on-hire period.
8. Marine vessels provided by Supplier shall meet or exceed Purchasers marine requirements
and shall conform to marine compliance documents and requirements applicable to the region
of installation.
9. Supplier shall provide an installation vessel superintendent to be the direct supervisor on the
vessel.

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10. Purchaser shall reserve the right to inspect work involved herein, perform nondestructive tests,
and reject any work found not to be in accordance with the contract, these specifications, or
the drawings.
a. Inspection shall be performed by Purchaser or Purchaser-authorized third party.
b. Supplier shall make work available to Purchaser representative at all times and shall
provide necessary facilities at no cost to Purchaser for inspection of the work and its
progress.
11. Purchaser shall have the right to inspect Suppliers tools, equipment, and materials to
determine their suitability for work, and to reject any equipment, tools, or materials deemed
unsuitable.
12. Suppliers survey equipment shall be verified by transit fixes on existing structures based on
coordinates provided by Purchaser.
13. Anchors of vessels entering work field shall not be deployed until notification to deploy is
issued by Purchaser.
5.0

INSTALLATION

5.1

General
1. Supplier shall provide labor, supervision, equipment, materials, and consumables required for
the safe and complete installation of the facilities.
2. Contract work scope shall be completed before offshore construction equipment is removed
from the job site.
3. As appropriate to the facility being installed, Supplier shall conduct launch, lift, flotation, and
upending analyses, as well as an on-bottom stability review for the jacket, to demonstrate that
the chosen methods shall result in a safe and controllable installation.
4. Supplier shall perform lift analyses for the topside components to demonstrate that the
methods chosen shall result in a safe and controllable installation.
5. Results of the analyses, procedures, etc., shall be submitted to Purchaser for review, comment,
and acceptance prior to loadout, according to a schedule agreed upon by Supplier and
Purchaser at the time of contract award.
6. Supplier shall design any appurtenances or structural modifications needed for installation of
the platform.
7. Design, fabrication, and installation performed by Supplier shall conform to
API RP 2A-WSD, all codes and specifications referenced therein, and this specification.
8. The design of installation aids and procedures shall conform to API RP 2A-WSD and this
specification.
9. Supplier shall perform erection, pile installation, leveling, alignment, field connections, field
modifications (if required), and completion and repair of components of the offshore facility in
accordance with project documents.
10. Barges, tugs, and vessels provided by Supplier for use during installation shall be classed by
the American Bureau of Shipping or have an equal classification from a recognized certifying
agency or bureau, as accepted by Purchaser, and currently in class with not less than 180 days
remaining before class renewal or dry-docking survey is required.

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5.2

FFS-SU-5219-A

Weather Forecasting
1. Throughout the installation operations, Supplier shall provide weather forecasting services.
2. Services shall consist of 24-hour and 3-day forecasts updated every 12 hours.
3. Forecasting information shall be available to Purchaser representative.
4. As a minimum, the following information shall be required in each forecast:
a. Seastate
b. Wave height and direction
c. Swell height and direction
d. Wind speed and direction
e. Barometric pressure
f.

5.3

High and low tide heights and times

Anchorage
1. Supplier shall provide Purchaser with surveying procedures to locate equipment, the platform,
and its components.
2. Supplier shall avoid prohibited anchorage areas and shall place any mooring system in a
manner and location that does not damage existing seabed installations such as flowlines,
cables, and pipelines.
a. Purchaser shall provide as-built field layout drawings indicating the locations of existing
seabed installations and prohibited anchorage areas.
b. Supplier shall carry out a seabed survey of proposed setup areas to verify information on
the as-built field layout drawings.
c. Supplier shall be responsible for any damage caused by Supplier to the existing
installations.
d. Prior to start of operations, Supplier shall set buoys or electronic locators to mark existing
pipelines and other underwater installations in the area of work.
3. Special care shall be exercised by Supplier near existing platforms and other installed facilityrelated items when installing anchors and mooring lines from construction barges and boats.
4. Before placing any anchors and mooring lines, Supplier shall define to Purchaser
representative the proposed location of anchors and mooring lines.
5. Anchoring plans shall be submitted to Purchaser for review and acceptance.
6. Purchaser shall reserve the right to have a representative present as follows:
a. During anchoring and moving operations
b. Aboard the vessel to oversee accuracy of the survey
7. At least eight weeks in advance of mobilization of the installation barge(s) or vessel, Supplier
shall furnish for Purchaser review a mooring analysis and mooring layouts indicating the
following:
a. Mooring spread line strengths
b. Pretensions
c. Spread angles

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d. Catenary curves
e. Anchor locations and water depths
f.

Water depth contours

g. Pipelines
h. Obstructions
i.

Clearances between anchors of the installation barge(s) or vessel

j.

