GSPC Pipeline AIM Format

INTEGRITY MANAGEMENT MANUAL &
INSPECTION REPORTING REQUIREMENTS
FOR
DEEN DAYAL FIELD OFFSHORE INSTALLATIONS
GUJARAT STATE PETROLEUM CORPORATION LTD
Doc Ref.: GSPC/AIMS/MAN/01
Gujarat State Petroleum Corporation Limited
GSPC/AIMS/MAN/01
REV NO. 0
ASSET INTEGRITY MANUAL & IRR
DATE: 12/11/2013
The use of this Manual is mandatory as per the Asset Integrity Management Policy
of the company.
Revision Control Sheet

Revision No
Rev-0
Rev- Draft A
Revision A
DESCRIPTION
DATE
Approved by :
George Mathew
Reviewed by Rajesh/P.Senthil Kumaran
Issued for use.
Manual draft issued for comments by GSPC
Draft Manual prepared by ABS Industrial Verifications,
issued for internal review.
12/11/2013
08/11/2013
25/10/2013
Notes:
1. Revision numbers, starting in alphabetic letters indicate Draft Issues for Review /
comments.
2. Revision numbers, starting from Zero in Numeric letters indicate Issue for
implementation & revision number of subsequent revisions will go upwards like 1,
2, 3 etc., onwards.
3. Any change to this Manual requires a formal Management of Change in
accordance with company procedure.
This document is confidential. No part of this document shall be duplicated or used, or

disclosed for any other purpose with out prior permission from GSPC.
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Table of Contents
1
INTRODUCTION ............................................................................................................. 3
1.1 OBJECTIVE............................................................................................................... 3
1.2 BASIS FOR THE INTEGRITY MANUAL .............................................................. 3
SCOPE OF THIS MANUAL ............................................................................................ 4
INTEGRITY MANAGEMENT SYSTEM DOCUMENTATION ................................ 4
INTEGRITY MANAGEMENT PROCESS .................................................................... 5
SAFETY CRITICAL ELEMENTS (SCE) ...................................................................... 6

5.1 SELECTION OF SCEs .............................................................................................. 6
5.2 INPSECTION MANAGEMENT PROGRAM & IRR ............................................ 11
5.3 SCE COMPONENTS & INTEGRITY PROGRAMS. ............................................ 12
INSPECTION MANUALS & REPORTING REQUIRMENTS (IRR). .................... 14
INTEGRITY MANAGEMENT PROGRAM IMPLIMENTATION. ........................ 14
INSPECTION DATA BASE MANAGEMENT. .......................................................... 16
MANAGEMENT OF CHANGE (MOC)....................................................................... 16
10 INCIDENT INVESTIGATION, ANALYSIS AND REPORTING............................. 16

11 DE-COMMISSIONING. ................................................................................................. 17
12 ORGANISATION, ROLES AND RESPONSIBILITIES. ........................................... 18
13 THIRD PARTY CERTIFICATIONS AND FOLLOW UP AUDITS. ....................... 18
14 REFERENCE DOCUMENTS ........................................................................................ 18
15 ABBREVIATIONS: ........................................................................................................ 19
16 ANNEXURES .................................................................................................................. 19
Annexure-I
: Inspection Manual & IRR for Jacket Structures DDW1 & PLQP
Annexure-II
: Inspection Manual & IRR Deck structure & Topside facilities.
Annexure-III
: Inspection Manual & IRR for Pipelines.
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1 INTRODUCTION
Gujarat State Petroleum Corporation Ltd. (GSPC), Gandhinagar, a Government of
Gujarat Undertaking is the operator of the Deen Dayal Field, an offshore exploration
block KG-OSN-2001/3 located on the East Coast of India. GSPC (Company) have
discovered significant reserves of gas in the Deen Dayal West (DDW) area and
accordingly installed an Early Production System (EPS) by setting up of Offshore
Wellhead Platform at KG #8 (exploration well) located 15 KM offshore from YanamKakinada Coast of Andhra Pradesh, India in 57 M water depth along with the
Process Platform and multiphase pipeline to transport gas and condensate to the
Onshore Gas Terminal (OGT) at Mallavaram, East Godavari, Andhra Pradesh for
gas processing.
1.1
OBJECTIVE
The objective of this Manual is to provide guidance for implementing an Integrity

Management system to ensure that all assets from offshore to the onshore terminal
are safely operated and maintained during its life cycle in a manner that the health,
safety and environmental requirements are adequately met.
In accordance with the Asset Integrity Policy, this manual is designed to support
GSPC to implement a proactive inspection and maintenance management program
prioritising the activities/ tasks on a risk based approach, maintaining integrity and
preventing incidents that can harm the people, environment or property.
1.2
BASIS FOR THE INTEGRITY MANUAL
This Manual is developed to meet the requirements of the following:

(1) Company Integrity Management Policy and requirements.
(2) Company HSE Management requirements.
(3) Design Basis and various specification requirements.
(4) GSPC Maintenance policy.
(5) Regulatory requirements as per P&NG Rule 2008.
P&NG Rule has set the following to be addressed in the inspection, maintenance
programme by the operator for offshore facilities to ensure safety, health &
environment related requirements are met during operation.
Chapter-VI, Clause 27 (4).The operator shall establish monitoring parameters
within each areas of activity in order to monitor matters of significance to
health, safety and environment, including the degree of achieving objectives.
Chapter-XVII, Clause 154, 155 & 156.
The operator shall establish
maintenance program for the facilities including machinery & equipment such
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that the fault modes which constitute a risk to health, safety or environment,
shall be systematically prevented by means of a maintenance programme.
2 SCOPE OF THIS MANUAL
The scope of this Manual covers the following facilities installed in the Deen
Dayal offshore field.
1. PLQP Process cum LQ Platform & DDW1 Well Head Platform that consists of
the following:
a. Well Head, X-mas Tree, SSV, SSSV and accessories.
b. Jacket, Risers and Appurtenance.
c. Deck Structure including heli-deck.
d. Topside facilities consists of:
i)
Wellhead assemblies.
ii)
Hydrocarbon production & processing facilities.
iii)
Mechanical equipment, Cranes.
iv)
Electrical, Instrumentation and control system.
v)
Utility system.
vi)
Living quarters.
vii)
Flare system.
viii)
Personnel protection, escape and emergency system.
ix)
Fire & Gas detection, control and mitigation system.
x)
Passive Fire protection.
xi)
Process control & Emergency Shutdown system.
xii)
Emergency escape, evacuation facilities etc.
2. Pipeline system: Pipeline from offshore to Onshore = 2 nos.
a. Launchers and ESD Valves.
b. Risers, SSIV.
c. Subsea Pipeline section.
d. Shore approach, Landfall and Onshore pipeline section.
e. Receiver, ESD Valve etc.
f. Emergency shutdown system.
3 INTEGRITY MANAGEMENT SYSTEM DOCUMENTATION

Integrity Management system documentation has following the Hierarchy in
documentation:
a. Asset Integrity Manual.
b. Manual-Inspection Program & Reporting Requirements for:
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Jackets and Risers.

Topside Facilities.
Process system (Equipment, piping, control system).
Fire & Gas detection and control system.
Emergency system, evacuation and rescue.
Deck structure & Heli Pad, Crane etc.
Pipeline system.
c. Formats for Reporting
4 INTEGRITY MANAGEMENT PROCESS
The Company philosophy is formulated to ensure the safe operation of the facilities
for their designed life (or greater) with all the risks kept as low as reasonably
practicable (ALARP).
Integrity management process follows the Plan Do Check Act (PDCA) cycle to
ensure that the desired integrity is achieved throughout the life cycle of the assets.
The first step in the process is development of the integrity management program
on a risk based approach, identifying all Safety Critical Elements (SCE) and
developing suitable integrity management program consisting of inspection,
monitoring & testing activities at appropriate intervals to ensure adequacy of their
performance throughout the design life of the facility.
The Integrity management program consists of:
Maintenance Management program.
Corrosion Management program.
Inspection /Monitoring program.
These programs include applicable tasks and procedures, job plans and inspection
reporting requirements (IRR) for surveillance, monitoring, preventive maintenance,
inspection, and testing activities etc.
Integrity management Plan (IM Plan) is developed by carrying out detailed
assessment of the threats / damage mechanism and specifying the type of
monitoring / inspection, required location of hotspots and assigning suitable
monitoring intervals based on risk level of the safety critical element.
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5 SAFETY CRITICAL ELEMENTS (SCE)

The company has established appropriate HSE and integrity management system
which are implemented at stages of design, procurement, manufacturing and
installation of the project.
The company has identified potential major accidental hazard events (MAHE) and
taken adequate mitigation and control measures to ensure that the HSE risk during
the life of the installation are brought to as low as reasonably practical (ALARP).
The company has carried out several safety studies such as Hazid, Hazop, QRA
etc., at various stages of the project identifying major hazards and implementing
necessary barriers for control of the hazards.
Asset Integrity Management is focused on the Safety Critical Elements (SCE) that
are responsible for the safe performance of the offshore facilities. Suitable integrity
management program is developed by identifying potential threats and damage
mechanism that can impact the SCEs during its life cycle and relevant inspection
reporting requirements (IRR).
The integrity management programme comprises of activities for monitoring
performance and technical condition, which will ensure that fault modes that are
developing or have occurred are identified and corrected timely. The programme
also contains activities for monitoring and control of failure mechanisms that may
lead to such fault modes.
5.1
SELECTION OF SCEs
Safety Critical Elements (SCEs) are those systems and components that provide a
safety benefit or could result in an increase in risk upon failure. The Safety Critical
Elements (SCEs) are defined as the safeguards that are capable of preventing,
detecting, controlling and/or mitigating the effects of a Major Accident Hazard
(MAH). SCEs are identified from the various Safety Assessments such as studies
e.g. HAZID etc. SCEs responsible for MAHs , and their risk level are evaluated
based on a risk matrix.
The following steps are adopted in the SCE determination process.
Step 1 - Identifying Major Accident
Major Accident Hazards (MAHs) are hazards that would initiate Major Accident and
consequently lead to high risk level. It follows that the MAHs will fall within the
unacceptable region of the Risk Matrix (see below) or be shown to lie in the
tolerable region (yellow). In addition, for an event to be classified as a Major
Accident, one of the following criteria must be met.
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A fire, explosion or the release of a dangerous substance involving death

or serious personnel injury to a person on the installation or who is
engaged in an activity in connection with it.
Any event involving major damage to the structure of the installation or
plant affixed thereto or any loss in the stability of the installation.
The collision of a helicopter with the installation.
Any other event arising from a work activity involving death of a single
person or serious injury to five or more persons on the installation or who
is engaged in an activity in connection with it.
Step 2 - Determination of Causes

Once the Major Accident Events are identified, their potential causes are to be
established. An example would be overpressure.
Other potential mechanisms or causes of failures are listed below:
Degradation
Corrosion
Erosion
Fatigue
Overpressure / over temperature
External loading
Defective equipment
Human error.
Risk Matrix
1
Rat
ing
Harm to
People
Multiple
Fatalities
( >5)
Major
Loss
time/
Injury or
Health
First Aid
Injury
Minor
injury
Loss or
Damage
to Assets
Effect on
the
Reputa
Environmen tion
t
Extensive
damage
Major
damage
Massive
effect
Major
effect
Has
Unlikely
occurred
Not heard
in the
off
industry
3
Has
occurre
d in our
group
4
Has
occurre
d in our
group
Internat
ional
impact,
Nationa
l
impact,
Local
damage
Moderate
effect
Minor
damage
Minor or
Localized
effect
Limited
impact
Slight
damage
Slight
effect
Slight
impact
HIGH RISK
Conside
rable
impact
MEDIUM RISK
7
LOW RISK
5
Has
occurre
d in
this
facility
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Following SCEs are identified for the PLQP, DDW1 and the pipelines.
Safety Critical
Items
Functional role towards

risk reduction.
Scope
Management
Prevent failures by
proactively managing
integrity by implementing
Standard operating
procedures, training of
personnel involved to
control human errors,
change management etc.
to maintain Risk with in
ALARP.
Management of
Quality, safety, integrity
through SOPs; Trainings etc.
Jacket,
Topsides Change management.
Pipeline
Helicopter operations
Reviews, assessments &
continuous improvements.
StructureJacket
Prevention of failure due

to loads and fatigue,
extreme environmental
loads, marine corrosion
etc.
Jacket
Structure Deck

extreme environmental
loads.
Topsides Deck structure including helideck
Critical
equipment,
Valves, Pumps..
Prevent failure due to

malfunctioning,
deterioration etc.
Wellhead system, X-mas tree

Topsides and SSV, SSSV, Pumps,
compressors etc
Pipelines and
Risers

to loads, extreme
environmental loads,
exceeding safe operating
limits and other potential
threats.
Pipeline
Process
Equipment,
Vessels, Piping
etc.

to loads, all kind of
recognized potential
threats and exceeding
safe operating limits.
Hydrocarbon process equipment,

Topsides Vessels, Vent Scrubber, Closed
Drain Vessel, Exchanges, etc.
Chemical
Injection System
Prevention of
deterioration due to
corrosion beyond design
limits.
Chemical injection storage, Handling

& injection facilities, control of
Topsides injection rates, Injection system
monitoring & control system etc.,
MAJOR COMPONENTS
Jacket structure, Piles &

foundations, Riser guards and
supports.
Pipelines and risers including all

fittings, coatings, supports and
corrosion protection system.
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Monitoring &
control devices

to parameters exceeding
safe operating limits.
Monitoring & control devices

input to DCS, Remote control
Topsides
panel (WHCP); Process control
system (PCS)
Relief, Vent &

Shutdown
system
Control of emergency
situations when
parameters exceeding
limits.
PSVs, SDVs, process control

Topsides instruments, ESDVs, BDVs, Flare
system
Fire and Gas

Detection
Detection of gas leaks

and fire.
F&G System, interface with

Topsides Emergency and Process
shutdown systems ESD, FSD.
Passive Fire
Protection
Mitigation of a fire event
Topsides PFP at pipeline ESDVs etc.
Active Fire
Protection
Mitigation of a fire event
Fire water system, Fire

Topsides extinguishers, Helideck
firefighting system).
Hazardous Area
Classification
Prevention fire in the

event of hydrocarbon
leaks by Control of
Ignition.
Topsides
Emergency Response in
Emergency
controlling a hazardous
Communications
event.
All Electrical Equipment located

in Hazardous area
Alarms, Safety critical

Topsides communication system &
Navigational Aids.
Emergency
power & lighting
Ensure support to all

critical equipment &
system required for
managing Emergency
situation.
Topsides
Evacuation,
Muster, Escape
& Rescue
Ensure safety of
personnel in case of
Emergency.
Escapes routes, Emergency

lighting including integral battery
Topsides
supply. Personal Safety
Equipment & LSA;
Pedestal Crane
Prevention of failures &

damages due to dropped
objects, collisions.
Topsides Pedestal crane- DDW1 & PLQP
Diesel portable generator set

Uninterruptible power supplies.
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SCE Functional Role towards Risk Reduction

Prevention approach to risk reduction minimizes exposure (likelihood) to the Major
Accident Hazard. Examples are: Vessels designed in accordance to API & ASME
codes; Pressure relieves are provided on vessels and designed in accordance with
API RP 520; High pressure alarms are provided etc.
Detection approach to risk reduction enables timely detection and transmitting
information to control point to avoid the situation reaching a level breaching the
limits and Major Accidents. Examples are: HC gas and flame detection system to be
designed for early detection by Gas detectors suitable for the expected hazard as
per API RP 14C requirement etc.
Control approach to risk reduction minimizes/limits scale, intensity and duration of
consequences from Major Accident. Examples are: Process control system which
prevents the parameters not getting beyond safe operating envelope;
Mitigation approach to risk reduction minimizes (i.e. limit and/: ESD system
designed to initiate a shutdown in case there is breach of safe operation limits.
Firefighting system designed to control the fire event and helps to maintain 1hour
rating for the platform structure in withstanding the fire event.
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5.2
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INPSECTION MANAGEMENT PROGRAM & IRR
Critical functions, for which the SCEs are responsible, are studied for failures in
detail through a failure mode effect and criticality assessment (FMECA) and main
cause of failures are identified. For each failure mode, the appropriate technical
measures for the prevention, detection, control and mitigation of major accident
events are determined relevant to the major accident hazards. Evaluation of the
failure modes helps in development of relevant monitoring & inspection
tasks/program and taking suitable corrective actions when required.
The SCEs are designed for safe performance during its life for the following
aspects:
Reliability: An item / systems ability to operate and perform its intended
function under given conditions for a given time interval.
Availability: a measure of the systems ability (state of readiness) to
operate (perform a required function) at any given instant of time under
given conditions.
Survivability: a systems capability to withstand the effects of an incident
prior to, and during, its operation (E.g.: fire, explosion etc.)
The inspection and monitoring programs are expected to confirm the ability of the
SCEs and components to continue their functions as specified during the life cycle.
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5.3
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SCE COMPONENTS & INTEGRITY PROGRAMS.
Details of the SCEs and their components and applicable programs are as
following.
Safety Critical
Major Components
Items
Integrity Management Programs
Management
Management of quality, safety,

integrity through reviews,
assessments for safety and SOPs
for DDW1 & PLQP
HSE Management; Integrity

