THE SHELL PETROLEUM DEVELOPMENT COMPANY OF NIGERIA LIMITED

FIELD INSPECTION MANUAL

ENGL/28/84/02
TABLE OF CONTENTS

1. INTRODUCTION
2 GENERAL REQUIREMENTS FOR INSPECTIONS
3. GENERAL INSTRUCTIONS TO INSPECTORS
4. DUTIES OF INSPECTORS
4.1 General
4.2 Civil
4.3 Structural
4.4 Mechanical
4.5 Piping
4.6 Welding
4.7 Non destructive evaluation
4.8 Pressure testing
4.9 Painting/coating
4.10 Electrical
4.11 Instrument
4.12 Pipeline
4.13 Safety

5 Reports

APPENDIX-1 - SPDC STANDARD CONSTRUCTION SPECIFICATION,

INDEX OF SECTIONS

APPENDIX-2 - SAFETY REPORT FORM

APPENDIX-3 - NOTIFICATION OF NON-CONFORMANCE

 INTRODUCTION
1.1 Scope and Objectives

1.1.1 The purpose of this Manual is to establish standard procedures, general duties
and responsibilities of Inspection Company Personnel, for the inspection and
progress reporting of their assigned projects within the Eastern and Western
Divisions of the Shell Petroleum Development Company of Nigeria Limited
(SPDC). Additionally, it highlights the responsibilities of the Project Engineers in
providing project information for the Inspection duties.

1.1.2 Inspectors are in continuous daily contact with the Contractors personnel. They
are the eyes and ears of SPDC on the activity site. The smooth running of the
construction site depends very largely on their attitude and conduct.

1.1.3 The Inspector has an obligation to SPDC to ensure that the work is executed in
the manner, which is set down in the Contract Documents. He also has an
obligation to SPDC to do everything possible to maintain, or improve, progress in
accordance with agreed construction schedule.

1.1.4 The Inspector has an obligation to ensure that work is performed in a safe manner
that the Contractor has authorization to work, that agreements are kept and that
regulations are obeyed.

1.1.5 The Inspector is in a position to observe continuously, on behalf of SPDC, all that
happens on the construction site. He therefore has to direct watchful and critical
attention over the complete activity area with a view to ascertaining factual
information. His outlook should not be contained within the limits of this Manual or
those prescribed in any inspection checklist.

1.2 Definitions

The following definitions are applicable throughout this manual.

1.2.1 Construction Specification, is The Shell Petroleum Company of Nigeria's Standard

Construction Specification (Sections 1 to 35), and also includes all additional
specifications/codes etc. referred to within those Sections 1 to 35, latest revisions.

1.2.2 Contract Documents, are the scope of work, approved construction drawings,
construction specifications, work procedures and schedules relevant to the project.
Specifically excluded from being within this definition are the condition of contract,
commercial and legal documents.

1.2.3 Contractor, is the party who has entered into an agreement with SPDC to provide
quality control and inspection services.
 1.2.4 Inspection Company, is the Company, which has entered into an agreement with
SPDC to provide quality control supplies or to provide a service.

1.2.5 Inspector, is an employee of the Inspection Company, who on behalf of the Project
Engineer monitors and reports the quality and progress of the service being
provided by the Contractor.

1.2.6 Project Engineer, in an employee of SPDC, who controls the execution of the
project.

1.2.7 Competent Person, is an employee of SPDC, who has met the requirements of
being appointed a competent person, by MD.

1.3 Responsibilities

The following responsibilities are applicable within the content of this manual.

1.3.1 The Project Engineer is totally responsible for the execution of the project scope of
work, including budget control, schedule, safety, quality and contract
administration. Included in the responsibility of safety is the covering and minute of
site safety meetings and the procurement of the work permits when required.

The Project Engineer is responsible for the quality of his project and the standard
of quality is determined by the Project Engineer and forms part of the Contract
Documents in the form of the Construction Specification.

1.3.2 The Inspector is responsible, to the Project Engineer, for ensuring that completed
work; materials and/or services furnished by the Contractor are in compliance with
the standard of quality of predetermined by the Project Engineer and documented
in the Contract Documents.

In addition, the Inspector is responsible for recording and reporting

progress/problems deviations in a daily report, and for ensuring procedures as
followed, regulations are obeyed and agreements kept.

1.3.3 A competent person is responsible for supervising the work procedures being
executed under the scope of a hot work permit.
2. GENERAL REQUIREMENTS FOR INSPECTORS

The following are the requirements of all Inspectors who perform

quality inspection work for the Shell Petroleum Development
Company of Nigeria Limited.

2.1 Physical Condition

The physical condition of the Inspector must be sufficiently good to permit him to
fulfil his duties. Good vision is vital, corrective aids such as glasses, if required,
must be used during inspections. Good hearing is also vital.

2.2 Appearance

An Inspector should be neatly dressed and well groomed, since his appearance
reflects upon both his own Inspection Company and SPDC.

2.3 Attitude

The Inspector must be self-motivated, conscientious and dedicated and his

attitude largely determines his effectiveness. All his decisions must be considered
impartial and consistent. Past experience and training should give the Inspector
the quality of mature judgement necessary to interpret the terms of the Contract
Documents.

2.4 Safety

The Inspector shall be completely familiar with all of the safety rules, regulations
and requirements of SPDC. He shall monitor the work of SPDC and the
Contractor to ensure a safe work environment. He shall direct the work to be
stopped if performed unsafely.

2.5 Knowledge of Drawings and Specifications

The Inspector must be able to read and thoroughly understand all drawings and
specifications applying to the section of the project on which he is working.

