Qa And Qc

Question 1

What is the duty holder

Answer 1

The Regulations specify & rely on VERIFICATION not CERTIFICATION
 Must be an appointed DUTY HOLDER who has authority to carry out a self-certification scheme.
 The Duty Holder will be a named individual of the operating company.
 He’s responsible for ensuring that the structure remains in a safe operational condition.

Question 2

What is an IVB

Answer 2

Regulations specify that verification must be obtained from an INDEPENDENT VERIFYING BODY (IVB)
There are four IVBs appointed by the regulations:
 Lloyds Register of Shipping.
 Det Norske Veritas / GL.
 Bureau Veritas.
 American Bureau of Shipping.

Question 3

Is there a statutory requirement to inspect structures.

Answer 3

There are no statutory requirement to inspect structures.
 Duty Holder must satisfy the IVB that a
structure does not require any inspection to ensure safety & obtain verification of this.
 The IVB has the authority to stop all
operations, if it considers that damage,
alterations or deterioration may impair its
ability to perform its design task.

Question 4

What will the duty holder do to satisfy the IVB

Answer 4

The Duty Holder will evolve a full inspection programme, that will ensure safety
 He must submit it to the IVB for
verification.
 He must appoint the IVB at the design
stage so that continuity of verification is
maintained.

Question 5

Ageing & Life-extension

Answer 5

 Were addressed explicitly for the first time in the 2005 revision of the (Safety Case) Regulations.
 This requires the submission to the HSE of a revised Safety Case where material changes to the previous Safety Case (life-extension) have occurred.

Question 6

What is the duty holders responsibility in regards to life extension

Answer 6

The Duty Holder has to demonstrate that:
 Major hazards due to ageing have been identified & adequately controlled.
 All relevant Statutory Provisions will be complied with.
 Deterioration must be integrated into an Asset Integrity Management (AIM) System & an associated plan.
 The plan will provide a link between the on-going assessment process & the inspection strategy.

Question 7

As offshore operators what is the role in setting up a Quality management

Answer 7

All Offshore Operators
Operate Quality Management Systems, which rely on Quality Assurance procedures to ensure that all management functions:
 Efficient Operations.
 Safety.
 Conformance to Legislation.
 Protection of Assets are completed effectively up to the required standards.

Furthermore, all these functions must be:
 Applied the same way every time.
 Actively Managed.
 Continuously Improved.

Question 8

Why is QC applied

Answer 8

The Quality Control is applied to ensure that:
 All processes associated with the
management system are complied with &
executed correctly.
 The processes meet the measured standard & that this fact is recorded.

Question 9

The QA for offshore structures.

Answer 9

Starts with written procedures & continues with the inspections, audits etc, that are certified & recorded throughout the structure’s life.

Question 10

QC for offshore structures

Answer 10

The QC follows the same path.

 Producing the documentation that verifies that the various processes have all been completed.

Question 11

Describe Database for QA

Answer 11

QA Systems make extensive use of databases
Advantages of a database system:
 The way the information is stored.
 Accessibility to the information is enhanced.
 Each item has a number of ‘tags’ so data can be accessed from different points.

Question 12

Example is an anomaly in a database

Answer 12

An anomaly reported on a horizontal brace on a Jacket can be accessed by:
 Type of anomaly, pitting, crack, etc.
 The member identification.
 Platform ID - will list the location of all
damage on the platform.
 Platform ID & defect type - will list the location of all defects of that type.

Question 13

What is trend analysis

Answer 13

Once the database is set up, trend analysis is facilitated & all the data required for any type of analysis is:
 More extensive.
 More easily accessed.
Documentation & record keeping are fundamental elements of any quality system.
The inspection reports, damage registers, fabrication drawings & records become part of the QA, forming the archives that prove structural integrity.

Question 14

What documents are kept

Answer 14

The offshore operators will maintain records for:
 Engineering assessments & analysis.
 Recording defects & damage.
 Maintaining the Damage Register.
 Monitoring unrepaired defects or damage.
 Modifying the existing IMR programme.  Evolving future structural designs.
 Compliance with SIs & verification by the IVB.