Management (MMS, PIMS,WIMS),
Standard Operating programs, Audit
& Review, Competency
management & Trainings.[ Refer
respective Manuals / documents for
program elements and
implementation program ]
StructureJacket
Jacket structure, Piles &

foundations, Riser guards and
supports.
Detailed integrity management

program & inspection reporting
requirements ref: Manual for under
water structures-IRR Annexure-I.
Structure Deck Deck structural including helideck

requirements ref: Manual for Deck &
Topsides structures-IRR Annexure-II
Critical
equipment,
Valves,
Pumps.
Wellhead system, X-mas tree and

SSV, SSSV, Pumps, compressors
etc
Integrity management program &

inspection reporting requirements
ref: Manual for Deck & Topsides
structures-IRR Annexure-II
Pipelines and
Risers
Pipelines and risers including all

fittings, coatings, supports and
corrosion protection system.
Integrity management program &

inspection reporting requirements
ref: Manual for Pipelines -IRR
Annexure-III
Process
Equipment,
Vessels,
Piping etc.
Hydrocarbon process equipment,

Vessels, Vent Scrubber, Closed
Drain Vessel, Exchanges, etc.
Program based on Risk Based

Inspection (RBI) assessment to be
developed and followed for pressure
vessels & piping.
Chemical
Injection
System
Chemical injection storage, Handling

& injection facilities control of
injection rates, Injection system
monitoring & control system etc.,
Program based on Risk Based

Inspection (RBI) assessment to be
developed and followed pressure
vessels & piping.
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Monitoring & control devices input to

Monitoring &
DCS, Remote control panel
control devices (WHCP); instruments and control
system for process system. APM
Relief, Vent &
Shutdown
system
Fire and Gas
Detection
PSVs, SDVs, process control

instruments, ESDVs, BDVs, Flare
system.
F&G System, panels, associated
logic in SCE listing, interface with
Emergency and Process shutdown
systems.
Passive Fire
Protection
PFP at pipeline ESDVs etc?
Active Fire
Protection
Fire water system, Fire

extinguishers, Helideck firefighting
system).
Hazardous
Area
Classification
Emergency
Communicatio
ns
Emergency
power &
lighting
Evacuation,
Muster,
Escape &
Rescue
Pedestal
Crane

All Electrical Equipment located in

Hazardous area
Alarms, Safety critical
communication system &
Navigational Aids.
Diesel portable generator set
Uninterruptible power supplies.
Escapes routes, Emergency lighting
including integral battery supply.
Personal Safety Equipment & LSA;
Pedestal crane- DDW1 & PLQP
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6 INSPECTION MANUALS & REPORTING REQUIRMENTS (IRR).

Inspection maintenance program details for the facilities in Deen Dayal field is
developed as Inspection Manuals (IRR) and attached to this document as below.
Annexure-I
PLQP.(A
Annexure-II : Inspection Manual & IRR Deck structure & Topside facilities.
Annexure-II : Inspection Manual & IRR for Pipelines.
: Inspection Manual & IRR for Jacket Structures DDW1 &
These documents includes the details on
Inspection / maintenance tasks
Applicable components & locations for inspection / testing.
Inspection schedules/frequencies.
Guidance / methodology for inspection & maintenance tasks
Reporting requirements and formats,
7 INTEGRITY MANAGEMENT PROGRAM IMPLIMENTATION.

In the operation Phase, inspection, monitoring & testing activities are performed
according the integrity management program / IRR. IN overall, the program shall
cover following activities.
Preparation of appropriate schedules.

Development of inspection/ monitoring work packs.
Performing inspections in accordance with the approved annual inspection
plan and inspection procedures.
Documenting the results & reports.
Data input to the database (if available).
Review / evaluation of findings and anomalies.
Review the anomaly acceptance criteria and make suitable
recommendations.
Review and approval of the findings and recommendations by the
authorised person.
Implementation of mitigation/ repairs or remedial works if required.
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Revision of annual inspection plans based on inspection/ monitoring carried

out.
The program implementation shall include following activities:
Perform inspections in accordance with the approved annual inspection

plan and inspection procedures.
Issue reports and create baseline data.
Assess the inspections, review findings and record anomalies.
Carry out repairs or remedial works.
Compile and issue report in accordance with the procedure on fitness of the
system.
Formal review of the Integrity Manual and update if required.
Review the anomaly acceptance criteria and change if required.
Produce revised annual inspection plans based upon the recently

performed risk assessments.
Produce inspection work packs.
Perform inspections.
Develop and recommend required mitigating or corrective actions as

necessary.
Planning & scheduling: The tasks identified for monitoring/ inspection /

maintenance are grouped and included in monthly, semi-annual, annual programs
etc for the ease of planning and execution of the activities, and follow up of the
program.
Follow up reviews & assessment: Where inspections / monitoring shows results
that is beyond acceptable limits, it shall be thoroughly investigated to find the root
cause and make appropriate correction in the operation. It shall follow below steps.
Investigate the problem.

Identify the root cause.
Recommend corrective or mitigating actions.
Re-visit the IM Plan/IRR and revise the inspection/ monitoring interval.
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8 INSPECTION DATA BASE MANAGEMENT.

Maintenance and Inspection Management data shall be managed in such a manner
that these are accessible as and when required. This database shall contain the
asset register, design and operating data, inspection history etc.
Appropriate data base shall be developed structuring the asset hierarchically and
referring to the specification, data sheet and detailed drawing to help the
implementation of IRR/IM Plan as well as to help in collection and collation of data
for further use and updating during the operation phase.
9 MANAGEMENT OF CHANGE (MOC).

All changes to the integrity organisation shall be in accordance with the approvals as
per the Management of Change procedures by authorised personnel.
It shall include:
Changes to Asset components.
Changes to the organisation.
Changes in the program, plans and procedures.
Changes in the operating conditions.
Modifications & Repairs.
All changes shall be within the permissible boundaries of the operating and design
envelope of the system. Any modification beyond these limits shall require revalidation of the system.
10
INCIDENT INVESTIGATION, ANALYSIS AND REPORTING.
Incident Investigation and Reporting shall be considered most important aspect for
maintenance of the integrity of the systems.
All accidents, incidents and near misses shall be reported, investigated in
accordance with HSE Management System. Additionally all integrity related
incidents should be assessed and if necessary investigated for potential impact to
health, safety and environmental damage.
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11 DE-COMMISSIONING.
DE-COMMISSIONING OF ASSETS / SYSTEMS.
Systems and components shall be replaced when the integrity objectives can no
longer be achieved. The replacement decision shall be made by the asset
owner in consultation with the support group from concerned discipline of
engineering, corrosion and materials engineering.
The asset shall then be left in a safe condition and arrangements made to write it off.
Some conditions for replacement are:
The asset / system can no longer be operated within the desired operating
envelope, e.g. required increase in capacity cannot be catered for or MAOP
has to be derated.
Projected operating expenditure is no longer economical, which shall include

all anticipated repair costs, clean-up costs of spills and loss of income.
If a future need for the asset in-situ or the materials is foreseen, then the systems
shall be mothballed in accordance with the Mothballing procedure.
If no future use is foreseen, then the asset shall be removed from site with
removal executed under asset ownership of the respective Business Unit and in
accordance with the Decommissioning Procedures.
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12 ORGANISATION, ROLES AND RESPONSIBILITIES.

Company have defined the Integrity management organisation for the Deen Dayal
field operations, which is part of the Company Operation Manual.
13 THIRD PARTY CERTIFICATIONS AND FOLLOW UP AUDITS.

The Deen Dayal field facilities are under third party certifications for fit for use, and
the integrity management programs are under periodic audits and reviews to
establish continued adequacy and compliance to regulatory requirements and for
safe operations.
Third party audits by the certifying agency shall be included in the Integrity
management program and shall be implemented appropriately.
14 REFERENCE DOCUMENTS
P&NG Rules 2008

GSPC HSSE Philosophy
GSPC Offshore facilities HAZID and QRA Reports for DDW1 and PLQP.
Electrical Design Basis
Instrumentation Design Basis
Process Design Basis
Structure Design Basis xx-xx.
Safety Study documents such as QRA, Hazid etc.
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15 ABBREVIATIONS:
The following abbreviations are used in this document.
AIMS
ALARP
CMS
CP
ESDV
IMS
IP
MAOP
MMS
PEMS
PIMS
RBA
RBI
SCE
WIMS
Asset Integrity management System

As Low As Reasonably Practicable BU Business Unit
Corrosion Management System
Cathodic Protection
Emergency Shutdown Valve
Inspection Management System
Intelligent Pigging
Maximum Allowable Operating Pressure
Maintenance Management System
Pressure Equipment Management System
Pipeline Integrity Management System
Risk Based Assessment
Risk Based Inspection
Safety Critical Element
Well Integrity Management System
Definitions
Asset: In the context of this document an asset is the facility such as Platform,
Pipelines etc.
Integrity: An asset has integrity if it operates as designed for its assigned life
(or greater) with all its risks kept as low as reasonably practicable.
16 ANNEXURES
Annexure-I
PLQP.(A
Annexure-II : Inspection Manual & IRR Deck structure & Topside facilities.
Annexure-III : Inspection Manual & IRR for Pipelines.
: Inspection Manual & IRR for Jacket Structures DDW1 &
19
INTEGRITY MANAGEMENT MANUAL & INSPECTION

REPORTING REQUIREMENTS
PIPELINE
FOR
DEEN DAYAL OFFSHORE INSTALLATIONS
DOC. REF: AIMS/PIPELINES/IRR-01
GSPC/AIMS/PL/IRR-01
Rev No.0
DATE: 12/11/2013
The use of this Manual is mandatory as per the Asset Integrity Management Policy of the
company.

Revision No
Rev- 0
Rev Draft A
Revision A
DESCRIPTION
Approved by : George Mathew

Reviewed by : Rajesh Pillai
Issued for use.
Manual draft issued for comments by GSPC.
Prepared by ABS Industrial Verifications India.-issued
for internal review
DATE
12.11.2013
08.11.2013
28.10.2013
Notes:
comments.
2, 3 etc., onwards.
This document is confidential. No part of this document shall be duplicated or used, or

disclosed for any other purpose with out prior permission from GSPC.
ii
GSPC/AIMS/PL/IRR-01
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TABLE OF CONTENTS:
INTRODUCTION .........................................................................................................................4
PURPOSE ......................................................................................................................................4
SCOPE ............................................................................................................................................4
MANUAL CONTENTS ................................................................................................................4
SAFETY CRITICAL ELEMENTS (SCE)..................................................................................4

5.1 Safety Critical Items ................................................................................................................5
INSPECTION MANAGEMENT PROGRAM ...........................................................................6

6.1 Risk Assessment & IM Planning.............................................................................................6
6.2 PIPELINE DATA....................................................................................................................9
6.3 Critical Components & Inspection Program: ........................................................................10
INSPECTION METHODOLOGY ............................................................................................14

7.1 General Survey (GVI) ...........................................................................................................14
7.2 Requirments for CVI: ............................................................................................................14
7.3 Wall thickness measurements: ..............................................................................................15
7.4 Weld inspections: ..................................................................................................................15
7.5 Risers section below sea-level ...............................................................................................15
7.6 Subsea Pipeline......................................................................................................................15
7.7 Onshore pipelines ..................................................................................................................16
7.8 Coating Health Survey ..........................................................................................................17
7.9 Internal Corrosion Monitoring ..............................................................................................17
7.10 Inspection of components ......................................................................................................18
INSPECTION REPORTING REQUIREMENTS:..................................................................19

8.1 Anomaly acceptance criteria & reporting .............................................................................19
8.2 Anomaly reporting ................................................................................................................20
8.3 Inspection Reports .................................................................................................................20
REVISIONS TO THIS MANUAL .............................................................................................20

9.1 Events initiating revisions .....................................................................................................20
10
REFERENCE DOCUMENTS ..................................................................................................21
11
DEFINITIONS/ TERMINILOGY .............................................................................................21
12
ANNEXURE ................................................................................................................................21
Annexure-I reporting formats.
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INTRODUCTION
Gujarat State Petroleum Corporation Limited (GSPC) is the operator of the Deen Dayal Field
(Block- KG-OSN/2001/03) situated at offshore from the Yanam-Kakinada coast of Andhra
Pradesh, India.
This Inspection and Maintenance Management Manual is developed for the Subsea Pipeline,
Risers, Riser Clamps, structural supports, onshore section of the pipeline including the shore
approach, subsea isolation valves (SSIV), PLEMs, Launchers and receivers etc. installed in
the Deen Dayal field, Linking offshore facilities of Process Platform (PLQP) and well head
platform (DDW1) in the KG Basin to the onshore terminal..
This Manual describes the philosophy and the scope for the inspection and maintenance
program, inspection frequencies, technical performance of inspection work and the
requirements for inspection documentation.
This document shall be treated as a guide for implementing the inspection and maintenance
program in compliance to various requirements.
PURPOSE
The objective of this manual is to provide suitable guidelines and the frame work for
maintaining the integrity of the Topside systems & processing facilities at the offshore platform
facilities to facilitate effective management of the inspection and maintenance programs and
demonstrate that the safety critical elements are capable, suitable and continue to function
safely throughout the operation phase achieving the required level of integrity to assure safety
and serviceability.
SCOPE
The scope of this Manual covers the following pipeline facilities linking the Deen Dayal
offshore field Platforms to the onshore that consists of the following:
20 Multiphase (Sour Gas + Condensate) Pipeline from PLQP to OGT
10 Effluent disposal pipeline form ETP to diffuser
MANUAL CONTENTS
This Manual consists of the following:

a. Inspection program and reporting requirements.
b. Reporting formats.
SAFETY CRITICAL ELEMENTS (SCE)
The company has established appropriate HSE and integrity management system which are
implemented at stages of design, procurement, manufacturing and installation of the project.
Details on the process of selection of SCEs are given in Section 5 of the Asset Integrity
Manual. SCEs applicable for the Pipelines are given below.
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5.1 Safety Critical Items

Pipeline system is identified as the main safety critical element (SCE) having following sub
items.
No.
Safety Critical
Items
Function
Description
Applicable Major
Components
HSE Management;
Integrity Management
Management
Prevention
Management of safety & integrity

through reviews, assessments ,
SOPs, Training etc. for Pipeline
system
Pipeline
Topsides
Prevention
Integrity of Pipeline Launcher and

ESD system.
Pipeline Riser
Prevention
Riser, Clamps, splash zone

coatings, pipe line up to 20M from
Jacket.
Detailed program ref:

section.
manual for underwater
structures.
Pipeline
Offshore
Prevention
Pipeline system, CP system, weight

& anti-corrosion coatings, SSIV etc.

section.
Pipeline
Onshore
Prevention
Pipeline, CP system, Receiver,

HIPPS System

section.
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INSPECTION MANAGEMENT PROGRAM
Integrity Management Program (IM Plan) is developed based on the DNV-RP-F116 "Integrity
Management of Submarine Pipeline Systems"
Risk Assessment of Pipeline System is performed by following process.
The pipeline network is broken into pipeline systems
The pipeline system is separated into sections and components
Potential threats are identified for each section
Assessment is performed on the Pipeline System for the identified threats for each section. The
Likelihood of Failure and Consequences of Failure are qualitatively assessed to determine the
preliminary risk level.
Component risk assessment is qualitatively performed for each component in the Pipeline
System, based on detailed inspection data and technical documents.
Hotspot assessment performs risk calculations for a given point registered in pipeline.
The condition of the whole pipeline system is assessed, based on the risk assessments
performed of the individual components.
The Results from the risk assessment are aggregated and presented in summary reports.
The evaluated risk is utilised to prepare detailed inspection plans. This also assists in optimising the
inspection activities based on criteria of risk, and provide a program for integrity management during
their remaining life.
6.1 Risk Assessment & IM Planning

