the main intention of this presentation is to give information my overall experience, as a Document Engineer in Oil and Gas sector (drilling equipment Top side)

1. 1
This presentation covers my experience as Document Engineer in
field of Oil and Gas sector (offshore drilling equipment (Top Side)

2. 2
Table of Content
 Offshore equipment
 Production life cycle
 Documentation life cycle
 Technical documentation
 hazardous area documentation

3. 3
Hydraulic power Unit
BOP trolley
Drill Line Drum
Underhull Guiding Arm
Rotary Table
Access Basket
Cathead
Offshore Rig Equipment (Upstream)

4. Supplier’s
documentation for
requirement
NORSOK Z-018
Supplier’s documentation for
requirement
NORSOK Z-018
Coding system
NORSOK Z-DP-001
Product Life cycle
Product life
cycle
Management
Code system:
NORSOK Z-DP-
001
Supplier’s
documentation
for Equipment:
NORSOK Z-018
Documentation
for Operation:
NORSOK Z-018
4

5. 2 Motor HPU (Hydraulic Power Unit)
Important Components:
 Electrical Motor;
 Axial Piston Pump;
 Heat exchanger
 Electrical Heater;
 High Pressure filters;
 Drain and Return filters;
 Hydraulic fluid Circulation Motor;
and Pump;
 Local control Operator Panel;
 Level Transmitters (H, L & LL);
 Pressure Transmitter;
 Pressure Gauges;
 Temperature Gauges;
 Temperature Transmitters;
 Emergency stop Buttons;
 Shut-off valves;
 Cables;
 Cable Glands.
El. Motor
Pump
Heat Exchanger
Oil heater
High Pr.
Oil filter
Pr. transmitter
Temp.
transmitter
Shut-off valve
Wire
Glands
Indicator
lamp
Selector
switches
Emergency
stop button
Local Control
Panel
5

6. WithBid
•Document List
SDRL: Supplier Document
Requirement List;
DRL: Document Requirement
List
•Design and Operation
Product description, brochures
and catalogues
•Exceptions from
specifications and other
requirements in the
query
Deviations, technical Queries and
Exceptions etc
•Production plan (from
fabricator)
•Equipment construction,
testing period (FAT)
•Weighing, Mechanical
completion
•Product Delivery
•Quality plan (Inspection
Test plan for OEM
supplier)
Afterorderacceptance
(DocumentationforOperation-DFO)
• Document List
• Production plan (from
Fabricator)
• Quality Plan
• HSE (Health, Safety and
Environment)
• General Arrangement/Main
Assembly drawing/Lubrication
drawing
• Electrical drawings
(Block/Sub-block diagrams,
Interconnection diagrams,
Loop diagrams)
• WPS (Weld procedure
Specification) and WPQR
(weld Procedure Qualification
Record)
• Hydraulic/Pneumatic Flow
diagrams
• Master Equipment List (MEL)
• Data Sheets(Mechanical(incl.
Hydraulic), Electrical &
Instruments)
• Calculations, performance
curves
• Test Reports for Electrical
Equipment as per relevant
regulations
• Utility Consumption Data
• Material Safety Data Sheets
(MSDS)
• Weight data sheet
• Weight Report
• Sound Data sheet
• Noise Test Report
• Cause and Effect
• Engineering Indexes
• Lubrication Schedule
• Ex-certificates
• Installation, Operation and
Maintenance (IOM) Index &
Manual
• Test Procedures (Factory
Acceptance Test (FAT)
Procedure; Incl. control
system)
• Lifting Gear Certificates
BeforeShipment/Deliver(DispatchDossier)
• General Arrangement/Lifting
Arrangement/Main assembly
• Hydraulic/Pneumatic Flow
diagrams
• Lifting and Installation Guide
Lines
• Material Safety Data Sheets
(MSDS)
• Acceptance of all Deviations
• Packaging List/Loose Item
List
• Transportation Drawings(if
any)
FinalDocumentation
• Master Equipment List (MEL)
• Data Sheets (Mechanical(incl.
Hydraulic), Electrical &
Instruments) (As built)
• Performance curves
• Flow diagrams (As Built)
• General Arrangement (incl.
foundation/interface)/Main
Assembly drawing/Lubrication
drawing (As Built)
• Electrical drawings (Block/Sub-
block diagrams, Interconnection
diagrams, Loop diagrams (As
Built)
• Manufacturing Record Book
(MRB) for client
• Certificates for Recertification
• Test Procedure (Pre-
commissioning/commissioning
procedures; witness by third party
(may be applicable)
• Ex-certification for Equipment
(where applicable)
6
Documentation Life cycle