Question 15

Name reporting systems and what they are

Answer 15

There are two types of reporting systems.
Full Reporting System.
Every component inspected, that has any deterioration or damage, no matter how minor, is reported as defective.
 This generates large volumes of data.  Much of it considered non-relevant.
 Reviewing takes time.
 Serious defects could deteriorate further.

Anomaly Based Reporting (The preferred system)
 Only items outside specified parameters are reported.
 Any other deterioration or minor damage is accepted, with the component being considered as ‘fit for purpose’.
 Every item included in the inspection programme is fully inspected, but only those outside the specifications are reported as defective.
This has several ramifications……

Question 16

What is Criteria of Non-conformance (CNC)

Answer 16

The Duty Holder must specify the
parameters for all types of damage or
deterioration.
His response to this is, that he evolves a
Criteria of Non-conformance (CNC)

All Inspection Personnel must be:
Fully qualified in the various inspection methods.
Skilled enough to make value judgements on the job site, in real time.
Apply the parameters laid down in the CNC.

There is a high level of responsibility on all
inspection staff to properly identify any
indication found (Is it an anomaly or not).
If a reportable defect is missed, it will remain undetected until the next scheduled inspection.

Reportable defects
 Will require some actions to be initiated in accordance with the instructions given
in the CNC.
 These actions may be to repair, monitor or to conduct further inspections.
 In any event, there will be more reports
& records generated, to prove that the
anomalies have been dealt with properly.

Question 17

Describe an IMR program

Answer 17

Structures must be inspected regularly.
Safety of personnel is of paramount importance & a regular IMR programme will ensure that structural failure is avoided, thereby safeguarding personnel.

Any structure will deteriorate in service.
 An IMR cycle will target & identify items
that require repair or replacement, in a
timely manner.
 As part of a planned, controlled
programme.
 Operators of an offshore structure must comply with requirements of Government
Legislation & Sis.

A properly implemented IMR programme.
 Will provide raw data, that can be entered into a database for computer analysis.
 Inspection data can also be used to evolve improved designs for new structures.

Question 18

Name 6 stages of a structure

Answer 18

The life of a structure is split into six stages:
 Design. 
 Production of Raw Materials. 
 Fabrication. 
 Launch & Commissioning. 
 In Service. 
 Decommissioning.

Question 19

what is QA at the design stage

Answer 19

Structural Inspection Programmes
 Instigated at the conception of the structure.
 Run throughout its life.
 Forms part of QM approach to structural engineering.
Statutory Regulations also require:
 Operators ensure structures are fit for design purpose.

QA/QC is an integral part of the design stage All the calculations & drawings have to be:
 Prepared & completed to specified
procedures.
 Have internal verification.
 Be in compliance with the standards.
At this stage, the Duty Holder will nominate the IVB.

 Verification of this is obtained from the IVB.

Question 20

Safety Critical Elements

Answer 20

Another design function is to calculate, identify & specify the numerous Safety Critical Elements (SCE) on:
 Jacket
 Platform Modules
 Systems & Sub-systems

Question 21

Sce continue

Answer 21

An SCE is any part or parts of an offshore installation:
 The failure of which, would cause or
substantially contribute to a major incident.
 Or a component the purpose of which is to prevent or limit the effect of a major
incident.

Examples of SCEs are…………

Systems:
 Primary structure.
 Fire & water systems.
 Fire & gas detection systems.
 Hydrocarbon containment systems. Sub-systems:
 Mooring system.
 Deluge system.
 Control panels. Equipment:
 Mooring system main bearing.
 Fire pumps.
 Fire detection heads.
 Electrical equipment in hazardous areas.

Question 22

Design stage

Answer 22

During the design stage:
 Decisions are made regarding materials used.
 Chosen with careful attention to their
suitability.
 Steel is given certification regarding casting
specification & material composition.
 Plates are serial numbered & totally traceable.