Risk assessment techniques
Different risk assessment approaches can be used. The ASME B31.8S outlines four of them, which
are the Subject Matter Experts, the Relative Assessment Models, the Scenario-Based Models and
the Probabilistic Models. Common for all the models is an evaluation of the probability of an event
and the consequences that this event will impose.
The risk matrix shall be defined including annual PoF, CoF and risk categories. The matrix should
preferably be defined by the operator and used across different assets.
Work selection matrices should also be defined, e.g. recommended inspection intervals dependent
on location in the risk matrix.
Probability of failure assessment
This recommended practice is primarily focused on structural integrity. Failure is caused by an
event resulting in either of the following:
loss of component or system function; or
Deterioration of functional capability to such an extent that the safety of the installation,
personnel or environment is significantly reduced.
Consequence Assessment.
Assessment of consequences of failure is to take the following into consideration:
Safety (personnel)
Environment
--- Economy
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Simple qualitative assessments is used using required detailing level depending on the objective of
the actual risk assessment e.g. basis for inspection planning or assessment of a critical finding. A
leveled approach is therefore recommended as detailed below.
Each segment is assessed against applicable threats to arrive at a probability (PoF) and
consequence (CoF) of failure factor. Segments are then ranked based on the PoF and LoF factors
and plotted as a 5 X 5 Risk Matrix. The five PoF categories considered in the matrix are,
insignificant, remote, in-frequent, occasional and frequent. CoF categories are minor, moderate,
major, critical and catastrophic.
A segment with HIGH risk ranking is examined for reasons of its high ranking and measures are
taken to bring down the risk level. These measures may include an increase in frequency of existing
inspection techniques, introducing a additional inspections etc.
There are a variety of different systems in use for conducting risk assessments on
pipelines.
For this study all point scoring methodology as following is adopted.
POINT SCORING
Point scoring systems have been developed by a number of industry experts. These involve
assigning points relating to different aspects of pipeline design, operation, history and
environment. This system is based on ASME B 31.8 S. Detailed methodology adopted is as under.
o
Pipeline failure and subsequent leakage are being caused mainly by external corrosion, internal
corrosion, pipe manufacturing defects, construction defects, operations mistakes, third party
damages, equipment (component) failure, outside force.
Based on the Statistical number of occurrence of leakage incidents in the industry as given in
PARLOC 2001-the update of loss of containment data for offshore pipeline by - The Health
and Safety Executive, The UK Offshore Operators Association and The Institute of Petroleum, a
incident weight factor is arrived at for the analysis.
High, medium and low categories of risk assessment due to external corrosion is based on life
of the pipeline, size, wall thickness of the pipeline, operating stress, environmental /soil
corrosivity characteristics, last date of assessment of hydro test, coating type, coating condition,
cathodic protection monitoring, hydro statistic test inspection results, last inspection result, Risk
factor values are assigned for high ,medium and low categories respectively 5, 2.5, and 1
For Internal corrosion, assessment is based on life of the pipeline, size ,wall thickness of the
pipeline, operating stress, MCI monitoring/bacteria culture, last date of assessment of hydro
test, availability of corrosion monitoring methods, operating parameters for corrosive
environment, expected flowing product analysis, implementation of periodical cleaning pigging
policy, performance of corrosion inhibitor dosing, bactericide dosing, hydro test results,. Risk
factor values are assigned for high ,medium and low categories respectively 5, 2.5, and 1
For manufacturing defects, assessment is based on age of the pipeline, pipe material
composition, age of pipe manufacturing process, operating pressure history, pipe seam type,
and joint factor taken during design. Risk factor values are assigned for high ,medium and low
categories respectively 5, 2.5, and 1
For construction defects, assessment is based on selection of pipe material, existence of
wrinkle or buckles, proper welding procedures, girth weld reinforcement, NDE information of
o
o
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welds, hydro statistic test inspection results, operating pressure and cyclic loading history. Risk
factor values are assigned for high, medium and low categories respectively 5, 2.5,and 1.
For incorrect operations or mistakes, assessment is based on availability operating procedure
review, audits of the operation, history of occurrence of failure due to incorrect operation. Risk
factor values are assigned for high , medium and low categories respectively 5, 2.5, and 1.
For failure of pipelines due to third party operations, assessment is based on method of laying,
policy of evaluation before berthing vessel on anchor, existence of pipeline near to the port/
harbour, position of pipeline crossing of international navigational channel, consideration of
trenching and burial in the laying stage, history of occurrence of failure in the past, availability of
information with the port authorities regarding the existence of pipeline, ROU encroachment
records by third parties. Risk factor values are assigned for high, medium and low categories
respectively 5,2.5, and 1.
For failure of pipelines due to equipment/ component, assessment is based on year of
manufacture of equipment /component, failure/maintenance information regarding ESD/control
valve/PLEM/SSIV/actuator of SSIV/riser/flange gasket, availability of procedure/policy/protocol
for monitoring and maintenance. Risk factor values are assigned for high, medium and low
categories respectively 5,2.5, and 1.
For failure of pipelines due to Weather Related and Outside Force, assessment is based on
pipeline age, pipe jointing method, Topography and Soil conditions, nearness to Earthquake
Fault, Ground Acceleration, and consideration of external loading due to outside force and
weather in the Stress Calculations in the design stage. Risk factor values are assigned for high,
medium and low categories respectively 5,2.5, and 1.
From the above consideration of risk probability information , for each considered segment risk
probability score is computed and converted into Likely hood of failure ( in the scale of 1 to 5)
Consequence damage due to failure of pipeline- Impact factor assessment is based on hazard
nature of flowing product, flow rate, pipeline size, and distance between sectioning valves,
accessibility & Emergency Response Preparedness, Shut down Response Time, nearness to
environmentally sensitive areas, population density, and pollution. From the above consideration
of impact factor information, for each considered segment consequence of failure score is
computed and converted into the scale of 1 to 100.
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6.2 PIPELINE DATA

A. 20" Sour Gas + Condensate Pipeline (21.5 Kms Offshore and 3 Kms. Onshore)
Design Pressure
161 Kg/Sq. cm (g)
Origin
PLQP
End
OGT
Design Life
30 years
Riser
28.6mm thk
Pipeline
19.1mm thk
Water Depth
Topside
components
Riser
Riser
Subsea Pipeline
Onshore Pipeline
OGT
58.1 M at PLQP
Pig Launcher
ESDV
NRV
Monel @Splash Zone
Riser Clamps
Bracelet anodes
0 M at LFP
SSIV- HPU [Ball valve]

Hydrualic Umbilicals
Lateral/Ball valves & relief
valve on lateral
Sacrificial anodes
IJ at LFP
MOV 1901 at IVS
MOV 1902 at OGT (SIV)
IJ at OGT
MOV 1903 @ Pig Barrel
Pig Barrel
B. 10" Effluent Disposal Pipeline (13.5 Kms offshore and 3 Kms. onshore)
Design Pressure
20 Kg/Sq. cm (g)
Effluent Treatment Plant
Origin
(ETP) Onshore
End
Diffuser, Offshore
Design Life
-Pipeline thk.
12.7mm
Water Depth
0- 13 meter
Diffuser
Subsea Pipeline
Onshore Pipeline
OGT
Sacrificial anodes
IJ at LFP
Ball valve at IVS
NRV at IVS
ICCP System
IJ at OGT
MOV 1101
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6.3 Critical Components & Inspection Program:
Inline Inspection (ILI)
From pig
barrel
(Launcher)u
p to riser at
splash zone
Internal Corrosion
LOW
External Corrosion
Equipment Failure
Internal Corrosion
UT survey-Pig Barrel,
associated piping
Pigging for internal
cleaning & residue
analysis
LOW
External Corrosion
SSIV to Land
Fall Point
Remarks
3 yearly
Yearly
OISD -139 Clause 4.3
Ultrasonic Wall
thickness survey
2 yearly
SDV inspection/Testing
6 months

UT survey at splash
zone
Ultrasonic Wall
thickness survey
cleaning & residue
analysis
5 yearly
OISD -139 Clause 5
UT survey at splash
zone
General visual
inspection of monel
sheeting at splash zone
UT survey
CP monitoring
Anode monitoring
Yearly
5 yearly
Yearly
Diver/ ROV Survey

5 yearly
Yearly
Yearly
3 yearly
5 year
3 yearly
riser underwater segment

OISD 139 Clause 4.5
Diver survey
OISD 138 Clause 4.8
SSIV Inspection
5 yearly
6
monthly
3 yearly
ROV survey
5 yearly
5 yearly
ROV survey shall be

performed after major
construction activities.
OISD -139 Clause 5

cleaning & residue
analysis
Yearly
Riser -Clamps & coating
Equipment Failure
SSIV functional test
Internal Corrosion
OISD -139 Clause 5
2 yearly
Mechanical
Third Party
Damages
5 yearly
General Survey
Visual inspection Diver

/ROV survey
From Riser
at splash
zone to
SSIV
Recommended
Inspection Interval
Threats of Concern
Risk Level
Segment
Identification
Inspection/ monitoring
Task
A. 20 Multiphase Pipeline (PLQP TO OGT) Integrity Management (IM) Plan
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External Corrosion
Weather Related &

Outside Forces
Third Party Damages
Internal Corrosion
Anode monitoring
3 yearly
CP monitoring
5 yearly
OISD 139 Clause 4.5
Visual inspection (
ROV/ROTV Survey)
5 yearly
Diver survey
( ROV/ROTV Survey)free span monitoring

( ROV/ROTV Survey)Lateral Displacement
Survey / Pipeline
exposure
5 yearly
5 yearly
Monitoring against un
authorized vessel entry
cleaning & residue
analysis
UT Survey -Pig Barrel &
associated piping
CP monitoring at all feed
points
CP monitoring at all test
station
Coating health survey
CAT / DCVG
Land Fall
Point to pig
barrel (Pig
Receiver at
OGT)
Continuo
us
5 yearly
OISD -139 Clause 5
Yearly
3 years
Monthly
Quarterly
5 yearly
Continuous potential
logging (CPL) survey
5 yearly
Visual inspection
Yearly
Visual inspection at
Road/ rail crossing
Quarterly
Visual inspection at inter

tidal zone
6
monthly
UT Survey, if exposed
2 yearly
Third Party Damages
ROW & ROU survey;

Pipeline marker, KM
Post & signboard survey
Yearly
Equipment Failure
Isolation valve
inspection /Testing
Functional test of
Insulation joint
External Corrosion
6
monthly
Yearly
General Monitoring
Water Content, H2S
1
& CO2
2 Corrosion Rate
Crude quality monitoring
Every shift
At OGT
ER Probe
Corrosion Rate
Corrosion products analysis
Microbial Corrosion
MIC/SRB
On line
Every
pigging
Monthly
At OGT , if available
Pigging product
analysis
At OGT
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Corrosion Inhibitor
Efficiency
Efficiency monitoring of
inhibitor & biocide
With
product
batch/ lot
change.
Iron Count
Check Iron count in free

water
15 days
12
Establish the optimised

corrosion injection
program.
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B. 10 Effluent disposal Pipeline from ETP to Diffuser - Integrity Management (IM)
Internal
Corrosion
Effluent
Treatment
Plant ( ETP) to
LFP
External
Corrosion
UT Survey
2 Yearly
CP monitoring at all
feed points
Monthly
CP monitoring at all
test station
Quarterly
Coating health
survey CAT / DCVG
5 yearly
Continuous
potential logging
(CPL) survey
Visual inspection
Road/ rail crossing
inter tidal zone
Third Party
Damages
Visual Inspection
along pipeline route
Equipment
Failure
Isolation valve
function Testing
Functional test of
Insulation joint
Internal
Corrosion
UT Survey
Anode monitoring
External
Corrosion
From LFP to
Diffuser
Weather
Related &
Outside
Forces
Third Party
Damages
Equipment
Failure
CP monitoring
Anode Monitoring
ROV/ ROTV survey
- Free span
ROV/ ROTV survey
- Lateral
Displacement /
Pipeline exposure
Monitoring against
un authorized vessel
entry
Cleaning of diffuser
13
Remarks
Recommended
Inspection
Interval
Inspection/
monitoring Task
Segment
Identification
Threats of
Concern
SEGMENTS No.
Plan
Thickness measurement at selected

critical locations. Examination of the
corrosive components present in
the service fluid. UT survey
frequency shall be reviewed based
results of two consecutive surveys.
5 yearly
Yearly
Quarterly
6 Monthly
yearly
6 Monthly
Yearly
5 Yearly
Frequency may be decided based

on thickness results obtained for
onshore segment
Once in 5
year
Once in 5
year
5 yearly
OISD 139 Clause 4.5

Diver survey
5 Yearly
5 Yearly
Continuous
Yearly
This frequency shall be reviewed

based on results of yearly cleaning.
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INSPECTION METHODOLOGY
7.1 General Survey (GVI)
Perform close visual inspection of the Riser & pipeline on topside, pig barrel, joints, supports and
bends to detect,
Signs of wall thickness loss

Pitting corrosion
Coating damages
Mechanical abrasion or dents/ deformation
Loose or damaged supports
Signs of leakages
Refer Appendix- 1, inspection report format for the respective item.
7.2 Requirments for CVI:

Close Visual Inspection (CVI) is defined as a visual inspection close enough to be able to
touch the component and clean it with a hand brush if necessary. CVI of components is not
accessible on foot and requires the use of scaffolding. As per the GVI, signs of local failure
and possible causes of failure shall be looked for during CVI.
CVI provides more detailed information than GVI and will detect smaller anomalies. CVI shall
include the following activities:
o
If the area inspected is wet it shall be dried using rags.
If loose paint, scale or corrosive products are present it shall be cleaned off using a hand
wire brush and/or a chipping hammer.
o
If lighting is not sufficient to closely inspect the area a torch shall be used to light up the
area.
Visual inspections will be carried out in order to determine corrosion levels in structure;
piping and critical equipments to identify the cause of corrosion.
o
o
Visual inspection will be carried out for passive Fire Protection (PFP) in order to
determine any damage.
o
CVI shall reveal any anomalies that can be detected by visual observations. Operations
outside the defined limits, change in physical appearance, and changes in locations, size, and
condition of the item under observations can be detected. CVI also will give an understanding
on the nature of damages, and the cause of such damages.
Refer Appendix- 1, inspection report format for the respective item.
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7.3 Wall thickness measurements:

Wall thickness measurements shall be made using digital Ultrasonic Testing (UT) equipment
having valid calibration certificate.
If satisfactory readings cannot be obtained on heavily corroded or pitted surfaces then the
surface should be fully cleaned and any loose coating, scale or other foreign deposits must be
removed.
A detailed procedure for UT shall be provided by the NDT Contractor.
Refer Appendix- 1, UTM-01 R0 for report format.
7.4 Weld inspections:

Removal of well-adhered paint coat is discouraged, hence weld-inspection, as far as possible,
shall be done using UT, that can be processed through coating instead of Magnetic Particle
Inspection (MPI). The use of MPI requires paint removal, which increases the risk of external
corrosion of the items inspected. However, if MPI is carried out for the detection of such items
as surface defects of fillet welds and any other where UT is not considered feasible,
appropriate paint-coat shall be immediately applied thereafter.
All surface flaw indications shall be confirmed by MPI after the removal of coating. The
purpose of MPI is to identify surface weld defects, locate them and measure their length.
Detailed procedures for MPI, UT, etc. shall be provided by the inspection Agency.
7.5 Risers section below sea-level

Refer to section 7 of IRR Manual for under water structures for details.
Refer Appendix- 1, RI-01 R0 , RClamp-01-R0 for report format.
7.6 Subsea Pipeline

Cathodic protection (CP) monitoring
Scope: Cathodic Potential measurements shall be carried out throughout the entire length of the
pipeline to check if,
Protection potential is within acceptable limits for steel
CP monitoring Methodology shall be established and approved prior to use.
ROV/ ROTV Survey

Scope: Visual inspection using ROV or diver shall be combined with a side scan sonar survey
on exposed pipelines to check,
Route and location
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Mechanical damage
Pipeline lateral movement
Debris
Free span locations and lengths
Kinks
Anchor scars and scouring
Seabed general conditions and features
Crossings and associated support locations
Rig spud can prints (if applicable)
Movements from previous known locations
Deliverables include scaled route drawings indicating water depth at 50-metre intervals and
locations in easting and northing.
Remotely-operated vehicle (ROV) survey

Scope: Confirm free spans, damages, debris or other anomalies found by the Side Scan Sonar
Survey.
Diver inspection
Scope: Diver survey shall be carried out only when required, in place of ROV Surveys to perform
the following functions.
Wall thickness measurements where corrosion is suspected.