Clearances between anchors of the installation vessels and nearby pipelines and subsea
hardware

k. Clearances between vessel moorings and existing platforms in the field


l.
5.4

Midline buoys, as applicable

Jacket Installation
1. Supplier shall provide necessary surveying services and equipment to position the jacket at the
installation site within the specified tolerances.
2. Purchaser shall designate the location of the jacket.
3. Installation tolerances shall be marked on drawings prior to start of installation.
4. Within 6 months prior to installation of the jacket, at a time agreeable to Purchaser, Supplier
shall survey the location to confirm the absence of debris or other obstructions on the seabed.
a. A detailed survey using a remotely operated vehicle (ROV) shall be required unless
Purchaser accepts an alternate visual inspection method.
b. Supplier shall remove from the seabed any debris that may interfere with jacket
installation.
c. Supplier shall bring to Purchasers attention the presence of debris not manageable by
ROV intervention.
5. Supplier shall make a visual inspection of the jacket prior to its launch or lift.
a. Any problems found during this inspection shall be reported to Purchaser representative.
b. If possible and practical, problems shall be corrected offshore prior to launch or lifting.
6. The decision to remove sea fastenings and launch or lift the jacket shall be made jointly by
Supplier and Purchaser.
7. Supplier shall install the jacket to within the tolerances specified for position, orientation, and
levelness.
8. Supplier shall demonstrate to Purchaser representative that the position, orientation, and
levelness of the jacket are within the limits specified.
9. Using an ROV, Supplier shall monitor any subsea docking or stabbing operations performed as
part of the installation process.
10. Docking and stabbing operations shall be recorded on video for Purchaser review.
11. For lift-installed jackets, applicable requirements from Section 5.7.2 shall apply.

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5.5

FFS-SU-5219-A

Pile and Conductor Installation


5.5.1

General
1. Supplier shall verify that any proposed pile add-on lengths are suitable for Suppliers
equipment and installation procedures.
2. Prior to stabbing and welding an add-on section, the driving head, if used, or the top
two feet of the previously driven pile section, shall be removed from the top pile
section, and the pile section top shall be beveled to the angle as shown in the
drawings.
3. Supplier shall cut padeyes, dogs, etc., off piles and grind smooth to within
1/8 inch (3 mm) of the pile wall.
4. Welding rods, slag, lugs, etc., shall not be allowed to fall into the annulus between
jacket leg and pile.
5. Driven conductor installation shall be subject to the same requirements as pile
installation.

5.5.2

Pile Handling
1. Supplier shall provide all pile handling equipment, such as internal and external lifting
tools (ILTs and ELTs), slings, shackles, and alignment frames.
2. Supplier shall take care in handling and stabbing pile add-on sections.
3. If, during lifting or stabbing a pile add-on, a dent, tear, or other deformity is created in
the stabbing guide, and it reduces the internal diameter more than 1 inch (25.4 mm),
the stabbing guide shall be repaired to no more than 1-inch (25.4 mm) reduction.

5.5.3

Pile Drivability Analysis


1. For each hammer type and pile makeup to be used, drivability analysis shall be
performed using wave equation analysis to verify that the proposed driving system
can achieve required pile penetration.
2. Drivability analysis shall be based on soil parameters specified in the geotechnical
report.
3. Analysis shall consider the influence of soil setup on driving resistance if a delay in
driving were to occur.
4. A parametric study shall be conducted to determine effects of hammer efficiency,
hammer cushion performance (if required), and variation in assumed soil damping and
quake parameters.
5. Drivability analyses shall be presented in a written report that includes the following
information:
a. Soil-pile-hammer parameters used in wave equation analyses.
b. Plots of upper- and lower-bound soil resistance to driving (SRD) versus depth for
plugged and unplugged conditions.
c. Plots of wave equation results in terms of driving resistance versus blow count.
d. Plots of expected blow count and driving stresses versus penetration for different
soil-hammer-pile systems analyzed.

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e. Recommendations, as appropriate, regarding the following details:


1) Hammer size and operating energy with respect to pile penetration.
2) Pile wall thickness to avoid overstressing and/or improve pile drivability.
3) Need for, and wall thickness of, a driving shoe and driving head to avoid pile
damage.
4) Add-on lengths to minimize the risk of refusal due to setup.
5) Potential for refusal.
6) Pile monitoring requirements (if deemed necessary based on drivability
analysis).
5.5.4

Pile Monitoring
1. Pile monitoring shall be performed in general accordance with ASTM D4945-08.
2. Pile monitoring shall be performed by a Supplier that Purchaser has accepted.
3. The following information shall be submitted to Purchaser for review and acceptance:
a. Name of pile monitoring Supplier
b. List of Suppliers completed projects
c. Names and qualifications of personnel who will perform services
4. Purchaser reserves the right to contract the services of the pile monitoring Supplier.
5. Supplier shall provide necessary support services to pile monitoring Supplier.
6. A description of pile sections to be monitored, together with pile monitoring
procedures and equipment (including spares and backup equipment) shall be
submitted to Purchaser for review and comment.
7. A description of the contents of a pile monitoring and installation report shall be
submitted to Purchaser for review and comment two weeks prior to beginning pile
driving.
8. If a pile reaches refusal prior to reaching design penetration, the following steps shall
be taken:
a. Instantaneous axial capacity of the pile at time of refusal shall be computed based
on monitoring data.
b. Results shall be provided to Purchaser to determine if the pile is acceptable at the
refusal penetration with respect to axial capacity, or if the pile needs to be driven
to design penetration, requiring removal of the soil plug.
9. Upon completion of pile installation for a platform, Supplier shall provide Purchaser
with the pile monitoring and installation report.