These documents are verified & filed as part of the QC function:
 Materials supplied to the fabrication yards are stored in controlled locations so that it remains fit for purpose & traceable.
 As it is issued, certification goes with it & it’s filed with the other documentation.

Question 23

Fabrication stage

Answer 23

QA & QC continue throughout the fabrication stage:
 Welding procedures are all carefully applied & certified.
 Concrete composition is monitored, confirmed & certified.
 All inspection data is verified & filed with the other documents, continuing the build up of the QA database.

Question 24

Installation Stage

Answer 24

Launching & Installation:
 Subjected to tight QC, & the relevant
supervision, inspection control & reporting continue to be implemented & recorded.
 At this stage the most extensive underwater inspection will take place.
 The inspection undertaken on the structure so far, has been extensive & will not be as comprehensive for the remainder of its life, but will continue un-interrupted.

Question 25

Base line Survey

Answer 25

The first major in-water inspection (Base Line Survey)
Will comprise of:
 The jacket & all underwater components, including SCE.
 The seabed will be inspected up to 50m from the base.
 A CP system survey will be completed,
including CP readings & an anode count to
confirm the presence & integrity of each
anode.

The Base Line Survey will confirm:
 The structure is in the correct position.  Whether any significant damage has occurred during installation.
 Any damage identified, is accurately reported & recorded.
 Any significant defects are highlighted for immediate rectification.

The structure will only be declared fit for purpose.
 When there are no reported significant defects.
 Any reported defects have been rectified.
 Re-inspected.
 Results accepted by the Duty Holder & verified by the IVB.
The Base Line Survey will be used to evolve or modify an ongoing inspection programme, that will last throughout the remaining life of the structure.

Question 26

In-Service Stage

Answer 26

The In-Service IMR Programme will ensure that adequate monitoring is accomplished to satisfy the requirements of:
 The Duty Holder
 Safe working practices
 To achieve verification by the IVB

The usual programme for in-service inspections is based on a 5-year cycle.
Some items are inspected each year while others are inspected less frequently within the 5-year cycle.
 Each year, 20% of all SCE are inspected as a matter of routine, so over the 5 years all will be inspected once.
 There is always the option to change the schedule, should the need to do this be identified.

Question 27

In-Service Stage

A typical Annual Inspection will include:

Answer 27

 CP survey.
 Inspection of all Risers, Conductors & Caissons.
 CVI of 20% of selected representative welds.
 MPI of 20% of selected representative welds.
 Complete GVI of the entire structure.
 Debris & Marine Growth survey.
 Scour survey.
 Items on the damage register may be monitored.
Annual inspection reports are monitored & used to update the damage register & to modify the IMR programme.

Question 28

Damage survey

Answer 28

Damage Survey
 Damage may occur at any time due to
environmental forces, accidents, failure etc.
 It’s required that all damage or incidents are reported - This doesn’t happen.
 Damage underwater cannot be seen unless there is an underwater inspection programme.

70% of damage found offshore is primarily due to:
 Collision by shipping
 Fatigue failure
 Dropped objects
The majority of this was discovered by routine inspections.
The basis of an inspection is to report anything that appears not in the “as made” condition.
Specific instructions may be contained in the damage survey workbook.

Question 29

Criteria of Non-Conformance

Answer 29

The Criteria of Non-Conformance
 Parameters issued by the Duty Holder’s eng. Dept.
 Define the limit of acceptance of any damage or defect.
 If an item is identified as not being in the as-built condition, the CNC is referred to.
 States whether the anomaly is reportable or considered
as being within the acceptable limits.

If an anomaly is found, the CNC includes either:
 Follow-up actions that are authorised to be implemented without further instructions.
 Has a table of technical specifications that lays
down these follow up actions.

The method for applying CNC is straightforward:
 When an item is identified as being outside the CNC, the actions in the Technical Specification are implemented.
 The item & all data concerning it, is recorded & submitted in the inspection report.
 Any authorised follow-up action is implemented & the fact that this has been done, together with the results of the actions taken, is recorded and reported.

