Corporate Head Office: Operations & Fabrication Yard:

Plot 5 Rahman Adeboyejo Street, Vandrezzer Industrial Base (VIB),

Lekki Peninsula Scheme 1, Lagos, Nigeria, No. 9, Trans-Woji Road, Woji Town,
Tel: +234 1 7739696; +234 1 7949696 Port Harcourt, Rivers State, Nigeria.
, <info@vandrezzerenergy.com> www.vandrezzerenergy.com RC: 661087

FORM W-INSPECTION AND TEST

PLAN
FOR
TB-2909 INVITATION TO TENDER

CALL-OFF CONTRACT
FOR
FABRICATION OF PLATFORM
DECKS, TOPSIDES, JACKETS
AND ASSOCIATED STRUCTURES
CLIENT:
ADDAX PETROLEUM DEVELOPMENT (NIGERIA) LIMITED
32 OZUMBA MBADIWE AVENUE
VICTORIA ISLAND
LAGOS
NIGERIA.
CALL-OFF CONTRACT FOR FABRICATION OF PLATFORM DECKS, TOPSIDES, JACKETS AND ASSOCIATED STRUCTURES
“TECHNICAL BID”

INSPECTION
&
TEST PLAN

INDEX

1.0 INTRODUCTION

2.0 INSPECTION INTERVENTIONS FOR MECHANICAL WORKS

a) SCOPE

b) APPLICABLE LEGEND

3.0 ITEMS OF INSPECTION FOR CONSTRUCTION

4.0 INSPECTION MATRIX

5.0 PRESSURE HYDRO TESTING PLAN

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“TECHNICAL BID”

INSPECTION & TEST PLAN

1.0 INTRODUCTION
ADDAX PETROLEUM DEVELOPMENT (NIGERIA) LIMITED, a company organised
and existing under the Laws of Nigeria with its registered office at 32, Ozumba
Mbadiwe Avenue, Victoria Island, Lagos, Federal Republic of Nigeria (hereinafter
referred to as “Company”), has a requirement for a Call Off Contract for
Fabrication of Platform Decks, Topsides, Jackets and Associated Structures
(hereinafter referred to as “Work”).

SCOPE OF WORK
The WORK which the CONTRACTOR is hereby required to perform is more
particularly described in Sections IV through XII of the CONTRACT and include
but not be limited to:

 Fabrication planning and fabrication management, and supply of all

fabrication personnel and equipment;

 Design and engineering as necessary with respect to contractor’s facilities,

equipment, and temporary works required, as well as that required to
facilitate pre-fabrication, assembly and pre-commissioning of the work.

 Pre-fabrication and assembly of the work, including site preparation as may

be required, together with all necessary pre-commissioning activities;

 All necessary interfaces with third parties and company’s other contractors;

 Inspection and testing of the work;

 Load out of the work

 Repairs and remedial work during the contract warranty periods;

And as may be directed by company:

 Additional design and engineering;

 Procurement and supply of materials and equipment for permanent

incorporation into the WORK.
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This Inspection and Test Plan provides the Control and Plans necessary to
provide products and services meeting ADDAX requirements/expectations from
the Engineering, Procurement function through to Pre-commissioning activities
during the execution of this project.

2.0 INSPECTION INTERVENTIONS FOR MECHANICAL WORKS

a) SCOPE

The scope of this Inspection and Test Plan is to establish the minimum
Inspection interventions requiring adequate monitoring and documentation
during the execution all phase of Works to be performed during the Call Off
Contract for Fabrication of Platform Decks, Topsides, Jackets and Associated
Structures Project which is being planned to be handled by VANDREZZER
ENERGY SERVICES LIMITED (VESL) for ADDAX.

These inspection intervention codes shall be agreed by all organizations

involved before starting of the mechanical work operations and the approved
Quality Control Plan shall be managed according by VANDREZZER inspection
team.

Where subcontractors activities are involved, they shall be managed in

accordance with the sub-contractors approved Quality Control Plan under the
supervision of VANDREZZER inspection team.

b) APPLICATION LEGEND
The below inspection intervention legends shall be used and agreed between
the involved organization before implementation of this Inspection Plan.