2.6 Knowledge of Testing methods

A number of test methods are available to the Inspector to help him to determine
whether the work meets the standards for quality. Senior and Grade I Inspectors
must be capable of evaluating the test results to ascertain if adequate information
was yielded to establish acceptance standards as specified in the Contract
Documents.
2.7 Records

The Inspector must be able to maintain adequate records. The inspection report
should be concise, yet complete enough to be clear to the reader unfamiliar with
the work inspected. Precise records not only protect the Inspector and SPDC,
they also assist him to adhere to a policy of uniform standards. The Inspector
should keep a personal diary to record outstanding business-related events of
each workday as it happens on the construction site.

2.8 Inspector's Guideline and work Manual

The Inspector will be issued/given access to a copy of the Contract Documents,

including any subsequent variations, relevant to his work. He is required to make
himself thoroughly familiar with those portions of the Construction Specification,
which pertain to the work he is inspecting and to be sure that he understands all
their provisions. He shall also know the meaning of those parts of the Contractor
Documents, which relate to the facilities, which the Inspector is likely to encounter
in his work.

2.9 Absence From Project

Inspectors must obtain permission from the Project Engineer for absence from
their assigned duty. At all other times the Contractor's work shall be witnessed by
an Inspector.

2.10 Personal Actions

An Inspector's action on the job must be exemplary. Violations of good work

practices may be grounds for SPDC to request the Inspection Company to remove
an Inspector from all SPDC facilities. Examples of some of these violations are:

2.10.1 The use or possession of intoxicants or drugs during SPDC working hours, or
reporting for work whilst under the influence of drugs or intoxicants.

2.10.2 Failure or refusal to obey a direct order from the Project Engineer.

2.10.3 Violent verbal abuse towards, or physical attack upon anyone during SPDC
working hours

2.10.4 Misconduct that endangers the safety, welfare, or reputation of SPDC, SPDC
employees, other Inspectors, Contractor's employees, or the general public.
 2.10.5 Soliciting or accepting gifts or gratuities from any Contractor.

2.10.6 Leaving assigned work areas without the Project Engineer's permission or
unacceptable time keeping.

2.11 Assigned Duties

The Inspector will receive an assigned work scope, compatible with his
experience, qualifications and grading, from the Project Engineer, in consultation
with the SPDC Quality Assurance Department, prior to commencing his duties. At
that time, he will ensure that he receives, or has full access to the relevant parts of
the Contract Documents. Also that he has knowledge of any work permits
required.

2.12 Construction Area

The Inspector shall acquaint himself with the construction area. He shall note the
instructions given by the Project Engineer concerning all underground lines or
cables, and any other possible hazardous conditions/situations that exist in the
construction area He will bring these points to the attention of the Contractor, who
will take precautions to protect these facilities during the execution of his contract.

Whenever any facility is damaged, the Inspector shall inform the Project Engineer.
He will also ensure that the Contract notifies those people who should be made
aware of such damage. Replacement or repair or damaged facilities will be co-
ordinated by the Project Engineer.

It is important that the Inspector appropriately records and reports all damages
incurred and the reason for the damage.

3. GENERAL INSTRUCTIONS TO INSPECTORS

3.1 Each Inspector will be issued/given access to a copy of the Contractor

Documents, including any subsequent variations, relevant to his work. He is to
make himself thoroughly familiar with those portions of the Construction
Specification, which pertain to his work, and to be sure that he understands all
their provisions. He should note all areas in which the Shell Petroleum
Development Company of Nigeria's Construction Specification is more stringent
than the applicable code, as in all such cases SPDC's Construction Specification
takes precedence. In cases of doubt he should refer to the Project Engineer for
guidance. He will keep any documents handed to him in a respectable condition
and the have them readily available for reference at all times.
3.2 The Construction Specification has been compiled in sufficient detail to avoid
misunderstanding. Should, however, any point arise which is not covered, the
Inspector should consult the Project Engineer.

3.3 The Inspector does not have the authority to instruct the Contractor to perform
any work or service, which is not in the Contract Documents. In addition, he
cannot instruct the Contractor to omit work that is specified in the Contract
Documents. All such variations must be communicated by the Project Engineer
and follow the procedures as prescribed by SPDC. The Inspector shall however,
notify the Project Engineer immediately it is apparent that the Contract Documents
require modification.

3.4 In each Inspectors area, one person usually the foreman or leading hand, will
be nominated by the Contractor as his representative. The Inspector shall deal
only with the Contractor's nominated representative on all matters relating to the
work.

3.5 The Inspector shall not supervise, instruct, order or in any manner attempt to direct
the Contractor's employees. Defective work shall be corrected through the
Inspector's contact with the Contractor's designated representative. At no time will
an Inspector take over a Contractor's crew or preparation.

3.6 The Inspector shall check that all work has full authorization to proceed, and that
schedules have been discussed with the relevant field Production Supervisor prior
to the start of any construction operation.

3.7 The responsibility for deciding on methods of working rests with the Contractor.
Advising the Contractor, should the Inspector have sufficient experience of the
operation to be performed, is permitted. Inspectors must not take any action or
make any statement, which could be interpreted as supervising or directing the
work. However, the inspector should immediately warn the Contractor's
representative if he notices any practice which contravenes any provision of the
Contract Documents, the safety or fire regulation or any other standing
regulations.

3.8 When Contract Documents require procedures for particular operations to be

submitted for approval, Inspectors shall watch
to see that all work is carried out within the tolerances set out in the approved
procedure, and in cases of any deviation, shall immediately warn the Contractor's
representative that the with stands to be rejected. The Inspector shall record full
details of deviations in his daily report.

3.9 Apart from the examples in 3.7 and 3.8 above, the Inspector's responsibility is
to accept or reject according to whether it
complies or does not comply with the Contract Documents, without reference to
the way in which the Contractor performed the work.
3.10 In cases of dispute the Inspector shall in no way depart from his ruling, but shall
refer the matter to the Project Engineer, and shall make a full record of the
circumstances.