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5.5.5

FFS-SU-5219-A

Pile Driving
1. Pile driving operations shall not begin before Purchaser has accepted the position,
orientation, elevation, and levelness (appropriate for the start of pile driving) of the
jacket.
a. Prior to sail-away of the jacket from its fabrication yard, Supplier shall provide for
Purchaser review a plan with procedures and timing for final leveling of the
platform.
b. Final leveling of the platform to specified acceptance criteria shall be performed
after piles are stabbed and partly or fully driven.
2. Hammers shall operate at the energy rating defined in the pile installation plan.
a. Hydraulic hammers shall be capable of operating at not less than 90 percent of the
energy setting used.
b. For diesel and steam hammers, the ram drop height shall never be less than the
nominal drop height less 4 in. (100 mm) as defined by the hammer manufacturer
for the specified energy rating.
c. Supplier shall have onboard the installation vessel at least two hammers of a rated
energy equal to or greater than that used in the accepted pile drivability study.
Unless relieved of this requirement by Purchaser, one of the hammers shall be of
the next larger incremental size.
3. Cushion blocks, if used, shall be inspected prior to initiation of driving of each pile
and shall be replaced, if necessary, to ensure that pile can be driven to penetration
without interruptions caused by failure of cushion blocks.
4. Piles shall be driven to the design penetration with no structural damage.
a. Add-on lengths shall be planned so that once design penetration is reached, no
pile girth weld is located between the pile cutoff point and one-half pile diameter
below the top of the jacket leg.
b. Piles shall be driven to design penetration in a manner that minimizes pile setup
during driving.
5. Once driving operations have begun, Supplier shall complete operations without
major delays between add-ons.
6. Purchaser shall be notified immediately if refusal is encountered before design
penetration is achieved.

5.5.6

Pile Driving Refusal


1. Pile driving refusal shall be identified by either of the following criteria:
a. The point at which pile driving resistance exceeds either 200 blows per foot for
five consecutive feet (165 blows per 25 cm), or 300 blows for one foot or less of
penetration (250 blows per 25 cm), with the hammer working at or above design
operating efficiency.
b. The point at which the combined stresses in the pile due to driving and the weight
of the hammer reach the maximum allowable stress based on pile monitoring
instrumentation (strain gauges mounted on the pile near the top of the add-on
section being driven) or drivability analysis performed for the pile-hammer-soil
conditions.

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2. Hammer size and operating energy with respect to the pile penetration where refusal
occurs shall be in accordance with the pile drivability analysis.
a. Depending on the rated energy of the hammer used, this requirement may be
altered by Purchaser, at Suppliers request, to reduce the risk of damage to the
hammer.
b. Supplier shall receive Purchaser acceptance for alternate requirements.
3. If the delay in pile driving operations is one hour or longer, the refusal criteria stated
above do not apply until the pile has been advanced at least one foot following the
resumption of pile driving. However, in no case shall pile driving continue if the blow
count exceeds 400 blows for one foot or less of penetration (330 blows per 25 cm).
4. If pile driving refusal occurs using a diesel or steam hammer and the pile driving is not
being monitored, Purchaser may request that Supplier replace the hammer with one of
equal or higher energy to evaluate whether the refusal is due to hammer inefficiency.
5.5.7

Supplemental Pile Installation Procedures for Pile Driving Refusal


1. If pile drivability analysis shows that pile driving refusal may occur prior to piles
being driven to design penetration, and that pile plug removal is required as a
supplemental aid to driving, then Supplier shall do the following:
a. Develop contingency plans and supplemental pile installation procedures
compatible with pile penetrations where soil plug removal is expected based on
pile drivability analysis.
b. Make available pile-top drilling or jetting equipment within a time period agreed
upon with Purchaser. The decision to use such equipment shall be made by
Purchaser representative.
2. Suppliers contingency plans and supplemental pile installation procedures shall be
submitted to Purchaser for review and comment.
3. Drilling or jetting operations shall be limited to removal of the soil plug inside the pile
and shall not extend beyond the pile tip.
4. If available soils data indicates the presence of rock at and below the pile tip, drilling
beyond the pile tip and through the rock layer may be advantageous, depending on the
hardness and thickness of the rock.
a. Supplier shall receive Purchaser acceptance to drill or jet through the rock layer in
advance of the pile tip.
b. Drilling or jetting shall be conducted in a controllable manner without adversely
affecting the capacity of the pile being remedied or any other foundation or well
element of the facility.

5.5.8

Offshore Welding on Piles


1. To ensure safe working and welding conditions, special care shall be taken in field
welding add-ons to main piles.
2. Scaffolding of proven quality and fit for purpose shall be used to provide safe working
conditions for welders.
3. Scaffolding boards shall be securely fastened.

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4. When protection is required to maintain appropriate welding conditions, complete


shielding shall be provided to protect the weld area from wind, moisture, and rain.
5. During rain, a collar shall be installed around the add-ons above the weld area to
prevent running water from making contact with the weld or heated zone.
6. Before performing required nondestructive examination (NDE), offshore welds on
piles shall be allowed to cool to 125F (52C) or less.
5.5.9

Jacket-to-Pile Shims
1. Jacket-to-pile shims shall be installed after pile driving is completed and before the
superstructure is in place.
2. Before shimming, piles shall be centered in the legs.

