ONGC B-22 FIELD DEVELOPMENT PROJECT

CONTRACT NO. MR/OW/MM/B-22/19/2008

Mohammad Sami Khan NPCC PROJECT NO. 8118
Lead Inspection Coordinator
11.05.11

NPCC Purchase Order Number : 0245-2010-20352-AC

Material Description :
Equipment Tag No : M-600
Equipment Title : DECK CRANES

QUALITY ASSURANCE PLAN

NPCC DOC. No: 0245-20352A-X002-001

VENDOR DOC. No: RE-20532-AC-031

NATIONAL PETROLEUM CONSTRUCTION COMPANY RAINA ENGINEERS

P.O. BOX 2058, ABU DHABI, UNITED ARAB EMIRATES C-6,SHREE RAM IND.ESTATE,
G.D.AMBEKAR ROAD,WADALA(W),
MUMBAI-400 031, INDIA.

2 07/05/2011 Issued for approval

1 29/3/2011 Issued for approval
0 14/03/2011 Issued for approval

REV DATE REMARKS CHK REVD APVD

VENDOR NAME: INSPECTION
REV. NO-02
M/S RAINA ENGINEERS, MUMBAI OWNER: ONGC PURCHASER:NPCC CATEGORY
Date:07/05/2011
(ISO 9001 & API CERTIFIED) A

ITEM NAME.:WELDER QUALIFICATION

SR CHARACTERSTIC/ QUANTUM OF REFERENCE ACCEPTANCE
STAGE ACTIVITY TYPE OF INSPECTION RECORD RE NPCC/TPI ONGC/ CA
NO. PROCEDURE CHECK DOCUMENT NORMS
1 WPS/PQR/WPQ Welder Qualification Test Report Review / 100% AWS D 1.1/2009F Rev.6 AWS D 1.1 I.R/ WPS/
H R R
Visual PQR/ WPQ
2 WPS/PQR/WPQ New Welder Qualification Test Report Review / 100% AWS D 1.1/2009F Rev.6 AWS D 1.1 I.R/ WPS/
H W R
Visual PQR/ WPQ
3 Pre-Inspection Meeting H H
ITEM NAME.:BASE
SR QUANTUM OF REFERENCE ACCEPTANCE
STAGE ACTIVITY CHARACTERSTIC TYPE OF INSPECTION RECORD RE NPCC/TPI ONGC / CA
NO. CHECK DOCUMENT NORMS
1 Material identification & Material identification Check test where M.T.C./Check
Stamp transfer for load Original M.T.C. / One sample per lot Test report
bearing members, original approved MTC /heat no. Mfg.Drawing Mfg.Drawing H W RW
is not available
2 Check for bevel edges of D.P. Test / M.P.I.
major load bearing weld Visual Random checking AWS D 1.1 / 2009F AWS D 1.1 / 2009F S.I.R. H R R
joints prior to welding
3 Welding a)Fit up Dimensional Mfg.Drawing AWS D1.1/2009F S.I.R. H RW R
b) Weld Visual Visual AWS D1.1 AWS D1.1/2009F I.R H RW R
c) D.P./ MPI Visual AWS D1.1 AWS D1.1 I.R H RW R
4 Final Dimensional Overall dimensions dimensional Visual 100% Mfg.Drawing/PS Mfg.Drawing /PS F.I.R.
H RW R

5 Ultrasonic Testing Welding NDT as per NDT plan API RP 2X API RP 2X lv.'C' UT reports H W RW
6 Radiographic Testing of Welding NDT as per NDT plan AWS D1.1 AWS D1.1 RT reports &
long seam of base pipe film H R R

7 Stress Relieving of the Visual AWS D1.1/ ONGC 2009F App. Procedure/ONGC Heat Chart
Flange 100% 2009F H R R

8 Machining overall dimensions dimensional 100% Mfg.Drawing Mfg.Drawing F.I.R.

H R R

9 Paint Test Certificates Reviewal 100% ONGC – Spec . 2005 Rev. 3 ONGC – Spec . 2005 M.T.C
including addendum, Rev. 0 Rev. 3 including H R R
addendum, Rev. 0
Surface preparation Anchor Profile Random checking ONGC – Spec . 2005 Rev. 3 25-50 Microns I.R
Protective coating
including addendum, Rev. 0 H RW R

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 Paint thickness( Final DFT) Digital coat measure Random checking ONGC – Spec . 2005 Rev. 3 FINAL DFT & ONGC I.R
including addendum, Rev. 0 SPEC 2005 REV.3 H RW RW

ITEM NAME.: BOOM ASSLY.