3.11 Inspectors are required to be on the construction site whenever work is in

progress. The Inspector shall arrange his schedule so as to spend sufficient time
on each phase of the job to perform a careful, thorough and adequate inspection,
in accordance with the instructions issued to him. Unless he advises to the
contrary, the Project Engineer will take for granted that he is spending, and is able
to spend, sufficient time on the work site to control the situation. The Inspector will
be personally responsible for ensuring the quality of work covered by his
assignment, is as specified and documented by the Project Engineer and/or in the
Contract Documents

3.12 For any work which is within the scope of the Permit to Work procedure, the
progress. The Inspector shall ensure that the Contractor has a Permit to work
prior to any operation being started, and that the Permit to Work requirements are
fulfilled. The Inspector shall halt work for any violation of the Permit to Work and
shall also inform the Contractor that no hot work shall be conducted whilst the
Competent Person is absent from the site.

3.13 Should it become necessary for the Inspector to leave the site while work is in
progress, he must first take steps to assure that the quality of the work does not
suffer thereby, He cannot halt work on the sole grounds absence, nor can his
order work to be redone because it was performed in his absence, unless he has
a very strong basis or justification for believing that the task has not been
completed satisfactorily. Such Rework would subject SPDC to claims for extra
work if, on examination, the work were found to be satisfactory. Therefore, the
Inspector must arrange his absence for when he can foresee exactly what will be
done, and when he will be able to check the work properly on his return.
Whenever the Inspector finds that for any reason he cannot adequately perform
his duties, he must immediately notify the Project Engineer.

3.14 The Inspector shall record and report to the Project Engineer details of all
defective work, and shall notify the Contractor verbally as soon as such defective
work is discovered. If the Contractor does not agree, or does not see about the
required rectification within a reasonable time, the Inspector shall request the
Project Engineer to issue to the Contractor written notification of the rejection
stating the manner in which the work does not meet the requirements of the
Contract Documents, see Appendix-3. A copy of the Notification of Non-
Conformance shall also be sent to the SPDC Quality Assurance Department.

3.15 Each Inspector will maintain a daily job diary. He will use this to make an on-the-
spot record of all the information to be given in his daily reports, together with any
other items of importance relating to the work. These would include notes on
problems arising, delays occurring and the reasons, accidents, non-acceptable
work with corrective measures, discussions with Contractor's personnel, etc. Each
 Inspector must realize that he may be called on, perhaps some time after the
event, to recall any incident and account for his own actions, and the existence of
notes are beneficial in such cases.

3.16 Inspectors shall be required to keep records of the progress of their respective
areas and report this progress on a daily basis in their report. This progress report
will be related as much as possible to the established schedules prepared by the
Project Engineer. All effort should be made to recognise delays or slippage's in
these schedules and these should be reported to the Project Engineer
immediately.

3.17 Inspectors shall liase with the relevant field Productions Supervisor, on the
reporting of progress, on any proposed change to the contract schedule and for
any co-operation may be required.

3.18 Inspectors shall keep accurate daily reports of work quantities completed
satisfactorily, of defective work and the plans, and submit these figures in his daily
report.

3.19 The Inspector will monitor the manpower and equipment available and will report
shortages that could effect the construction schedule to the Project Engineer.

3.20 The Inspector will monitor the conduct of the Contractor's personnel and the
condition of his tools and equipment, to ensure their compliance with the Contract
Documents. Written warning of an unsafe action by the Contractor, or failure to
maintain procedures, or any violation of the safety procedures or any violation of
the safety regulations shall be issued at the construction site. Any verbal warnings
shall be noted in the Inspectors daily report and the Inspector will submit to the
Project Engineer a detailed safety report, see Apppendix-2, for action required and
signature. Repetitive violation will initiate the same procedure and the Contractor
will be advised by the Project Engineer, of the options available to SPDC under
the conditions of the Contract Specification, (see 35.1.1).

3.21 Inspectors should be on the alert to notice and report any cases of loss, damage,
or improper use of SPDC supplied materials, or any contravention of fire, safety, or
other applicable regulations.

3.22 Inspectors will endeavour at all times to maintain an acceptable working

relationship with the Contractor's personnel, and should co-operate to the fullest
possible extent to assist in the progress and smooth running of the project. This
must not, however, be allowed to prejudice the quality of workmanship, which is
the first consideration at all times.

3.23 Inspectors will not seek, nor accept, favours from Contractors personnel, so that
there can be no possibility of their being influenced in their judgement.
3.24 Inspectors who are placed on standby by SPDC will report daily to and at a time
agreed with the appropriate SPDC representative, to confirm their availability for
assignment.

4. DUTIES OF INSPECTORS

4.1 General

4.1.1 In many instances the scope of the project may demand that one
Inspector will be responsible for two or more areas of inspection. The
Shell Petroleum Development Company of Nigeria's Standard
Construction Specification (Section 1 to 35 contains the technical
specification and notes the codes which govern the works to be
performed, and with the project scope of work and drawings define the
areas of the Inspectors specific duties. Copies of all this data shall be
available to the Inspectors.

4.1.2 The Inspector shall be responsible, in addition to the foregoing general

requirements and instructions, plus the requirements designated in any
assigned check list, for but not limited to the following applicable duties.

4.1.3 In the event that the Inspector is uncertain of the duties that apply to the
project to which he has been assigned, e.g. flowline lifting, ROW
protection, lubrication oil tank fabrication, etc. he shall seek clarification
from the Project Engineer and the SPDC Quality Assurance Department.

4.2 Civil

To ensure the Contractor adequately performs site clearing, grading, drainage, soil
testing, compaction, excavation, concrete mix, concrete tests, concrete placement,
equipment grout preparation, grouting, piling, dredging, roads, site finish and
fencing, etc. according to the Contract Documents, the responsible Inspector
shall, where applicable.

4.2.1 Be fully conversant with the requirements of the relevant sections of the
SPDC Standard Construction Specification (e.g. Sections
1,3,4,5,6,7,8,11,12,15,16, 30, 31 and 35).

