Dimensional Control

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DIMENSIONAL CONTROL PROCEDURE

DOCUMENT Nr. 00-ZA-E-G09611 Rev. 00

Date 02.01.2012 Sheet 2 of 57

INDEX INDEX.........................................................................................................................................................2 AMENDMENTS and revisions .................................................................................................................5 1

Introduction....................................................................................................................................6 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12

Scope of Work & Definition ........................................................................................................6 Contractual Definitions & Acronyms ..........................................................................................6 Responsibilities & Obligations....................................................................................................7 Codes & Standards....................................................................................................................7 Company Documents ................................................................................................................7 Contractor Documents ...............................................................................................................7 Procedures Document Objective ...............................................................................................8 Owner Specification Document..................................................................................................8 Contractor Procedures document ..............................................................................................8 Dimensional Control Activities ...................................................................................................9 Types of Structures....................................................................................................................9 Structural & Fabrication Terminology ......................................................................................10

2

General Surveying Procedure....................................................................................................11

3

Equipment ....................................................................................................................................14 3.1 3.2 3.3 3.4 3.5 3.6

4

General Equipment, accessories and hand tools ....................................................................14 Equipment - Site security and verification................................................................................15 Equipment Storage & Transportation. .....................................................................................16 Equipment Register .................................................................................................................16 Computers................................................................................................................................16 Printers.....................................................................................................................................16 Documentation & Project Drawings ..........................................................................................17

4.1 4.2 4.3 5 5.1 5.2 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.4

Documentation Control ............................................................................................................17 Shop Drawings.........................................................................................................................17 Company Reference Drawings ................................................................................................17 Precise Computerized Surveying ..............................................................................................17 Theoretical Structural Model ....................................................................................................17 Instrumentation ........................................................................................................................19 Geometric Surveying Programs...............................................................................................19 Free Station..............................................................................................................................19 Resection .................................................................................................................................20 Stakeout ...................................................................................................................................20 Tie Distance .............................................................................................................................21 Calibration ................................................................................................................................22

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DIMENSIONAL CONTROL PROCEDURE

DOCUMENT Nr. 00-ZA-E-G09611 Rev. 00

Date 02.01.2012 Sheet 3 of 57

5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 6

Dimensional Control Process ....................................................................................................42 6.1 6.2 6.3

7

Flow Chart................................................................................................................................42 Instrument & Survey data management ..................................................................................43 Computer File data management ............................................................................................44 SURVEYMAX - 3D geometric Program......................................................................................45

7.1 8

General Operating System ......................................................................................................45 CAD 3D Program .........................................................................................................................46

8.1 8.2 9

Control Network Philosophy.....................................................................................................23 Network Control Survey Methods ............................................................................................24 Checking the Reference Control Network ...............................................................................24 Structural Reference Marks .....................................................................................................25 Instrument Position and Real Time Surveys............................................................................25 Tube marking out & references................................................................................................25 Tube surveys - Instrumentation ...............................................................................................30 Determine the structural axis of a Tube using Instrumentation ...............................................33 Multi-Component Tubular Alignment – Fit up or Post Weld survey.........................................33 Beam / Column structural surveys using instruments..............................................................37 Structural Piping and interface.................................................................................................40 Temperature effects and correction application.......................................................................40

Rhinoceros version 4.0 ............................................................................................................46 Theoretical Structural Modelling ..............................................................................................46 Tolerances....................................................................................................................................47

9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.16

Jacket & Deck Interface distance.............................................................................................47 Jacket Interface diagonal distance...........................................................................................47 Jacket & Deck Interface vertical position .................................................................................47 Jacket & Deck leg or column Interface spherical position .......................................................47 Jacket Leg Straightness...........................................................................................................47 Jacket Bracing in the horizontal plane (elevation) ...................................................................48 Deck Adjacent Legs distances.................................................................................................48 Deck Diagonal Legs distances.................................................................................................48 Deck Columns diagonal distance.............................................................................................48 Deck Column straightness & verticality ...................................................................................48 Deck Column elevation ............................................................................................................48 Deck Diagonal Distance between corner Columns .................................................................48 Deck Bracing elevation ............................................................................................................48 Deck Beams & Girders centre-line position .............................................................................48 Beam Flanges ..........................................................................................................................48 Can position within the Jacket Leg ..........................................................................................48

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DIMENSIONAL CONTROL PROCEDURE

DOCUMENT Nr. 00-ZA-E-G09611 Rev. 00

Date 02.01.2012 Sheet 4 of 57

9.17 9.18 9.19 9.20 9.21 9.22 9.23 9.24 9.25 9.26 9.27 9.28 9.29 9.30 9.31 10

Reports .........................................................................................................................................51

10.1 10.1.1 10.1.2 10.1.3 10.2 10.2.1 11

Piles straightness, seam rotation, end squareness, circumference & ovality..........................48 Tubular Straightness................................................................................................................49 Tubular Local Straightness (Shell Plate) .................................................................................49 Tubular Circumference ............................................................................................................49 Tubular Local Out-of-roundness (Local Indentations) .............................................................49 Ovality or Roundness...............................................................................................................49 End Squareness.......................................................................................................................50 Node Stub locations.................................................................................................................50 Work Point location ..................................................................................................................50 Appurtenances .........................................................................................................................50 Anodes .....................................................................................................................................50 Padeyes ...................................................................................................................................50 Walkways .................................................................................................................................50 Joint Mismatch .........................................................................................................................50 Penetrations .............................................................................................................................50

Production Reports ..................................................................................................................51 Dimensional and level inspection carried out shall be recorded..............................................52 Report Sheet for Roundness and circumference inspection carried out shall be recorded ....53 Cover Sheet of Dimensional Control Report............................................................................54 Certification reports..................................................................................................................55 Cover Sheet of Dimensional Control Certificate ......................................................................55

Safety ............................................................................................................................................57

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DOCUMENT Nr. 00-ZA-E-G09611

DIMENSIONAL CONTROL PROCEDURE

Rev. 00

Date 02.01.2012 Sheet 5 of 57

AMENDMENTS AND REVISIONS

Amendment and revision

Date

X1

02/05/2011

Issued for IDC

GS

A

01/06/2011

Issued for COMPANY Comments / Approval

GS

00

02/01/2012

Issued for CONSTRUCTION

GS

Page

Description

Yard Manager

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DIMENSIONAL CONTROL PROCEDURE

DOCUMENT Nr. 00-ZA-E-G09611 Rev. 00

Date 02.01.2012 Sheet 6 of 57

1

INTRODUCTION

1.1

SCOPE OF WORK & DEFINITION

The purpose of this document is to describe the methods and procedures applied for Dimensional Control measurement during the construction of steel structures by Contractor. The Methodology applied and described in this procedure can be separated into four distinct areas:-

1.2



Structural Modeling in CAD & Geometry a) Theoretical Structural Model b) CAD programs c) Geometric 3D data analysis



Measurement Systems, Survey Controls & Reporting d) Instrumentation e) Accessories & Tools f) Geometric programs Instrumentation g) Network Control & Geometric Surveying Control references h) Reports



Geometric & Structural Position & Tolerances i) Vertical & Horizontal Alignment j) Ovality & Out-of-Roundness k) Squareness l) Shape Deformation m) Dimensions & Angles n) 3D Co-ordinates



Project Documentation & References o) Company Specification p) Contract Procedures

CONTRACTUAL DEFINITIONS & ACRONYMS

COMPANY

Saudi Arabian Oil Company (IK) / Aramco Overseas Company B.V. (OOK)

CONTRACTOR

Snamprogetti Saudi Arabia Ltd (IK) and Saipem S.p.A. (OOK)

SUBCONTRACTOR

All Subcontractors and Vendors

MAIN CONTRACT

Contract awarded to CONTRACTOR

PROJECT

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DOCUMENT Nr. 00-ZA-E-G09611

DIMENSIONAL CONTROL PROCEDURE

Rev. 00

Date 02.01.2012 Sheet 7 of 57

QC

Quality Control

DC

Dimensional Control

1.3

RESPONSIBILITIES & OBLIGATIONS

Quality Control Manager

verifies the document and signs the document

DC Project Surveyor

Co-ordinate the inspection activities and verify the QC Report for completion. Inform the Company to verify and inspect all As Built surveys by way off a RFI document (Request for Inspection)

Dimensional Surveyor

Measure the dimensions and prepare the report. Sign the report document. Inform the Company to verify and inspect all As Built surveys by way off a RFI document (Request for Inspection)

Construction Department

Perform the work as per the requirements of the Contract drawings, IFC Drawings, Aramco Standard and Quality Plan

Welding Inspector

Perform the welding and welders surveillance with verification of the correct application of the project WPS

1.4

CODES & STANDARDS

ISO 9001:2005

Quality Management System

AWS D1.1

Steel Structural Welding Code

API RP2A-WSD

Recommended practice for planning, design & constructing fixed offshore platform working stress design

API-RP2B

Fabricated Structural Steel Pipe

API 5L

Specification of Line pipe

1.5

COMPANY DOCUMENTS

Saudi Aramco

Standards

SAES-M-005

Design and construction of fixed offshore platforms

DE-119893

Procedure for Structural fabrication, load-out and tie-down of offshore structures

1.6

CONTRACTOR DOCUMENTS

00-ZA-E-G09600

Project Quality Plan

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DOCUMENT Nr. 00-ZA-E-G09611

DIMENSIONAL CONTROL PROCEDURE

Rev. 00

Date 02.01.2012 Sheet 8 of 57

00-ZA-E-G09607

Control and monitoring of Measuring Devices

00-ZA-E-G09605

Quality Records Procedure

1.7

PROCEDURES DOCUMENT OBJECTIVE

This procedure serves as a control document to ensure that the fabricated and assembled structure is maintained within the requirements of the Company’s specified tolerances. It describes in detail the methods used to undertake Dimensional Control measurement and what systems are used. This document is specifically relevant to the surveying systems and methods adopted by Contractor in order to meet the requirements of the owners Specification Document. It has been specifically adapted for the construction of ARAMCO Wasit Projects. The surveys and methods defined in this document are pertinent for the use of LEICA 3D electronic Total Station series1100 & 1200 instrumentation systems.