5.6

Grouting
5.6.1

General
1. Suppliers grouting equipment, cement mixing procedures, grouting procedures, and
contingency plans shall be submitted to Purchaser for review and comment.
2. Redundancy shall be provided in planning grouting operations so that if equipment
fails, standby equipment can be made operational to limit downtime to not more than
10 minutes.
3. If a stoppage lasts for more than 30 minutes, Supplier shall flush grouting equipment
and grout delivery system, and shall discard any grout in the mixer.
4. Piles shall be driven to grade prior to commencement of grouting operations.
5. Before the superstructure is set, a grout crush-strength test shall be performed on the
grout used in the legs to verify it has reached the required 24-hour strength.
6. If a compressive strength greater than the value given in Section 5.6.2 is required to
support setting of the superstructure, Supplier shall take measures to ensure that
proper strength is achieved before proceeding.
7. If saturation diving services may be needed to remedy an offshore grout-installation
problem, Supplier shall make provisions in advance of loadout for mobilization to site
of appropriate personnel and equipment.
8. As part of offshore grouting, Supplier shall spread the necessary hoses, stingers, and
other equipment to grout the piles in case of grout system or packer failure.
9. Supplier shall submit to Purchaser contingency plans for addressing failures or
damages to the following:
a. Inflation lines
b. Packers
c. Grout delivery system
10. Any grout spilled on the jacket shall be washed off with seawater before it hardens.

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5.6.2

FFS-SU-5219-A

Grout Mix
1. Supplier shall supply a non-shrinking or expansive-type Portland cement grout with a
minimum compressive strength of 1,500 psi reached in 24 hours and 5,000 psi reached
in 28 days.
a. Required density of grout slurry shall be 16.0 0.2 pounds per gallon
(1917 24 kg per cubic meter).
b. Thickening time for mix at 70F (21C) shall be at least 1.5 times the anticipated
pumping time.
2. Supplier shall submit the proposed mix design according to a schedule agreed upon by
Supplier and Purchaser at the time of contract award.
a. Mix design shall be accompanied by test results to indicate compressive strength
at the end of 12 hours, 24 hours, 3 days, 7 days, and 28 days, and initial set time at
70F (21C).
b. Supplier shall receive Purchaser acceptance of the mix design prior to beginning
field operations.

5.6.3

Procedure
1. Supplier shall submit grout installation procedure to Purchaser for acceptance prior to
loadout, according to a schedule agreed upon by Supplier and Purchaser at the time of
contract award.
2. The annulus between the pile and jacket leg or pile sleeve shall be fully grouted at the
specified density.
3. A minimum volume of grout shall be pumped at the specified density equal to 1.25
times the theoretical volume required to fill the grout lines and annulus.
4. A minimum of 0.25 times the volume required to fill the grout lines and annulus shall
be pumped after steady returns are observed at the overflow ports.

5.6.4

Quality Control
1. Measurement of grout slurry densities shall be made using a pressurized slurry density
balance in the manner described in API Specification 10A. The balance shall be
calibrated in a laboratory prior to use.
2. Grout density shall be monitored by densitometers during grouting operations.
a. Supplier shall provide redundant densitometers and additional parts.
b. Before starting to pump grout to each annulus, densitometer calibration shall be
checked by measuring the density of material passing through it with a
pressurized slurry density balance.
3. During the grouting process for each leg, four samples shall be taken and used as
follows:
a. To verify that the slurry weight does not go lower than 15.8 pounds per gallon
(1893 kg per cubic meter).
b. To use in preparing test cubes for strength testing.

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4. Density of each sample shall be measured with a pressurized slurry density balance.
a. Six grout cubes shall be made from each sample.
b. Cubes shall be molded in accordance with ASTM C109.
5. Cubes shall be placed in a thermostatically controlled curing tank immediately after
manufacture.
a. Cubes shall be cured at the design temperature until removed for testing.
b. Design temperature shall be set based upon the prevailing temperature at the
grouting depth within the water column.
c. Curing tank shall be filled with freshwater or seawater.
6. One cube from each sample shall be crushed at ages of 12 hours, 24 hours, 3 days,
7 days, and 28 days, in accordance with ASTM C109, and shall be witnessed by
Purchaser.
5.7

Superstructure Installation
5.7.1

General
1. Superstructure components installed offshore, including integrated decks, module
support frames, modules, and skids shall be installed within specified tolerances.
2. Supplier shall place into service the navigation aids on the superstructure and shall
maintain them in working order throughout installation operations.
3. A two-barge lift shall not be used unless written acceptance from Purchaser is
obtained.
4. If the superstructure was designed for a float-over instead of a lifted installation,
Supplier shall submit at time of contract award, for Purchaser review and acceptance,
the float-over plan including vessel data; structure weight and center-of-gravity data;
installation procedures, drawings and mooring patterns; and limiting weather
conditions.

5.7.2

Rigging Design
1. Supplier shall design and provide riggingincluding slings, shackles, spreader bars,
and link platesso that lifts comply with requirements in this section.
2. Final weights and center-of-gravity positions shall be based on detailed weight
takeoffs (including appropriate contingencies) or actual weighing.
3. A modified lift weight shall be used to determine the design sling load. It shall be
calculated by multiplying the sum by 1.1 for impact.
4. Design sling load shall be calculated using the modified lift weight in a rigid-body lift
analysis, which accounts for distribution of weight in the structure and for any
hanging/skew angle.