7. Quality Plan (Inspection
Test Plan)
• Detail events for
Manufacturing process
• WPS (Weld procedure
Qualification) and
WPQR approval,
Welding, NDE
testing/witness, Flushing
procedure, Pressure
testing and Painting etc.
• Client holding and witness
events
• NDE testing/witness,
weighing, pressure
testing and Painting etc.
• Third party holding and
witness events
• Weighing, NDE witness
before and after testing,
Factory Acceptance
Test Procedure (FAT)
Master Equipment List
(MEL)
• List of Main components,
which are necessary for
Machine/Equipment
functioning.
• It is for TAGged
components. It contains
drawing cross reference,
Outer dimensions,
weight, Parent tag,
Primary tag, auxiliary tag
etc.
Data sheets
• Data sheet for all
Mechanical/Hydraulic
components, Electrical
components and
Instruments,. Example;
• Data sheet from
Supplier (temperature
Transmitter)
• NORSOK data sheet
instrument
• NORSOK data sheet for
Induction Motor
Design and Lifting
calculations, performance
curves
• Design analysis and
calculations
• For example, Offshore
Standard DNV-OS-E101
• Lifting calculations
• Heat exchanger
calculations
• Electrical Motor
Performance curves in
conjunction with Hydraulic
Pump
• Electrical Motor routine
test Reports
Utility Consumption data
• Electrical consumption for
Elec. Motor, Solenoid
valves, Indicator lamps,
Selector switches, Oil
heater, Pressure and
Temperature Transmitter
• For example, Main
Motor: 3ph, 230/460 V,
100KW; Oil circulation
motor: 3ph, 10kw,
Heater: 1ph,3KW;
Electrical Lamps: 24 vdc
; Selector switch: 24vdc;
etc.
• In case of Mechanical
equipment it shall contain
Hydraulic consumption
data, Electrical
consumption. If it contains
radio remote control
panel; battery power,
utility charging
specification
• For example, Trolley:
supply Pressure: 207
barg (absolute
pressure); Hydraulic oil
flow rate: 50 l/min;
Return Oil flow rate: 5
l/min; Drain oil flow rate:
5 l/min.
Material Safety Data
Sheets (MSDS)
• Safety instructions for
Material used in Product
• Chemical composition of
Material used
• Contact information
incase of emergency
• Handling Guidelines while
transporting
• For example, product
contains
• Hydraulic Oil type,
• Lubrication oil type ,
• Oil based Protective
coating.
Importance:
All reviews, witness
and holding points
will be realised at
the production
starting phase
7
Technical Documentation
Continue…