Detailed inspection and NDT on selected locations of pipeline where removal of
marine growth or coating is required.
CP measurements where ROV cannot access.
Diver Inspection, when required shall be integrated with any Subsea Survey of Offshore
Structures and Subsea Pipelines in the vicinity.
7.7 Onshore pipelines

Buried segment (Visual inspection)
Scope: Visual Inspection is carried out to check pipeline for,
Right of way
Route and location
Damage coating holidays (at accessible areas)
CP systems (transformer-rectifier)
wall thickness (at accessible areas)
Where pipelines are inaccessible, possible corrosion or damage may be assessed by monitoring
the performance of the CP system or coating conditions.
Above ground / Exposed segment

Scope: Visual Inspection is carried out to check pipeline for,
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Right of way and crossings

Pipeline marker, KM Post & signboard survey
Signs and extent of any corrosion
Mechanical damage
CP systems (transformer-rectifier)
Coating deterioration and damage
Supports
Extent of vegetation
Human Activities
Wall thickness at selected locations
Soil erosion, scouring and free spans at intertidal zone
Note: NDT shall be conducted where signs of corrosion or damage are present. Internal
inspection shall be carried out in selected important accessible areas.
Refer report formats RoW-01-R0IJ-01-R0, CPcurrent-01-R0, PSP 01-R0, CJB-01-R0, TRper01R0, Casing On-Off-01-R0, Inst On-Off-PSP at TLP -01-R0, given in Appendix 1.
7.8 Coating Health Survey

Scope: Current Attenuation Survey, CAT is used to measure the overall condition of the coating
on a pipeline based on the application of electromagnetic field propagation theory.
Data collected may include,
Depth,
Coating resistance and conductance
Anomaly location, and anomaly type.
Direct-Current Voltage Gradient (DCVG) test is used to locate coating holidays and characterize
corrosion activity by measuring,
Change in electrical voltage gradient in the soil along and around a pipeline.
7.9 Internal Corrosion Monitoring

In Line Inspection
Scope: Intelligent Pigging tools, capable of measuring both internal and external damage are used
to check,
Diameter reductions
Corrosion / erosion features, both external and internal
Rate of corrosion
Pipeline integrity
Residual life
ILI methodology & procedure shall be established and approved shed prior to carrying out the
inspection.
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Cleaning Pigging and Residue Analysis

Scope: To descale and clean the inside of pipeline and conduct pig residue examination to
understand the condition of pipeline and decide subsequent pigging frequency.
Residue examination may provide,
Evidence of microbial action

Iron count in water
Indicative corrosion rate
Note: Internal surface shall be monitored for corrosion and erosion by suitable methods such as
probes, weight loss coupons, sampling, thickness gauging and monitoring fluid characteristics.
7.10 Inspection of components

Inspection of Valves
Scope: To check and confirm if the condition of the Valve and accessories is suitable for operation.
Inspection shall check the following.
Accessibility for operation

Condition of valve platforms
Hand wheels for manual operation
Remote/ buttons for auto
Lubrication, where applicable
Flanges and seals
Condition of motor and electric connections, where applicable
Integrity of umbilical and end connections
Function test of Valves

Scope: To check and confirm if the Valve is maintained in good condition so that it is available for
service, when required.
Function test shall include the following.
Shut down using auto and manual modes for ESDV

Operation of Hydraulic Power unit
Remote operation of SSIV
Manual operation of SSIV
Partial closure MOV using auto and manual modes.
Refer ESDV-01-R0, SSIV-01-R0, Appendix 1, for report formats
18
GSPC/AIMS/PL/IRR-01
REV NO. 0
DATE : 12/11/2013
INSPECTION REPORTING REQUIREMENTS:
Urgent reports shall be generated for anomalies detected during the survey, as per the Anomaly
table below.
Report of the work shall be made on the completion of each activity as per the formats included in
this manual.
8.1 Anomaly acceptance criteria & reporting

All anomalies and their acceptance criteria for structure, piping and static equipment shall be as per
this table.
ANOMALY
Weld defects
REJECT CRITERIA
Any cracks, incomplete or absent
welds
Corrosion
Greater than 3 mm depth, on at

least 15% of circumferential area
for tubulars or surface area for
beams.
Thickness
Less than 75 % nominal wall

thickness (based on wall
thickness of surrounding good
material), covering at least 15 %
of circumferential area or surface
area
Physical
damages
Any major damage due to

physical impact / overload or
relative movement, leading to
rupture or severance
Vibrations
Any prolonged vibration.
19
REPORTING REQUIREMENTS
o Record weld, position, extent and type of
anomaly on drawing.
o If surface weld crack suspected, do MPI
to investigate weld
o Take Photograph
o Fill in anomaly datasheet.
o Measure area of corrosion, % cover in
area, max. depth and diameter of pits,
and average depth and diameter of pits.
o Record component, position and details
on drawing.
o Take UT Wall Thickness reading on worst
corroded area and take nominal WT next
to corroded area.
o Photograph, stand off of area, close up of
largest pit.
o Fill in anomaly datasheet, with sketch
and details of UT readings.
on drawing
o Take (additional) UT Wall Thickness
readings to establish extent of anomalous
area
o Photograph
o Fill in anomaly datasheet, with sketch and
details of UT readings.
o Dimension damage.
on drawing.
o Take close-up and stand-off photography.
o Cordon/barrier off affected areas.
o Notice severity, frequency and effect
(amount of deflection).
o Identify reason or source.
o Record affected components and details
of vibration on drawing.
Degradation of
coatings/
rusting
Damage to
paintings
Lack of
Integrity
GSPC/AIMS/PL/IRR-01
REV NO. 0
DATE : 12/11/2013
Rusting to the extent of 15 to

20% of surface rusted
o
Any insecure, loose, misaligned
or broken components that can
lead to accident.
Example:
o Loose handrail
o Loose grating (without clips)
o Grating too small
o Missing grating
o Hazardous debris which may
fall and hit someone
o grating installed the wrong
way
o protruding steel
o
o
o
Record component, position, description

of damage and area size in m2 on
drawing.
Photograph damage.
Record component, position and describe
on drawing.
Reinstate if possible (e.g. loose bolts),
and note on drawing action taken.
Take close-up and stand-off photographs
if not reinstated.
8.2 Anomaly reporting

Reporting shall be as per attached format in Appendix.
8.3 Inspection Reports

To demonstrate that the safety critical system and the components are suitable and continue to
meet their performance requirements, inspection /monitoring records shall be maintained. Such
records must be retained for the life of the installation, and shall be covered under a suitable Data
Management system and kept updated.
The Certification Agency (CA) shall verify and confirm periodically by audit and witnessing
compliance to the recommended inspection monitoring program. The inspection reports along
with the CA recommendations shall be maintained and followed up. The reports shall also
contain information on the scope and extent of the examination undertaken, and clearly identify
the equipment verified. Formats appended to this document shall be used for reporting.
REVISIONS TO THIS MANUAL

9.1 Events initiating revisions
This manual may require changes that are triggered by events such as:
Physical changes to installation (e.g. modifications, additions).

Damage / incidents.
Change in record-keeping systems.
Results feed-back from completed verification activities.
Results of any safety assessments.
Out-come of any studies/ analyses, etc. carried out.
20
GSPC/AIMS/PL/IRR-01
REV NO. 0
DATE : 12/11/2013
Updates may also be initiated based on:

the results from inspection, monitoring and testing activities
the results from any integrity assessment
changes in operating parameters or any other changes that may affect the total threat picture,
or
if any changes occur in the authority requirements or in any other premises and assumptions
for the period in question.
10 REFERENCE DOCUMENTS
ASME B 31.4
ASME B 31.8
ASME B 31.8 S
ASME B 31 G
P & NG Regulations
OISD Standards & Guidelines 138 and 139
11 DEFINITIONS/ TERMINILOGY
ABBREVIATION/TERM
MEANING
CVI
Close Visual Inspection, defined as being close enough to be

able to touch the component and clean it with a hand brush, if
necessary. CVI of components not accessible on foot
requires abseiling, or the use of scaffolding
General Visual Inspection, without need to clean, prepares a
site, or arranges special access. If normal access is not
available, GVI is done from a distance, with the help of
binoculars.
Magnetic Particle Inspection
Not applicable
Non-Destructive testing
Ultrasonic Testing
GVI
MPI
N/A
NDT
UT
12 ANNEXURE
Reporting formats.
21
INSPECTION REPORTING FORMATS
for
PIPELINES
DEEN DAYAL OFFSHORE FIELD
GUJARAT STATE PETROLEUM CORPORATION LIMITED
DOC. REF: AIMS/PIPELINE/IRR-01
GUJARAT STATE PETROLEUM CORPORATION LTD.

RISER CLAMP MONITORING
Report No: ..
Date of report:
Date of previous inspection. :
Platform name :
Service Fluid : .
Pipeline Size & Designation : Inspection contractor: ..
Inspected by:
Drawing No.:.
Visual Inspection
Clamp No. & Type
Riser Clamp Tag No:
Visual inspection of clamp
Visual inspection of welds
CP values at Riser Clamp (-ve)

2
3
4
Remark
Clamp Clearance
Location
Clamp No. & Type

Top
12 O'clock
3 O'clock
6 O'clock
9 O'clock
Sketch:
Comments:
Bottom
Clamp No. & Type

Top
Bottom
Clamp No. & Type

Top
Bottom
UT THICKNESS MEASUREMENT
Report No: ..
Date of report:
Platform name :
Pipeline size & Designation :
.
Drawing No.:
Pipeline thickness: .
Service fluid : .
UT contractor:
UT equipment Details :
Equipment Make & Serial No:
Frequency:
Size:
Type of Probe:
Couplant:
Calibration:
Details of section where

UT is carried out
UT
Location:
UT 01
UT 02
UT 03
UT 04
UT 05
UT 06
UT 07
UT 08
UT 09
UT 10
Location on pipeline
12 O'clock 3 O'clock 6 O'clock
Sketch:
General Survey, Visual Inspection

Observations
Comments
Notes:
From
To
9 O'clock
Remarks:
1. For all pipeline, thickness measurement to be carried out as per above figures.
2. All UT locations shall be permanently marked for evaluation of corrosion rates.
3. Thickness measurement to be carried out at 100 mm grid pattern
RISER INSPECTION
Report No: ..
Date of report:
Platform name :
Pipeline size & Designation : Service fluid: .
Riser From: To: .
Drawing No.:
Inspection Contractor:
Design
Thickness
Sketch:
Observations
Comments
Available
thickness
(Range)
Overall
Riser
condition
Clamp
Type &
condition
Coating
type &
condition
Damage /
Corrosion
Weld Joint
condition
Remark
BARREL INSPECTION RECORD

Report No: ..
Date of report:
Last Date of inspection:

Service fluid:...
Pipeline size /designation :

Drawing no: ..
Pipeline ID :
Position ( Verticle / Horizontal): ..

Visual Inspection: ..
Relief Valve :
Pressure Gauge:
Vent Connection:
Drain Connection:
Closure: ...
Pure Connectors:
Pig Indicators: .
Main Line Valve: .
Kicker Valve:
Barrel ( Internal): .
Remarks:

ESDV MONITORING
Remark
No
Sealant
Injection
Yes
Completeness
of Operation
Turning angle
Through
SCADA
(Remote mode)
Open
( 0 - 100 %)
Close
( 0 - 100 %)
Open
( 0 - 100 %)
Close
( 0 - 100 %)
Open
( 0 - 100 %)
Close
( 0 - 100 %)
Open
( 0 - 100 %)
Close
( 0 - 100 %)
Open
( 0 - 100 %)
Close
( 0 - 100 %)
Oil Level
Position of valve
/ vertical)
Approach Details
Location
Size
Tag number
Through
Solenoid
(Pneumatic)
Service fluid: ..
Acceptance standard / Verification documents:
Inspection Contractor: .
Inspected by: ..
Hydraulic
(Local
Manually)
Platform name :
Pipeline size & designation : .
.....
P&ID /Drawing no.:
Oil/ Gas leakage if any
Date of previous inspection :
(Horizontal
Report No: ..
Date of report:

SSIV MONITORING
Remark
Completeness
of Operation
Turning angle
Through
SCADA
(Remote mode)
Hydraulic
(Local
Manually)
Open
( 0 - 100 %)
Close
( 0 - 100 %)
Open
( 0 - 100 %)
Close
( 0 - 100 %)
Open
( 0 - 100 %)
Close
( 0 - 100 %)
Open
( 0 - 100 %)
Close
( 0 - 100 %)
Oil/ Gas leakage if any
Oil Level
(Horizontal
Position of valve
/ vertical)
Condition of Umbilicals
Service fluid: ..
Acceptance standard / Verification documents:
Inspected by: ..
Location
Platform name :
Pipeline size & designation : .
.....
P&ID /Drawing no.:
Size
Tag number
Report No: ..
Date of report:

INSPECTION OF INSULATION JOINT
Report No: ..
Date of report:
Pipeline size/designation : .
Service fluid: ..
Inspection contractor: .
Inspected by: ..
Location
IJ
IDENTIFICATIO
N
Section
Measured PSP
ON/OFF PSP (-) ve v/s CSE
Up-side
Down-side
Chainage
ON
OFF
ON
OFF
Resistance ,
Remarks

PIPE TO SOIL POTENTIAL (P.S.P) MONITORING
Report No: ..
Date of report:
Pipeline size/ Designation : Service fluid: .

Inspection contractor:
Inspected by:
AC input
DC Output
CPS
No. Voltage (V) Current (A) Voltage (V) Current (A)
TLP
No
Type of
TLP
Location
Ground Bed
Resistance in
Reference Voltage
(-V)
Other Reading
Chainage
PSP (V) Type of Value
(m)
reading (V)
Remark
Performance of the Cathodic Protection System

Actual surface
area protected (
Total length to be Total surface area to be
Actual length
% of
protected ( m)
m)
protected ( Km)
protected (Km)
protection

CP CURRENT MONITORING
1
2
Report No: ..
Date of report:
Pipeline size/ Designation : .

Service fluid: .
3
4
5
6
7
8
11
12
13
14
15
16
17
18
19
20
21
22
Location
Sector
Chainage
Name
Current in Amp for Year .

Base
Jan
Feb
March
April
May
June
July
Aug
Sept
Oct
Nov
Dec

ROW SURVEY
Report No: ..
Date of report:
Pipeline size/ designation : .
Service fluid:
Inspected by: ..
P&ID No:
Sr.
No.
Alignment Sheet No
Section Details
Location
Starting Chainage in mtr End of Chanage in mtr
Present Condition of
ROW
Action taken by
Date

MONITORING OF CJB
Report No: ..
Date of report:

Service fluid: .
Inspected by:
Pipeline size/ Designation :
Location
Chainage
Section No
CJB Number
CPS /Section
details
Measured
TR NR
Pipeline
Details
Current in
Amps
Total
Remarks

TR UNIT PERFORMANCE MONITORING
Report No: ..
Date of report:

Service fluid: .
Inspected by:
Pipeline size/ Designation :

Service: ..
Sr.
No.
CP Station
NR
Mode
AC Input
V
TR Unit Performance
DC Output
PSP Reading
Reference
Internal
External
V
A
Electrode
Remark

REPORT FORMAT TEST STATION MONITORING
Report No: ..
Date of report:

Service fluid : ..
Inspection contractor: .
Inspected by: ..
Section No.
CPI No.
Location
Chainage
Section Name
TR Output
Volts
Amp
Remarks: All potential values are against Cu/CuSO reference cell.
PSP in Volts
Pipe
Pipe
Remarks

CASING ON / OFF SURVEY
Report No: ..
Date of report:

Service fluid:
Inspected by:
Location
Section No.
CPI No.
Section Name /
Crossing details
CSP
Chainage
ON/OFF CSP
) ve v/s CSE
Remarks: Measured casing pipe to soil potentials in (-) ve V v/s CSE
ON
OFF
(-
Pipe to Casing
Resistance,
Remarks

INSTANT ON/OFF PSP READING AT TEST POINTS
Report No: ..
Date of report:

Service fluid : ..
Inspecticontractor: .
Inspected by: ..
Location
Section No.
CPI No.
Section Name
Measured PSP
ON/OFF PSP (-) ve v/s CSE
Pipe
Casing
Chainage
ON
OFF
ON
Resistance,
OFF
Remarks
INTEGRITY MANAGEMENT MANUAL &

UNDERWATER INSTALLATIONS
FOR
DEEN DAYAL OFFSHORE INSTALLATIONS
DOC. REF: AIMS/UW/IRR-01
GSPC/AIMS/UW/IRR-01
Rev No.0
INSPECTION REPORTING REQUIRMENTS
DATE: 12/11/2013
The use of this Manual is mandatory as per the Asset Integrity Management Policy
of the company.