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5. For normal offshore conditions, slings shall be sized to have a safety factor of 4 for the
manufacturers rated minimum breaking strength of the cable compared to design
sling load.
a. With Purchaser acceptance, this safety factor shall be increased when unusually
severe conditions are anticipated, and may be reduced to a minimum of 3.0 for
carefully controlled conditions.
b. When applicable, the factor shall be adjusted as required by standards such as
IMCA M 179, ISO 7531, and ISO 2408.
6. Shackles shall contain permanent markings indicating their safe working load (SWL).
7. The load in shackles and other fittings shall not exceed manufacturers rated SWL and
shall be used only if the rated SWL is based on a minimum safety factor of 3.0.
8. Lifting slings shall be of sufficient lengths to ensure that the true angle of any sling
with respect to the plane through the lifting points is not less than 60 degrees.
9. Supplier shall obtain Purchaser acceptance if it is necessary to use a sling angle of less
than 60 degrees.
10. The offset between the center of the crane hook and the center of gravity shall ensure
that the allowable item tilt and the crane hook strength are not exceeded. If this offset
is greater than 3 feet (1 meter), Supplier shall bring it to Purchasers attention for
review and comment.
11. Paired slings for a particular lift shall be of the same diameter and type and shall have
the same lay.
12. Each sling shall be assigned a unique number and shall have a valid certificate from a
recognized certification authority. (At Suppliers request, Purchaser may waive this
requirement for small utility lifts.)
13. Slings shall be new or in a well-maintained condition, having no damage and being
capable of carrying loads up to their designated breaking strength.
14. Slings and other rigging elements shall be positioned to incorporate the measured
lengths of rigging elements.
15. For lift weights in excess of 2,000 tons (1,800 metric tons), the use of cable-laid slings
with hand splice-type eye terminations shall require Purchaser acceptance.
16. Procedures for sling handling shall be developed and followed.
a. Procedures shall include minimum bend radii, weather protection, corrosion
protection, and proof testing.
b. Procedures shall be submitted to Purchaser for review and comment according to
a schedule agreed upon by Supplier and Purchaser at the time of contract award.
c. Evidence that these procedures have been followed since certification shall be
available to Purchaser upon request.

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5.7.3

FFS-SU-5219-A

Certification and Testing


1. Cranes, slings, grommets, and shackles shall have valid certificates from a recognized
certification authority.
2. Certificates shall be available for inspection at Purchasers request.
3. Testing and certification shall be carried out according to industry standards, such as
IMCA M 179, ISO 7531, and ISO 2408, as follows:
a. Samples from each rope that is a part of the unit ropes shall be tested to
destruction.
b. Calculated breaking load of the total cable-laid rope shall be based on these tests.
c. The following certificates shall be issued for each sling or grommet and shall be
available to interested parties on request:
1) Consolidation test certificate
2) Certificate of dimensional conformity
3) Certificate of examination
4. Shackles shall have a traceable proof-load certificate.
a. Shackles shall be free of dents, gouges, cracks, etc., that would degrade the
condition of the shackle.
b. There shall be no welds or weld marks on a shackle.
c. Misshapen shackles shall not be used.

5.7.4

Sling Inspection
1. Slings and grommets shall be inspected by a Supplier lift superintendent as follows:
a. Before each use.
b. At least once every six months if the sling or grommet is in use.
c. Before putting the sling or grommet into long-term storage.
d. Before putting the sling or grommet into use if it has been stored for more than six
months.
2. If any damage to the sling is found during inspection, a calculation of the reduced
break strength (and lifting capacity) of the sling shall be provided to Purchaser.
3. The sling shall be withdrawn from service and referred to a third-party inspector for
examination if the total number of visible broken wires in any length of cable-laid
sling, or single-part grommet exceeds 5 percent of the total number of wires in the unit
rope.

5.7.5

Lifting Procedures
1. Supplier shall provide step-by-step operational procedures for each lift exceeding
50 tons (or whatever local regulations dictate if more stringent).
2. Procedures shall include the following:
a. Pre-rigging arrangement showing sling and shackle layout.
b. Weight and center of gravity of lift.

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c. Sling type, manufacturer, size, rated SWL, and certificate.


d. Shackle type, manufacturer, size, rated SWL, and certificate.
e. A drawing (in plan view) indicating the following:
1) Position of derrick vessel and cargo barge relative to platform for each lift.
2) Crane capacity at pickup and setting radii.
f.

A drawing (in elevation view) showing the crane vessel with package suspended
from the crane at maximum lift height and radius.

g. Method of communication between crane operator and other personnel during lift.
h. Limiting weather/seastate conditions.
5.7.6

Protection of Equipment
Supplier shall use spreader bars and other lifting apparatus, as required, to prevent damage
to equipment from contact with slings.

5.7.7

Lifting Eyes
1. Unless otherwise noted on drawings, the difference between the diameters of lifting
eye holes and the nominal shackle pin diameter shall not exceed 3/32 inch (2.4 mm)
for pins less than 2 inches (51 mm) in diameter, or 4.5 percent of pin diameter, with a
maximum of 3/16 inch (4.8 mm) for pins 2 inches (51 mm) in diameter or greater.
a. If the difference between diameters exceeds this amount, tight-fitting pipe
bushings shall be installed inside the lifting eye holes, unless additional
calculations demonstrate to Purchasers satisfaction that bearing stress is
acceptable.
b. Thickness of these bushings shall not be included in computing lifting eye
strength.
c. Supplier shall verify that fabrication Supplier test-fits shackles and pins according
to specifications.
2. The difference between the nominal thickness of padeyes and the nominal inside
width of the shackle at the pin shall be at least 3/8 inch (9.5 mm) for padeyes less than
3 inches (76 mm) thick, or 1/2 inch (13 mm) for padeyes 3 inches (76 mm) thick or
greater, with a maximum difference as specified by shackle manufacturer.
3. If this maximum difference is exceeded, shim plates shall be added on both sides of
the padeye.