P PERFORM OR PRIMARY RESPONSIBILITY

H HOLD POINT
W WITNESS POINT
V VISUAL INSPECTION
D DIMENSIONAL INSPECTION
R DOCUMENTATION REVIEW
A APPROVAL
% PERCENTAGE OF INSPECTION (as applicable)
M SPOT CHECK ACTIVITY

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“TECHNICAL BID”
Furthermore, the functions responsible for the inspection activities are referred to
under the VANDREZZER Inspection Requirements column.

Where the responsible functions is indicated within the section title, the whole
sections inspection points shall be under the same function’s responsibility.

Where certain inspection points require specific qualified function, this shall be
referred to within each inspection points.

The Quality Control Supervisor remains at all times and in any case responsible or
verifying the fulfilment of this Inspection Plan

2.0 ITEMS OF INSPECTION FOR CONSTRUCTION

INSPECTION CODE:

P - Perform or primary responsibility for inspection, testing or report

preparation.

R - Review Documentation of Activity

M - Spot Check Activity

W - Witness Activity

H – Hold

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“TECHNICAL BID”

RESPONSIBILITY
ITEM ACTIVITY
VENDOR VANDREZZER ADDAX OTHER
1.0 Piping
1.1 Material Certification P M
1.2 Welding Plan and Welding P M W
1.3 Welder’s Performance P M
1.4 Production Test of Weld (if required) P M
1.5 Post Weld Heat Treatment (if required) P M
1.6 Radiographic Examination (as applicable) P M W
1.7 Hydrostatic Test (when required) P M W
Liquid Penetrant and/or Magnetic Particle
1.8 P M W
Examination (if required)
1.9 Dimensional Check and Visual Inspection P M W
1.10 Check of Marking P M
1.11 Flushing and Cleaning of Lines P M W
Inventory and Inspection of Mechanical Equipment
1.12 P M
(Valves, Gaskets, Bolt, etc)
2.0 Concrete
2.1 Raw Material Specification P M
2.2 Mix Design/Laboratory Result P M
2.3 Trial Mix Design for Concrete and Asphalt Surface P M W
2.4 Production Control (Slump and 3 Test Specimens) P M
2.5 Grouting Material, Mix and Pour P M W
3.0 Structural Steel
3.1 Material Certificates P M
3.2 Welding Plans and Welding P M W
3.3 Dimensional Check and Visual Inspection P M W
4.0 Painting
4.1 Painting Material P M
4.2 Surface Check P M
4.3 Surface Preparation Check P M W
4.4 Dry Film Thickness Check P M W
4.5 Final Visual Checks P M
5.0 Electrical/Instrumentation
Field Purchased Material for Compliance to
5.1 P M
Specifications
5.2 Insulation Resistance Check P M
5.3 Earthing resistance check P M
5.4 Terminal connection tightness check (visual) P M W
5.5 Functional check P M W

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“TECHNICAL BID”
6.0 INSPECTION MATRIX
REFERENCE VERIFYING LEVEL OF INSPECTION REQUIRED
ITEM DESCRIPTION OF QC ACTIVITY DOCUMENT DOCUMENT
NUMBER REFERENCE VANDREZZER SUBCON ADDAX
NDT NON DESTRUCTIVE TESTING (NDT)

During Operations
%

Monitor NDT performance in accordance to relevant %

NDT.1
specification

NDT performance Radiorgraphic Exam NDT Inspector

NDT.2 H
Report H
a. Radiography
- indicate zero datum
- check i.d. markings on film
- film development
- film evaluation
- check archival life of films
- check developed films identification and storage
b. Ultrasonic Examination (where required U.T. Examination
Ultrasonic Exam.
of vessel wall thickness H H
Report

Monitor issue of NDT reports, monitor NDT results and take

QC Supervisor
appropriate actions in case of a systematic pattern of
NDT 3 V,R R
defects.

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“TECHNICAL BID”
REFERENCE VERIFYING LEVEL OF INSPECTION REQUIRED
ITEM DESCRIPTION OF QC ACTIVITY DOCUMENT DOCUMENT
NUMBER REFERENCE VANDREZZER SUBCON ADDAX

NCR NON CONFORMITIES AND CORRECTIVE

ACTIONS

Identify non-conformities or collect information and raise Non Conformity QC Supervisor W,V,R
NCR.1 non conformity report if any when necessary Report W,V,R

Non – conformity can be any one of the following viz:

1. Lack of established working Plans

2. Lack of implementation of established Plans
3. Non compliance of the project specifications
requirements.
4. Non availability of supporting quality documentation
5. Failure of production or special process
6. Non availability of Plan to cover a process / activity.
7. Material defects / shortages / damages.