1.8

OWNER SPECIFICATION DOCUMENT

This document describes and defines the Dimensional tolerances and the Scope of Work requirements for the project. It specifically relates to the allowable positional tolerance of component parts relative to their theoretical design positions. In this Specification Standard, it defines the minimum and maximum out-of-position tolerance allowable as a dimension or dimensional ratio (usually in millimeters) and graphically displays some individual cases. Also, certain additional tolerances may be specified on the Project Drawings relative to a specific structural item. Additionally, agreed dimensional limitations may be approved by the Company Project Engineer or the Certifying Authority. In either case, an agreed ‘Technical Specification’ document between the owner, certifying authority and the main contractor will be applicable to the construction of the project.

1.9

CONTRACTOR PROCEDURES DOCUMENT

This document is a contractual requirement of the Contractor as instructed by COMPANY in the Specification Document. It refers to the MEASUREMENT METHODOLOGLY and PROCEDURES used by Contractor or subcontractor in order to meet the Dimensional Control requirements as detailed in the owners Specification. These two documents (Company Specification and Contractors Procedures) have individual reference numbers. All Dimensional Control reports will make reference to these documents quoting the applied document numbers.

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DIMENSIONAL CONTROL PROCEDURE

DOCUMENT Nr. 00-ZA-E-G09611 Rev. 00

Date 02.01.2012 Sheet 9 of 57

1.10 DIMENSIONAL CONTROL ACTIVITIES The primary objective of Dimensional Control is to ensure that the product conforms to the required dimensional tolerances as indicated in the owners Specification Standards document. In order to achieve a product that conforms to the required dimensional tolerances the following surveying Activities shall be undertaken: a) b) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q)

Project Structural CAD Model Construction Yard Control Network reference marks Ground reference marks Structural and component marking out and reference marks Temporary Support positions Structural Frame layout and monitoring Individual component dimensions and cut lengths Member alignment and shape surveys CAD simulation of component & sub-assembly fit-up Fit-up phase surveys at sub-assembly stage (PRE-WELD) Secondary fit-up surveys after any necessary adjustment Reports of the component Fit-up Production Reports Recommendations for welding sequence Post weld component and sub-assembled surveys Jacket erection phase surveys and adjustments Final As-Built surveys and certification Structural Load out and Barge setting out and control Heavy lift control

The survey data information from the assembly stage will allow verification of the component lengths and positions thus ensuring the compatibility with adjoining block components. At each of the stages, any structural out-of-tolerance will be reported and highlighted to the Production Department by way of registered reports. Recommendations for structural adjustment or welding sequences will be made in order to rectify structural position or the effect of welding. Post-weld or As Built surveys of the components will be undertaken once a structural block has been welded. These surveys will be documented as a Quality Control Certification Report. 1.11 TYPES OF STRUCTURES This procedure document relates specifically to the construction of structures for the Oil and Gas Industry. These structures include, but are not limited to, the following types:

Platform Jacket

Platform Deck

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DIMENSIONAL CONTROL PROCEDURE

DOCUMENT Nr. 00-ZA-E-G09611 Rev. 00

Date 02.01.2012 Sheet 10 of 57

1.12 STRUCTURAL & FABRICATION TERMINOLOGY : Final phase of structural construction for measurement certification As built survey Barge Bumpers : Structure attached to the upper jacket to moor barges safely Beam : Primary and secondary structural support component Boat landing : Structure attached to the upper jacket to allow personnel access Bollard : Tubular structure attached to the upper jacket for mooring boats Brace : Horizontal, vertical or diagonal tube connecting to legs or braces Buoyancy Tank : Structure attached to the Jacket to increase floatation properties CAD : Computer Aided Design graphically creates a measureable structure Caisson : Subsea conduit pipe used for seawater and cleaning waste services Can : Section of structural steel pipe with no girth weld seam Column : Primary structural vertical tube (Leg) in a Deck Conductor Guides : Group of guides at elevations that assist in the drilling process Conductor : Tube that guides the drilling bits and tubes Conforming : Structural component position is within the specified tolerance limits Crane Pedestal : Tubular structure attached to the deck to support a rotating crane Deck : Main upper platform structure that supports operation services Diaphragm : Steel frame placed inside a leg or tubular to create airtight areas Elevation : Structural reference level of the Jacket or Deck Fit-up : Initial phase of assembly with components tack welded Flare Boom : Structure attached to the Deck to allow the burning of excess gas Girth weld seam : Tubular circumferential butt-weld seam used to join tubes together Installation Aides : Antenna and small supports to place GPS positioning systems IR : Infrared beam of light with a narrow wave length used for measurement Jacket : Main sub-sea platform structure that supports the Deck J-Tube : Subsea conduit piping used for services to & from the platform LAT : Lowest Astronomical Tide reference level 0.000m for the platform Leg batter angle : Inclination angle of the main jacket leg relative to the vertical plane Leg: primary structural support component of the jacket Lifting Bollard : Tubular lug to attach crane slings for lifting purposes Longitudinal weld seam : A butt weld seam which is parallel to the axis of the pipe LWS : Longitudinal Weld Seam or Pipe Weld Mill pipe : Structural pipe consisting of multiple cans joined by girth welds Module : Individual deck sub-structure that contains service facilities Mud-mat : Horizontal structure at the bottom of each leg reduce penetration Non-conforming : Structural component position is outside the specified tolerance limits Padeye : Crane lifting lug on the top of the jacket or deck for installation Pile: Pipe driven through the leg/sleeve to fix the jacket to the seabed Pipe weld : Longitudinal weld seam made after the plate steel has formed a pipe Plate steel : Sheet of steel plate that is formed into tubes, cones or beams Plate weld : Longitudinal weld seam between flat plates to make larger plates or pipe Platform : Offshore structure used to drill and process crude oil and gas Post weld Heat Treatment : Relieves structural stress caused through the welding of a component Post weld : Second phase of assembly with the components welded Prism : Glass or plastic with reflective qualities to aid infrared measurement Rigging Platform : temporary structure at the top jacket to assist installation offshore Ring Stiffener : Internal or external steel ring to strengthen a tubular component

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DIMENSIONAL CONTROL PROCEDURE

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Date 02.01.2012 Sheet 11 of 57

Riser RL Single seam pipe Skid beam Sleeve Tack Weld Tolerance Total Station

: Subsea conduit piping to export gas or oil under high pressure : visible Red Laser beam that reflects from most surfaces without a prism : Can with one longitudinal weld seam made by a continuous weld process : Support beam that supports the Drilling module : Vertical tubular structure attached to a Leg to guide a pile : small amount of welding to join steel components at Fit-up stage : Allowable positional displacement of a structural component : Electronic Theodolite with computerized functions & 3D measurement

2

GENERAL SURVEYING PROCEDURE

2.1

All final As Built measurements shall be carried out by using either a Total Station theodolite or Dumpy level.

2.2

All un-calibrated measuring equipment shall not be used.

2.3

The main and sub-assemblies sketch showing the working or reference points for dimensions and elevation shall be prepared by the production supervisor, prior to any inspection.

2.4

Dimensional surveys shall be performed immediately after fit-up and after final welding.

2.5

Dimensional surveys shall also be performed on the entire structure assembly control point at a minimum frequency of once each month.

2.6

Dimensional survey report shall be submitted to the Company’s Representative no later than one (1) days after each survey.

2.7

Reports shall highlight non conforming dimensions. The Contractor shall submit a proposed remedial action for each non conformance.

2.8

Ovality of the Jacket legs shall be measured both prior to and after Load out of the jacket and results to be presented to Company to determine the stress level of the Jacket leg can sections.

2.9

If any conflict to Scope of work or any other Company requirement, the same will prevail

2.10 During the Fabrication, the Production personnel shall prepare the correct and actual working points, centre lines and position to erect. 2.11 The simple technique to determine a correct and accurate centre line of the tubular or pipe is to use spirit level and L-square. (see: Spirit level and L-square as shown in Figure 1) The ‘x’ dimension shall represent the half pipe diameter (½Ø), the technique shall carried out on both sides of tube and the mean distance will mark the true centre-line on the top. This can be applied in the horizontal (as shown) and vertical axis (side centre-line).