SR QUANTUM OF REFERENCE ACCEPTANCE

STAGE ACTIVITY CHARACTERSTIC TYPE OF INSPECTION RECORD RE NPCC/TPI ONGC/ CA
NO. CHECK DOCUMENT NORMS
1 Material Identification & Material identification Check test where One sample per lot Mfg.Drawing / PS Mfg.Drawing / PS M.T.C./ Check
stamp transfer only for load Original M.T.C./ original /heat no. Test report
bearing members approved MTC is not H W RW
available
2 a)Fit up Dimensional Mfg.Drawing AWS D1.1 S.I.R. H RW R
Welding b) Weld visual Visual AWS D1.1 AWS D1.1 / 2009F I.R H RW R
c)D. P. / MPI Visual AWS D1.1 AWS D1.1/2009 F I.R H RW R
3 Dimensional /checking Overall dimensions dimensional Visual 100% Mfg.Drawing Mfg.Drawing F.I.R. H R R
4 Protective coating Paint Test Certificates Reviewal 100% ONGC – Spec . 2005 Rev. 3 ONGC – Spec . 2005 M.T.C
including addendum, Rev. 0 Rev. 3 including H R R
addendum, Rev. 0
surface preparation Anchor Profile random checking ONGC – Spec . 2005 Rev. 3 25-50 Microns I.R
including addendum, Rev. 0 H RW R

Paint thickness( Final DFT) Digital coat measure Random checking ONGC – Spec . 2005 Rev. 3 FINAL DFT (365-450 I.R
including addendum, Rev. 0 micron ) ONGC spec H RW RW
2005

ITEM NAME.:CRANE MOUNT

SR QUANTUM OF REFERENCE ACCEPTANCE
STAGE ACTIVITY CHARACTERSTIC TYPE OF INSPECTION RECORD RE NPCC/TPI ONGC/ CA
NO. CHECK DOCUMENT NORMS
1 Material identification & Material identification Check test where One sample per lot / Mfg.Drawing Mfg.Drawing M.T.C./
Stamp transfer only for load Original M.T.C./ original heat wise. CheckTest
H W RW
bearing member approved MTC is not report
available
a) Fit up Dimensional Mfg.Drawing AWS D1.1 S.I.R. H RW R
2 Welding b) Weld Visual Visual AWS D1.1 AWS D1.1/2009 F I.R H RW R
c) D.P./MPI Visual AWS D1.1 AWS D1.1 Sec. 6 I.R H RW R

3 UT of longitudinal joint of Welding NDT App. NDT PLAN API- RP-2X / 2009F API- RP-2X / 2009 F & UT Reports
H W RW
Cone AWS D1.1

4 UT of weld joints between Welding NDT App. NDT PLAN API- RP-2X / 2009F API- RP-2X / 2009F- UT reports
H W RW
cone & flange Lv.C
5 Radiographic Testing of Welding NDT App. NDT PLAN AWS D1.1/ ONGC 2009F AWS D 1.1 /ONGC RT reports &
H R R
long seam of Cone 200F RT Film

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 6 Stress Relieving of the Visual App. Procedure/ONGC Heat Chart
Flange Ring of Crane Mount 100% AWS D1.1/ ONGC 2009F 2009F H R R

