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Fabrication

FABRICATION

Offshore Projects Consultants can provide a turnkey design-and-build service, taking a project from the initial engineering requirements through fabrication, inspection, testing and final documentation.
Through our network of fabricators in the Netherlands, China and the UK, we can bring together the engineering and manufacturing capability suited to the project’s location, technical requirements and delivery schedule. Clients have a single point of contact for coordinating the design and build.

From Design to Fabrication

We develop designs with fabrication and assembly in mind, considering material availability, weld access, manufacturing tolerances, handling and inspection requirements from the outset.
Our scope can include engineering calculations, 3D models, fabrication drawings, material specifications and bills of materials, followed by technical support throughout manufacture. Keeping engineering involved during fabrication allows queries and proposed changes to be assessed against the original design requirements.
This approach supports the delivery of lifting equipment, equipment foundations, seafastening structures, temporary works and bespoke marine and offshore fabrications.

Fabrication Standards and Quality Control

OPC works with fabricators capable of delivering structural steelwork to Execution Class 3 (EXC3) under EN 1090-2. EXC3 sets demanding requirements for the control of fabrication, including material traceability, welding coordination, qualified welding procedures and personnel, inspection and documented quality records.
For offshore projects, we can also coordinate fabrication to the requirements of DNV-OS-C401, Fabrication and Testing of Offshore Structures, where specified. The applicable standards, inspection requirements and acceptance criteria are established for each project and incorporated into the fabrication specification and inspection and test plan.

Inspection and Testing

OPC can coordinate third-party inspection and testing throughout fabrication, with hold points and witness points agreed before work begins.
Support can cover material identification, joint preparation and fit-up inspections, dimensional checks, welding inspection and non-destructive testing (NDT). Where required, we can also develop load-test procedures and coordinate test arrangements, independent witnessing and post-test inspection.
Inspection findings and fabrication queries can be referred directly back to the engineering, helping resolve issues while maintaining the design intent.

Manufacturing Record Books

We can compile complete Manufacturing Record Books (MRBs) to the agreed project requirements, providing a traceable record of the materials, fabrication processes, inspections and tests associated with the finished equipment.

Depending on the scope, the MRB can include:

  • Material certificates and traceability records.
  • Welding Procedure Specifications (WPSs) and supporting qualification records.
  • Welder qualification certificates and continuity records.
  • Welding consumable certificates and procedures for storage, handling, drying and issue.
  • Inspection and test plans, weld maps, fit-up and dimensional inspection records.
  • NDT procedures, personnel qualifications and examination reports.
  • Load-test procedures, certificates and inspection records.
  • As-built drawings, operating instructions and relevant third-party release documentation.

Documentation requirements are addressed during manufacture so that the final handover package reflects the equipment as built.

Discuss Your Requirements

Whether you need engineering support for your preferred fabricator or a complete design-and-build package, contact OPC to discuss the scope, fabrication location and required delivery.