‘X’

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DOCUMENT Nr. 00-ZA-E-G09611

DIMENSIONAL CONTROL PROCEDURE

Rev. 00

Date 02.01.2012 Sheet 12 of 57

L-Square

Water Level

CL

i.

Figure 1 : Location and Reference Point 2.12 Dimensional check shall be done before and after cutting of any structural materials for fabrication. 2.13 The production personnel shall be responsible for establishing or marking the working point and centreline on the structure item to be check. 2.14 The established working point for dimension check shall not be changed during fabrication until completed the full fabrication. b. The Production Supervisor and QC inspector shall check the overall dimensions and verified for straightness, roundness, etc. for the sub-assembly panel before welding work and final dimension check after welding shall be carried out by qualified dimensional surveyor. 2.15 Sub-assembly structures shall be welded adhering strictly to the welding sequence, Dimensional and levelness inspections shall be carried out before commence the welding and after completion of welding work on the panel. 2.16 The tubular centre-line & reference points on main members and branch members shall be done by using low stress die stamping to ensure permanent marking even after blasting. 2.17 A verticality alignment check of the Deck Columns shall be done by using three dimensional surveys (Total station) by a qualified dimension surveyor. For short piece such as pipe to pipe or beam to beam with less than 3 meter in length, split level may be use to check the levelness and straightness at A and B orientation as shown in Figure 2. 2.18 The straightness and levelness check shall carry out at two longitudinal planes with rotated not less than 90º 2.19 Leveling check of Deck Column shall be done by using level equipment.

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DOCUMENT Nr. 00-ZA-E-G09611

DIMENSIONAL CONTROL PROCEDURE

Rev. 00

Date 02.01.2012 Sheet 13 of 57

Split Level

0º (A)

Steel Ruler

90º (B)

270

180º

Working Point

Figure 2 : Straightness Check For tubular and Beam

2.20 The overall dimension of the structure and relative positioning of the individual sub-assemblies shall be checked by using calibrated measuring tape and precise equipment such as theodolite and dumpy level as shown in Figure 3. 2.21 Topside decks, vertical columns and other members shall be dimensionally, level and vertically inspected. 2.22 The assembly of support trusses for the main structure shall be set square and in alignment by the fabrication department. 2.23 The erection of framing or deck platform structure shall be on a flat and level surface. The main structure shall be adequately supported during fabrication. 2.24 The setting of components in elevation shall be carried out by using water level.

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DIMENSIONAL CONTROL PROCEDURE

DOCUMENT Nr. 00-ZA-E-G09611 Rev. 00

Date 02.01.2012 Sheet 14 of 57

2.25 Straightness of deck column, deck bracing, girders, beams etc. during fabrication shall be measured by using a taut string stretched or theodolite depend on the length of the item/ member and the measurement shall be made at a point of greatest deviation as shown in Figure 3. 2.26 Sizes of welding, edge preparation and joint fit-up configuration shall be measured by using welding gauge. 3

EQUIPMENT

3.1

GENERAL EQUIPMENT, ACCESSORIES AND HAND TOOLS

Tape measure Is a steel measuring gauge that is calibrated to measure correctly at 20°C.? They can be of various lengths from 3 to 100 metres Theodolite / 3D Total Station A precise optical instrument that is electronically operated and computer programmed. It can measure distance, horizontal and vertical angles and instantly determine the position of an object in the format of a three dimensional (3D) co-ordinate. It can store data and display results onto its own LCD screen. All data can be downloaded or uploaded into a computer using a PCMCIA memory card or ‘Flash Card’ Dumpy Level A precise optical instrument to determine and measure the level of a component platform, subassembly panel etc. Taut wire Usually a wire that is pulled taught and straight to check and measure the alignment, straightness, levelness of a beam, pipe or tubular. Welding Gauge A gauge tool that is used to check and measure the weld gap size, high-low of tubular, pipe and others such as under-cut and material thickness. Tri-Square It is a measuring ruler to use for marking and measure the squareness. Water Level Flexible tubing filled with coloured water and used as a gauge to measure and mark the same level at individual structural areas that are at a distance apart. Straight Edge It is a steel ruler use to guide and mark a straight line. Used in conjunction with a scribe marker Levelling stadia A metrically marked measuring gauge, use together with a Dumpy Level in order to determine the level of a component.

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DOCUMENT Nr. 00-ZA-E-G09611

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Date 02.01.2012 Sheet 15 of 57

Split level & Plumb Bob It is a piece of metal which is tied with string to measure the centre-line and alignment in between the panel. Curv-o-mark Specific tool used to mark the axis or angle line on a tubular component (see section 5.1) Digital Thermometer Used to measure the temperature of a steel component that is being surveyed. The resultant temperature differences, of the steel component, can be used to quantify the thermal expansion or contraction due to the temperature changes (differences) between of separate surveys of he same component. This is only applicable to instrument surveys. Listed and shown below are some necessary measuring accessories and hand tools. a) b) c) d) e) f) g) h) i) j) k) l) m) n) o)

Spirit Levels –300mm length Steel Marker Punch Steel Marker Scribe Small steel square 150mm x 200mm Curv-o-Mark (tubular top dead centre) Small hammer Chalk Line in case Wire brush small Paint marker Chalk marking stick 3m or 5m measuring tape 20m or 30m measuring tape Reflective prismatic tapes Carrying bag Chartwell Survey book

Other items not pictured, include: p) Spike and mini prism. q) Weld gap gauge. 3.2

EQUIPMENT - SITE SECURITY AND VERIFICATION.

Apply the following guidelines for the security of the instrument a) Checks will be made to ensure that the tripod works properly and that all bolts and screws are tensioned properly. A loose tripod component can cause the internal electro-level to malfunction and signal an operating error. It will also give inaccurate results even over short distances. b) Verification of the instrument Calibration option will be made on a regular basis. Set up the instrument on one face and adjust the electro-level bubble to within a 2” range. Rotate the 180deg to the opposite face and check if it is within a 5” range. If it is not, then apply the Calibration option. c) Check periodically that the Laser Red light is in alignment with the telescope axis. This check is obligatory after transportation over a long period. d) When the instrument is set up ensure that it will not interfere with other engineering activities. e) Always ensure that the instrument is attached to the tripod by means of the tripod/tribrach screw attachment.

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DOCUMENT Nr. 00-ZA-E-G09611

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f)

Do not allow other third parties to touch or use the instrument.

g) Check and be aware what is happening within the vicinity of your working area. h) Never set up the instrument with welding or other cables straddling the tripod legs. If they are pulled they may interfere with the tripod legs and pull the instrument over. i)

Never leave the instrument unattended in a busy engineering environment. If necessary cordon off the instrument area with hi-viz bunting tape.

j)

When coordinating the instrument position, within a Network Control System by the resection method, always check into a third control point to verify the positional accuracy.

k) Ensure that, when using the instrument in the reflectorless mode (laser distance) make sure that the beam is not no interference of the distance takes place. l)

3.3

At the termination of the survey check into a Network Control reference station to verify that the instrument position has not moved during the course of the survey. If the results are not satisfactory carry out another complete structural survey. EQUIPMENT STORAGE & TRANSPORTATION.

a) All survey instrumentation items will be kept in a secure, ordered and dry environment. b) Instruments will be regularly cleaned and made dry prior to storage. c) Instruments will be made secure during transportation and if necessary placed into a padded cardboard box for extra protection. 3.4

EQUIPMENT REGISTER

A register of all surveying and measuring equipment will be established by the Quality Control Department. It will list the equipment item, reference number, relevant documentation and calibration/servicing records. 3.5

COMPUTERS

Portable computers (laptops) are used to generate complex 3D geometric CAD drawings of the theoretical structures. For security all survey data shall be downloaded into remote Data storage units to ensure that important records are retrievable. 3.6

PRINTERS

Printers are used to generate paper hard copies of surveys and report documentation.

ARABIYAH & HASBAH OFFSHORE AND ONSHORE FACILITIES CONTRACT No. (OOK) 6600026283 / (IK) 6600026284 DIMENSIONAL CONTROL PROCEDURE

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4

DOCUMENTATION & PROJECT DRAWINGS

4.1

DOCUMENTATION CONTROL

A filing system shall be established to maintain an ordered control of all survey related work and correspondence. This section refers specifically to all paper generated documentation. For computer generated documentation, see section 6.2. Main Files shall be numerically marked and titled. Titles will include the following: 1. Specification, Standards and Procedures. 2. Correspondence. 3. Equipment Register. 4. Methodology Statement and Equipment Instruction documents. 5. Reference Control Network. 6. Production report register 7. Certification report register 8. Structural surveys register per Block or major unit. 9. Node Surveys 10. Setting out Register. 11. Piping or Tubular survey register 12. HSE safety Documents & Procedures 13. Load out barge and sea-fastenings 14. Site Surveys All Files shall contain a covering Index or Register sheet which will log the documents in consecutive number order and date entry. 4.2

SHOP DRAWINGS

All construction surveys will be relative to the shop drawings. In the event of a drawing error, or lack of structural detail, the engineering office will be informed. These drawings will be in A3 format and will be kept in various titled files in order to separate and isolate individual structures. Strict control will be maintained by the issue of revisions and the updated current Construction Drawing List. Superseded drawings will be discarded. If drawings are required for site work then a copy will be made from main file register. No original file drawing will be removed from the office. 4.3

COMPANY REFERENCE DRAWINGS

These drawings (Project Drawings) will be in A3 format and kept in its own filing system. They will be used for reference only. 5

PRECISE COMPUTERIZED SURVEYING

5.1

THEORETICAL STRUCTURAL MODEL

The principle philosophy of modern construction measurement is being able to compare the actual structure and components to the theoretical designed concept. The methodology applied herein requires a complete structural model of the structures to be developed in CAD. This model will be developed as a vertical structure and based on the construction drawings. (see typical models below)

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Additional structural models will be developed with structures in the horizontal position and as individual Rows. Individual structural elements such as Boat Landings, Barge Bumpers, Elevations and Conductor Frames can be created from the principle structural model in the vertical. All surveys of actually fabricated individual components and main structural elements will be developed in CAD and will be compared to their relative theoretical models. The accuracy of the actual fabricated components will be determined and quantified by this comparison.