7
Fit up Fit up Dimensional 100% Mfg.Drawing Drawing S.I.R. H R R

8
Machining of flange overall dimensions Dimensional 100% Mfg.Drawing Mfg.Drawing F.I.R. H R R

9 Protective coating Paint Test Certificates Reviewal 100% ONGC – Spec . 2005 Rev. 3 ONGC – Spec . 2005 M.T.C
Rev. 3 including H R R
addendum, Rev. 0
Surface prepration Anchor Profile Random checking ONGC – Spec . 2005 Rev.3 25-50 micron
I.R H RW R
Paint thickness( Final DFT) Digital coat measure Random checking ONGC – Spec . 2005 Rev.3 FINAL DFT (365- 450 I.R
micron) ONGC Spec H RW RW
2005

ITEM NAME.:YOKE
SR QUANTUM OF REFERENCE ACCEPTANCE
STAGE ACTIVITY CHARACTERSTIC TYPE OF INSPECTION RECORD RE NPCC/TPI ONGC/ CA
NO. CHECK DOCUMENT NORMS
1 Material Identification & Material identification Check test where One sample per heat Mfg.Drawing Mfg.Drawing M.T.C./ Test
stamp transfer only for load Original M.T.C./ original no/ lot wise reports
bearing members approved MTC is not H W RW
available

3 Welding a)Fit up Dimensional Mfg.Drawing AWS D1.1 S.I.R. H RW R

b) Weld Visual Visual AWS D1.1 AWS D1.1 / 2009F I.R H RW R
c) D.P./MPI Visual AWS D1.1 AWS D1.1 Sec.6 I.R H RW R

4 Dimensional / Visual Overall dimensions dimensional Visual 100% Mfg.Drawing Mfg.Drawing F.I.R.
H RW R
checking
5 Protective coating Paint Test Certificates Reviewal 100% ONGC – Spec . 2005 Rev. 3 ONGC – Spec . 2005 M.T.C
H R R
Rev. 3
Surface preparation Anchor Profile Random checking ONGC – Spec . 2005 Rev. 3 25 to 50 microns I.R
H RW R
Paint thickness( Final DFT) Digital coat measure Random checking ONGC – Spec . 2005 Rev. 3 FINAL DFT(365-450 I.R
including addendum, Rev. 0 micron) ONGC Spec H RW RW
2005

ITEM NAME.:CABIN FOR DRIVER

SR QUANTUM OF REFERENCE ACCEPTANCE
STAGE ACTIVITY CHARACTERSTIC TYPE OF INSPECTION RECORD RE NPCC/TPI ONGC/ CA
NO. CHECK DOCUMENT NORMS
1 Dimensional / Visual Overall dimensions dimensional Visual 100% Mfg.Drawing Mfg.Drawing F.I.R.
checking H R R

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 2 Protective coating Paint Test Certificates Reviewal 100% ONGC – Spec . 2005 Rev. 3 ONGC – Spec . 2005 M.T.C
including addendum, Rev. 0 Rev. 3 including H R R
addendum, Rev. 0
Surface preparation Anchor Profile Random checking ONGC – Spec . 2005 Rev. 3 25 to 50 microns I.R
including addendum, Rev. 0 H RW R

Paint thickness( Final DFT) Digital coat measure Random checking ONGC – Spec . 2005 Rev. 3 FINAL DFT(365-450 I.R
including addendum, Rev. 0 micron) ONGC Spec H RW RW
2005

ITEM NAME.:DIESEL ENGINE

SR QUANTUM OF REFERENCE ACCEPTANCE
STAGE ACTIVITY CHARACTERSTIC TYPE OF INSPECTION RECORD RE NPCC/TPI ONGC/ CA
NO. CHECK DOCUMENT NORMS
1 Performance testing a)Full Load test for 4 hours Test at manufacturer's 100% Customer specification Customer specification Test Report
b)10% overload test for 1 works
hour
c)Fuel consumption H W W
governing test

ITEM NAME.: WIRE ROPE

SR QUANTUM OF REFERENCE ACCEPTANCE
STAGE ACTIVITY CHARACTERSTIC TYPE OF INSPECTION RECORD RE NPCC/TPI ONGC/ CA
NO. CHECK DOCUMENT NORMS
1 Wire rope Test reports Visual 100% Customer specification./ Mfg. API 2C or better M.T.C.
H R R
Drg 5301F
2 Breaking strength Breaking strength Test at vendors site Breaking of one Customer specification./ Mfg. Customer specification./ Test reports
sample piece of the Drg 5301F Mfg. Drg H W R
batch

ITEM NAME.: MAIN & AUX. HOOK ASSLY.