8. Weight Data sheet
• Estimated weight of the
equipment
• Outline dimensions
• Centre of Gravity (COG) of
equipment (estimated)
• Once equipment ready
after FAT, as weighed data
and estimated/calculated
COG of the equipment
• Auxiliary structure Weight,
if used along with Actual
machine
• Actual COG of based on 4
point method, if weight for
product is 10Tonne above
• Information about Weighing
Device
• Location information where
the Equipment weighed
(Indoor or outdoor)
• If it outdoor; mention the
environment conditions at
the time of weighing
(Temperature, wind speed,
humidity & address of the
location)
Weight Report
• Weighing certificate
• Calibration certificate for
weighing device ( single
point and Four point)
• If COG is calculated by
estimation; evidence of the
how it is calculated
• If COG is calculated by 4
point method (compression
load cell method); evidence
of the how it is calculated
• Still picture evidence if
possible
• Information of Weather
condition at the time of
weighing, such as
temperature, humidity,
wind speed and location
(indoor or outdoor)
Sound data sheet and Report
• NORSOK data sheet as
per S-002
• Historical or Supplier
estimated Noise level of
the equipment measured in
db (Decibels)
• Description of test
Procedure; micro phone
location, calibration
certificate for device, etc
• If noise level is beyond the
agreed value; noise
mitigation methods
Cause and effect
• Depend upon
project/Product, Cause and
effect diagram/document
can be established for
following scenarios (as per
NORSOK standard Z-001):
• APS (Abandon platform
shut down);
• ESD 1 (Emergency Shut
down);
• ESD 2 (Emergency Shut
down);
• PSD (Process Shut
down).
Engineering Indexes
• Instrument Index
• It contains minimum, tag
number, OEM (original
equipment manf. name),
model number I/O (DI,
DO,AI or AO), drawing
reference, Ex code (Ex d,
Ex de, Ex ia etc), Gas
Group (IIA, IIB, IIC or II),
temperature classification
(T1, T2,T3,T4, T5 or T6),
Ex certificate number, set
points, calibration ranges,
instrument range etc.
• Electrical equipment Index
• Hazardous equipment
index
• Cable index
• Typically consists of
Cable type, colour of
cable, cable Voltage
Rating, Tag to Tag
information, component
interface, gland type
used/specification.
• Junction box index
• Typically consists of OEM
name, Model number,
terminal type/size, Ex
certificate no. if
applicable.
• Lubrication index
• Typically consists of
Lubrication type, lubrication
quantity and drawing
reference with lube point
location
• Manufacturing Record
Book (MRB) index
Installation, Operation and
Maintenance (IOM) index
• Organization contact
information, HSE aspects,
warranty and guarantee etc
• GA drawing, lifting,
handling & installation
guidelines, technical
description, main data,
noise data sheet & spare
parts list (refer NORSOK
std Z-018).
8
Continue…
Technical Documentation

9. Manufacturing Record Book (MRB) index
• Calibration certificates (Instruments
which are part of the Equipment and
which have been used in to test the
instruments) ,
• PSV certificates (Pressure Safety Valve ),
• Type Approval certificates ( DNV:DVR
certificate; Design Verification Report, in
case new equipment),
• Pressure Test certificate,
• Material certificates,
• Material Traceability Procedure and List,
• Weld Procedure Specification (WPS) and
Weld Procedure Qualification
Record(WPQR),
• NDE is procedure,
• NDE (Non-destructive
Examination)Qualification Records,
• NDE Reports,
• Paint Procedure Specification and Paint
Procedure Qualification Record (PPQR),
• Paint Reports/Certificate,
• Fabricator’s statement of Conformity,
• Certificates for re-certification
Lubrication Schedule
• A detail schedule/documented evidence
for lubrication of equipment. Such as
Date for lubrication, Quantity used and
next schedule of lubrication (in tabulated
format or any suitable means)
Lifting Gear Certificates
• There are various lifting equipment are
used in offshore equipment.
Example:-
Lifting slings (4-legged (4 legged bridle
slings), 2-legged; combination of Master
link, sling wires, shackles) and spreader
beam.
Certificates
 Design Verification Report (DVR)
DVR is issued when equipment is new
designed (it contains information that
followed up by surveyor, such as design
codes, standards used for design
verification and design specification).
 Inspection Release Note(IRN)
An IRN shall only be issued if the
component is delivered prior to issuance
of final product certificate (PC). A final PC
shall not be issued if there are non-
conformances to the equipment or
system. The IRN shall be used with
detailed description of the non-
conformances, and shall always be
replaced by a certificate when all non-
conformances are closed.
 Product certificate (PC)
PC should be issued for all category I
equipment and systems(including control
systems)
PC will be issued upon successful
completion of design verification,
fabrication survey and review of final
documentation. As stated above, PC can
not be issued if design verification or non-
conformances are outstanding.
 Type Approval
Typical issued for mass produced
products
9
Continue…
Technical Documentation

10. Hazardous Area
10

11. Objective:
Introduction to terminology used in
Hazardous area Certificate and their
applications
11

12. 1. Purpose
2. Hazardous Area certificate types
3. EC Type Examination Certificate
4. EC Type Examination Certificate number
5. Atex code
6. Equipment Protection type
7. Hazardous Area
8. Gas zone classification
9. Temperature classifications
Topics
12

13. Purpose
 All Mechanical, electrical & instruments used in equipment can
capable of producing heat and sparks, this heat may cause for
ignition with the oxygen-gas mixture which is already present in the
atmosphere (ambient and operating conditions). To
control/mitigate this effect, certain methods are followed.
 When equipment/product is at bid/Concept level, it important to
realize where the equipment is going to be installed, what kind of
components needs to be purchased and what kind for certification
is required.
 At a same time, all information in conjunction with components
need be documented and submitted to Certifying Authority and
approved before it is ready for shipping.
13