Zulf 480 Jacket in 3D

Zulf 480 Jacket - elv. +5.500m

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5.2

INSTRUMENTATION

Modern electronic theodolites, also known as ‘TOTAL STATIONS’, will be used to undertake surveys. Their precision and functionality ensures dimensional accuracy and capacity to record data in order to meet the requirements of the client’s specification and approved structural tolerances. These types of theodolites contain integral geometrical surveying programmes and have a specified measurement accuracy that is higher than the minimum structural tolerance as required by the owners Specification document. Total Station manufacturer Series Type TCRA1101 & TCRA1201 Angle Accuracy Distance accuracy Infrared Distance accuracy Laser Memory card Working temperature range Calibration.

LEICA Geosystems - Switzerland TPS1100 & 1200 Computerised / Electronic 1” 2mm 3mm Compact Flash card 32MB -20deg C to +50deg C Self-calibrating corrections to manufactures.

Leica instruments have a Laser measurement function (RL) which allows a distance to be taken to inaccessible points or structural locations. The measured slope distances and the instruments electronic vertical and horizontal angles are recorded automatically. The point co-ordinates are instantly calculated recorded in the PCMCIA memory card and displayed on the LCD screen. 5.3

GEOMETRIC SURVEYING PROGRAMS

The instrumentation (Leica) contains internal geometric programs that are applicable to Dimensional Control and are used to position the instrument and measure to the structural components: 

FREE STATION

co-ordinates the position of the instrument using 3 reference stations



RESECTION

co-ordinates the position of the instrument using 2 reference stations



STAKEOUT

sets out a point from a co-ordinated instrument (2D or 3D model)



TIE DISTANCE

calculates a distance between two surveyed points or more

5.3.1

Free Station

This Program uses three Control Network reference stations to position the instrument (X). The first two reference stations (e.g. R5 and R10) are used will position the instrument within the Control Network. The instrument automatically searches for the co-ordinates of all three stations that are filed in the instruments PCMCIA data memory card. Then, the instrument will prompt to operator to input the reference number (e.g. R17) of the third reference station. Once this is co-ordinate is entered the instrument will automatically turn to the reference station and it is observed. The residual errors will determine the positional accuracy. See Fig. A. If the program fails to calculate this is due to incorrect station data or station/reflector selection. If this happens, the ERROR box will display. (See ERROR DISPLAY section 7.4).

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Known Co-

R5

R1 Known CoR5 & R10 are used to calculate the position of STN Third Station

STN X Calculated Co-

R1 Known Co-ordinates

Fig. A – FREE STATION uses two Stations (R5 & R10) to calculate and one to verify (R17) the position of STATION X within the Control Network.

5.3.2

Resection

This program and the screen display is similar to the ‘FREE STATION’ program but uses only two stations. There is no calculation (‘CALC’) function necessary with the RESECTION program. Known Known R5 R10 Co-

Co-ordinates

R5 & R10 are used to calculate the position of STN X

STN X Calculated Co-ordinates

Fig. A – RESECTION uses two Stations (R5 & R10) to calculate the position of STATION X within the Control Network.

5.3.3

Stakeout

This program allows an individual point (Pnt. 2) or a number of points that have known co-ordinates to be positioned and SET OUT within a related network control co-ordinate system (R5 & R10).

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Known Co-ordinates

R5

R10 Known Co-ordinates

RESECTION R5 & R10 are used to calculate the position of STN X

Point to STAKEOUT Pnt.2

STN X

Known 3D Co-ordinates

Calculated Co-ordinates

Fig. A – STAKEOUT 3D will automatically rotate to the Pnt.2 position using the calculated bearing. The distance is verified by measuring in RL or IR mode to the surface or a target. The program will display the position error.

5.3.4

Tie Distance

This program measures the distance between two points and has two methods of calculation and display. Methods: POLYLINE or RADIAL mode POLYLINE Mode allows the measurement between consecutive sets two points.

C

B A

Distance 2 Distance 1

Results : Distances A to B : B to C: RADIAL Mode measures the distances from a single point to other individual points

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B Distance 1 Distance 2

C

A

Results: Distances A to B: A to C:

5.4

CALIBRATION

The calibration of the instrument is initially set in the manufacturers’ factory. These are known as the FACTORY SETTINGS. The instruments are standardized to measure correctly at 20degrees Centigrade and all angular alignment CORRECTION values are ZEROED. Each instrument will be calibrated and serviced annually and hold valid manufacturers’ or approved agents’ ‘Certificate of Calibration’ document. This document will be filed in the Contractor QA/QC departments’ Equipment Calibration Register. A copy of the certificate will be made available for the client. The instruments have an integral operating system that allows the instrument to self-calibrate. This selfcalibration operation is located in the Main Menu, INST. CALIBRATION. This function will verify all the instruments angular values or errors and adjust the CORRECTION values accordingly. The Instrument Calibration function checks the following angular attributes of the instrument:a) b) c) d)

l&t i c&a i/c/a

-

Compensator (electro-level bubble) Longitudinally and Transversely Vertical Index error Horizontal Collimation error & Tilting Axis Index – Collimation - Axis

All of these corrections will be checked on a regular basis and recorded. Standard Distance corrections or PPM corrections (Parts Per Million) Leica instruments are calibrated and set in the factory (Factory Settings) to measure at the Standard distances. They contain an internal program which allows the operator to take account of and input the current ambient atmospheric conditions (atmospheric pressure and ambient temperature). The measuring system uses infrared light and red laser light to measure distance, but the speed of these two light mediums are not constant. They are affected by the pressure and temperature of air. The resultant atmospheric PPM correction will be applied for each survey. The instrument will automatically adjust the measured distances to the Standard factory settings.

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5.5

CONTROL NETWORK PHILOSOPHY

A REFERENCE CONTROL NETWORK shall be established within the Construction Yard and the various Workshops. The primary function of the Network is to act as a permanent referencing system in order to position accurately (in any location) the Instrument measuring equipment. The Control Network will allow the operator to be dimensionally IN CONTROL of the SPACE about the structure. A Control Network is a group of co-ordinated survey stations (points) that have known three-dimensional (3D) co-ordinates (E: N: Z) relative to a common geometric grid. The Control network survey station can be Pillar station or adhesive reflective prismatic target. They shall be permanently fixed at structurally stable locations throughout the project assembly areas. The Control Network is used to accurately reference and co-ordinate a surveying instrument relative to the theoretical structural model. The three dimensional positional accuracy of the instrument within the Control Network will be +/1mm.

Site Control Network with the jacket position

Site Control Network Stations in RADIAL format

The survey stations shall be surveyed to an accuracy of 0.5mm and form the basis for structural measurement control. The coordinated network shall be relative to the theoretical structural design. Therefore, during the course of the structural assembly each component can be surveyed to verify its actual position relative to the theoretical model.

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Ground Pillar Control station no. 2 with a circular prism. Prismatic reflective stations G1 & G2 are positioned on the pillar.

A reference control network of survey stations shall be established at each fabrication area and the main assembly area. The network survey stations shall be located in areas of high visibility. Important care must be taken to ensure that the locations will be unaffected by movement including linear thermal expansion or contraction. Each point will be individually code referenced (e.g. A01, A02 etc). In certain cases concrete pillar stations or ground marks shall be used where visibility is limited. The Network shall also be used to monitor structural movement (shrinkage, expansion, subsidence or accidental movement) of the components and the structure. The position of the structure and its co-ordinates in the construction yard will be relative to the Network Control co-ordinate system. All CAD models of the structure (in Rhinoceros) shall be positioned to the same co-ordinate system as the Network Control 5.6

NETWORK CONTROL SURVEY METHODS

The control stations shall be surveyed in groups, as it is normally impossible to view all the survey stations from a single position. The initial survey shall incorporate the longest possible visible base line (station to station). This first survey shall be the primary FIXED base-line survey and shall be surveyed at least three times until the residual errors are less than 1mm. The base line shall be incorporated into subsequent group surveys. In order to quantify the co-ordinates of each survey station it shall be necessary to surveyed them at least three times from different locations. Each group survey will be superimposed over initial survey and a best-fit 3D geometric coordinated system will be created. Residual 3D errors from these surveys should not be more than 1mm per survey station point. 5.7

CHECKING THE REFERENCE CONTROL NETWORK

The Survey Stations shall be checked on a regular basis (usually monthly) to ensure the accuracy and stability of the Network. The results of each survey shall be recorded & documented in the Survey Control Network File. Each survey shall indicate the accuracy obtained and highlight any ambiguity or difference to the original data.