Revision No.
Rev-0
Rev- Draft A
Revision A
DESCRIPTION
Approved by :
George Mathew
Reviewed by :
Stephen Pinto
Issued for use
Manual draft issued for comments by GSPC
Manual prepared by ABS Industrial Verifications,
issued for internal review.
DATE
12/11/2013
08/11/2013
25/10/2013
Notes:
comments.
2, 3 etc., onwards.
This
document
is confidential.
shall be
be duplicated
duplicatedororused,
used,oror
This
document
is confidential.No
Nopart
partof
ofthis
this document
document shall
disclosed
for any
other
purpose
without
priorpermission
permission from
of GSPC.
disclosed
for any
other
purpose
with
out prior
GSPC.
ii
GSPC/AIMS/UW/IRR-01
Rev No.0
DATE: 12/11/2013
TABLE OF CONTENTS:
1.
INTRODUCTION .............................................................................................................................. 5
2.
PURPOSE ......................................................................................................................................... 5
3.
SCOPE ............................................................................................................................................... 5
4.
MANUAL CONTENTS..................................................................................................................... 5
5.
SAFETY CRITICAL ELEMENTS (SCE)....................................................................................... 6

5.1 Safety Critical Elements........................................................................................................ 6
6.
INSPECTION MANAGEMENT PROGRAM ................................................................................ 7

6.1 Inspection Program ............................................................................................................... 7
6.1.1 SCE Components & Inspection Program - PLQP ...................................................... 7
6.1.2 SCE Components & Inspection Program-DDW1 ....................................................... 8
7.
INSPECTION METHODOLOGY .................................................................................................. 10

7.1 As-Built Survey ..................................................................................................................... 10
7.2 Spider Deck .......................................................................................................................... 10
7.3 Splash-Zone ......................................................................................................................... 11
7.4 Monitoring the corrosion trends ......................................................................................... 11
7.5 Marine Growth Survey ........................................................................................................ 12
7.6 Marine Growth Removal ..................................................................................................... 12
7.7 Debris Survey/Removal ...................................................................................................... 12
7.8 Monitoring Scour / Mud mats ............................................................................................. 13
7.9 Exposed Piles....................................................................................................................... 13
7.10 Conductor / Conductor Guides .......................................................................................... 14
7.11 Cathodic Protection Survey................................................................................................ 14
7.12 Visual Weld Inspections...................................................................................................... 15
7.13 Critical weld Inspections [Type II & III] ............................................................................. 16
7.14 Riser Inspection ................................................................................................................... 17
7.15 Pipeline Inspections ............................................................................................................ 20
7.16 Appurtenances ..................................................................................................................... 20
7.17 Damages ............................................................................................................................... 21
7.18 Flooded Member Detection ................................................................................................ 22
7.19 Suggested Remedial works ............................................................................................... 22
8.
SELECTION OF DIVING AGENCY ............................................................................................ 25
9.
INSPECTION JOB PACKS .......................................................................................................... 28
10. INSPECTION REPORTING REQUIREMENTS ........................................................................ 29

10.1 Anomaly acceptance criteria & reporting ......................................................................... 29
10.2 Anomaly reporting................................................................................................................ 32
10.3 Inspection Reports............................................................................................................... 32
11. REVISIONS TO THIS MANUAL .................................................................................................. 32
iii
GSPC/AIMS/UW/IRR-01
Rev No.0
DATE: 12/11/2013
11.1 Events initiating revisions ................................................................................................... 32

12. REFERENCE DOCUMENTS ...................................................................................................... 33
13. DEFINITIONS/ TERMINILOGY ................................................................................................. 34
14. ANNEXURES .................................................................................................................................. 34
Annexure-A: Recommended schedules for Inspection & Maintenance of Jacket

structures
Annexure-B: Reporting formats.
iv
1.
GSPC/AIMS/TOP/IRR-01
Rev No.0
DATE: 12/11/2013
INTRODUCTION
Gujarat State Petroleum Corporation Limited (GSPC) is the operator of the Deen Dayal
Field (Block- KG-OSN/2001/03) situated at offshore from the Yanam-Kakinada coast of
Andhra Pradesh, India.
This Inspection and Maintenance Management Manual is developed for the underwater
structures viz. Jacket, Risers, Riser Clamps, Piles, Conductors, Barge Bumpers, and
other structural appurtenances etc. installed for offshore facilities of Process Platform
(PLQP) and well head platform (DDW1) in the KG Basin.
This Manual describes the philosophy and the scope for the inspection and maintenance
program, inspection frequencies, technical performance of inspection work and the
requirements for inspection documentation.
This document shall be treated as a guide for implementing the inspection and
maintenance program in compliance to various requirements.
2.
PURPOSE
The objective of this manual is to provide suitable guidelines and the frame work for
maintaining the integrity of the Topside systems & processing facilities at the offshore
platform facilities to facilitate effective management of the inspection and maintenance
programs and demonstrate that the safety critical elements are capable, suitable and
continue to function safely throughout the operation phase achieving the required level of
integrity to assure safety and serviceability.
3.
SCOPE
The scope of this Manual covers the following facilities installed in the Deen Dayal
offshore field:
PLQP Process cum LQ Platform & DDW1 Well Head Platform that consists of the
following:
a. Jacket Structure.
b. Risers and Riser Clamps.
c. Appurtenances.
4.
MANUAL CONTENTS
This Manual consists of the following:

a. Inspection program and reporting requirements.
b. Reporting formats.
5.
Rev No.0
DATE: 12/11/2013
SAFETY CRITICAL ELEMENTS (SCE)
The company has established appropriate HSE and integrity management system
which are implemented at stages of design, procurement, manufacturing and installation
of the project.
Details on the process of selection of SCEs are given in Section 5 of the Asset Integrity
Manual. SCEs applicable for the underwater structures are given below.
5.1
No.
Safety Critical Elements

Safety
Critical
Element
Management
Structure
Jacket
Function
Applicable
Components
Description
Management systems
Prevent
failures
by
proactively
managing
integrity by implementing
Standard
operating
procedures, training of
Prevention
personnel involved to
control human errors,
change management etc.
to maintain Risk within
ALARP.
HSE management
Operation
Management
Integrity
Management.
SOPs, etc
Integrity
of
Jacket,
supporting the Platform
Topsides.
Jacket structure, Piles
Prevention
& foundations, Riser
guards and supports.
extreme
environmental
loads, marine corrosion
etc.
Rev No.0
6.
DATE: 12/11/2013
INSPECTION MANAGEMENT PROGRAM
Critical functions, for which the SCEs are responsible, are studied for failures in detail
through a failure mode effect and criticality assessment (FMECA) and the main causes
of failures are identified. For each failure mode, the appropriate technical measures for
the prevention, detection, control and mitigation of major accident events are
determined that are relevant to the major accident hazards. Evaluation of the failure
modes helps in development of relevant monitoring & inspection tasks/program and
taking suitable corrective actions when required.
The inspection and monitoring programs are expected to confirm the ability of the SCEs
and components to continue their functions as specified during the life cycle.
6.1
Inspection Program
Details of the SCEs and their components and applicable programs are as follows:
6.1.1
SCE Components & Inspection Program - PLQP
S.
Component Failure Causes
No.
Risk
Inspection/ maintenance
Category task.
Overload due to static,

problems related to the
environment,
overstressing critical joints etc.
2
3
4
Jacket
Primary
members
Anodes
Load due to excess marine

growth.
Failure due to Fatigue
loads
and
developing
cracks.
Primary members affected
by
external
impacts
causing
dents
and
damages.
Corrosion leading to loss of
thickness and failure of
members.
Splash Zone Marine Corrosion.

Flooded
member
Internal
corrosion
failure of members.
H
H
and
L
Reference
Critical joints identified from

analysis reports, monitored Once in 5 years
through CVI & NDT.
Maintain marine growth
within the design thickness
limits.
Critical joints identified from
analysis reports, monitored
through CVI & NDT.
st
P&NG Rule30 Max- 5

years
nd
Survey 1 & 2
year, thereafter
twice in 5 years
OISD
Once in 5 years
Certification
Condition survey- GVI.

If severe such as holes, etc. Condition based.
analysis would be required.
st
Spider Deck
Accelerated corrosion due
&
to sea water splashing.
appurtenanc
Coating damages.
es
Support clamp damages &
increase
in
load
to
supporting
members,
riser
Riser &
supports. failure.
Corrosion due to splash
zone coating failure /
Frequency
nd
Survey 1 & 2
CP level & Wall-thickness
OISD /
year, thereafter
monitoring.
Certification
once in 5 years
Wall
thickness,
CP
Twice in 5 years
monitoring
Conditional,
in
Visual survey & NDT if
case any holes or
required.
cracks noticed.
Annual GVI.
GVI.
UT
Wall-thickness Others
monitoring paint condition. conditional.
GVI.
Twice in 5 years.
CVI.
5 yearly.
CP & UT Wall-thickness
Rev No.0

external damages.
DATE: 12/11/2013
monitoring.
st
Pipeline
Piles
Pipeline free span / un

supported sections.
Exposed piles.
6.1.2
S. No.
Component
Risk
Category
Failure Causes
Jacket
Primary
members
Anodes
Load due to
marine growth.
Primary
members
affected
by
external
Impacts causing dents
and damages.
Marine corrosion leading
to loss of thickness and
failure of members.
Marine Corrosion.
Flooded
member
Internal corrosion
failure of members.
Failure due to Fatigue

loads and developing
cracks.
Splash Zone
Pipeline
Twice in 5 years.
and
Support clamp damages

& increase in load to
supporting
members,
riser failure.
Corrosion due to splash
zone coating failure /
external damages.
Pipeline free span / un
supported sections.
Inspection/
maintenance task.
Frequency
Maintain marine growth

within
the
design
thickness limits.
Critical joints identified
from analysis reports,
monitored through CVI
& NDT.
Condition survey- GVI.
If severe such as holes,
etc. analysis would be
required.
st
GVI.
P&NG Rule30 max- 5

years
nd
Survey 1
& 2
year,
thereafter
twice in 5 years
OISD
Once in 5 years
Certification
Condition based.
nd
Survey 1
& 2
CP level & WallOISD /
year,
thereafter
Certification
thickness monitoring.
once in 5 years
Wall
thickness
monitoring
CP Twice in 5 years
monitoring.
Conditional in case
Visual survey & NDT if
any holes or cracks
required.
noticed.
GVI.
UT
Wall-thickness
Annual GVI.
monitoring
paint
Others conditional
condition.
Reference
Critical joints identified

from analysis reports,
Once in 5 years
monitored through CVI
& NDT.
st
Accelerated
corrosion
Spider Deck &
due
to
sea
water
appurtenance
splashing.
Coating
s
damages.
Riser &
supports.
excess
Visual surveys
SCE Components & Inspection Program-DDW1
Overload due to static,

problems related to the
environment,
overstressing critical joints
etc.
Visual surveys
Failure of guide support

members due to conductor
Conductors
movements when guides
missing.
10
Visual survey
nd
Survey 1 & 2
year, thereafter
once in 5 years
st
nd
Survey 1 & 2
year, thereafter
once in 5 years
Twice in 5 years.
CVI.
CP
&
UT
Wall- 5 yearly.
thickness monitoring.
st
nd
Survey 1
& 2
Visual survey
year,
thereafter
Piles
10
Exposed piles.
Failure of guide support

members
due
to
Conductors
conductor
movements
when guides missing.
Visual surveys
Visual surveys
Rev No.0
DATE: 12/11/2013
once in 5 years
st
nd
Survey 1
& 2
year,
thereafter
once in 5 years
Twice in 5 years
Note: The inspection frequencies specified above are based on OISD guidelines, current international
practices and best industry practices. These shall be updated with more detailed engineering analysis
based on RBI assessments or advanced structural analyses in future.
7.
Rev No.0
DATE: 12/11/2013
INSPECTION METHODOLOGY
Inspection of jackets shall cover the items from (+) 2 m above the spider deck level down
up to 30 meters away from riser/pipeline weld or flanged joint at sea-bed level, and
includes:
The leg/pile transitions.
The jacket structure including mud mats.
Pipeline up to 30 m from riser/pipeline flanged joint.
Appurtenances such as:
o
Boat Landing.
o
Barge Bumpers.
o
Boat Fenders etc.
Conductor & guide supports.
Riser and Riser supports.
7.1
As-Built Survey
As-built survey is carried out to confirm that the Jacket installation confirms to the as-built
drawings.
Verify the presence, integrity and arrangement of all legs, bracings, skirt piles,
conductors, conductor frames, sumps, pump caissons, anodes and miscellaneous
attachments. Any variations from the AS-BUILT drawings are to be highlighted.
If additional members are to be observed, measure the diameter and wall thickness and
take adequate metrology along with a suitable sketch.
Reporting requirements:
Report any deviations with respect to structural members and number of anodes if it is not
matching with the drawings.
7.2
Spider Deck
Visually inspect the following for degradations due to marine corrosion, coating damages,
external damages etc.
Hand-rails.; Gratings.
Spider Deck tubular members.
Leg/pile weld joints [castellated weld joint].
Conductor guides.
Sump/pump caissons.
Any other miscellaneous piping and attachments.
Visually inspect the condition of the above- water structural members at the splash zone
area. Take photographs of any defects/anomalies found.
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Reporting requirements:
Photographs.
Damage/ Anomaly reports.
7.3
Splash-Zone
The splash zone area will be as defined in the applicable drawings and/or Scope of Work
and/or Job-Pack.
Carry out a detailed splash zone coating inspection [type, extent, damage, etc.]
on all surface breaking structural members [Legs and vertical diagonal members
(VDM)] close to the mean sea level as the sea conditions permit.
Take one (1) wall thickness measurement if submerged and
One (1) CP measurement on the parent metal [without damaging the coating, if
any] of each leg and main member.
In case of degradations, corrosion damages or any other anomalies noticed, carry out
detailed visual inspections (DVI) followed by NDT. More readings will be required in case
of any anomaly. It shall be reported with photographs and inspection details.
Reporting requirements
Photographs.
Damage/ Anomaly reports.
Wall thickness survey reports.
7.4
Monitoring the corrosion trends
To monitor corrosion and Marine growth over a period of time, subject one weather-side
leg to additional inspection as follows:
Remove a vertical strip of marine growth approximately 100mm wide from the top
of the
zone of fouling, down to EL (-) 3m. or the lowest tide level, whichever
is deeper.
In the presence of well bonded, uniform epoxy or paint coating, the coating shall
not be
removed. In such cases the presence of coating shall be highlighted
in the final report.
Visually inspect the cleaned strip and report any corrosion or damage.
Wall thickness survey reports
Commencing at EL (+) 6m or 2m above spider deck level, (whichever is higher,
and finishing at the bottom of the cleaned strip) take wall thickness readings at
the following locations:
o
At 0.5m intervals down the leg.
o
In all areas of corrosion where loss of wall thickness is apparent. In the
case of pitting, pit-depths shall be measured with an approved instrument.
11

o
7.5
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DATE: 12/11/2013
At any locations specifically requested by the Client and/or Third Party

Inspection/ Certification agency.
Marine Growth Survey
Select member identified for thickness survey and carry out similar measurements on the
Marine growth.
Weather-side Leg:
o
Take measurement at 5 meter intervals down the leg from the sea level to
elevation (-) 40 meters inclusive & thereafter at 10 meter intervals down
the leg from EL (-) 50 meter to the seabed.
o
Take the above measurement either through a circumferential reading or
depth gauge.
o
Briefly describe the species composition of the fouling at each level.
All members:
o
Make a general visual assessment of the extent of marine fouling on all
braces. This may be carried out as a part of the AS-BUILT survey.
o
Estimate the average thickness of 'firm' marine growth on each member.
o
Estimate the maximum thickness of 'firm' marine growth on each member.
Anodes:
o
Estimate the thickness of marine growth on each anode.
Photographs.
Marine Growth thick ness readings.
7.6
Marine Growth Removal
Remove all marine growth off all members, bracings, risers, conductors, clamps, Anodes
etc.
7.7
Debris Survey/Removal
Debris is materials lying in and around the Jacket, which can interfere with the CP of the
Jacket.
Carry out a full debris survey of the structure and the surrounding seabed out to
10 meters from the structure, on all risers and out to 20meters from the tube-turn
along all the pipelines.
Remove all debris from the jacket, riser, pipelines, (out to 20meter) where
possible without the aid of rigging or tuggers etc.
Wherever an item of debris which is in contact with a part of the jacket / risers /
pipelines is removed, the under lying area is to be inspected for signs of damage
and/or corrosion.
o
DVI & NDT is to be carried out for any damage found.
12
7.8
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DATE: 12/11/2013
Report the location and description of all the major items of debris on the jacket /
risers / pipelines which could not be removed.
Monitoring Scour / Mud mats
Visually inspect the condition of the mud mats and report during the base line survey.
During subsequent surveys, this shall be limited to a visual survey and CP monitoring.
7.9
Measure the profile of the seabed relative to the bottom level horizontal bracings,
and record the water depth during the Base line survey.
Four equi-spaced (90 degree apart) intervals around all main legs and skirt piles.
The node and further at 2 meter intervals along all major (leg or leg /skirt pile)
bracings out to four meter from the nearest leg / skirt pile.
In case of scouring, measure the water-depth at 2.0m intervals along the seabed
out to 4 meters from the structure.
If the member is buried, measure the depth of burial from the seabed to the top
of the members or indicate the percentage burial depth. If the member is
partially-buried report the percentage burial.
Measure the profile of the seabed relative to all pipelines at 2m intervals along
the pipeline out to 20 meters from the tube turn or the end of any unsupported
suspension.
In the case of bracing/ pipelines unsupported at seabed, the measurement is to
be taken with reference to the bottom of the member to the seabed at the
locations indicated in fig. 2.1 and 5.5.81.
Exposed Piles
Monitoring is limited to exposure and CP readings.
Note the presence of any exposed piles at the seabed and measure the length of
the pile visible at 4 equi-spaced points around it (i.e. 90 degrees apart).
Take one Cathodic potential reading on all exposed piles.
Take two wall thickness readings spaced 180 degrees apart on all exposed piles.
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DATE: 12/11/2013
Conductor / Conductor Guides
Carry out a general visual inspection of the conductor and the conductor guide frame
assemblies at each jacket level, noting areas of damage or movement. Wherever conductor
guides are missing, same shall be reported.
Visually inspection conductor guides weld joints for any damages.
7.11
Cathodic Protection Survey
Carry out a general visual inspection of the Anodes, their locations, attachments and confirm
the numbers and report following:
Verify the presence of all the anodes on all members, launch trusses, risers and
pipelines out to 20m from the tube turn or the touchdown point of any
unsupported span, whichever is further.
Confirm the attachment status [by physically shaking] all the anodes.
Note any missing or damaged anodes. Where such anomalies are found the
member to which the affected anode is/was attached shall be cleaned at that
point and inspected for damage. Report any damage found and remedial action
taken.
If low cathodic potential readings are obtained in a particular region of the
structure, remove all major marine growth and corrosion product from the anodes
in that area and retake the C.P. readings 24 hours later.
Estimate the volumetric wastage of all the anodes as follows:
A.
0%
to 25%
depleted
B.
>25% to 50%
depleted
C.
>50% to 75%
depleted
D.
>75%
depleted
Cathodic Potential Measurement