14. Hazardous Area certificate Types
Below are the two examples;
 ATEX certification (European standard; certification for
Hazardous area)
 CSA Group (Canadian standard; certification for Hazardous
area, apart from this certification may vary depend upon
the province)
Note:
− There are different certifications available, it may vary from country to
country, but at a same time same certification may be applicable.
− Once all parties agrees with certification OEM can start production.
14

15. EC type examination certificate
ATEX (ATmosphères EXplosives) certificate
15

16. EC type examination certificate number
For example, data sheet and Ex certificate
for Indicator lamp and lamp module
PTB 99 ATEX 3114 U
For example,
Notified body
Eg:- PTB, TUV,
CESI, SIRA etc.
Product
identification
number
Atex
certification
number
“X” (for equipment)
If the sign X“ is placed after the certificate number,
it indicates that the equipment is subject to special
conditions for safe use specified in the schedule to
this certificate.
“U” ( for component)
If the Sig “U” is place after the certificate number, It
indicates that this certificate should not be
confounded with certificates issued for equipment
protective systems. The component certificate
serves as a basis for the issuing for certificates for
equipment or protective systems.
16

17. Ex de IIB T6 Gb
(Marking to IEC/EN Standard 60079-0)
GROUP I MINES
GROUP II GAS
GROUP III DUST
IP Grade(Ingress Protection)
Ex. IP68
1 digit : protection against solid objects
2 digit: protection against water
ATEX code
17

18. Few Example;
IEC 60079-1; “d” (Equipment Protection by flame proof enclosure)
IEC 60079-1; “e” (Equipment Protection by Increased safety)
IEC 60079-11; “i” (intrinsic safety)
Equipment protection type
18

19. Zone classification (94/9/EC –European commission)
Zone 0:
A place in which an explosive atmosphere consisting of a mixture with air of
flammable substances in the form of gas or vapour is present continuously or for
long periods or frequently.
Zone 1:
A place in which an explosive atmosphere consisting of a mixture with air of
flammable substances in the form of gas is likely to occur in normal operation
occasionally.
Zone 2:
A place in which an explosive atmosphere consisting of a mixture with air of
flammable substances in the form of gas is not likely, but if it does occur, will
persist for a short period only.
Zone 0
Zone 1
Zone 2
Safe Area
19

20. Gas Groups
Based on ignitability of gas-air (minimum ignition energy) mixture, gas
groups are divided into 3 groups.
These are IIA, IIB and IIC:
 IIA: Acetone, ethane, benzene, petrol, butane, Propane, methane;
 IIB: Ethylene;
 IIC: Hydrogen, acetylene.
Severability;
− If selected component is suitable for IIC gas group it can be used in for IIA
and IIB atmosphere;
− If selected component is suitable for IIB gas group it can be used in for IIA
atmosphere;
− If selected component is suitable for IIA gas group it can be used in for IIA
atmosphere only.
IIC gas group is more severe .
20

21. Temperature classification
 The temperature classification indicates maximum surface
temperature of component which is allowed to reach during its
normal operation
 When selecting a product, ensure the temperature class of the
product is below the minimum ignition temperature of the
explosive atmosphere
− If component/product
selected for T6, it is suitable
for T1 to T6 category only,
− If component/product
selected for T3, it is suitable
for T1 to T3 category only.
T6 is more tougher requirement
For example,
if pressure transmitter has T4 classification, the surface temperature during
operating condition or any amount of heat generated by malfunction should
not cross 135ºC.
21

22. Standards
• NORSOK standard Z-018 Supplier’s documentation
requirement
• NORSOK standard S-002 Working Environment
• IEC 60079-1; “d” Equipment protection by Flame proof
enclosure
• IEC 60079-7; “e” Equipment protection by Increased safety
• IEC 60079-11: “i” Equipment protection by intrinsic safety
• DNV-OS-E101; offshore standard, Drilling plant
• DNV-2.7-1; Standard for Certification; offshore containers
• NORSOK standard Z-001 Documentation for Operation
22