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Procedural checks shall be made during the course of normal engineering survey activities. In these cases individual survey stations will be checked against their current co-ordinates. 5.8

STRUCTURAL REFERENCE MARKS

Reference Marks or Work Points shall be placed on the structure at major structural intersection positions. These points shall be marked on a sprayed white paint surface, hard punched and reference numbered for easy identification and visibility. Each Reference Mark shall have its own theoretical 3D co-ordinate (Easting, Northing and Elevation) relative to the Structural Model. An actual As-Built survey of these points shall be undertaken in order to determine the ‘Best Fit’ axis line position of the structure. 5.9

INSTRUMENT POSITION AND REAL TIME SURVEYS

The Instrument can be positioned accurately within the Reference Control Network by using the internal ‘RESECTION’ program. Two known Reference Survey Stations will be surveyed in order to co-ordinate the instrument within +/-1mm. In addition, real-time positional surveys of structures can be made as they are being moved into their theoretically correct locations. 5.10 TUBE MARKING OUT & REFERENCES Reference marks will be created on a structure in order to identify the actual positions for a column or tube. They mark the following: - centre-line, axis, ¼ line, work point, elevation, profile development line, tubular circumferential line, penetration and cut-line. The importance and accuracy of the marking-out of these points is fundamental to the overall dimensional quality of the structure. Care and accuracy will be applied at all times during the marking out process. All marks will be clearly punched, scribed and identifiable for permanent usage during the construction phases. The points to be marked out will be recorded on a sketched sheet noting the dimensions and angles used. The original sketches will be signed, referenced numbered, checked and filed in the Setting-out Register. They mark the following:a) b) c) d) e) f)

Beam or Tube centre-line. Tube ¼ lines. Work point (structural intersections on a Node). Structural Elevation. Profile cut line or shape development line. Tubular circumferential line, penetration and cut-line.

The importance and accuracy of the marking-out of these points is fundamental to the overall dimensional quality of the structure. Care and accuracy must be applied at all times during the marking out process. All marks must be clearly punched, scribed and identifiable for permanent usage during the construction phases. Tube Measurements In order to mark out the reference lines and Work Points the first objective is to measure the dimensions of the tube. These measurements are:-

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Longitudinal Weld Seams

Outside surface circumference

Tube bevelled at both ends Diameters Circumferential Weld Seam

Tube non-bevelled (flat ended) at both ends

Length

a) b) c) d) e) f)

Wall Thickness

The tube length, bevel-to-bevel or flat end to flat end, at each side. The circumference at both ends using a flat 20m or 30m tape. The tube wall thickness. All horizontal or longitudinal weld seam positions. Note the identification number. Internal diameters (orthogonally positioned). The flat profile tape is placed around the Tube end and straightened. The circumference measured at the 100mm mark is 4.251m. True circumference di 4 151

Setting out a ¼ line using a ‘Curv-o-mark’

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All this information will be drawn and recorded in a Survey note book (Chart well Survey Book) Marking out Tube ¼ Lines Definition: - These are reference lines, on the exterior or interior surface of a tube, that are set at 90 degrees relative to each other and parallel to the axis of a tubular pipe. Their circumferential position is determined by the position of the longitudinal Weld Seam. See Fig. D Usage: - The four-quarter reference lines of a tube are marked in order to position other members that join the main tube.

.

0° ¼

The positions of these lines are set out relative to the design drawings. The drawings will show the position of the lines relative to the longitudinal weld seam.

Tube diameter = 1 000m

L / Weld seam at 45 deg

90° ¼ line

270° ¼ line

¼ to ¼ line arc dist. = 785.5mm

180° ¼

Tube Circumference arc dist. =

Fig. D - A sectional view of a tube: showing a 45deg weld seam with four-quarter lines. Method of marking a) Measure the circumferences at both ends. As tubular pipes are never exactly fabricated to their correct theoretical diameter, it is important to measure the actual circumferential distances at both ends of the tube. b) Calculate the arc distances for the ¼ lines and weld seam angle.

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If the tubes’ circumferential arc distance is 3.142m, then the ¼ lines are equal to 785.5mm arc distance. The 45 deg. L / Weld to ¼ line will be 393mm. c) To calculate the theoretical arc distances use the formulae: - 2 x π x r = circumference (Where: - π = 3.14159 ; where: - r = radius of the tube) Note: Definition of Pi or π: - is a geometric constant and is the numerical ratio of the diameter to the circumference of a circle. Pi ratio value is approximately 1 to 3.14159. Therefore, if the diameter is 1.000m then the circumference is 3.14159m.

Circumference Diameter =1.000m

Diameter

Circumference Rolled out = 3.142m

d) In chalk, set out a ¼ -line parallel relative to the Tube axis and the longitudinal weld seam. Use a Curv-o-mark or spirit level and metric tape to set the first line. e) Check all the circumferential distances that are marked. If they are correct, then proceed to punch mark the lines, as shown in the photograph below. g) Mark out, using a hammer and punch, the 100m end reference points and the Work points (as shown in the photograph below).

Marking out of a Work Point.

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g) Check all dimensions and then reference the lines & WP in paint.

Marking out of a ¼ line, at 45 degrees from the longitudinal weld seam, on a 1-metre diameter tube. h) Sketch and Record the data in the survey book. The points marked will be recorded on a sketched sheet noting the dimensions and angles used. The original sketches will be signed, referenced numbered, checked and filed in the Setting -out Register.

The marking out of a reference point exactly 100mm from the bevelled end of a tube. The points are punch marked and then reference painted.

The Curv-o-Mark is used to mark set-out a point on a tube and then develop a line so that it is parallel to the axis of the tube. In order to mark a horizontal or vertical position on a tube, the rotating angle gauge has to be aligned correctly to the reference lines at 0 degrees or 90 degrees. ENSURE that the orientation reference line, on the face of the gauge, is aligned with the required bubble angle. 1. For the horizontal or side position set the reference line to coincide with the 90 degree arc position. 2. For the vertical, top or bottom position set the reference line to coincide with the 0 degree arc position.

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Setting the bubble to 90 deg in the Horizontal position

CURV-O-MARK orientation reference Line

Setting the bubble to 0 deg. in Vertical position Top of Sliding Centre Pin Rotating Bubble CURV-O-MARK orientation reference Line

Rotating Angle Gauge

Feet supports Centring Pin Marking Point Once the bubble is centred, using a light hammer hit the top of the sliding pin to mark a first reference point. This will punch a small mark into the steel tube side wall. Without moving the central rotating gauge, turn the centre finder 180 degrees to view the bubble on the opposite face. Place the sliding pin point close to the first point. Once the bubble is centred, hit the sliding pin at the top to mark a second point. The MEAN of the first and second reference points will be the MEAN / true position of the tube axis line. Mark this mean point with a larger punch mark and chalk reference. Repeat this marking process at the other end of the tube or at the locations where the tube alignment has to be determined. 5.11 TUBE SURVEYS - INSTRUMENTATION Tube surveys are carried out in order to determine accurately the: -

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a) b) c) d) e) f) g)

best-fit centre-line (BFC) of a steel tube or of connecting tubes an actual axis intersection point (WP) or (IP) tube lengths ovality out-of-roundness circumference weld seam locations, circumferential and longitudinal

Method 1 of surveying on the outside surface a) Individual points can be surveyed on a pre-marked circumferential line on the outside surface of a tubular using the instrument’s laser reflectorless function (RL). b) Survey the ends 100mm reference points – in order to determine the tube length c) The circumferential line must be perpendicular to the axis of the steel tube. For best results it is better to mark a circumferential line either in chalk or paint in certain cases, it is also possible to follow, at an offset, the circumferential weld seam of the tubular. In this instance, positional care of the laser must be taken and follow an offset line of at least 20 to 100mm from a circumferential weld seam. This is due to the distortion of the tubular within close proximity of the weld seam area. Group 1 > 10

Group 11 > 20

CL

Laser shot locations in RED d) For accurate results, it is best to take a minimum of eight evenly spaced positional laser or infrared readings/shots around the tube on a pre-marked circumferential line. Method 1 of surveying on the outside surface e) The number of surveyed positions depends on the diameter of the tube. The greater the tube diameter will mean the greater the number of points necessary to be surveyed. f)

These results are processed in the ‘Circle Fit’ option of the ‘SurveyMax’ 3D geometric program. Each GROUP of points is processed and the data results indicate the tube radius at each point and the overall mean tubular radius. This will determine the best-ft Centre (BFC) and detail the radius of each point surveyed. An acceptable survey result will show these radii to be within 3mm of the theoretical radius of the tube.

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g) The accuracy of the survey and the form shape of the tubular can be immediately compared to the theoretical radius. h) Out-of-Roundness and Out-of-Circularity can be determined using this method.