All Cathodic potential measurements shall be carried out in accordance with approved
procedures.
Cathodic potential readings shall be taken as follows, unless otherwise specified

that one reading is to be taken at each location. They shall be taken:
On all members in the splash zone, on all nodes, midpoint between nodes on
main legs and braces, and all exposed piles.
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In the case of skirt piles, to confirm good pile to pile guide cathodic protection
continuity, one reading shall be taken at the top of each sleeve and one on the
corresponding pile immediately above the sleeve.
On all the areas of damage.
On all the areas affected by coating damage in the splash zone.
At all locations where evidence of corrosion has been found.
On all conductors and conductor guides.
On nodal welds.
On risers.
On pipelines.
7.12
Take still photos of all damaged anodes, remains or old attachment points of all
missing anodes.
CP Readings shall be reported for all members.
C.P readings lower than the specified limit shall be included in an urgent report.
The minimum acceptable level of protection on a cathodic protected structure in
seawater is -800mV (-0.800V) relative to a standard silver/silver chloride half-cell.
The C.P. readings obtained should be within the range of -850 to -1000mV and
any readings which are less negative than -840mV should be reported
immediately.
Report if the depletion level is more than 50% for further necessary actions.
Visual Weld Inspections
Node/Weld Identification
Welds are identified simultaneously along with the designation of chord [the
member/node which is continuous through the joint and on to which all other intersecting
components are attached] at which the weld is located followed by the brace designation.
For example:
NE11/MD51, NE11/ME51, MJ95/MJ74.
Inspection Requirements:
Clean the complete weld on all selected welds. Cleaning is to encompass a

50mm wide margin on either side of the weld cap at each location and is to be of
a standard that is sufficient to allow detailed visual inspection of the cleaned area
to satisfy the diver/inspector.
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Where protective coating is present it shall not be removed. In such cases the
coating condition as well as any obvious defects is to be reported.
All cleaned areas shall be visually inspected and the location, orientation and
size of any significant defects recorded.
Take one cathodic potential reading in the centre of the weld cap in each cleaned
area.
During the base line inspection, (as built/baseline' inspection) carryout one wall
thickness reading on the parent metal on either side of the weld cap in each
area. Where well-bonded, even protective coating is present the reading shall be
taken through the coating. In such cases the presence of the coating shall be
highlighted when the readings are presented in the final report.
7.13
Critical weld Inspections [Type II & III]
Type II & III welds are those identified as critical ones with higher probability of failure due
to high stress caused because of operating loads, environmental loads and fatigue loads
etc. These shall be identified from design & engineering analysis documents and issued
along with the job packs for inspection.
Preparation
Remove marine growth using an H.P. water-blaster or a similar item. Clean the
weld cap to a bare metal finish, heat affected zone (H.A.Z.) and a margin 100mm
wide to either side of the weld cap, using a grit blaster and/or hydraulic wire
brush.
Clean the metal surface according to the Swedish Standard 21/2A or equivalent,
which specifies a dull/flat finish. Hydraulic wire brushing produces a shiny surface
unsuitable for video or photography; hence this method shall only be used as a
contingency in the event of grit-blaster failure. Hand wire brushing or any other
hand-cleaning technique is not acceptable under any circumstances.
Remove all areas of foreign material, for example slag, within the toe of the weld
or the weld cap itself, if possible, prior to any inspection since such inclusions
may mask any underlying defect.
After cleaning, and prior to any inspection, make suitable [oil based crayon or
similar] datum reference markings on the entire length of the specified weld
without any damage [i.e. no more than 2mm deep into the metal].
Visual Inspection
Inspect every section of the weld and the adjacent parent metal.
Measure the location of each and every anomaly observed during visual
inspection or M.P.I. and record according to the datum marks, to an accuracy of
+/- 1mm. Report the side of the weld on which the anomaly is located.
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For Type-II inspection the weld shall be checked at two diametrically opposite sides
150mm long each. For Type-III, it shall be full circumference inspection.
Non-Destructive Testing (ACFM, LIZARD/EMA, M.P.I., U.T. and C.P)
Carry out ACFM or LIZARD/EMA, or Magnetic Particle inspection at specified locations,

or a visual inspection, if a significant defect is located which requires further investigation.
Take UT wall thickness readings adjacent to all the welds as follows:
Both sides of the weld cap, at four equi-spaced locations (i.e. 90 degrees apart)
around the length of the weld.
Take Cathodic Potential readings on the weld cap at two diametrically opposite locations
for nodal and girth welds and at one point midway along the length for seam welds.
DVI.
NDT reports.
Photographs.
CP & wall thickness report.
7.14
Riser Inspection
Scope commences at the insulation joint or 2 meters above the spider deck, whichever is
higher, and finishes at the bottom buttweld or flanged joint of the tube turn.
General
After metrology, prepare a sketch / key plan of the structure with the location of
all risers, size from (platform) to (platform), service (oil/gas/well fluid/gas lift/water
injection), operating pressure and temperature, diameter, type/location of
coating, bare metal areas, location of clamps, tube-turn, etc.
Record any abrasion, distortion or other physical damage to either the coating or
the riser itself.
Measure the position of each riser at all horizontal-bracing framings in the
following manner:
o
Measure from the inside of the nearest main leg to the centre back of the
riser.
o
Measure from the outside of the horizontal member to the back of the
riser.
Record the location of the bottom butt weld of the tube turn relative to the
structure.
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DATE: 12/11/2013
Remove all debris around the riser / clamps / tube turn.

Record all areas of bare metal. Clean all such areas and carry out wall thickness,
C.P measurement, and visual inspection for damage and/or corrosion to the
parent metal.
Record the position of the tube turn relative to the seabed. If the tube turn is
firmly supported, remove any clamped knee brace.
Measure the touchdown point from the tube turn. Support using sand-bags, if the
free span is in excess of the allowable limit as per design. Only after the free
span support is provided, any knee brace present is to be removed.
Marine Growth Removal

Marine growth removal shall be done such that it shall not exceed the design criteria
Riser Clamps
Using water blast clean all riser clamps, support stubs, attachment welds and
0.5m of the riser above and below each clamp.
Report the type of clamp present at each level. Clamps will be identified by their
standard Mark" numbers.
Inspect all clamps (including telescope and brace clamps) for damage /
misalignment. Check the condition of all clamps bolts. Check bolts tightness
using a suitable wrench. All loose /missing bolts are to be tightened or replaced.
Replace any missing or severely damaged clamps.
Inspect all riser clamps for the presence of neoprene liners. In the case of nonconcrete-coated risers, the replacement of any missing clamp liners is
mandatory. In the case of concrete coated risers, the missing liner needs to be
replaced only where its absence results in tolerance between the clamp and the
riser.
Visually inspect and confirm the integrity of all attachment welds and jacket
bracing(s), particularly at the end of all gusset plates.
Measure all (riser, telescopic, member) clamp tolerances and if it is
unacceptable, (i.e. the clamp is not secure) the packing is to be installed.
Report/record any evidence of vibration or movement of risers.
When an area of bare metal extends behind a clamp, report to the Client / TPIC
Representative. [As per an approved procedure, the clamp may have to be
opened, and the riser cleaned and inspected prior to the application of new
coating.]
Inspect the riser for corrosion / damage at the clamp edges.
Wall Thickness
Wall thickness readings shall be taken on all risers at (a) 4 cardinal points on all bare
metal areas and (b) all areas of corrosion/pitting.
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DATE: 12/11/2013
Splash Zone
Clean the corroded / rusted portion of the riser to bare metal by hydraulic /
pneumatic wire brush at points where the splash zone coating is not present.
Make 100mm grid in the bare metal areas of the riser and record the minimum
thickness reading in each grid. In the case of risers which have diameters that
are 4 inches or less, grids shall be drawn at 4 equal spaced points around the
circumference of the riser pipe (i.e. 90 degrees apart) and at 100mm vertical
intervals.
The grids may be changed to a higher one [such as 500 mm x 500 mm, etc., i.e.
less stringent] or a more stringent one [such as 50 mm x 50 mm in pitted areas],
based on the visual condition and in consultation with the Client / Third Party
Inspection/Certification Agency.
Carry out the inspection between (+) 2 meter above the spider deck clamp top
(datum) and down up to C level clamp.
In the case of Monel sheathing in the splash zone, carry out visual inspections of
Monel to riser top and bottom circumferential weld joints after proper cleaning.
Top weld joints shall be checked by Dye penetrate testing. Monel longitudinal
seam welds shall also be visually inspected. The condition and location of Monel
plugs shall be checked and if found loose shall be tightened and reported to
Client / Third Party Inspection/Certification Agency.
If any dent is noticed on the riser pipe, dent dimensions shall be measured or
recorded. MPI of the dented area shall also be carried out.
Photographs of the riser above MSL shall be taken before and after the painting
work.
Cathodic Protection of Risers
Confirm the presence, location and secure the attachment of all anodes.
Comment and then remove all major growth and corrosion from the surface of all
anodes. Record any painted or partially painted anodes, remove the paint by
water blasting if necessary.
Estimate the volumetric wastage of all anodes as per 3.1.8 above.
Photograph the most severely depleted (>50%) anode on each riser.
Take cathodic potential reading as follows:
o
o
o
o
o
o
On each anode and on the adjacent pipe to confirm electrical continuity

between the two areas.
On the entire exposed field joint welds.
On all the areas of exposed bare metal.
On either side of any mechanical pipe joints.
On riser clamp caps, clamp saddles and the risers adjacent to all clamps.
At the back of all uncoated tube turns (100 mm grid).
19
7.15
Rev No.0
DATE: 12/11/2013
Pipeline Inspections
Scope of inspection is up to 30m away from the bottom butt-weld or flanged joint of riser
tube turn.
7.16
Triangulate the approach paths of all pipelines relative to the adjacent jacket
face.
Triangulate the location of all pipeline crossings.
Visually inspect all pipelines out to 30m from the tube turn and report any
damage, corrosion or other anomalies found.
Measure/record the profile of the sea-bed relative to all pipelines at 2m intervals
along the pipeline out to 20 meters from the tube turn.
Record condition of bolts/nuts of any flanged joints for loose nuts, missing nuts,
etc.
Check/record the condition of coating.
In case bare metal exists, measure/record UT wall-thickness at 4 cardinal points,
and CP.
At tube turn, measure/record the offset distance between the riser and the
nearest suitable member of the jacket.
Record all crossing pipelines and the distance between them. Record the
presence of any wedge between the pipelines in contact with each other, and the
condition at the contact point.
Appurtenances
This covers inspection of the following:
Boat landing / fenders/ access ladders.

Launching skids / trusses.
Sump pipes and their supports/guides.
Pump caissons and their supports / guides.
Mud mats.
Boat Landing / Fenders / Access Ladders
Verify the presence and location of all boat landings/fenders and access ladders.
Clean (but DO NOT remove any paint / coating) and carry out a visual inspection
of all welds attached to these appurtenances. The welds at both the ends of stubbraces should be cleaned and inspected.
Clean using water-blast and inspect all attachment clamps. Replace any missing
bolts/damaged clamps and tighten all loose bolts.
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DATE: 12/11/2013
Inspect all areas of the boat landings, fenders and access ladders for damage /
corrosion. In the case of boat landings and access ladders note in particular any
damaged or missing grating, steps or handrails which may render them unsafe.
Photograph all such appurtenances and all anomalies found during their
inspection.
Launch Trusses
Visually inspect the launching trusses and their attachment welds for damage or
corrosion.
Anode inspection of the launching truss can be limited to one anode per level for
monitoring purposes only.
A CP survey of the launch truss is not required, it is only important to ascertain
the integrity of the connection (with respect to C.P) of the launch truss to the
primary structure.
Sumps/Pump Caissons and their supports/guides
7.17
Confirm the location of all sumps/pump caissons and inspect them and their
supports/guides for damage or corrosion.
Note the extent of marine fouling in sump termination/caisson entries. Remove,
by water blasting if necessary, any excess fouling found to be present.
All attachment welds and/or clamps are to be cleaned using water blast and
inspected.
Retighten all loose clamps/bolts, replace any missing clamps/bolts and re-align
any misaligned clamps.
Check the condition of any grating over sump terminations/caisson entries.
Photograph all sump terminations/caisson entries (after cleaning, if necessary)
and take photographs of attachment points/clamps if any anomaly is observed.
Damages
Carry out GVI/DVI & NDT as according to the damages.

Take sufficient detailed measurements to determine accurate dimensions of, and
to precisely locate, the defect.
Carry out taut-wire out-of-straightness measurements (in two planes at 90
degrees) on all significantly-damaged structural members, risers and pipelines.
Measure the depth and orientation of all dents or other structural defects. Use a
straight-edge to determine the depth of localised defects.
In the case of holes, dents, wire rope or similar scars in underwater members,
take CP and UT wall thickness measurements.
Report/record weld cracks immediately.
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All damages shall be immediately reported with information on possible cause of

the damage.
Take still photographs of the damage. Include sketches.
Detailed report including measurements and NDT reports.
All major damages shall be brought to the notice of the certifying agency immediately.
7.18
Flooded Member Detection
Flooded member detection may be required on selected braces only (usually vertical
diagonal members, horizontal perimeter members and primary horizontal diagonal
members). If members are flooded, an additional general visual inspection is required to
determine the cause of flooding. If through-thickness cracking of the nodal welds at the
ends of the flooded member is suspected to be the cause of the flooding, then a detailed
inspection of these nodal welds is required.
7.19
Suggested Remedial works
Remove and recover all significant debris, within the capabilities of the spread,
from the structure and up to at least 20m away from structural members and
pipelines and report any damage caused by the debris and all debris that for any
reason cannot be recovered to the surface or removed. Remove or cut all wire
ropes crossing the pipeline.
Remove any riser elbow supports which prevent access for riser elbow wall
thickness measurements. Replace all supports removed to the preferred
distance of three (3) metres along the pipeline from the lower riser elbow buttweld.
Support all free spans which exceed the allowable length. Refer to the pipeline
database for details of allowable free spans PRIOR to the inspection.
Secure all loose attachments on the boat landing, if any are present.
Insert missing neoprene liners in the riser clamps unless the risers are designed
to be in electrical continuity with the platform. Remove any neoprene liners from
riser clamps where the riser is designed to be in electrical contact with the
platform. Confirm the pipelines cathodic protection status from the pipelines
database PRIOR to the inspection and rectification.
Tighten all loose bolts. Replace all missing nuts/bolts including lock nuts.
Remove redundant riser clamps and replace damaged clamps.
Secure all loose anode mountings.
Replace missing anodes.
Replace all depleted (>90% depleted) anodes.
Remove all riser knee braces.
Clean and remove obstructions from the sump and caisson intakes.
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DATE: 12/11/2013
All open flood valves should be closed or otherwise sealed. If the valves are
jammed some form of bung closure should be inserted, or the valve should be
sealed using a "splashtron" compound (or equivalent).
Replace / repair missing / damaged gratings, hand-rails, etc. on spider deck, boat
landing, etc.
Replace any missing Barge Bumper vertical member chain.
Replace missing/damaged or install new continuity cable to improve low CP
readings. Re-check CP readings 24 hours later to improve it.
Replace missing riser clamps.
At sea-bed, install a suitable wedge such as rubber sheet or wooden wedge, etc.
between two or more pipelines in contact with each other.
In the case of any weld crack, a hole may have to be drilled under the
instructions of Client/Third Party Inspection/Certification Agency at the ends of
the crack in order to arrest the propagation of the crack. Further actions include
metrology, photos, NDT, etc.
Note: All Remedial Tasks are to be carried out under Client and/or Third Party
Inspection/Certification agencys instruction.
Still photographs
Still photographs will be required in case of any damages, discrepancies, anomalies etc.
such as the following examples:
Corrosion.
Hole in member.
Bent member.
Dent in member.
Missing member, clamp.
Loose nuts/bolts.
Missing clamp liner.
Free span of pipeline.
Scour.
Before its removal/relocation, large debris in/near jacket.
Missing coating.
Ultrasonic wall thickness