5.8

Accessories
5.8.1

Navigational Aids
1. Supplier shall place temporary navigational aids on the structure whenever
construction equipment is not alongside the structure.
a. These shall include beacons in synchronous flashing Morse code U
(5 nautical miles [9 km]) and a foghorn (2 nautical miles [3.5 km]), and shall
conform to requirements of U.S. Coast Guard 33 CFR 67.
b. Where local regulations are different from U.S. Coast Guard directives, the more
stringent regulations shall be followed.

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2. Supplier shall maintain the navigation aids in operating condition until construction
under this contract is completed.
3. Supplier shall correct any loss or damage that occurs due to failure to place and
maintain navigational aids.
4. Permanent aids to navigation provided by Purchaser shall remain operating at
completion of installation of the offshore facility.
5.8.2

Installation Guides
1. Supplier shall design installation and alignment guides for offshore lifts to aid
installation and prevent damage during lifting and setting.
2. Drawings of these guides shall be submitted to Purchaser according to a schedule
agreed upon by Supplier and Purchaser at the time of contract award.
3. Drawings shall include critical dimensional control results to be obtained during
fabrication and shall include details for removal.
4. Supplier shall verify that permanent structures being installed have been checked for
local stresses induced by forces from the installation guides.
5. Guides and bumpers shall be dimensioned for contact based on the following
assumptions:
a. Package tilt may be up to 4 percent in both the longitudinal and transverse
directions.
b. Packages may be rotated in plan by 3 degrees from intended orientation at time
of initial contact with primary alignment guides.
c. Packages may be misaligned transversely by 5 feet (1.5 m) from intended
position at time of initial contact with primary alignment guides.
d. Packages may be elevated up to 10 feet (3 m) above final support level at time of
initial contact with primary alignment guides.
6. Alignment guides shall be compatible with specified setting tolerances unless final
positioning is obtained by other means.
7. Stresses during setting operations shall not exceed normal allowable values in
permanent structural members.
8. A one-third increase in normal allowable stresses shall be permitted in temporary
guides if local yielding of temporary members does not result in overstress of a
permanent member.
9. When an inclined surface on a guide is intended to adjust the horizontal position of a
module during descent, the angle of the inclined surface shall not be more than
30 degrees from vertical.
a. Guides of this type shall have a vertical guide face below the inclined surface.
b. Height of the vertical face shall prevent the module from landing at another
support point before it is off the inclined surface.

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10. Design impact forces shall be as follows:


a. These forces shall be applied simultaneously for each primary vertical guide that
provides horizontal restraint in one direction only.
1) Horizontal (perpendicular to guide face): 10 percent of module weight.
2) Horizontal (parallel to guide face): 5 percent of module weight.
3) Vertical (parallel to guide face): 1 percent of module weight.
b. If one of the primary guides provides horizontal restraint in two directions, both
horizontal components shall be assumed to equal 10 percent of the module
weight.
c. These forces shall be applied to vertical secondary guides that are contacted after
most of the lateral motion has been damped out by module contact with primary
guides.
1) Horizontal (perpendicular to guide face): 5 percent of module weight.
2) Horizontal (parallel to guide face): 1 percent of module weight.
3) Vertical (parallel to guide face): 1 percent of module weight.
d. When a module is lowered onto an inclined surface, a vertical force equal to
10 percent of the module weight shall be resolved to find the force acting
perpendicular to the surface. The appropriate horizontal forces shall be applied
simultaneously.
5.8.3

Installation Aid Removal


1. Installation aids and their connections including guides and riggings, flotation tanks,
and temporary structures for scaffolding shall be removed without damaging
permanent structures.
2. Removal stubs shall be ground flush and inspected before coating.
3. Flood and grout lines and their supports shall be removed down to elevation
25 feet (7.6 m) mean low water (MLW).
4. If removal of scaffolding brackets or flood and grout lines near the water surface is
considered unsafe because of their proximity to water, Supplier may request
permission to leave them in place.

5.9

Tolerances
5.9.1

General
Installation tolerances shall be checked by Supplier when requested by Purchaser and
when necessary to meet the requirements of this specification.

5.9.2

Position
1. Supplier shall provide surveyors who use a global positioning system.
2. The position of an offshore structure that does not require precise location (e.g., one
that will be bridge-connected to another platform or placed over an existing well) shall
be placed within a radius of 10 feet (3 m) of the target position designated by
Purchaser.