Method 2 of surveying at the open ends

Best-Fit-Centre

(BFC)

Prism targets

a) Place a minimum of 4 or 5 reflective targets (magnetic prismatic cubes) at each the end of the tube. Make sure that the face of each target is exactly placed at the end of the tube, on the bevel or flat end. b) Using the instrument (co-ordinated into the local Control Network) survey the inside diameter of the tube at each target prism position. Survey both ends of the tube. c) The results are processed in the ‘Circle Fit’ option of the ‘SurveyMax’ 3D geometric program. d) The Circle Fit will calculate the centre co-ordinates of the targets (the centre of the tube). Method 2 of surveying at the open ends

An example showing reflective prisms placed at one end of a recently rolled tubular. These prism locations will determine the Best-Fit-Centre of the tube end - BFC.

IMPORTANT Do not place the targets within 100mm of the longitudinal weld seam. There is a tendency that the tube circumference shape in this area can be flattened out.

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Weld

Targets 200mm

5.12 DETERMINE THE STRUCTURAL AXIS OF A TUBE USING INSTRUMENTATION For accurate results it is best to take a minimum of 8 evenly spaced positional laser or infrared readings/shots around the tube on a pre-marked circumferential line. The number of surveyed positions depends on the diameter of the tube. The greater the tube diameter will mean the greater the number of points necessary to be surveyed. These results will be processed in the ‘Circle Fit’ option of the ‘SurveyMax’ 3D geometric program which determines the best-fit centre. Each point is processed and the data results indicate the tube radius at each point and the overall mean tubular radius. The accuracy of the survey and the form shape of the tubular will be immediately compared to the theoretical radius. Out-of-Roundness and Out-of-Circularity will be determined using this method.

5.13 MULTI-COMPONENT TUBULAR ALIGNMENT – FIT UP OR POST WELD SURVEY Detailed below is a practical and accurate method for surveying the alignment of Jacket legs, Piles and Tubular sections, without the need for network positioning or office processing. Results can be given on site at the location of the component being measured. It will provide results of the components alignment and display results on the instruments LCD screen:1. Direct offset errors of the tubular sections relative to the actual tubes’ zeroed reference points. 2. The alignment results, for both the Vertical and Horizontal alignment of the tubular sections, are displayed on the instruments LCD control panel screen showing in co-ordinate format the easting co-ordinate [theoretically 0.000E] and the height [theoretically 0.000Z] of each point surveyed.

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Objective: 1. Measure the vertical and horizontal alignment and lengths of two or more tubular sections before welding (FIT-UP) or after welding (POST WELD). Equipment: 1. Leica TCRA electronic theodolite with laser measurement. 2. Curv-o-mark, 3m tape, Spirit level, chalk marker, cubic reflective tape. Method: 1. Mark out the five reference points A, B, C, D, E using a Curv-o-Mark, spirit level, 3m tape, chalk and marker. 2. Check the OVALITY of the Tubes in the VERTICAL and HORIZONTAL axis at each end to ensure they are within tolerance - (Dmax – Dmin tolerance = +/- 6mm) 3. The Curv-o-Mark has to be used on two faces. (see method section 5.1) 4. Points A, B, C and E will be marked 100mm from their corresponding bevels. All the marks including point D, see section figure below, will refer to the side (90° - side ¼ line) and top (0° - top ¼ line) quarter-lines. 5. Check the vertical distance from the top (0°line) to the side at the (90° line) using a spirit level.

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Spirit Level Check dimension

Curv-o-Mark

0º line

90º Line References A-B-C-D-E

6. Set the Electronic theodolite instrument within 10 metres of the tubular to be measured. 7. Use the ‘TIE DISTANCE’ program, measure the slope distances between the reference points B > C > D > E)

(A >

8. Record the levels and level differences of the reference points (A, B, C, D, E). 9. Select two of the reference points as ZERO datum for the alignment (A and E) 10. Apply 0.000E co-ordinates to points E and A. This will mathematically give the bearing from point E to A as 360º 11. Apply 0.000N and 0.000Z to point E.

A

B

C

D

E

Inst. Set up

12. Use program ‘RESECTION’ to co-ordinate the instrument using the applied co-ordinates point A and E. Input the co-ords of the reference stations manually into the program when prompted. (Tie Distance A > E = 35.055m) A < E bearing 360º A

Apply Co-ords. for Point A. 0.000E 35.055N 0.015Z

B

C

D

Inst. Set up

E

Apply Co-ords. for Point E. 0.000E 0.000N 0.000Z

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Survey results and analysis:

Bevel to bevel – distance = 35.255m

A

B

C

D

E

Inst. Set up Points A to E – distance = 35.055m Point A. Co-ords. 0.000E 35.055N 0.001Z

Point B Co-ords. 0.006E 32.205N 0.006Z

Point C Co-ords. 0.007E 32.000N 0.005Z

Point D Co-ords. 0.005E 17.000N - 0.002Z

Point E. Co-ords. 0.000E 0.000N 0.000Z

+E

Results 1. Horizontal alignment (90°) - (Easting displacement from references – View from above)

0

B

C

5

N

7 D

0

E

-E

A

6

Results 2. Vertical alignment ( 0° ) -

A

(Height displacement from reference - View from above)

B +1

+6

C +5

D -2

E +0

3. An additional survey check would be to take levels on the top or bottom ¼ line to verify the vertical alignment. 4. The lengths of the tubular sections can also be deduced by analysing the Northing co-ordinates of each point and adding the 100mm reference distances to obtain the overall lengthens, bevel to bevel or square end. Fit-up Alignment Survey - Location of Reference Points

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These points are accurately set-out on the side of the cans and verified. Case 1 – with two singular cans – at one fit up location Case 2 – with two single cans welded with a single can – at one fit up location Case 3 - with three single cans welded with three single cans welded– at one fit up location Note: All previously welded cans must have a Post Weld Certificate that certifies the alignment as conforming. Straightness tolerance = 1mm per 1m up to 10mm for lengths in excess of 4m 5.14 BEAM / COLUMN STRUCTURAL SURVEYS USING INSTRUMENTS

Description Steel beams and columns are used to construct Deck structures. Most deck structures are rectangular in design and are composed of beams welded together forming frames at each elevation. The frame is strengthened at the main intersections by the insertion of Structural NODES.

Node Joint - Beam

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There may be many elevations within a deck structure and the number depends on its facility and design function. Each elevation will have vertical beams (columns) or tubulars welded at structural intersection points. These columns will support the next elevation directly above. Fabrication and surveying of a deck frame commences at the FIT UP assembly stage. None of the beams are fully welded together at this stage. Surveying commences with marking the structure: a) Centre node points. b) End of beam centres at 100mm off set from the bevel.

Part of a Deck Frame being fabricated in the workshop. Note the Joint position and in the centre will be marked the structural Work Point - (WP).

The next stage is to place the targets at each of the reference points and survey them relative to a local Control Network. Reflective Target - CUBE

The top of a Node Joint. The Work Point (WP) is marked by a prismatic tape Target.

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The WORK POINT is the centre of the node structure and is set-out and pop-marked. The adjoining beams have to be aligned to this central point. Shown below is the end of beam reference point. It is positioned 100mm from the bevel end and the centre line of the beam. This position is relative to the design AXIS (centre-line) of the deck elevation. The design drawings refer to this point as the Top of Steel (TOS). For the Structural model, this point relates to the WIRE FRAME design. The actual elevation for this particular TOS is Elevation +12.000m.

Centre of beam –reference point exactly 100mm from the bevel end.

It is important that the marking out of centre of a beam or the intersection of beam and column joints (nodes) are referenced correctly. The construction drawings indicate the dimensions between the structure relative to the centre line and intersection of the A beam/column centre or intersection position can be determined by locating the flange centres and flange ends using the ‘DIST’ then ‘REC’ function of the instrument. The distance (‘DIST’) is measured first to within 5mm visually of the beam end. The instrument telescope axis is then moved horizontally to the beam end/side position and the measured horizontal bearing is recorded (‘REC’). These individual points can be processed in the ‘SurveyMax’ 3D geometric program and exchanged to the CAD program by DXF file.

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The beam can then plotted and its actual position relative to the theoretical model can be determined. Three dimensional vector arrows will indicate the actual position from its theoretical position. Beam elevations can be determined by measuring directly to the surface of the structural element using the laser (RL) function.

A basic Deck structure with 2 elevations joined by vertical and diagonal tubular columns.