Issue of corrective action request after agreement with the

Corrective Action
NCR.2 superintendent. W,V,/D,R W,V,/D,R
Report

NCR.3 Monitoring implementation of corrective actions W,W/D,R W,V,/D,R

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REFERENCE VERIFYING LEVEL OF INSPECTION REQUIRED
ITEM DESCRIPTION OF QC ACTIVITY DOCUMENT DOCUMENT
VANDREZZER SUBCON ADDAX
NUMBER REFERENCE
PI PIPING
Checking if the following date has been marked on Piping Details A
PI.1 Constr. Engr.
isometric or construction drawings and they conform to the Drawings V/R
requirements
a) Weld number
b) W.P.S reference
c) NDT Requirements
d) Material marketing and identification
PI. P I PI N G I N S T A L LA T I ON / E RE C T I ON

PI.2 Check dimensions and fit-up of piping components before V/D %

erection.

PI.3 Check cleanliness and damages of bevel, bore and faces of %

piping materials V/D
P1.4 Check for correct location of permanent pipe supports. V/D %

COMPONENTS CHECK LIST

VALVES:
a) Check for correct valve’s flow direction
P1.5 b) Verify flange squareness
c) Verify bolt hole alignment
d) Verify correct insertion of studs/bolts types
e) Ensure correct tightening valves and sequence
f) Check valve’s tag number

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“TECHNICAL BID”
REFERENCE VERIFYING LEVEL OF INSPECTION REQUIRED
ITEM DESCRIPTION OF QC ACTIVITY DOCUMENT DOCUMENT
VANDREZZER SUBCON ADDAX
NUMBER REFERENCE
THREADED FITTINGS
a) Check for the state of the thread
b) Check for cleanliness of the thread %
P1.6 V
c) Check for correction application of sealing compound.
d) Check for correct tightening
SUPPORTS
a) Check for correct location of supports
P1.7 V/D,R %
b) Check if the correct type is installed
c) Check Welding and NDT of supports
P1.8 V I S U A L I N S P EC T I ON A N D F I N A L C H E C K S
a) Verify that all installed piping components comply with
applicable isometrics, drawings and P&1 Diagram
V/D,R V/D,R
b) Verify that equipment aligns with piping flanges
c) Verify that the completed system is punch listed
P1.9 Incorporate all As-Built information in isometrics
drawings and diagrams
STR. STRUCTURAL
STR. 1 Alignment and fit-up checklist R. A
STR.2 Before permanent assembly confirm that components are
on a level plan.
Check dimension and fit-up of structures before erection As-Built Piping Mech. Supervisor W
STR.3 Details DWGS V/D
Verify that there is no straining of members during fit-up
STR. 4 Confirm alignment of components after lack Welding V/D W

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“TECHNICAL BID”
REFERNCE VERIFYING LEVEL OF INSPECTION REQUIED
ITEM DESCRIPTION OF QC ACTIVITY DOCUMENT DOCUMENT
VANDREZZER SUBCON ADDAX
NUMBER REFERENCE
BOLTED CONNECTION
Carry out the following decks on noticed connections
a) Check that hole dimensions are in such are in
such a way as not to cause damage to both
thread
b) B) Check for alignment of bolt holes
STRS.5 V W
c) After insertion, check that bolt head and nuts
rest squarely no metal that head and nuts rest
squarely on metal face.
d) Verify correct type, length and protrusion of
bolt beyond nut.
e) Confirm that nuts are locked at required
tightening values.
REMOVAL OF TEMPORARY
ATTACHMENTS
a) Check that removal is performed by thermal
cutting.
b) Check that cutting on temporary attachment
STR 6 V/D W
was performed 3mm from joining point
c) Verify that from the cut off location, stud is
ground off to parent metal
d) Ensure that no damage is done to the parent
metal as a result of removal of temporary
structures.