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3. If the structure is to be located over an existing well or template, the tolerance of the
guidance system shall govern.
4. Platforms to be bridge-connected to another structure shall be located with a net
4-foot (1.2-m) radius tolerance with respect to the bridge support centerlines, unless a
higher value is specified on the design drawings.
5. Within 4 weeks of completing installation, Supplier shall submit to Purchaser a
positioning report, which shall include the following information:
a. Final location, position, elevation, levelness, and orientation of platform and
associated components
b. Locations of any pipelines installed
6. Where Purchaser has reason to require tolerances that are more stringent than those
stated above, the more stringent tolerances shall apply.
5.9.3

Orientation
Orientation of the jacket shall be within 2 degrees of the orientation specified on
construction drawings.

5.9.4

Level
Top of the jacket shall be leveled to a tolerance of 0.5 degrees in every direction.

5.9.5

Deck Elevation
Unless Purchaser agrees to another value to accommodate field adjustment, the elevation
of each deck shall be within 3 inches (76 mm) of the elevation specified on construction
drawings, relative to top-of-jacket elevation.

5.9.6

Deck Level
Deck shall be leveled to a tolerance of 0.087-percent (0.05-degree) slope in every
direction.

5.10

Pollution Prevention
1. Operations shall be conducted to preclude pollution of the ocean or of waters of adjacent
streams and navigable waterways.
2. Disposal of liquid waste materials into the waters shall be limited to saltwater and other
materials that have been treated for removal of oil or other constituents that may be harmful to
aquatic life or injurious to life and property.
3. Effluent shall conform to local regulations and marine pollution (MARPOL) requirements.
4. Supplier shall not dispose into the water nonliquid waste materials that may be harmful or
hazardous to life or property, or that result in an unsightly appearance.
5. Supplier shall prevent steel and other debris from falling into the ocean in and around the
offshore structure(s).

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5.11

FFS-SU-5219-A

Workmanship
Workmanship shall be in accordance with the following requirements for paint, protective
coatings, and welding.
1. Supplier shall perform original and necessary touch-up painting to provide an in-place
structure, completely painted and coated in both splash and atmospheric zones.
2. Uncoated field-installed braces, field splices, weld areas, and exposed surfaces and piles shall
be painted by Supplier.
3. If environmental conditions at the time result in unsafe working conditions, or if the result
would be poor-quality application, Supplier may negotiate with Purchaser to apply primer
only and to transfer the final painting to the hook-up Supplier.
4. Work shall be completed to Purchasers satisfaction prior to acceptance of the structure.

6.0

SUPPLIER REQUIREMENTS

6.1

General
1. Supplier shall verify that all items necessary for platform installation comply with the
drawings and specifications, and are present at the site when needed.
2. These items shall include the following:
a. Lifting eyes and lugs, padears, lifting attachments, etc.
b. Rubber diaphragm closures
c. Cover plates
d. Launch skids
e. Pile followers
f.

Mechanical connectors

g. Pile plugs
h. Grout packers

6.2

i.

Lifting slings

j.

Shackles

Damage Repair
1. Supplier shall repair any damage caused during installation and shall submit repair proposals
and procedures to Purchaser for review and comment.
2. Repairs may be required immediately or at a future date, as directed by Purchaser.
3. Repairs shall not be initiated until accepted by Purchaser.
4. Damage to platform coatings, including pile top and shim connections, deck-leg connections,
and damage from other field welds shall be re-coated by Supplier in accordance with
Section 5.11.

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6.3

FFS-SU-5219-A

Scrap Material
1. Scrap material, including pile and conductor cutoffs and miscellaneous items remaining after
platform installation, shall become the property of Supplier.
2. Supplier shall dispose of scrap.

6.4

Cleanup
1. After installation Supplier shall remove miscellaneous installation piping, including reach
rods, from structure.
2. Materials shall become the property of Supplier.
3. Cleanup shall be in accordance with Purchasers instructions.
4. Platform shall be cleaned of oil, grease, and other materials before Supplier leaves the job site.

7.0

DOCUMENTATION REQUIREMENTS

7.1

Installation Manual
1. Supplier shall prepare an installation manual for Purchaser review and acceptance; manual
shall be submitted in sections according to a schedule agreed upon by Supplier and Purchaser
at the time of contract award.
2. Installation manual shall consist of step-by-step procedures, sequence of operations,
equipment utilization, contingency measures, and schedules for all phases of the offshore
work.
3. Manual shall include the following information:
a. Detailed mobilization plan for offshore equipment, including descriptions of equipment.
b. Barge positioning and anchoring locations (presented pictorially) to determine possible
interference with pipelines or other platforms.
c. Intended schedule or sequence of events planned for the installation work.
d. Pre-sail checklist of items to be inspected or confirmed.
e. Arrangement of facilities on cargo barges.
f.

Pre-installation seabed survey to be performed.

g. Pre-launch or pre-lift inspections to be carried out.


h. Details for launching or lifting jacket from barge, based on load distribution, lift
equipment capabilities, orientation for setting, and environmental conditions.
i.

Jacket upending procedure including stability calculations to maintain hook load, if


applicable, and orientation.

j.

Jacket setting and leveling procedures.

k. Procedures for maintaining on-bottom stability during installation.


l.

Pile installation procedures including drivability analysis, pile add-on calculations,


fit-up/alignment procedures and equipment, pile hammer operations and calculations,
grouting operations, and contingency procedures.

m. Details for lifting the superstructure from the barge based on load distribution, lift
equipment capabilities, orientation for setting, and environmental conditions.