5.15 STRUCTURAL PIPING AND INTERFACE The surveying techniques used to position piping elements are similar to those described in 5.2. An additional requirement is to determine the pipe end bevel and will be achieved by measuring to the 100mm reference marks or to the best-fit centre of the bevel. These surveys are useful in determining any pipe over or under length as well as position. 5.16 TEMPERATURE EFFECTS AND CORRECTION APPLICATION All steel structures are affected by the ambient temperature and more importantly by direct sunlight exposure. Ambient temperature change upon a steel structure will affect it uniformly. Whereas, direct sunlight will significantly deform a structure. The effect of both of these thermal conditions on a steel structure will be taken into account when considering measurement or positional setting-out. Additionally, local structural heating due to welding activities can also have an effect on overall measurement and structural shape. The design dimensions for the steel structures and measuring tapes are standardized to the temperature of +20deg C. Therefore, when measuring between two connected points using a calibrated measuring tape or steel band it will not be necessary to apply a temperature correction to the measured dimension. However, when surveying by instrumentation it will be necessary to apply a correction factor to the calculated distance between the same two connected points. In order to determine the correct distance the temperature of the steel must be known. The correction factor will be: -

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Correction factor to the measured distance = (20 - ST) x (C x D) where: 20 = standardised structural temperature 20° C ST = Steel Temperature in °C C = Coefficient for the linear expansion of carbon steel = (0.0000125)* D = Distance measured at steel temperature * Variable depending on the class of steel. Example: D= 30m : ST = 40°C : Correction factor = (20 – 40) x (0.0000125 x 30) = -0.008m Therefore, True distance at 20°C = (30.000m – 0.008) = 29.992m The effect of direct sunlight (solar radiation) on a steel structure in terms of structural movement is significant. With an ambient temperature in the shade of 30deg C the actual surface temperature of steel exposed to direct sunlight can be as high as 60 to 70deg C. This solar absorption creates a structure with surfaces of differing temperatures. One side of the structure will be considerably warmer that it’s opposite side. The locations, of this thermal absorption, also changes throughout the day light hours. This daily effect will cause the structure not only to change longitudinally but more significantly to bend laterally. Consequently, under these conditions the value of surveying steel structures accurately becomes very limited. Therefore, when surveying a structure that is exposed to direct sunlight the general applications and conditions to apply will be as follows: a) Survey a large structure during the early hours before sunrise. b) Measure and record that the surface temperature of the structure at several locations at beginning and end of the survey. Verify that it is evenly distributed. c) Mark the structure with fixed reference points and incorporate these points into the structural survey. They will be the ‘MONITORING POINTS’. d) Reference the structure by means of a short reference distance to a fixed independent object.

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DIMENSIONAL CONTROL PROCESS

6.1

FLOW CHART

The diagram below illustrates the surveying process from initial instrumentation structural surveys to the final reporting stage. In addition, recommendations will be made in order to benefit the Production process, structural integrity and dimensional tolerances.

Instrumentation 3D Total Station

Survey and record the data in a GSI file format. within the instrument’s internal detachable PCMCIA memory flash Card.

PCMCIA Memory Card

GSI file transfer

SurveyMax 3D Geometry

Download the recorded survey data into SurveyMax. Analysis, edit and process the survey data. SAVE as CRD File

Laptop Computer

DXF file transfer

RHINOCEROS 3D CAD

Download DXF file into Rhinoceros CAD to create the survey. Process and SAVE as a CAD Dwg File format

Reports CAD & Paper

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6.2

INSTRUMENT & SURVEY DATA MANAGEMENT

The Leica TCRA1100 & 1200 series management filing system will be implemented to maintain an orderly arrangement of the survey data. This sequence of storage will make the process of data retrieval much easier. Every point surveyed will be number coded and displayed on the instrument control panel. The following gives an example for Project control: Instrument – Leica TCRA1101 or 1200 Name of management

Stored Data

File type

Data Job Management

Network Control Stations

File 01.GSI

Meas Job Management

Surveys and Points

File 02.GSI

Additionally, the surveyed data and component surveyed will be drawn and recorded in a Chartwell Survey Book. These drawings will aide the correct process CAD component development. An example of a component sketch is shown below :The survey sketch and points surveyed shall be d in the drawn in a Survey book: a) The node sketch and the point locations shall be drawn NEATLY & written LEGIBLY. Somebody else may have to interpret the sketched details!

Chartwell Book Survey

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c) Survey sketch details will include: Date, component number, stage, survey point locations, number of the point, weld seam orientation, dimensions, bevels or flat ended, BFC circumferential radius laser group shots, reference point shots, elevation and top view sketch. 6.3

COMPUTER FILE DATA MANAGEMENT

The filing of data on all Dimensional Control computer systems will be managed to the following criteria:

Project Name

DXF Files

Rhino Files

SurveymaX

Drawings

Reports

Job Files

Job Files

Shop Drawing

Production

Geometry

Cont. Network

Design Drwgs

Certificates

Project Files will be maintained in an alphabetic and component order

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SURVEYMAX - 3D GEOMETRIC PROGRAM

7.1

GENERAL OPERATING SYSTEM

SurveymaX is a three-dimensional geometric program that is used to generate the survey data into a refined mathematical structure for analysis, adjustment and future CAD development. It also has the capacity to analyse data and verify the accuracy and shape of structural objects. SurveymaX operates in Microsoft Windows format. a) The purpose of SurveymaX is to provide a selection of routines for data manipulation and calculation. Such routines are useful in the connection of Dimensional Control and Industrial Surveying. b) The fundamental structure of Surveymax is that there are three types of data lists windows. This dimensional control procedure will only utilise the Co-ordinates (Crds) and Memo windows. Co-ordinates window (Eastings: Northings: Height); containing co-ordinates. Observation window (Horizontal angle: Vertical angle: Slope Distance) survey observations. Memorandum window shows the calculation results in a printable format. On the mouse: left ‘Click’ to pop up the required window format. Crds

Obs

Memo

c) The user has several options available for generating, manipulating and processing the data in these lists. Programs include: Circle fit: Best-fit: Rotation: Translation: Mean:

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d) The surveyed data will be ‘Downloaded’ directly into the program from various types of electronic measurement equipment. His manual relates only to the Leica manufactured equipment systems. e) The results of the processing will be stored for future use, or can be ‘Uploaded’ to other applications. f) All data deduced will be exported to the design modelling software using the ‘dxf’ file export format. The data will export to ‘Rhinoceros’ and AutoCAD. 8

CAD 3D PROGRAM

8.1

RHINOCEROS VERSION 4.0

Modelling ‘Rhinoceros’

Rhinoceros is a 3-D NURBS (Non-Uniform Rational B-Splines) modelling program for ‘WINDOWS’. Rhino and can create, edit, analyse, and translate NURBS curves, surfaces and solids in WINDOWS. NURBS geometry is a mathematical representation that can accurately define any shape from a simple line, circle, arc, or box to the most complex 3-D free form organic surface or solid. Rhinoceros can interface with more than 37 supported file formats, including: - DWG, DXF, POV, UDO, VRML, BMP TGA, JPG and IGES. It will analyse points to determine geometrical differences and evaluate precisely the area, volume, direction, curvature, angle, radius, length between points or groups of points three-dimensionally. There are no limits to size, complexity or degree. The four view-ports screen display shows: - Perspective 3D, Top view, Front view, and Right view. These can be worked as individual ports or all together. All data processed in ‘SurveymaX’ is imported into Rhinoceros by ‘DXF’ (Drawing eXchange File) file and will operate in a ‘Rhino.3dm’ file format AutoCAD drawings will import into Rhinoceros using ‘Dwg’ file format. To operate Rhinoceros it is recommended to have a minimum computer capacity of: - Pentium 3 or dual processor, Windows Xp/Vista, 60GB hard disk, 2MB RAM or more and graphics facility. Survey data will be imported into Rhinoceros and the actual structural models will be created. These actual structures will be compared to the theoretical model and differences can be displayed. Reports will be created from these CAD comparisons. 8.2

THEORETICAL STRUCTURAL MODELLING

Structural Modelling is the fundamental part of computerised industrial surveying. The co-ordinates of the structural model are relative to the Control Network within the construction yard. Therefore, every part of the model structure, including any structural surface, can be quantified and given theoretical three-dimensional co-ordinates (X,Y,Z).

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Knowing these structural co-ordinates allows the positioning and surveying of the actual structure and also comparing them against the theoretical structural position. Errors or displacements can thus be derived to the nearest millimetre.

9

TOLERANCES

9.1

JACKET & DECK INTERFACE DISTANCE The distance between adjacent leg or column centrelines, at the top of Jacket and bottom of the Deck structure, shall be maintained with +/- 10mm from the design dimension.

9.2

JACKET INTERFACE DIAGONAL DISTANCE The diagonal distance between opposite leg or column centrelines, at the top of Jacket and bottom of the Deck structure, shall be maintained with +/- 10mm from the design dimension.

9.3

JACKET & DECK INTERFACE VERTICAL POSITION The vertical difference between adjacent leg or column centrelines, at top of Jacket and bottom of the Deck structure, shall be maintained with +/- 10mm from the design elevation.

9.4

JACKET & DECK LEG OR COLUMN INTERFACE SPHERICAL POSITION The position of the centre of Leg or Column relative to the shall be maintained within a spherical (3D) position of +/-5mm - (+/-5mm northing; +/-5mm easting; +/-5mm height).

9.5

JACKET LEG STRAIGHTNESS The straightness of the Jacket main Legs shall be within +/-10mm

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9.6

JACKET BRACING IN THE HORIZONTAL PLANE (ELEVATION) All bracing in the horizontal plane shall be positioned within a tolerance of ± 15 mm.

9.7

DECK ADJACENT LEGS DISTANCES Horizontal distance from the centerline of any Leg to the centerline of the Leg adjacent in any direction shall be within a tolerance of ± 10 mm of the drawing dimension.