4.2.2 Check Contractor site layout and notes to verify the location is according
to Contract Documents. Ensure bench marks are in place and protected,
and that control movement is adequate and permanent.

4.2.3 Ensure the clearing and grubbing is completed according to the contract
documents
4.2.4 Ensure all areas have adequate drainage.

4.2.5 Verify the location, size and depth of excavation to ensure conformance
with the Contract Documents.

4.2.6 Ensure the approved fill material is being used properly compacted; in
layers and within the specified water central limits.

4.2.7 Verify that fill areas are properly prepared prior to starting fill.

4.2.8 Ensure fill do not exceed the requirements of the Construction

Specification.

4.2.9 Check backfill of excavations for proper compaction.

4.2.10 Ensure location, elevation and materials are correct for road sub-grade
and sub-base.

4.2.11 Verify finish grade, materials, and materials thickness and elevation.

4.2.12 Check tank pad location and size for conformity to the contract
documents.

4.2.13 Ensure slopes are firm and will not erode.

4.2.14 When dredging is required, review the amount of material as to the

containing area and the disposition of water returning to the dredging source.

4.2.15 Determine requirements for final survey of depth and limits of dredge.

4.2.16 Check piling and layout, and verify horizontal and vertical control of piling
as specified in the Contract Documents.

4.2.17 Ensure sand and cement stored on site is properly protected from
weather.

4.2.18 Check that the design mix of each class of concrete prior to pouring is in
accordance with the Contract Specification

4.2.19 Ensure the forms for concrete are properly placed, prepared and secured.
 4.2.20 Verify reinforcing steel/mesh and embedded items are correct and in the
right location before each pour.

4.2.21 Ensure concrete is being properly placed and finished according to the
Construction Specification.

4.2.22 Ensure Contractor is curing concrete in accordance with Construction

Specification and that no equipment is placed on ''Green'' concrete.

4.2.23 Ensure foundations are properly prepared and the specified grout is used
and properly cured.

4.2.24 Senior or Grade 1 Inspectors shall observe testing and sampling made by
the contractor to ensure that they are in accordance with the Contract
Specification

4.2.25 Senior or Grade 1 Inspectors shall maintain a record of tests and samples
taken and the result of the soil compactions, concrete slump tests, concrete
compressive tests, road paving tests, piling logs and tank foundation reports.

4.2.26 Ensure that the Contractor collects and returns any surplus or required
scrap, SPDC owned materials to stock area, and the work area is cleared of
rubbish and reinstated to an acceptable standard as per the Construction
Specification.

4.2.27 Maintain samples of approval materials on site and verify that all materials
activities are to the approval standard and quality.

4.2.28 The Inspector shall be fully conversant with SPDC's HSES Regulations and
his personal responsibility to enforce HSES including the stopping of work.

4.2.29 Ensure that all temporary work sharing formwork scaffolding etc. are within
the specified safety requirements and that all means of access are correctly
postponed and to specification

4.3 Structural
To ensure the contractor adequately performs the construction of building, structures, pipe
supports, platforms, etc. according to the Contract Documents the responsible Inspector
shall, where applicable:

4.3.1 Be fully conversant with the requirements of the relevant sections of the
SPDC standard construction specification (e.g. Sections 1, 13, 14 and 35).

4.3.2 Inspect all structural steel as received to ensure correct fabrication and
marking.
 4.3.3 Observe steel erection to affirm that members are not damaged in
handling

4.3.4 Ensure that structures are assembled using the correct rivet or bolts to
verify the torque of all bolts, to ensure they are not left loose or over stressed.

4.3.5 Ensure that welding check as per Section 4.6. are conducted, as
applicable, to any structural welding work.

4.3.6 Ensure all attachments, stiffeners, and braces are in the correct locations
and attached according to the Contract
Documents.

4.3.7 Senior or Grade 1 inspectors shall observe and record all test to ensure
that the installations have met the safety and design requirements as specified in the
Contract Documents.

4.3.8 Ensure that the Contractor collects and returns any surplus, or required
scrap, SPDC owned and materials to stock, and the work area is cleared of
rubbish and reinstated to an acceptable standard as per the Construction
Specifications.

4.4 Mechanical

To ensure the Contractor installs engines, rotating equipment, compression

facilities, pumps, turbines, boilers, heaters, vessels, furnaces, exchangers, etc.
according to the Contract
Documents, the responsible Senior or Grade I Inspector shall, where applicable:-

4.4.1 Be fully conversant with the requirements of the relevant sections of the
SPDC Standard Construction Specification (1,9,28 and 35).

4.4.2 Inspect equipment unloading, storage, and handling to ensure it will not be
damaged.

4.4.3 Check equipment alignment before and after grouting.

4.4.4 Inspect vessel tray nozzles, vessels loading of internals, etc. to ensure
correct location and attachment.

4.4.5 Inspect fan coolers for proper installation, blade pitch sheave size,
alignment, etc.

4.4.6 Check belt tension and coupling alignment before and after attachments,
are in accordance with the Contract Documents.
 4.4.7 Inspect heater and boiler refectory, gaskets, doors and spring hangers are
set in accordance with the Contract
Documents.

4.4.8 Inspect cooling towers for proper components and erection.

4.4.9 Ensure there is no strain exerted on components on erection.

4.4.10 Observe and record all tests to ensure that the installations have met the
safety and design requirements as specified in the Contract Documents.

4.4.11 Ensure that the Contractor collects and returns any surplus, or required
scrap, SPDC owned materials to stock, and that the work area is cleared of
rubbish and reinstated to an acceptable standard as per the Construction
Specification.

4.5 Piping

To ensure the Contractor install all piping, valves, fittings, etc. according to the
Contract Documents, the responsible Inspector shall, where applicable:

4.5.1 Be fully conversant with the requirements for the relevant sections of the
SPDC Standard Construction Specification (e.g. Section 1,24,33,34, and 35).