UT wall-thickness readings will be required in the following cases:
Corrosion.
Rusting.
Pitting.
Loss / damage of coating.
As a part of the as-built survey and Type II/Type III surveys.
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DATE: 12/11/2013
General Notes
Coating
Any existing coating shall not be removed for any visual/NDT inspection except where
specified. CP, UT wall-thickness readings, etc. if required to be taken shall be done at
missing coating areas.
Depth Readings
Record the date and time in which all the depth readings are taken.
Discrepancies/Damages
Still photos and sketches are required for all damages, discrepancies, anomalies, etc.
If any anomaly, discrepancy or damage etc. is significant, additional
measurements or inspection or NDT as required by the Client / Third Party
Inspection/Certification Agency will also be required.
In the case of a serious defect during General Weld Inspection, for example
cracking being observed, full cleaning and detailed inspection shall be carried out
on the affected weld.
Cathodic Potential
Any remedial action for improvement in CP will require re-taking the CP readings
24 hours later to verify that the improvement has indeed occurred.
Contact C.P. measurements are required; remote CP measurements are not
acceptable.
In case of a significant anomaly between any finding or measured reading [e.g.
UT wall thickness, CP value, etc.] and the specified reading, the same shall be
re-checked by another diver.
Type II/III welds

Selection of welds to be inspected will be taken from the list of low fatigue life / high stress
welds and will be included in the Job-Pack. 50% of these welds are to be inspected as
Type II [General Weld Inspection] and the remaining by Type-III [detailed inspection
including NDT]. During the next inspection campaign, Type II welds shall be inspected as
Type III, and vice versa.
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DATE: 12/11/2013
Procedures
Procedures related to ACFM, LIZARD/EMA, M.P.I., U.T. and C.P shall be based on
international codes/standards, and shall be approved by Client / Third Party
Inspection/Certification Agency. With regard to MPI, flexible cable techniques will be
given first preference, followed by prod and then yoke, and lastly permanent magnets.
Triangulation
This may be carried out by means of diver hand-held sonar (either passive or active), or
by taking physical measurements to fixed reference points on the structure such as the
main legs on the adjacent face.
Remedial jobs
8.
All critical remedial jobs will be as per an approved procedure supported by

approved risk assessments.
Before carrying out any remedial job, supporting documents such as records,
sketches, photographs, video etc. will be required.
SELECTION OF DIVING AGENCY
Inspection/Diving Agency
Should possess valid (a) ISO 9001 or similar, and (b) IMCA certifications. Each
certification should be at least 2 years old.
Should have carried out at least two similar jobs [full jacket] in the last 5 years
Will be subjected to pre-mobilization audit by the Client / Third Party
Inspection/Certification agency as per applicable IMCA requirements.
Diving Methodology / Spread
Air Diving.
Saturation Diving.
The methodology that is proposed to be utilized by the Agency shall be submitted
for Client / Third Party Inspection/Certification Agencys approval with proper risk
assessments of each identified critical activity.
Each dive should be preceded by a Briefing Meeting and end-of-dive meeting
with minutes highlighting the critical findings / actions recorded.
Divers shall use Hat-Mounted Camera for all dives including shallow dives and
monitored by the diving supervisor in Control Room.
One Supervisor shall monitor and be in control of only one Diver at a time.
25
Rev No.0
DATE: 12/11/2013
Minimum on-site diving personnel shall be as per IMCA requirements.

Video recording of all inspection work is required as records. This shall be
submitted along with Diving Agencys Inspection Report.
Dive Control Room shall be in a proper cabin.
Reporting
At site, Daily Log Books, minutes of meetings, incident reports, etc. shall be as
per applicable IMCA requirements.
Inspection Report shall be a comprehensive detailed report with inclusion of all
records, photos, sketches, etc. Contractors Inspection Report format will be
reviewed during the pre-mobilization audit.
Diving Vessel
Should be classed by a reputable IACS Society.

Should have been involved in at least one similar job [full jacket] in the last 5
years.
Personnel
Diving Superintendent
o
At least 10 years overall experience in jacket inspections/surveys and 5
years as a Diver.
o
Should have carried out at least two similar jobs [full jacket] in the last 5
years.
o
Logbooks signed by Client should be available as evidence.
o
Medical fitness certificate.
Diving Supervisor
o
At least 10 years overall experience in jacket inspections/surveys and 5
years as a Diver.
o
Should have carried out at least two similar jobs [full jacket] in the last 5
years.
o
Logbooks signed by Client / Diving Superintendent should be available as
evidence.
o
Inspection / Report Coordinator

o
Should be an Engineering graduate with NDT Level II qualifications of at
least 2 years.
o
Should have experience of at least one similar job within the last 5 years.
o
Should be available at all times at the offshore site.
o
Responsible for all site meetings and minutes.
26
Rev No.0
DATE: 12/11/2013

Inspection divers
o
At least 6 years overall experience, with at least 2 years as an Inspection
Diver.
o
Should have carried out at least one similar jacket job in the last 5 years
so as to carry out same activity/inspection.
o
Logbooks signed by Client / Diving Superintendent / Diving Supervisor
should be available as evidence.
o
Qualification, NDT certificates.
o
Medical fitness certificate including eye test.
o
Country divers are not acceptable.
Construction divers
o
At least 3 years overall experience as a Diver.
o
Should have carried out at least two similar jobs in the last 5 years.
o
Logbooks signed by Client / Diving Superintendent should be available as
evidence.
o
Qualification certificates.
o
o
Will not carry out any inspection.
o
Country divers are not acceptable.
Technicians
o
At least 3 years of overall experience.
o
o
Riggers
o
At least 3 years overall experience.
o
o
o
Safety Officer
o
At least 3 years overall experience.
o
o
o
o
Should be available at all times at the offshore site.
Diving equipment

Inspection/Certification agency as per applicable IMCA requirements.
27
Rev No.0
DATE: 12/11/2013
NDT Instruments
Calibration certificates of all the instruments shall be available on site at all times.
Functional tests shall be demonstrated during pre-mobilization audit.
Inspection/Certification agency as per IMCA requirements.
Safety
9.
Safety Manual covering all the aspects of the scope of work including risk
assessments should be submitted for review.
Safety Officer shall be present on the site at all times.
Safety briefing should be carried out before the start of job and de-briefing at the
end of job with the minutes submitted to the Client.
Functional trials such as escape to chamber within the prescribed time, etc. shall
be demonstrated at the site before commencement of diving operations.
All equipment including Generator set, etc. shall be certified as fit for use for
offshore work by a reputable Third Party Inspection/Certification Agency.
Pressure vessel/chambers, etc. shall be certified by a Competent Authority
before release by a reputed Third Party Inspection/Certification Agency.
Notwithstanding the on-board presence or absence of Client/Third Party
Inspection Agency/others, it is understood that the Diving Agency is responsible
for all safety/health/environmental issues related to the execution of the work.
Before the first dive, the on-site audit of installed systems shall be carried out by
Client/Third Party Inspection Agency.
INSPECTION JOB PACKS
Inspection job packs for each inspection campaign shall be developed with reference to
the relevant inspection program.
The Job-Pack shall include:
A description of the inspection scope, listing components to inspect and the
corresponding inspection technique.
A reference to the anomaly Criteria for acceptance.
A reference to the standard.
A reference to all relevant inspection and testing procedures.
The details of the component to be inspected, joint details, framing details, anode
lay outs, specifications, as built data etc.
A photocopy of the marked up drawings from the previous inspection, with details
of anomalies, and on which the inspectors made amendments.
A list of un-rectified anomalies from the anomaly database, highlighting which
ones shall be inspected.
A print-out of anomaly photographs.
Anomaly reporting formats.
28
10.
Rev No.0
DATE: 12/11/2013
Urgent reports shall be generated for anomalies detected during the survey, as per the
Anomaly table below.
Report of the work shall be made on the completion of each activity as per the formats
included in this manual.
10.1
Anomaly acceptance criteria & reporting
All anomalies and their acceptance criteria for the underwater structure & components
shall be as per this table
Anomaly
1. Weld
defects
Reject Criteria
Any cracks, incomplete
or absent welds.
Reporting Requirements
o
o
o
o
o
2. Corrosion
Greater than 3 mm
depth
o
o
o
o
o
3. Thickness
4. Physical
Less than 75%

nominal wall thickness
(based on wall
thickness of
surrounding good
material), covering at
least 15 % of
circumferential area or
surface area.
Any major damage
o
o
o
o
o
Record weld, position, extent and type of anomaly on

drawing.
If surface weld crack is suspected, do MPI to
investigate weld.
Take Photograph.
Fill in anomaly datasheet.
Subsequent remedial action may include arresting the
crack by drilling a hole at each end of the crack as per
an approved procedure and under instruction of
Client/Third Party Inspection\Certification agency.
Measure area of corrosion, % cover in area, maximum
depth and diameter of pits, and average depth and
diameter of pits.
Record component, position and details on drawing.
Take UT Wall Thickness readings as per a grid pattern
on worst corroded area and take nominal WT next to
corroded area.
Photograph, stand-off of area, close up of largest pit.
Fill in anomaly datasheet, with sketch and details of UT
readings.
Subsequent remedial action may include NDT, paint
coating if above water, etc.
Report if less or more than the specified thickness.
Take (additional) UT Wall Thickness readings to
establish extent of anomalous area.
Photograph.
Fill in anomaly datasheet, with sketch and details of UT
readings.
Dimension damage.
29

damages
5. Vibrations
due to physical impact

/ overload or relative
movement, leading to
rupture or severance.
Any prolonged
vibration.
o
o
o
o
o
o
6.
Degradation
of coatings/
rusting
Damage to
paintings
7. Lack of
Integrity
Rusting to the extent of

15 to 20% of surface
rusted.
o
o
o
8. Conductor
movement
Any insecure, loose,

misaligned or broken
components that can
lead to accident.
Example:
o Loose handrail.
o Loose grating
(without clips).
o Grating too small.
o Missing grating.
o Hazardous debris
which may fall and
hit someone.
o Grating installed
the wrong way.
o Protruding steel.
Any movement within
guide at any level
9. Riser
movement
Any movement within

clamp at any level
10. Low CP
readings
Any reading less

negative than
(-) 840mV
o
o
o
Rev No.0
DATE: 12/11/2013

Take close-up and stand-off photography.
Note severity, frequency and effect (amount of

deflection).
Identify reason or source.
Record affected components and details of vibration on
drawing.
Subsequent remedial action may include arresting the
vibration suitably.
Record component, position, description of damage
and area size in m2 on drawing.
Photograph damage.
Report CP if underwater. If low, proceed as per 10.
below.
Record component, position and describe on drawing.
Reinstate if possible (e.g. loose bolts), and note on
drawing action taken.
Take close-up and stand-off photographs if not
reinstated.
Note severity, frequency and effect (amount of

deflection).
o Record affected components and details on drawing.
o Subsequent remedial action may include arresting the
movement by means of wooden or similar wedges.
o Note severity, frequency and effect (amount of
deflection).
o Record affected components and details on drawing.
o Subsequent remedial action may include- Tightening or replacement of clamp nuts/bolts
- Arresting the movement by means of wooden or similar
wedges.
o Report extent/area of low CP readings
o Report condition of nearest anode, and attachment.
o Subsequent remedial action may includeo Cleaning nearest anode and re-checking for improved
CP 24 hours later
o If not, installing continuity cable and re-checking CP 24
o
30
11. Anode
depletion
- Depletion beyond
50%
- Missing anode
12. Scour
Scouring close to or
more than the
designed scour
13. Pipeline
free -span
Freespanning close to
or more than the
designed value.
14. Missing
member
Absence of member
wrt drawings/sketches
furnished with JobPack
15. Hole in
member,
flooded
member
Any hole, flooding of

member
16. Missing
or loose
nuts/ bolts
17. Missing
clamp
Missing or loose nuts/

bolts
-Missing clamp
-Member partly outside
the clamp
19. Settling
of jacket
Offset of riser near/at

tube-turn [horizontal
distance between riser
and jacket structure at
sea-bed level] less or
more than that
specified
Settling of jacket into
the sea-bed
DATE: 12/11/2013
hours later, which process to continue until satisfactory

readings are obtained.
As applicable,
o Report percentage depletion.
o Report presence of marine growth, paint coating, etc
o Report integrity of anode/member attachment
o Photos, lay-out/location sketches
o Subsequent remedial action may includeo Checking CP on the member on which it is/was
attached
o Restoring CP by replacement of anode and/or
installation of continuity cable
o Report depth of scouring at several points on each
member so as to obtain a fair idea
o Photos, sketches giving adequate details
o Subsequent remedial action may includeo Supporting with grout bags or similar
o Actions as per results of analysis
o Report depth of freespanning at several points on each
member so as to obtain a fair idea
o Photos, sketches giving adequate details
o CVI along the length of pipeline for any bends, dents,
absence of coating, etc.
o Subsequent remedial action may includeo Supporting with grout bags or similar
o Actions as per results of analysis
o Immediate reporting required.
o Photos, sketches
o Subsequent remedial action may include- Installing clamp-type [or similar] member after results
of analysis.
o Immediate reporting required.
o Photos, sketches
o Subsequent remedial action may include- After results of analysis, installing clamp-type [or
similar] doubler plate with corrosion inhibitor
o Report with photos
o Report condition of member that is/was supported.
o
o
o
o
18.
Deformation
in Riser
Rev No.0
o
o
o
o
Immediate reporting required.

Photos, sketches
Subsequent remedial action may includeReplacement of clamp
Immediate reporting required.
Photos, sketches
Subsequent remedial action may includeSuitable arrangement to arrest the abnormal offset.
Make suitable marking or similar arrangement above

water level to determine/measure the amount of settling
31
10.2
Rev No.0
DATE: 12/11/2013
Anomaly reporting
Reporting shall be as per formats in the attachment.

10.3
Inspection Reports
To demonstrate that the safety critical system and the components are suitable and
continue to meet their performance requirements, inspection /monitoring records shall be
maintained. Such records must be retained for the life of the installation, and shall be
covered under a suitable Data Management system and kept updated.
The Certification Agency (CA) shall verify and confirm periodically by audit and witnessing
compliance to the recommended inspection monitoring program. The inspection reports
along with the CA recommendations shall be maintained and followed up. The reports
shall also contain information on the scope and extent of the examination undertaken,
and clearly identify the equipment verified. Formats appended to this document shall be
used for reporting.
11.
REVISIONS TO THIS MANUAL
11.1
Events initiating revisions
This manual may require changes that are triggered by events such as:
32
12.
Physical changes to installation (e.g. modifications, additions).

Damage / incidents.
Change in record-keeping systems.
Results feed-back from completed verification activities.
Results of any safety assessments.
Out-come of any studies/ analyses, etc. carried out.
REFERENCE DOCUMENTS
API RP 2A.
API RP 2C.
OISD Standards & Guidelines 130,132,137.142,145,153,174.
As-built documentation for PLQP & DDW.
33
Rev No.0
DATE: 12/11/2013
13.
Rev No.0
DATE: 12/11/2013
DEFINITIONS/ TERMINILOGY
ABBREVIATION/TERM
CVI
GVI
MPI
N/A
NDT
RE
UT
14.
MEANING
Close Visual Inspection, defined as being close enough to be
able to touch the component and clean it with a hand brush, if
necessary. CVI of components not accessible on foot requires
abseiling, or the use of scaffolding.
General Visual Inspection, without need to clean, prepares a
site, or arranges special access. If normal access is not
available, GVI is done from a distance, with the help of
binoculars.
Magnetic Particle Inspection.
Not applicable.
Non-Destructive Testing.
Reliability Engineer.
Ultrasonic Testing.
ANNEXURES
Annexure-A: Recommended schedules for Inspection & Maintenance of Jacket

structures
Annexure-B: Reporting formats..
34
35
INSPECTION REPORTING FORMATS

(Annexure-B)
for
OFFSHORE UNDERWATER STRUCTURES
DEEN DAYAL OFFSHORE FIELD
GUJARAT STATE PETROLEUM CORPORATION LIMITED
DOC. REF: AIMS/UW/IRR-01
Table of Contents
Sl. No.
Format Description
ANOMALY REPORT
AS-BUILT SURVEY
BARGE BUMPER / BOAT FENDER INSPECTION
CALIBRATION LOG
CONDUCTOR INSPECTION
DYE PENETRANT TEST REPORT
RISER INSPECTION SUMMARY
SCOUR SURVEY
SPIDER DECK INSPECTION
10
SPLASHZONE INSPECTION - RISER
11
SPLASHZONE SURVEY - LEG / MEMBER
12
GENERAL VISUAL WELD INSPECTION (TYPE II
13
WELD INSPECTION SUMMARY [TYPE III]
14
INSPECTION REPORT - VIDEO LOG
Anomaly Report
Gujarat State Petroleum Corporation Ltd
Platform:
Report No.:
Location:
Date:
Item / Component:
Inspector:
Anomaly type:
Inspection Co:
Weld/Area No.
(delete as
appropriate)
Tasks carried out ()

GVI
CVI
MPI
UT
Vibration
Drawing Ref:
Readings / Condition / Comment
Photo taken
Stand-off
Sheet:
Close-up
1
2
3
4
5
Anomaly Sketch (with weld / area numbers)
Likely Cause of Anomaly:
ATTACHMENT: Job-Pack, relevant Drawing copy(ies) marked up with anomaly, NDT reports, photos.
of