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“TECHNICAL BID”
REFERNCE LEVEL OF INSPECTION REQUIED
VERIFYING
ITEM DESCRIPTION OF QC ACTIVITY DOCUMENT DOCUMENT
REFERENCE VANDREZZER SUBCON ADDAX
NUMBER

VISUAL INSPECTION AND FINAL CHECKS

a) Confirm that all installed structures comply

W/A
STR. 7 with applicable isometrics, drawings and V/DR
diagrams.
b) Confirm that level and height are within
acceptable tolerance
c) Confirm that the completed system is punch
listed accordingly.

Update applicable isometric structural drawings with all

R
STR.8 AS-BUILT information R

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REFERNCE VERIFYING LEVEL OF INSPECTION REQUIED
ITEM DESCRIPTION OF QC ACTIVITY DOCUMENT DOCUMENT
VANDREZZER SUBCON ADDAX
NUMBER REFERENCE
MEC MECHANICAL

EQUIPMENT INSTALLATION Mech.

Supervision
H
MEC.1 a) Confirm that equipment is free from
damage and is complete in accessories H
H
b) Confirm the surface where equipment
is to be installed is properly prepared H
W
c) Check that equipment before
tightening of bold down holts V/D
W
d) Confirm integrity of anti-vibration H
A
mountings V
W
FINAL VISUAL INSPECTION

a) Confirm that all installed equipment

Mech. H
MEC.3 conform to applicable drawings and H
Completion
diagrams
Certificates H
b) Check for correct alignment of H
Ready for start-
equipment to piping flanges
Up W
c) Verify that the completed system is V/D
certificates
punch listed accordingly
W,V,R,A
Incorporate all As-Built information in W.V.R
MEC.4 isometric drawings and diagrams
R
H

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“TECHNICAL BID”
4.0 PRESSURE HYDRO TESTING PLAN
A. INTRODUCTION
This Pressure Hydro Testing Plan is designed for the testing of piping works in a manner to avoid
unnecessary delay during the execution of Construction and Installation of New Ovhor Manifold Skid
and Support Project which is being planned to be handled by VANDREZZER ENERGY SERVICES
LIMITED (VESL) for ADDAX.

B. SCOPE
This Plan pertains to activities related to pressure testing of the Piping Spools, and Pipeline Sections
in order to ascertain its’ integrity and proper installation condition prior to commissioning.
C. REFERENCES
Standard construction specifications base on ISO 9001/9002: For Pressure Testing
D. RESPONSIBILITY
D.1 The Site Construction Manager shall be responsible for the implementation of these
Plans.

D.2 The Site Engineer shall be responsible for correct application of this Plan.

D.3 The QA/QC Engineer shall be responsible for inspection activities related to this Plan by
way of Quality Control inspection personnel and also for collection and filling of Quality
Control documentation.

E. EQUIPMENT AND PRESSURE TEST FACILITIES

The equipment to be employed for pressure testing shall be of good working condition.

They include the following:-

E.1 Flushing Pump
E.2 Pressurising Pump
E.3 Calibrated Test Instrument e.g. Pressure gauges, Thermometers, and Pressure and
temperature recorders.
E.4 Water Filling (Portable).

F. PROGRAM AND TESTING SCHEDULE

ADDAX representative shall be given 48 hours notice to stating actual date and time such tests,
checks and inspections are due to commence.

Testing schedule shall be developed prior to any hydro-testing, detailing the duration and preparing

isometric for each section to be tested and construction of temporary works and test provision.

The test section shall clearly be identified by isometrics and P&I drawings. This is to ensure that each
has sufficient vents and drains.

G. PRE-TEST PREPARATION
Operations prior to introduction of test medium shall be as follows:-

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G.1 Prior to proceeding with any hydrostatic testing of Piping the following
documentation shall be prepared and where appropriate, signed by both
VANDREZZER and ADDAX representatives.
a) Checklist
b) Piping erection Report
c) Erection acceptance Report
d) Pipe Testing Reports

G.2 Two Pressure Gauges (calibrated) shall be installed with pressure rating not
exceeding 1.5times of test pressure. The gauges where possible, shall be at the
lowest and highest elevation but shall be in any case at the maximum distance
possible away from one another.

G.3 All valves in the test section shall be in the open position (Ball valves and plug valves
½ open) unless specifically directed otherwise in writing by ADDAX’s representative.
Relieve valves and bursting discs shall be removed and their connections blanked off.