4.5.2 Inspect warehousing and storage of material to ensure the material will
not be damaged.

4.5.3 Observe the type/size of pipe and fittings interlude to ensure that these
are in accordance with the Contract Documents.

4.5.4 Ensure valves, gaskets, stud bolt/lengths, pipe supports and hangers,
insulation shoes and insulating kits are correct and installed as specified in the
Contract Documents.

4.5.5 Ensure all pipewoek is correctly aligned and that no strain is transmitted to
equipment or other pipework, or that any undesirable strain in exerted onto the
pipe support or hangers.

4.5.6 Co-ordinates stress relief scheduling with the Contractor, and maintain
a daily record.

4.5.7 Check underground piping to ensure it is installed to the correct depth

and in accordance with the Construction Specification.

4.5.8 Ensure bolts are tightened in correct sequence and to the correct
 torque.

4.5.9 Ensure the thread sealant used on screwed pipe fittings conforms to
the requirements of the Construction Specification.

4.5.10 Verify that no pipe or equipment will interfere with valve operation.

4.5.11 Check steam tracing to ensure that they are adequate.

4.5.12 Check steam tracing to ensure correct installation of expansion loops.

4.5.13 Ensure that the Contractor collects and returns any surplus, or
required scrap, SPDC owned materials to stock and that the work is
cleared of rubbish and reinstated to an acceptable standard as per the
Construction Section.
4.6 Welding

To ensure the Contractor performs acceptable welding on piping, boilers, heaters,

vessels, tanks, structural members and miscellaneous equipment according to the
Contract Document, the responsible Inspector shall, where applicable.

4.6.1 Be fully conversant with the requirement of the relevant sections of the
SPDC Standard Construction Specification (e.g., Sections 1,2,21 and 35).

4.6.2 Not weld on any pipe or make welding test.

4.6.3 Senior or Grade I Inspectors shall witness the preparation of welds for
the qualification of the welding procedures and the performance of the
qualification test, all in accordance with the provisions of the Construction
Specification. he will record all details and determine whether the
procedures have qualified.

4.6.4 Senior or Grade I Inspectors shall conduct qualification tests on

welders in accordance with the Construction Specification and record
particulars of such tests.

4.6.5 Ensure each welder is in possession of a valid qualification card and

maintain a record of qualified welders for each project, also ensure that
each welder has an identifying symbol.

4.6.6 Ensure all welding is carried out in accordance with the qualified
procedures, including joint design and by qualified welders and that each
weld is identified by the welder's symbol.

4.6.7 Check that low hydrogen electrodes are oven dried for the specified
time and temperature, also that the electrodes are maintained in heated
quivers up to the time of actual use.
4.6.8 Ensure each bead and weld groove is cleaned of all slag and scale
by power tools, In addition, ensure high points in the bead and cluster
porosity are removed by grinding.

4.6.9 Visually examine each field weld and adjacent area to ensure it free
of all slag, weld splatter and are burns, and determine whether it complies
with the Construction Specification.

4.6.10 If weather conditions are such that the quality of the weld would be
impaired, halt welding in agreement with the Construction Specification
until conditions are satisfactory or until the Contractor has taken adequate
measures to protect the work.

4.6.11 Ensure each weld is numbered and recorded in the manner stated in
the Construction Specification.
4.6.12 Co-ordinate with the Inspector responsible for NDE to determine
whether defective welds may be repaired under the provisions of the
Construction Specification and, if so, ensure repair is performed in
accordance with the qualified repair procedure.

4.6.13 Ensure defective welds are cut in line with Construction

Specifications, pipe ends are properly rebevelled and check for lamination
and that re-welding is in accordance with the qualified procedure.

4.6.14 For structural welding ensures joint design is in accordance with that
specified in the welding procedure before the first pas in made.

4.6.15 Ensure filler metals and fluxes are stored and handled in accordance
with the manufacturers recommendations, to avoid damage and exposure
to moisture. The use of filler metals and fluxes, which show signs of
damage or deterioration, shall be prohibited.

4.6.16 Check pipe and fittings prior to welding to ensure there is no physical
damage and that they are prepared as required by the Construction
Specification.

4.6.17 Ensure Contractor's personnel clean the inside of each joint of pipe or
fitting to welding in position.

4.6.18 Keep notes on the performance of each welders and if any welder
consistently performs unacceptable welds suspend him until he has been
re-tested and accepted.

4.6.19 Ensure that the Contractor reinstates the work area to an acceptable
standard as per the Construction Specification.
4.7 Non-Destructive Evaluation

To ensure the Contractor provides acceptable welds according to the Contractor

Documents, the responsible Inspector shall, where applicable:-

4.7.1 Be fully conversant with the requirements of the relevant

sections of the SPDC Standard Construction Specification (e.g.
Section 1,20,21, and 35)

4.7.2 Verify qualifications of the radiographic personnel are in

accordance with established procedures and Construction
Specification.

4.7.3 Verify radiographic procedure complies with acceptable

standards as outlined in the Construction Specification and that
qualified and approved procedures are used consistently for the
duration of the project.
Verify numbering system of radiographs is in accordance with
Construction Specification.

4.7.5 Check equipment throughout the project, to include expiration

date of film, thickness and hole size of pentameters, viewing
equipment, X-Ray sets, gamma source, etc.

4.7.6 Senior Grade I Inspectors shall review radiographs for quality,

technique and interpretation and maintain weld history record.

4.7.7 Ensure processed radiographs storage and fillings are in

compliance with the Construction Specification.

4.7.8 Implement and enforce safety measures as stipulated in the

construction Specification for the safety of personnel.

4.7.9 Prior to ultrasonic, dye penetrate testing or magnetic particle

inspection ensures procedures are in accordance with the
Construction Specification.

4.7.10 Ensure ultrasonic test equipment and calibration complies

with the requirements of the Construction Specification.