9.8

DECK DIAGONAL LEGS DISTANCES The diagonal distances of the rectangular plan layout for opposing deck legs shall be identical to within a maximum difference of 19mm.

9.9

DECK COLUMNS DIAGONAL DISTANCE Diagonal distances between columns shall be within +/-13mm

9.10 DECK COLUMN STRAIGHTNESS & VERTICALITY The verticality of deck Columns shall be maintained within 10mm. Such deviation shall not be more than 3mm per 3m length. 9.11 DECK COLUMN ELEVATION The elevation (level) of the tops of all deck columns shall be related to the elevation on the drawing within a tolerance of ± 13mm. 9.12 DECK DIAGONAL DISTANCE BETWEEN CORNER COLUMNS Diagonal distance between centerline to centre line of any diametrically opposite corner columns shall not exceed 19 mm. 9.13 DECK BRACING ELEVATION All braces in a horizontal plane shall be held vertically within ± 13 mm from planned dimension. 9.14 DECK BEAMS & GIRDERS CENTRE-LINE POSITION At their ends, the centre line of all deck beams should be within ± 13 mm of the drawing location. At no point along the centre line should any beam be out of line more than ± 19 mm horizontally, or ± 13 mm vertically. 9.15 BEAM FLANGES Tilting of flanges for sections 305mm and under shall not be more than 6 mm and for sections over 305mm shall not be greater than 8 mm. 9.16 CAN POSITION WITHIN THE JACKET LEG The node or tubular section ‘’Can’’ shall be positioned as part of the Jacket leg within ± 25mm of the theoretical position as shown on the structural drawings. 9.17 PILES STRAIGHTNESS, SEAM ROTATION, END SQUARENESS, CIRCUMFERENCE & OVALITY. The straightness deviation in a Pile shall be maintained as follows:-

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i) 3mm deviation in any 3m tubular length ii) 10mm maximum in any 12m tubular length iii) 13mm maximum deviation for any tubular greater than 12m length The longitudinal weld seams of each adjoining Pile Can shall be rotated a minimum of 90 degrees. End Squareness of the Pile shall be within +/-5mm Circumference of the Pile shall be within ± 1% of the nominal circumference or within ± 13mm, whichever is lesser. Ovality of the pile shall not exceed 1% of the nominal diameter or 6mm, whichever is the lesser. 9.18 TUBULAR STRAIGHTNESS Tubular allowable straightness deviation shall be as follows:i) 3mm deviation in any 3m tubular length ii) 10mm maximum in any 12m tubular length Straightness should be checked at 0° and 90° at every fit-up location. The location of Post Weld Straightness measurements are not stated in the Specifications 9.19 TUBULAR LOCAL STRAIGHTNESS (SHELL PLATE) Local straightness is defined as the deviation of the shell plate from the straight generator of length ‘L’ parallel to the theoretical centre line of the tube. This tolerance shall not exceed 1.0%L or 20% of the plate wall thickness (T) whichever is the lesser, except for access ways where the maximum tolerance shall be 3mm. Where L = the length of shell plate being examined and measured. 9.20 TUBULAR CIRCUMFERENCE The measured external circumference shall not depart from the nominal external circumference by more than recommended in API Spec 2B section 6.3 These dimensions shall be measured at the end of each rolled Can. The outside circumference at any point in a length of pipe shall be within ± 1% of the nominal circumference or within ± 13mm, whichever is lesser. 9.21 TUBULAR LOCAL OUT-OF-ROUNDNESS (LOCAL INDENTATIONS) Local Out-of-roundness is defined as the difference between the actual form and the ideal circular form of the section as measured using a 20º arc gauge. This check is required to locate unacceptable flat or high spots. No specific tolerance is stated. 9.22 OVALITY OR ROUNDNESS Ovality is defined as the difference between the measured maximum and minimum internal (or external) diameters The difference shall not exceed 1% of the nominal diameter or 6mm. maximum for wall thicknesses up to and including 50mm. For wall thickness exceeding 50mm, the maximum permitted deviation shall not exceed the ratio of 1:8 of the wall thickness.

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For pipe exceeding 1220mm. in diameter, a maximum deviation of 13mm shall be permitted provided the circumference tolerance is maintained within ± 6mm. 9.23 END SQUARENESS The ends of the tube shall be cut perpendicular to the longitudinal axis within the following tolerances. Tubular of nominal external diameter up to and including: 2000mm = ±1mm Tubular of nominal external diameter greater than: 2000mm = ±3mm 9.24 NODE STUB LOCATIONS An intersecting brace and associated centre lines shall be positioned within the tolerance given below in relation to the true position as derived from the geometry of the structure shown in the drawings. Primary intersection points 3mm. If the WP tolerance is 3mm this would make the tolerance for the stub at 0mm !! 9.25 WORK POINT LOCATION The actual work point of a primary intersection point shall be positioned within the tolerance given below in relation to the true position as derived from the geometry of the structure shown in the drawings. Primary intersection points 3mm. Where is this written? 9.26 APPURTENANCES Appurtenances shall be positioned within ±3mm in relation to the theoretical position as derived from the drawings. 9.27 ANODES Anodes shall be positioned within 25mm of the location shown on the drawings. However, anodes shall not be attached within 75mm of any other structural weld measured from weld toe to weld toe. 9.28 PADEYES Padeyes shall be located within ±0.5 degrees of the final orientation marked in the drawings. 9.29 WALKWAYS Walkways elevation, Landing and Stairway Location horizontally and vertically shall be within ± 15 mm of drawing dimensions. 9.30 JOINT MISMATCH Joint mismatch (vertical displacement) between plates, tubulars and other structure shape edges (bevels) shall not exceed 3 mm. 9.31 PENETRATIONS Shall be positioned within +/-15mm of their theoretical position, as indicated on the relevant drawings.

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REPORTS

10.1 PRODUCTION REPORTS These reports relate specifically to the construction phases of the project work. Dimensional Control structural surveys will be undertaken at various stages of construction. These stages will be as follows: a) Individual component a) Fit-up with elements tack welded at assembly stage. b) Post weld after final welding of all elements. c) Post heat stress relief. (If applicable) IMPORTANT NOTE: A component FIT-UP survey may prove that an items’ position is outside the required dimensional tolerance. However, this situation may be acceptable as the effect of the welding process and the structural shrinkage will move the item to within the required dimensional tolerances. A Production Survey Report sheet(s) will show in plan view a drawing of the component. Data results and other information shown on the reports will be as follows: a) Actual dimensions. b) Theoretical dimensions c) The difference between the actual and theoretical dimensions in millimeters and indicated as a positive or negative value. d) Structural Reference Points usually zeroed. e) Work point vector arrows indicating the actual structural position of the item surveyed from its theoretical location with values in millimeters. f) Grid or Row identification numbers. g) Structural elevation references. h) Welded or Fit-up positions stated. i) Structural positions, out-of-tolerance, to be highlighted. j) An indication of Conformity or Non-conformity to the structural tolerances. The structural components will be checked at each stage of fabrication in accordance with the requirements of the Company’s specification and this procedure. All tolerances relate specifically to the final completed structure. A referenced numbered Cover Report sheet will be attached to the survey report and will indicate the following details:a) Project name and reference number b) Date of survey c) Report number d) Surveyors name and signature e) Item identification number f) Drawing number reference g) Applicable Procedure reference number h) Construction phase i) Number of Sheets j) Measuring equipment used k) Comments l) Conforming or Non confirming

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10.1.1 Dimensional and level inspection carried out shall be recorded

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10.1.2 Report Sheet for Roundness and circumference inspection carried out shall be recorded

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10.1.3 Cover Sheet of Dimensional Control Report

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10.2 CERTIFICATION REPORTS Final structural As Built certificates will be issued after the termination of welding and the removal of any structural restraints. These certificates will be based on a final survey of the structure while it is still being supported in the horizontal position on its saddle supports and prior the UP-ENDING rotation into a vertical position. The As Built certificates will show the positions for the following structural items:a) Interface work point positions of the jacket legs at the connection elevation with the Deck structure. b) The main leg work point positions at each main elevation c) The structural reference points will be ZEROED and all succeeding surveys shall be based on the same zeroed references d) All other surveyed locations shall be based on these ZEROED reference points e) The structural work point positions at each intersection for each ROW f) Conductor Guide positions at each elevation. g) Pile Sleeve positions and guides. h) Riser locations i) Caisson locations j) J-Tube locations k) Buoyancy tank as built and position l) Installation aid positions m) Positions of the Boat Landings and Barge bumpers. n) Other structural items The certificates will show the structural Work Point positions by means of:a) A vector arrow indicating the directional error from its required theoretical position. b) The measured displacement from its theoretical position in millimeters. c) An elevation position indicating the elevation difference in millimeters from the theoretical elevation.

10.2.1

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Cover Sheet of Dimensional Control Certificate

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11

SAFETY

All project work must be carried out responsibly and within the HSE safety guidelines and regulations in force on the construction sites allocated for this project. Dimensional Control personnel shall ensure that all daily measurement activities are carried out in full respect of the safety rules, without risking their own and other peoples’ safety.