SR QUANTUM OF REFERENCE ACCEPTANCE
STAGE ACTIVITY CHARACTERSTIC TYPE OF INSPECTION RECORD RE NPCC/TPI ONGC/ CA
NO. CHECK DOCUMENT NORMS
1 Main & Aux.hook Test report Visual 100% Mfg.Drawing Mfg.Drawing M.T.C. H R R
2 Proof load testing Proof load testing Test at double the 100% Mfg.Drawing No permanent R.I.R. H W R
SWL. deformation/Std.

ITEM NAME.: BOUGHT-OUT COMPONENTS

SR QUANTUM OF REFERENCE ACCEPTANCE
STAGE ACTIVITY CHARACTERSTIC TYPE OF INSPECTION RECORD RE NPCC/TPI ONGC/ CA
NO. CHECK DOCUMENT NORMS

Page 4 of 6
 1 a) Gear Box M.T.C / Check Test Report / Visual 100% Mfg.Drawing/App.P.S Mfg.Drawing Test Report H R R
b) Hyd. Motor Routine&Type Test
c) Hyd. Pump Report/Calibration Report
d) Slew Ring & Its Bolt, Nuts
e) Electrical &
Instrumentation (Light
Fixtures, Panels, etc)

ITEM NAME : DECK CRANE ASSEMBLY & FINAL TESTING

SR QUANTUM OF REFERENCE ACCEPTANCE
STAGE ACTIVITY CHARACTERSTIC TYPE OF INSPECTION RECORD RE NPCC/TPI ONGC/ CA
NO. CHECK DOCUMENT NORMS

FACTORY ACCEPTANCE Main host & Auxiliary hoist Customer spec. 5301F -API
1 TEST & FINAL load & speed test at Various Test 100% 2C & Approved FAT Customer spec. 5301F F.I.R H W W
INSPECTION Radi as per Load chart procedure

Speed Test for Main &

2 -/- -/- -/- -/- -/- H W W
Aux.Swing

3 OverLoad test -/- -/- -/- -/- -/- H W W

Emergency Load lowering

4 -/- -/- -/- -/- -/- H W W
mechanism
Functional test including
safety alarm & shut down,
5 Limit Switch Operation for -/- -/- -/- -/- H W W
Boom & Hook,air craft light
& working light

6 Final Dimentional Checking -/- -/- -/- -/- -/- H W W

Protective coating-final DFT

7 -/- -/- -/- -/- -/- H W W

Operability test (All drive

motions & working of safety
devices) at offshore & at RE
8 -/- - -/- -/- -/- H W W
factory including Dynamic/
Static loads as per capacity
chart.

9 Functional test of Engine

-/- -/- -/- -/- -/- H W W
starters
10 Noise & Vibration Test -/- -/- -/- -/- -/- H W W
11 Load indicator operational
-/- -/- -/- -/- -/- H W W
test

Page 5 of 6
 Final Documentation review
12 & issue of release note, -/- -/- -/- -/- -/- H H H
placement of API medallion

PREPARED BY REVIEWED BY APPROVED BY

LEGENDS: RE : RAINA ENGINEER, CA : CERTIFICATION AGENCY, H: HOLD, W: WITNESS, R: REVIEW, RW: RANDOM WITNESS, S.I.R.: STAGE
INSPECTION REPORT, F.I.R.: FINAL INSPECTION REPORT, R.I.R.: RECEIVIING INSPECTION REPORT.PS : PURCHASE SPECIFICATION.

Notes:
1) All structural material shall not be older than 2 years by the time of final use.
2) Painting Thickness(DFT) for all the components shall be carried out at the time of FAT randomly.
3) Inspection realease note to be issued byTPI / ONGC-CA.

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