G.4 It shall be ensured that during pressure testing no movement, thrusts or forces can
occur during the test.

G.5 Prior to flushing of pipe works, all control valves shall be removed and replaced with
spool pieces

G.6 Prior to flushing all isolating valves of the level gauges shall be in the closed position.
After flushing the isolating valves of the level gauges shall be opened where
applicable.

G.7 All safety valves shall be removed before flushing and shall be checked by ADDAX for
piping” and sealing where applicable

G.8 Flow meters shall be removed before flushing and reinstalled upon completion of
the hydro-testing. Where required spool pieces shall be installed.

G.9 Filter elements of strainers shall be removed before flushing and reinstalled before
hydro-testing.

G.10 The open drain/closed drain pumps shall be removed before flushing reinstalled
upon completion of hydro-testing.

G.11 All impulse line shall be disconnected from the process equipment or piping prior to
flushing and reconnected after completion of the hydro-testing.

G.12 Continuous recording of hydrostatic pressures and ambient temperatures

throughout the test duration on approved calibrated recorders.

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G.13 The following items shall either be removed and replaced with temporary spool
pieces or isolated by blanks
- Safety valves
- Control valves
- Equipment/machinery
- Instrumentation

G.14 The items to be tested shall be adequately vented and drain facilities available where
possible.

H. PRESSURE TESTING AND INSPECTION

H.1 Water shall be introduced to the piping system to be tested from the lowest point
and all vents left opened until air has been expelled.
H.2 The system shall be flushed until the flushing water leaving the system is clean.
H.3 The system shall then be pressurized at a moderate constant rate of 1.5 bars every
20 minutes, i.e. pressurization is stopped and the system checked for leaks at 20
minutes intervals.
H.4 Allow for stabilization period when the pressure is 70% of the test pressure.
H.5 Vents shall be closed for several hours until such a time is established that the
temperature of the water within the tested section has completely stabilized.
H.6 At this point checks shall be carried out for leaks and such leakage rectified when
necessary as per specification. Where repairs to leaks may require hammering of
stud-bolts or the use of air-impact wrenches, the system shall be depressurised
H.7 The system shall then be pressurized to the required test pressure of 1.5 MOP of the
weakest link in the system under test and shall be depressurised.
H.8 Repairs and Re-test shall continue until the specified test pressure can be
satisfactorily maintained for the specified test duration.
H.9 Should ADDAX consider that the result of the test duration, pressure and leakage
test are inconclusive, VANDREZZER shall extent the test for a period equal to the test
duration of extra time, as ADDAX may consider necessary in order to obtain
conclusive result.

I. DEPRESSURIZATION AND WATER DISPOSAL

On completion of the Test duration and acceptance obtained from ADDAX, the system tested shall
be depressurised and water used for the test disposed. The disposal of the test water shall be as
directed by ADDAX representative. Blanks shall be removed where applicable, Gaskets & Bolts finally
tightened.

J. COMPLETION OF HYDROTEST AND TEST REPORTS

Test reports and charts shall be submitted to ADDAX for approval after satisfactory completion of the
pressure test and the reports shall contain the following information:
- Confirmation of the starting time Date
- The system under test and installation name
- The recorder element range
- Test start and stop signatures
- Who witnessed and accepted the test on behalf of ADDAX.

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Test shall be started and stopped in the presence of the persons authorised to witness these tests on
behalf of ADDAX.

On no account shall closed valves be utilized for pressure containment in a system under test.
The containment shall be effected by suitably rated spades, blind flanges or Welded on dome end
caps.
Upon completion of the hydro-test of the piping system, the leak-free tightness of any valve
specified as “100% tight shut-off” shall be verified.
Safety of all employees and the public during the pressure testing is of paramount importance and
this can be achieved by the following viz:
- Availability of sufficient and efficient Safety Personnel.
- The whole area under test shall be barricaded with rope and appropriate warning signs
e.g. “KEEP OFF PIPING UNDER PRESSURE” shall be put in place.
- Human traffic shall be controlled by dedicated personnel
- Fire watch/extinguisher shall be dedicated and safe hand tools shall always be used.
- Hydro-testing personnel shall at all times be in liaison with CASHES officer.
- The system under test must be adequately vented to exclude any possibility of air
pockets.
- Blanking-off shall be ensured to be of correct rating and that such items, in particular
screwed plugs and connections, are not liable to be ejected during testing, e.g. as a result
of thread failure or inadequate thread engagement.
- System shall not be subjected to any form of shocking loading, such as hammer testing
whilst undergoing strength tests.
- Systems subjected to maximum test pressure should not normally be approached for
close inspection until after a reasonable period of time has elapsed.
- Seawater shall be considered as a testing medium for systems where fresh water is
unavailable. However, this shall be done only with prior written permission of ADDAX.
In all cases where seawater is used this must first be inhibited. There will be cases where
inhibited seawater is unsuitable and in such circumstances special provisions must be
made to obtain clean fresh water.
- Where a pressurising medium other than water is used, care shall be concerned.