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n. Rigging diagrams with weight and center-of-gravity location for lifts in excess of 50 tons
(45 metric tons).
o. Plans for installation of accessories and removal of installation aids.
p. Installation plans and procedures for offshore-installed skids and modules, including shim
details.
q. Structural completion plans.
r.

Underwater inspection plan.

s.

Vessel certification documents.

t.

Contingency plans for various equipment failures.

u. Deck and equipment package installation sequence.


v. Field survey procedures, including details of proposed positioning systemproprietary
name, manufacturer specifications, base stations, calibration procedures (both onshore and
offshore, including frequency and extent of check calibrations), and rejection criteria and
method of determining positioning error.
w. Definition of proposed data against which platform elevations shall be defined.
x. Technical specifications of equipment used and proposed calibration checks (for
establishing orientation data).
y. Details of instruments (and checks) to be used for leveling.
7.2

Drawings, Calculations, and Records


1. Prior to loadout, according to a schedule agreed upon by Supplier and Purchaser at the time of
contract award, Supplier shall submit to Purchaser calculations pertaining to installation
activities, including the following:
a. Loadout analyses
b. Transportation and seafastening analyses
c. Launch analyses
d. Lifting analyses
e. Upending analyses
f.

Stability analyses

g. Pile-handling analyses
h. Pile-driving analyses
i.

Pile add-on designs

j.

Crane vessel capacity curves

k. Cargo arrangement and order of lifting


l.

Center-of-gravity data for lifted and launched components

m. Lift vessel mooring analysis

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2. Calculations may be submitted separately in individual reports as they become available.


3. Results and conclusions from studies and calculations shall be included in the installation
manual.
4. A plot showing existing flowlines, pipelines, and other platforms and facilities, provided by
Purchaser, shall be included in the drawings.
5. Supplier shall maintain at the work site a complete and up-to-date file of drawings.
6. Pile-driving records shall be obtained and logged using a Purchaser-accepted format.
7. Documentation and drawings (native files as well as PDF versions) shall be provided to
Purchaser in electronic form (i.e., CD-ROM, DVD, or mass-storage USB drives).
7.3

Lift Vessel Certification


1. Supplier shall submit documentation of lift vessel certification for review, comment, and
acceptance by Purchaser according to a schedule agreed upon by Supplier and Purchaser at the
time of contract award.
2. Supplier shall provide the following information:
a. Current certification documentation for both vessel and crane(s)
b. Load history for the crane for the last 2 years
c. List of structural modifications and repairs made to the crane over the last 10 years
d. Crane maintenance program
e. Age of the various wire ropes making up the crane lifting mechanism

8.0

QUALITY ASSURANCE PROVISIONS

8.1

Tests
Prior to loadout, Supplier shall witness and approve the testing of installation devices (such as
flooding systems, grouting systems, and diaphragms) installed by fabrication Supplier.

8.2

Inspections
8.2.1

Offshore Welds
1. Field welds of piles shall be 100 percent visually and ultrasonically inspected.
2. Welding inspectors shall meet the qualifications and standards required by American
Welding Society (AWS).
3. Supplier shall furnish qualified personnel and suitable equipment for ultrasonic
inspection.

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8.2.2

FFS-SU-5219-A

Post-Installation Subsea Survey


1. After completion of platform installation operations, Supplier shall conduct a
complete survey of the submerged portion of the jacket.
2. Survey shall inspect the condition of the following items:
a. Permanent jacket members
b. Mudmats and depth of penetration
c. Sacrificial anodes
d. Cathodic protection system
e. Seabed (including jacket mudline framing)
f.

Riser clamps and preinstalled risers

g. Pull-tube bell mouths and messenger lines, as appropriate


h. Coating in the splash zone
3. Survey shall also inspect for presence of installation aids or temporary work, and for
debris within or near the jacket.
4. Supplier shall remove cables and debris left hanging or resting on the structure and
any debris on the seabed within 50 feet (15 m) of the jacket.
5. Supplier shall bring to Purchasers attention the presence of items not manageable by
ROV intervention.
6. Survey shall be recorded on videotape.
7. After removal of debris and other items required for completion of the work, the final
video survey records shall be forwarded to Purchaser.
8.2.3

Inspection Points
1. Minimum requirements for inspection points for various offshore activities shall be as
shown in Table 1.
2. Supplier shall notify Purchaser when an inspection point is reached.
3. Supplier shall provide the inspections listed, where W = Witness, S = Spot Inspection,
and R = Record Review.

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Table 1:

FFS-SU-5219-A

Requirements for Inspection Points

Inspection

Supplier

Purchaser

W/R

Jacket

Installation Aids

Upending

Positioning

Fit-Up

Visual

NDE

Driving

Removal of Attachments

Jacket Level

S/R

Fit-Up

Visual

NDE

S/R

Sampling

Testing

S/R

Overflow

Lift

Fit-Up, Level, and Position

Final Weld Visual

NDE

S/R

Fit-UpDimensions

Visual

NDE

S/R

Pre-Removal Inspection

Visual Inspection (Above Water)

Diver/ROV Inspection (Underwater)

S/R

NDE (Above Water)

Bottom Survey
Jacket Pre-Lift/Launch

Piling

Jacket to Pile Shims

Grouting

Deck

Accessories Installation

Accessories Removal

W = Witness

June 2010

S = Spot Inspection

R = Record Review

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