4.7.11 Inspect materials to be used for dye penetrate testing and

magnetic particle inspection and ensure they are as stipulated in
Construction Specification.
 4.7.12 Ensure techniques to be used to prepare the surface for
inspection will not obscure possible defects.

4.7.13 Witness all tests to ensure compliance with the approved

procedures, record results and issue in a report containing
procedure used and a sketch of the examined area.

4.7.14 Ensure that the work area is left clear of rubbish as per the
Construction Specification.

4.8 Pressure Testing

To ensure the Contractor adequately executes the approved pressure testing

procedure according to the Contract Documents, the responsible Inspector shall,
where applicable:

4.8.1 Be fully conversant with the requirements of the relevant sections of

the SPDC Standard Construction Specification (e.g. Sections 1,29,35).

4.8.2 Ensure all pressure/temperature gauges/recorders, dead weight

testers, etc. have current certificate and obtain copy of certificate for
inclusion into the test report.
4.8.3 Co-ordinate all pressure tests with Contractor and other Inspectors to
ensure there is no interference with project progress or other project work,
also to ensure no equipment is damaged by excessive pressure.

4.8.4 Ensure all lines to be tested are clean, flushed and where applicable
pigged, prior to testing in accordance with the Construction Specification.

4.8.5 Ensure blinds are correctly located and are of the correct size and
type.

4.8.6 Ensure all air is bled from system prior to applying pressure. On
pipeline test, witness and verify all records of fill volumes, pressure and
pressure/volume charts to determine air content.

4.8.7 When testing pipelines, witness loading and recovering of all pigs,
check gauging plate before launch and upon recovery. Record every
events and timing in detail.

4.8.8 In the event of a failure of a pipeline, record in addition to the failure

details, all labour and equipment placed on standby, plus additional
labour/equipment required actively searching and exposing the failure.
Records to be verified by Contractor's foreman.
 4.8.9 In the event of a failure record all details of the leak or rapture. Where
the Contractor freely accepts liability for the leak, e.g. poor weld, incorrect
flange assembly, repairs and reset may proceed.

4.8.10 In the event of a failure where the liability is not freely accepted by the
Contractor or the Inspector considers that it may be later disputed, e.g.
poor weld on a pre-fabricated skid, SPDC supplied material failure, record
all equipment placed on standby, and consult the Project Engineer for
additional instructions.

4.8.11 Witness all piping tests to ensure compliance with the Contract
Documents, sign/date all records and charts and completes a
comprehensive report containing as a minimum where applicable.

- Filling, testing and dewatering procedures.

- Instrument calibration certificate
- Pipeline profile noting elevations, instrument connection,
injection connections.
- Piping system schematic noting instrument connections, vents,
injection connections.
- Filling logs and records
- Additive specification and required concentration
- Details of gauge plate
- Pressurization stabilization records
- Pressure/temperature charts
- Pressure/temperature records
- Pressure/volume curves

4.8.12 Ensure that the Contractor collects and returns any surplus, or
required scrap, SPDC owned materials to stock, and that the work area is
cleared of rubbish and reinstated on an acceptable standard as per the
Construction Specification.

4.9 Painting/Coating

To ensure the Contractor adequately prepares all pipe, fittings, steel, etc.
prior to wrapping, insulating, painting, etc. and to ensure the coating is applied all
according to the Contract Document, the responsible Inspector shall, where
applicable:

4.9.1 Be fully conversant with the requirements of the relevant sections of

the SPDC Standard Construction Specification (e.g Section 1, 10,
22,23,24 and 35)

4.9.2 Observe unloading, warehousing, storage of materials to ensure they

 are safely stored and are not damaged in handling or by the elements,
and that they conform to the Construction Specification.

4.9.3 Ensure the pipe, equipment, steel, is cleaned by mechanical methods

and/or hand in accordance with the Construction Specification.

4.9.4 Determine if the Contractor's equipment is maintained clean and in a

suitable condition for the application for the application of the
painting/coating materials as required by the Construction Specification.
4.9.5 Visually inspect the prepared surface for acceptability and for dents,
gouges, grooves, notches or other damage and determine whether these
are injury defects according to the Construction Specification.

4.9.6 Co-ordinate with the Inspector responsible for welding and NDE to
ensure all defects including rejected welds are cut out or repaired prior to
painting/coating.

4.9.7 Observe the weather conditions in the area and ensure that all area
and ensure that all Construction Specification restrictions on working on
moist, hot, cold surfaces or in unsuitable conditions are enforced.

4.9.8 Verify that the shelf life of the coating materials has not expired and
report quantities/reason for rejection of materials.

4.9.9 Verify paint/tape wrap is applied in accordance with the manufacturers

recommendations with regards to primer thickness and thickness and
drying times: that the correct overlap is maintained and that wrinkles are
not present, all in accordance with the requirements of the Construction
Specification.

4.9.10 Ensure all coated pipe to be placed underground, check with a

holiday detector, maintained within the specified voltage limits, and that
all-defective area are repaired and rechecked.

4.9.11 Inspect hot/cold insulation for correct installation type and thickness,
and that all joints covering, straps, etc. are in accordance with the
Construction Specification.

4.9.12 Inspect successive coats of paint to ensure manufacturers

instructions with the regards to maximum ration, pot life, solvent addition,
application, wet film thickness and over-coating times have been strictly
adhered to.

4.9.13 Verify that surface cleanliness adhesion and dry film thickness,
colour and visual standard, no sags of runs, are all in compliance with the
requirements of the Construction Specification.
 4.9.14 Be aware of any hazardous materials and ensure any additional
safety requirement is enforced.

4.9.15 Ensure that the Contractor collects and returns any surplus, or
required scrap SPDC owned materials to stock, and that the work area is
cleared of rubbish and reinstated to an acceptable standard as per the
Construction Specification.