K. SAFETY
Safety of all employees and the public during the hydrostatic pressure testing is of paramount
importance and this can be achieved by the following viz:
- Availability of sufficient and efficient Safety Personnel at all times during pressure testing
activities.
- The whole area under test shall be barricaded with hazard tape and appropriate warning
signs e.g. “KEEP OFF PIPING UNDER HYDROSTATIC PRESSURE” shall be put in place.
- Human traffic shall be controlled by dedicated personnel
-
- Fire watch/extinguisher shall be dedicated and safe hand tools shall always be used
provide certified stand by fire extinguisher.
- Hydro-testing personnel shall at all times be in liaison with CASHES officer.
- The system under test most be adequately vented to exclude any possibility of air
pockets.
- Blanking-off shall be ensured to be of correct rating and that such items, in particular
screwed plugs and connections, are not liable to be ejected during testing, e.g. as a result
of thread failure or inadequate thread engagement.

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- System shall not be subjected to any form of shocking loading, such as hammer testing
whilst undergoing strength tests.
- Systems subjected to maximum test hydrostatic pressure should not normally be
approached for close inspection until after a reasonable period of time has elapsed.
- Where a pressurising medium other than water is used, care shall be concerned.
- Follow PTW strictly.
- Toolbox meeting prior to work commencement.
- Strict supervision should be enforced.
- Adhere to Plan.
- Use appropriate PPE.
- Use PFD when servicing close to water bodies.
- Restrict movement around the Hydrotest operation/activities area.

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L. ATTACHMENTS

HYDROTEST PACKAGE

 VANDREZZER FORM QR 066 – PRESSURE TEST REPORT

 VANDREZZER FORM QR 067 – HYDROSTATIC TEST AND TEMPERATURE DATA RECORD
PRESSURE TEST REPORT
PROJECT: ACTIVITY:
CLIENT: ADDAX DATE:
CONTRACT NO.: REPORT NO.:

DRAWING NOS: FIELD

LINE NOS:

DATE TEST PERFORMED:

FROM POINT:

TO POINT:

TEST PRESSURE:
DURATION OF TEST
REMARKS

SIGNATURE:

VANDREZZER QC PERSONNEL ADDAX REPRESENTATIVE

NAME: NAME:

TITLE : TITLE :

SIGN: SIGN:

DATE : DATE :

FORM QR - 066 (REV. 01) 07:01:12

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M. HYDROSTATIC TEST AND TEMPERATURE DATA RECORD
PROJECT: LOCATION:

CLIENT: ADDAX PACKAGE NO.:

CONTRACT NO.: CONTRACTOR:

JOB NO.: SHEET OF
SYSTEM/ SERVICE: DATE:

PIPE DATA: SPEC.:____________ GRADE: _____________

OD:____________ WT: _____________
TEST PRESSURE RANGE:
MIN.:______________ MAX.:____________ TEST MEDIUM: ____________
INSTRUMENT DESCRIPTION

ITEM RANGE CALIB. DATE SERIAL NO. MANUFACTURER

Pressure Recorder
Temperature Recorder
Pressure Gauge
Deadweight Tester

GAUGE DEAD WEIGHT AMBIENT PIPE METAL

TIME REMARKS
PRESSURE PRESSURE TEMPERATURE TEMPERATURE

TESTING FIXTURE DESCRIPTION/ REMARKS: (OPTIONAL)

TEST WITNESSED:
VANDREZZER QC PERSONNEL ADDAX REPRESENTATIVE
NAME: NAME:
TITLE : TITLE :
SIGN: SIGN:
DATE : DATE :

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