PageNo.
ReportNo.
Dive MarineGrowth
Comment/
Anodes
No.
Avg.
Max.
%
Spec. Actl. Wast.
Anomaly
(mm) (mm) Max.
Range
ASBUILTSURVEY
Memb.
C.P.
(VE)
SpiderDeck/LevelA
LevelB
LevelC
LevelD
LevelE
LevelF
LevelG
Anyother
Comment/Anomaly:
Note:Ifanyanomalyispresent,pleaseNumberinColumn&ReferinCommentBox.Attachphotos,
relevantsketches,etc.asapplicable.
NameofDivingContractor:
InspectionEngineer:
Vessel:
Platform:
DivingSuperintendent/Supervisor:

Page No.
BARGE BUMPER / BOAT FENDER INSPECTION

LEG
BOLTS
JKT. FACE
DATE
DIVER
DIVE No.
TIGHT
LOOSE
MISSING
REPLB.
PIT %
COATING
CRACK
Report Ref.:
LEG
BOLTS
ANOM.
BF-1
DATE
DIVER
DIVE No.
TIGHT
LOOSE
MISSING
REPLB.
NIL
NIL
NIL
PIT %
COATING
CRACK
ANOM.
TIGHT
LOOSE
MISSING
REPLB.
PIT %
CPP
COATING
ANOM.
BF-1
BF-2
BOLTS
JKT. FACE
BF-2
TIGHT
LOOSE
MISSING
REPLB.
BOLTS
WELDED
PIT %
COATING
CRACK
ANOM.
BF-3
BF-3
BF-4
BF-4
FENDER UNIT
FENDER UNIT
DAMAGED
SECURE
DAMAGED
SECURE
CORROSION
MISSING
CORROSION
MISSING
SHEAR UNIT
SECURE
REPAIRED
(NONE)
SHEAR UNIT
DISLOCATED
SERVICEABLE
LEG
SECURE
REPAIRED
JKT. FACE
DATE
DIVER
DIVE No.
TIGHT
LOOSE
MISSING
REPLB.
DISLOCATED
SERVICEABLE
LEG
BOLTS
(NONE)
JKT. FACE
DATE
DIVER
DIVE No.
TIGHT
LOOSE
MISSING
REPLB.
PIT %
COATING
CRACK
ANOM.
TIGHT
LOOSE
MISSING
REPLB.
PIT %
C.P
COATING
ANOM.
BOLTS
PIT %
COATING
CRACK
ANOM.
BF-1
BF-1
BF-2
BF-2
TIGHT
LOOSE
MISSING
REPLB.
BOLTS
BOLTS
PIT %
CPP
COATING
ANOM.
BF-3
BF-3
BF-4
BF-4
FENDER UNIT
FENDER UNIT
DAMAGED
SECURE
DAMAGED
SECURE
CORROSION
MISSING
CORROSION
MISSING
SHEAR UNIT
SECURE
REPAIRED
(NONE)
DISLOCATED
SERVICEABLE
SHEAR UNIT
SECURE
REPAIRED
COMMENTS :
NameofDivingContractor:Vessel:Platform:
InspectionEngineer:Superintendent/Supervisor:
NONE
DISLOCATED
SERVICEABLE

Page No.
Report Ref.
CALIBRATION LOG
Location
1st Dive of project:
Last Dive
UT Wall thickness instrument S. No.:

Calibration Certificate No.:
Calibration Certificate validity date:
CP Meter S. No.:
Calib. Cert. No.:
Calib.Cert.validity date:
Wall Thickness (MM)

Calibn.
Date
Time
5.0
10.0
20.0
20.0
Cathodic Potential (-V)

Sign
Zn.
Mg.
Meter(S)
Pre-Dive.
Dive No.
Serial No.
Date
Meter(S)
Pre-Insp.
Post-Insp.
Pre-Dive.
Dive No.
Serial No.
Date
Meter(S)
Pre-Insp.
Post-Insp.
Pre-Dive.
Dive No.
Serial No.
Date
Meter(S)
Pre-Insp.
Post-Insp.
Pre-Dive.
Dive No.
Serial No.
Date
Meter(S)
Pre-Insp.
Post-Insp.
Pre-Dive.
Dive No.
Serial No.
Date
Meter(S)
Pre-Insp.
Post-Insp.
Pre-Dive.
Dive No.
Serial No.
Date
Meter(S)
Pre-Insp.
Post-Insp.
Pre-Dive.
Dive No.
Serial No.
Date
Meter(S)
Pre-Insp.
Post-Insp.
Pre-Dive.
Dive No.
Serial No.
Date
Meter(S)
Pre-Insp.
Post-Insp.
Pre-Dive.
Dive No.
Serial No.
Pre-Insp.
NameofDivingContractor:
InspectionEngineer:
Vessel:
Platform:
Sign

Page No.
CONDUCTOR INSPECTION
Report Ref.:
Sketch showing the lay-out of conductors/guides
COND.C.P. READING
No.
LOCATION
Level C
C.P. VALUE (-ve) AT HORIZONTAL BRACING

Level E
Level G
Level J
Level L
Level N
CONDUCTOR
COND. GUIDE
2
CONDUCTOR
COND. GUIDE
3
CONDUCTOR
COND. GUIDE
4
CONDUCTOR
COND. GUIDE
5
CONDUCTOR
COND. GUIDE
6
CONDUCTOR
COND. GUIDE
7
CONDUCTOR
COND. GUIDE
8
CONDUCTOR
COND. GUIDE
9
CONDUCTOR
COND. GUIDE
10
CONDUCTOR
COND. GUIDE
11
CONDUCTOR
COND. GUIDE
12
CONDUCTOR
COND. GUIDE
DIVE No. :
COMMENTS:
STRUCTURE
CONDUCTOR / CONDUCTOR GUIDE CATHODIC POTENTIALS

DATE
DWG. No.
SHEET
OF

PageNo.
DYEPENETRANTTESTREPORT
ReportRef.
Structure:
Date:
Time:
DiveNo.
Item:
Diameter:
WeldLength:
DatumLocation:
Node/WeldLocn.:
Cleaning:HPWater
HPWater/Grit
Other(Specify):
ViewingConditions:
BrightSunlight
HydraulicWireBuff
HandWireBuff
SurfaceFinish:
SubduedSunlight
Darkness
LightSource:
DyePenetrantType:
No.
MagnafluxNonChlorinatedType.
(mm)fromDatum
Start
Stop
Type,LocationandSizeofIndication/Sketch
Comments/TestRestrictions:
NoCrackIndicationFound.
WeldinGoodCondition.
Photosattached.

RISERINSPECTIONSUMMARY
PageNo.
ReportNo.
Platform:
To/From:
TempC.:
Diameter:
NominalW.T.:
Installn.Date:
Recommendations/References
TUBE ANODES AND C.P.

TURN,SCOUR,ETC.
WALL THICKNESS
STATUS
MARINE GROWTH
STATUS
CLAMP LINER
STATUS
CLAMP TYPE &

COND
COATING TYPE & COND
DAMAGE /
CORROSION
Subj.
RiserNo.:
Service:
Pressure(P.S.I.):
Comments/WorkCompleted
NameofDivingAgency:
InspectionEngineer:
Vessel:
SCOURSURVEY
PageNo.:
(+valuesindicateamountofburialtotopofmember,valueindicatescour.Allinmm).
Report.No.:
Locn.
Scour/
Depth
Time
Locn.
Scour/
Depth
Time
Locn.
Scour/
Depth
Time
Locn.
Scour/
Depth
Time
No.
%cover
(m)
Date
No.
%cover
(m)
Date
No.
%cover
(m)
Date
No.
%cover
(m)
Date
Burial
Burial
Burial
Burial
31
61
91
32
62
92
33
63
93
34
64
94
35
65
95
36
66
96
37
67
97
38
68
98
39
69
99
10
40
70
100
11
41
71
101
12
42
72
102
13
43
73
103
SketchindicatingLocationNo.isattached.
NameofDivingAgency:Vessel:Platform:
InspectionEngineer:DivingSuperintendent/Supervisor:

Page No.
SPIDER DECK INSPECTION
Report Ref.:
SpiderDeck:
1.
2.
3.
4.
5.
Handrailsdamaged.Size:
Handrailsmissing.Size:
Gratingsdamaged.Size:
Gratingsmissing.Size:
Ladder(Sp.decktocellar
deckcondition):
Risers:
Size:
Conductors:
Condition:
Bargebumper:
TotalNo.:
TotalNo.:
1.TotalNo.:
A1
a)
b)
c)
d)
Sidewise:
A2
A3
A4
B1
Sump:
PumpCaisson:
BoatLanding:
B/LBetween:
UpperStage:
1.
2.
3.
4.
5.
6.
7.
Laddercondition:
Bracings:
Rubbingstrakes:
MiddleStage:
1.
2.
3.
4.
5.
6.
7.
Laddercondition:
Bracings:
Rubbingstrakes:
LowerStage:
1.
2.
3.
4.
5.
6
7.
B2
B3
No.ofbumper:
Securingchain/rope:
Rubberfender:
Nuts/Bolts/Clamps:
Laddercondition:
Bracings:
Rubbingstrakes:
AccessLaddercondition:
Totalbracings(B/L):
Totalrubberstrakes(B/L):
WorkOutstanding:
Photos&sketchesofalldiscrepanciesareattached.
Stages:
B4

SPLASHZONEINSPECTIONRISER
PageNo.:
DETAILEDU.T.READINGS
REF.NO.:
PLATFORM:
CROSSREF.SHEET:
TO:
CLOCKPOSn.
12o/c
9o/c
ReportRef.:
RISERNO.:
SERVICE:
DIA.:
DATE:
6o/c
VESSEL
3o/c
12o/c
PIT
PIT
PIT
PIT
PIT
PIT
PIT
PIT
PIT
PIT
PIT
PIT
PIT
PIT
PIT
PIT
PIT
PIT
COMMENTS:

RISERMARKEDOUTIN100m.m.SQUARESFROMDATUMTO
ALLDIMENSIONSAREINm.m.FROMDATUMi.e.TOPOFSPIDERDECKCLAMP
ENTERMAXIMUMPITDEPTHBELOWU.T.READING.
3o/c
CALIBRATIONLOGUTMETERS
DATE/
MTRS
DIVER'SNAME
CYG.NO.
WALLTHICKNESS(MM)
CALIBN.
PRE.INSP.
POSTINSP.
TIME
10
15
20
30
12o/c
6o/c
9o/c
12o/c
1
2
3
4
9o/c
6o/c
3o/c
GRID100mmX100mm
READINGSTAKENATCENTEROFEACHGRID


PageNo.
SPLASHZONESURVEYLEG/MEMBER
SpecifiedLeg
Elv.(m)
(+)/()
CorrosionSurvey
UTSpec UTRdg.
(mm)
ReportNo.
(mm)
Dive
Memb. Coating
No.
Leg.Ref.
Start
W.T.(mm)
Ends
Spec.
Rdg1 Rdg2 Rdg3
EndofCoatingDepth:
Comments:
NameofDivingAgency:
Vessel:
Platform:
InspectionEngineer:
C.P.
Dive
(mV)
No.

PageNo.
ReportNo.
GENERALVISUALWELDINSPECTION(TYPEII)
WeldNo.
WallThicknessReadings(mm)
Chord
Brace
Memb. Spec.
12
Memb. Spec.
CPReadings(ve)
12
12
Dive
No.
Anomaly
Comment/AnomalyReport:
Note:IfAnomaliespresent,pleasenumberinColumn&ReferCommentBox.Attachphotos,sketches.
NameofDivingAgency:
InspectionEngineer:
Vessel:
Platform:

PAGE NO.
WELD INSPECTION SUMMARY [TYPE III]
REPORT REF. :
STRUCTURE :
DATE :
DATUM LOCN. :
WELD LENGTH :
CLEANING :
H.P. WATER
NODE NO :
NODE / WELD LOCN. :
H.P. WATER/GRIT
WELD NO. :
HYDRAULIC WIRE BUFF
OTHER (specify) :
HAND WIRE BRUSH
SURFACE FINISH :
SA 2.5
PRE-TEST
FLUX TESTED O
& 90
RESIDUAL FLUX PRESENT

AREA DEMAG'D:
YES
TO WELD
YES
NO
NO
N/R
YES
DEMAG CONFIRMED BY FLUX TEST :

VIEWING CONDITIONS :
MPI SPEC'S
POST-TEST
RESIDUAL FLUX DETECTION AND DEMAGNETISATION RECORD

AC
COILS
AREA DEMAG'D :
YES
DC
NO
INK TYPE :
DAYLIGHT
N/R
YES
SUBDUED SUNLIGHT
WHITE
HWDC
PERMANENT MAGNET
DEMAG CONFIRMED BY FLUX TEST :
BRIGHT SUNLIGHT
LIGHT SOURCE :
INK MAKE(S) :
MAGNETISATION
METHOD USED :
DARKNESS
BLACK
BOTH
FLUORESCENT
MIXTURE OF BOTH
MAGNAGLOW 14A
EQUIPMENT :
COILS
AMPS :
AC
PRODS
ELECTRO-MAG
PERMANENT MAG
COIL TURNS.
AMP TURNS :
POSITIVE BCI CHECKS AT (mm)
SUMMARY OF FINDINGS :
TASK
CLEANING
DATE
DIVE NO.
314
TASK
STAND-OFF PHOTOGRAPHY
PRE-TEST
DEMAG.
D.V.I.
314
314
MOSAIC PHOTOG.
PRE-GRINDING.
M.P.I. PHOTOG. PRE-GRINDING
M.P.I.
314
MOSAIC PHOTOG. PRE-GRINDING.
C.P.
MEASUREMENT
U.T.
MEASUREMENT
GRINDING &
RE-M.P.I.
POST-TEST
DEMAG.
314
M.P.I. PHOTOG.
PRE-GRINDING
VIDEO
314
314
DATE
DIVE NO.
REFERENCES

INSPECTIONREPORTVIDEOLOG
PageNo.
ReportRef.:
TapeNo.:
Sheet1of1
DIVER
Date
COLOUR
B&W
SIT
Other
Subjects:
Tape
Count
Time
Remarks

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INTEGRITY MANAGEMENT MANUAL &

INSPECTION REPORTING REQUIREMENTS

DEEN DAYAL FIELD OFFSHORE INSTALLATIONS

GUJARAT STATE PETROLEUM CORPORATION LTD

Doc Ref.: GSPC/AIMS/MAN/01

Gujarat State Petroleum Corporation Limited

ASSET INTEGRITY MANUAL & IRR

Revision Control Sheet

This document is confidential. No part of this document shall be duplicated or used, or

Gujarat State Petroleum Corporation Limited

ASSET INTEGRITY MANUAL & IRR

SCOPE OF THIS MANUAL ............................................................................................ 4

INTEGRITY MANAGEMENT SYSTEM DOCUMENTATION ................................ 4

INTEGRITY MANAGEMENT PROCESS .................................................................... 5

SAFETY CRITICAL ELEMENTS (SCE) ...................................................................... 6

INSPECTION MANUALS & REPORTING REQUIRMENTS (IRR). .................... 14

INTEGRITY MANAGEMENT PROGRAM IMPLIMENTATION. ........................ 14

INSPECTION DATA BASE MANAGEMENT. .......................................................... 16

MANAGEMENT OF CHANGE (MOC)....................................................................... 16

10 INCIDENT INVESTIGATION, ANALYSIS AND REPORTING............................. 16

: Inspection Manual & IRR Deck structure & Topside facilities.

: Inspection Manual & IRR for Pipelines.

Gujarat State Petroleum Corporation Limited

ASSET INTEGRITY MANUAL & IRR

The objective of this Manual is to provide guidance for implementing an Integrity

BASIS FOR THE INTEGRITY MANUAL

This Manual is developed to meet the requirements of the following:

Gujarat State Petroleum Corporation Limited

ASSET INTEGRITY MANUAL & IRR

3 INTEGRITY MANAGEMENT SYSTEM DOCUMENTATION

Gujarat State Petroleum Corporation Limited

ASSET INTEGRITY MANUAL & IRR

Jackets and Risers.

Gujarat State Petroleum Corporation Limited

ASSET INTEGRITY MANUAL & IRR

5 SAFETY CRITICAL ELEMENTS (SCE)

Gujarat State Petroleum Corporation Limited

ASSET INTEGRITY MANUAL & IRR

A fire, explosion or the release of a dangerous substance involving death

Step 2 - Determination of Causes

Gujarat State Petroleum Corporation Limited

ASSET INTEGRITY MANUAL & IRR

Functional role towards

Prevention of failure due

Prevention of failure due

Topsides Deck structure including helideck

Prevent failure due to

Wellhead system, X-mas tree

Prevention of failure due

Prevention of failure due

Hydrocarbon process equipment,

Chemical injection storage, Handling

Jacket structure, Piles &

Pipelines and risers including all

Gujarat State Petroleum Corporation Limited

ASSET INTEGRITY MANUAL & IRR

Prevention of failure due

Monitoring & control devices

Relief, Vent &

PSVs, SDVs, process control

Fire and Gas

Detection of gas leaks

F&G System, interface with

Mitigation of a fire event