Question 30

Data sheets

Answer 30

The Documentation in an anomaly-based system is:
 Normally, in the form of standardised data sheets & is commonly on a computer-based system.
 Engineers become familiar with one method of presentation, saving time when reviewing data.
 Ensures that all the required information is included & does not rely on memory.

Data report sheets will be reviewed & form the basis for:
 Follow-up or additional inspection programmes.
 Maintenance or repair projects.
 Engineering analysis required by the Duty Holder.
 Reports submitted to the IVB for verification.
On completion of review action, the reports will be archived to become part of the QA records for the structure.

Question 31

Scope of work

Answer 31

A central feature of an anomaly based system will be a defined Scope of Work for each inspection campaign.
This will detail:
 Extent of the inspection.
 The components to be inspected.
 The required tasks.
The Scope of Work will be contained in the workbook issued at the start of the campaign & is part of the contractual documentation.

Question 32

The workbook

Answer 32

The Workbook will contain:
 The scope of work. 
 All the required drawings. 
 The list of inspection tasks. 
 Blank data sheets. 
 The procedures. 
 Anomaly report forms. 
 The CNC. 
 Daily report forms.
 Relevant extracts from the damage register.

The Damage Register forms a crucial part of the documentation.
 Any damage is recorded on the register, along with the repair action taken.
 Any new damage identified during an
inspection will be added to the register.

Question 33

Data sheets

Answer 33

Data Sheets.
 Are computer generated & the inspection will be recorded directly onto a computer.
 It is becoming more prevalent that data
gathered during the inspection is input into a database.
 Accessible by any authorised party, an
advantage which lends itself to engineering analysis.

Data Sheet Design
 The first question is what is its purpose? Is it part of a QA system?
 If it is, there must be a procedure that goes with it, as it performs the function of applying the requirements of the procedure & ensuring that nothing is left out.
 Provides validation that procedural
requirements have been met.

Question 34

What is included in a data sheet

Answer 34

Fields on the data sheet will normally allow the following to be recorded: 
 Customer, Client or Sponsor. 
 Data sheet reference number. 
 Contracting Company. 
 Any specialist equipment used. 
 Location (platform). 
 What cleaning standard. 
 Type of component & ref No. 
 Inspection Controller’s name. 
 Resource used to gather the data (ROV, Diver).
 Comments not covered
 Dive number. elsewhere.
 Date.
 Anomalies. 
 Signatures.
 Drawing of the component. 
 Page number.

Question 35

CP Survey reporting requirements:

Answer 35

 Visual assessment of anode condition.  % of anode wastage. 
 Sacrificial anode stub integrity. 
 ICCP cable-duct integrity & electrode
connection. 
 Marine growth build up on any anodes. 
 Metallic debris in contact with the structure. 
 CP readings at specified sites. 
 Photographs of representative anodes.

Question 36

Coating Inspections:

Answer 36

Coating Inspections:
 Note the % present of topcoat, primer & bare metal.
 Note any blistering, burst them - if client permits & try to collect a sample of any deposit.
 Assess the condition of the steel under any blister.
 Note the % of any paint cracking, sagging, wrinkling or flaking - with the extent.
If inspecting Monel, look closely for any breaks or deformation, in the Monel surface.

Question 37

CVI Procedure.

Answer 37

 GVI to assess any gross damage & MG
build-up. 
 Clean to SA2½ 75mm either side of the
weld. 
 Establish the datum - position a tape
measure & mark up the clock positions. 
 Measure & record the overall weld length. 
 Complete the CVI.

Question 38

Requirements for offshore inspection equipment

Answer 38

Equipment used during an inspection programme must be certified to conform with legal & QA requirements.
 Electric equipment should be tested 6 monthly.
 Electric equipment must be tested for safety each time it is used - RCD’s should be tested daily.
 All inspection equipment should be calibrated before & after each use.
 Competent person calibrate all electric equipment at intervals prescribed & certify this fact.