4.10 Electrical

To ensure the Contractor installs and test all lighting and power conduct wire
fittings, and wiring termination's etc. according to the Contract Document , and the
responsible Senior or Grade I Inspector shall:

4.10.1 Be fully conversant with the requirements of the applicable sections of

the SPDC Standard Construction Specification (e.g. Sections
1,17,27,32,33, and 35)
4.10.2 Observe unloading, warehousing, storage of equipment to ensure it is
not damaged in handling or by the elements.

4.10.3 Ensure equipment, has correct hazardous area zone classification

for its proposed location and that the equipment is complete and as
specified in the Contract Documents.
4.10.4 Ensure that for buried cables, the cable trench is of adequate
depth and free of objects which could damage the cable, the cable is free
of kinks and damage, and the backfield and tiles are positioned all in
accordance with the Construction Specification.

4.10.5 Ensure power and signal cable separation is maintained, that

cables are correctly identified, supported, fastened, gland and terminated
all in accordance with the Construction Specification.

4.10.6 Confirm earthing system is in accordance in the Contract

Documents and that the earth resistance value achieved is acceptable.

4.10.7 Witness and accept/reject all testing as required in the

Construction Specification and record all results.

4.10.8 Ensure that the Contractor collects and returns any surplus,
required scrap, SPDC owned materials to stock and that the work area is
cleared of rubbish and reinstated to an acceptable standard as per the
Construction Specifications.
4.11 Instrument

To ensure the Contractor installs, calibrates, tests, etc, all pneumatic and/or
electrical instruction, etc. according to the Contract Documents, the responsible
Senior or Grade I Inspector shall:

4.11.1 Be fully conversant with the requirements of the applicable

sections of the SPDC Standard Construction Specifications e.g. Section
1,17,18, and 25)

4.11.2 Observe unloading, warehousing storage of instruments to

ensure they are not damaged in handling or by the elements.

4.11.3 Visually inspect instrument air lines for support and

workmanship, also instrument supports and positions for compliance with
the Contract Documents.

4.11.4 Ensure instrument airlines are air cleaned before they are connected
to instrument.

4.11.5 Verify instruments and equipment are complete and tagged, as

specified in the Contract Documents.

4.11.6 Ensure that for buried cables, cables, the cable trench is of adequate
depth and free of objects which could damage the cable, the cable is free
of kinks and damage, and the backfield and tiles and positioned all in
accordance with the Construction Specification.

4.11.7 Ensure and signal cable separation in maintained, the cables are
correctly identified, supported, fastened, glanded and terminated all in
accordance with the Construction Specification.

4.11.8 Witness instrument calibration, loop continuity and insulation tests and
record results.

4.11.9 Ensure that the Contractor collects and returns any surplus, or
required scrap, SPDC owned materials to stock and that the work area is
cleared of rubbish and reinstated to an acceptable standard as per the
Construction Specification.

4.12 Pipeline

To ensure the Contractor performs according to the Contract Documents the

responsible Inspector shall, in addition to any of the applicable foregoing sections.

4.12.1 Be fully conversant with requirements of the applicable sections of the

 SPDC Standard Construction Specification (e.g. Sections
1,2,3,10,20,21,22,23,24,27, 29,33,34, and 35).

4.12.2 Ensure that the Contractor preserves the R.O.W. boundary markers
and that the R.O.W is graded to allow suitable travel.

4.12.3 Ensure any cuttings are made in a manner that the soil can be
restored in its natural condition and that loose soil is removed from the
trench line so that the pipeline will not be constructed in a fill area.

4.12.4 Ensure topsoil is removed and properly stocked at the designated

location.

4.12.5 Ensure that as far as possible the grading does not interfere with
natural drainage. Where this not possible, see that the Contractor takes
proper measures for temporary drainage.

4.12.6 Inspect the cutting of fences and the installation of temporary gates
and see that any agreements with landowners are observed. Report any
off R.O.W damage, e.g. to private property, roads, etc. in detail.

4.12.7 Ensure the correct positioning of the pipe on the R.O.W and that the
Contractor strings the pipe in such a way as to leave access gaps across
the R.O.W.

4.12.8 Ensure all handling and transportation of pipe is carried out in

accordance with the Construction Specification and that hook, slings etc.
are correctly used.
4.12.9 Mark and report any damages pipe in the prescribed manner as
stated in the Construction Specification.
4.12.10 Determine that the Contractor's trenching crew completes the trench
in full accordance with the Contract Documents.

4.12.11 Verify that provision is made for adequate clearance between the
pipeline and any other buried facilities as stipulated in the Contract
Specification.

4.12.12 Note any natural drainage channels and see that the Contractor takes
proper precautions against possible flooding, or against restriction of flow
in such channels.

4.12.13 Before welding ensure cold bends are acceptable.

4.12.14 Ensure the Contractor provides an adequate number of the correct

skids and that they are properly placed to keep the pipe securely in
position.
4.12.15 Ensure joints are in proper alignment, that the longitudinal weld
seams are correctly placed, and that line-up clamps are filled correctly.

4.12.16 Ensure the stringer beads are properly applied. if defects are present,
determine whether these can be repaired within the provisions of the
Construction. In no case will repair of cracks be authorised.

4.12.17 Ensure that unacceptable stringer beads are cut out immediately, and
see that acceptable stringer beads are properly cleaned before the hot
pass is laid.

4.12.18 Check that the hot pass is properly applied. If the welding procedure
specifies a maximum time interval between stringer bead to be overnight
without the hot pass.

4.12.19 Visually inspect that the hot pass is left clean and ready for
successive beads and that all repair have been completed.

4.12.20 Periodically check that the following crew is keeping pace, so that the
filling runs are being deposited within the allowed after hot pass, as set
out in the approved welding procedure.

4.12.21 Visually inspect each bead to make sure that is properly cleaned
before the application of the next bead.

4.12.22 Examine each field weld visually and determine whether it complies
with the Construction Specification.

4.12.23 When the requirement for radiography is less than 100% determine
which welds are to be radiograph.

4.12.24 Ensure the Contractor uses night caps and leaves no open ends of
pipe overnight or when work is suspended.

4.12.25 Inspect the ditch to ensure it is clear of rocks, sticks, welding rods and
other debris and that dewatering is completed, and padding is sufficient,
where necessary, prior to lowering pipe.

4.12.26 Check that a holiday detector set to the correct voltage i s run over the
line just prior to lowering, and that all damaged area and skid marks are
properly repaired and checked. Examine damage areas to ensure that the
pipe has not been gouge or grooved.

4.12.27 Ensure that slings and cradles used are of the approved type and are
in acceptable condition, also that there is adequate space in the ditch to
remove the slings without damaged the coating.
4.12.28Check that the pipe contour conforms everywhere to the ditch contour
 and that anchors, weights, and all special assemblies are installed as
specified in the Contract Documents.

4.12.29 Check that cathodic protection tests points and markers are
markers are correctly installed in the designated locations and that the
leads are not damaged during the backfill operation.

4.12.30 Ensure backfill material is free from sticks, can, welding rods,
coating materials and other debris. Where the backfill contains hard clods,
etc. ensure that the initial cover over the pipe is properly screened free
from pieces that could damage the coating. In areas where the top soil
has been set aside, ensure this material is used only for the final layer.

4.12.31 Ensure that the Contractor collects and haul away all cans, bottles
cartons and scrap materials also that all surplus SPDC owned materials
are returned to stock.

4.12.32 Ensure that the Contractor reinstates the area to an acceptable

standard as per the Construction Specifications.

4.13 Safety

To ensure Contractor executes all work and performs all services according to the
safety requirements of the Contract Documents, the responsible Inspector shall:

4.13.1 Immediately report all violation of any safety regulations in the

Contract Documents and of any violation of safe working procedures, also
if extreme hazards conditions prevail suspend work. See appendix 2 for
report.

4.13.2 Be fully conversant with the requirements of the SPDC Standard

Construction Specification Sections that pertain to the scope of the work
and in particular to Section 35.

4.13.3 Be fully conversant with the safety requirements of all other

codes/specifications and regulations that are specified in the Contract
Documents.

4.13.4 Be fully conversant with the SPDC Permit to work system and the
scope of its applicability.

4.13.5 Ensure that the Contractor is aware of all safety requirements/

precautions on the Permit to Work and that these are enforced.
4.13.6 Ensure Permit to Work has not expired.

4.13.7 Ensure all work has the required authorization to proceed before any
operation commences.

4.13.8 Liase with the relevant field Production operations and that suitable
precautions are taken to control the operation and situation.

4.13.9 Ensure Contractor's staff are fully supplied with the specified and
applicable safety and protective equipment.

4.13.10 Ensure Contractor's staff are fully supplied with the specified and
applicable safety and protective equipment.

4.13.11 Ensure Contractor has an adequately stocked First Aid Kid on site
and that it is easily accessible at all times.

4.13.12 Ensure Contractor has the specified safety equipment on site, that it is
accessible and used correctly, (e.g. safety barriers, warning notices,
lifelines harness and fire extinguishers).

4.13.13 Ensure Contractor uses approved transport for personnel

movements, open vans or trucks are not approved.

4.13.14 Ensure Contractor tools are in an acceptable condition, that voltage of

electrical hand tools are as required by the specifications and that all tools
are suitable for use in hazardous area when applicable.

4.13.15 Ensure Contractors equipment is in an acceptable condition, that all

moving parts are guarded and that it is suitable for use in hazardous areas
when applicable.

4.13.16 Ensure Contractor handles dangerous/inflammable materials, e.g.

fuel, gas cylinders, in a safe manner and that the storage facilities are
acceptable and clearly identified.

4.13.17 Ensure Contractor maintains the site in an acceptable condition and

disposes of waste in a safe manner and to an approved location.

4.13.19 Ensure adequate precaution, e.g. warning notices, barriers, are

enforced during radiographic work.

4.13.20 Ensure during any test that only essential personnel are permitted in
the test area.

4.13.21 Ensure there is a full time attendance by the Contractor's personnel

 throughout the test period.

5. REPORTS

Refer to "General Guide to Inspection Reporting" specification number

ENGL/28/84/03 latest issue.

SPDC F.I.M - APPENDIX 1

SHELL PETROLEUM DEVELOPMENT COMPANY OF NIGERIA LIMITED

STANDARD CONSTRUCTION SPECIFICATION

INDEX OF SECTIONS

SECTION TITLE REVISION

S-1 General Requirement

S-2 Right of way and access roads
S-3 Clearing, grading and surface stripping
S-4 Earth work at construction sites
S-5 Road and location construction
S-6 Timber ground mat specification
S-7 Tank pads and bundwalls
S-8 Soil stabilization
S-9 Surface treatment and sealing
S-10 Coating wrapping and concreting of field joints
S-11 Fencing
S-12 Concrete and cement finish work
S-13 Building Construction
S-14 Structural Steel
S-15 Sewage/sewage treatment and drainage
S-16 Water supply systems
S-17 Electrical
S-18 Instrumentation
S-19 Mechanical equipment
S-20 Radiographic inspection and other NDT
S-21 Welding
S-22 Painting
S-23 Yard coating wrapping and concreting of line pipe
S-24 Station and Manifold piping and tie-ins
S-25 Pipeline Construction
S-26 Repair of Steel Pipelines
S-27 Cathodic Protection of Test Points
S-28 Standard Vertical Storage Tanks
S-29 Pressure Testing
S-30 Marine Construction and Piling
S-31 Helicopter Landings Pad
S-32 Installation of Cathodic Protection Equipment
S-33 C.P. Isolating Joints and Insulating Flanges
S-34 Hot Tapping of Steel Pipelines
S-35 Safety
S-36 Dredging