Ocean Fab’s principals have a 31 year history of Topside, Drilling, Subsea and Marine fabrication projects. We have been approved for sub-assemblies and weld procedures from the largest contractors in the oil and gas sector. We have experience and are pre-approved for fabrication and installation for projects such as large skid packages for topside brake cooling units, gas production and gas processing skid frames and sub-assemblies, 3D laser scanning of offshore platforms for engineering load bearing analysis (prior to the arrival of our installation team), Pipeline End Terminations (PLETS), Jumpers, Frames, Mudmats, Reels, Pullheads, Field Joint Coating, and many other subsea related activities including: Engineering, Installation, Construction, and Emergency Repairs.
Logistics including heavy big rig trucks rolling all over Texas and Louisiana for onshore, inland seas, offshore and subsea support.
33 acre Quayside facilities on the Houston Ship Channel for offshore logistics: Mobilization, Heavy lifting, SIT, Layouts, Staging – or whatever our client / contractor needs.
Health – Safety – Environment
“ABOVE ALL ELSE”
HSE ( Health Safety and Environment ) QC ( Quality Control ) QA ( Quality Assurance )
Our safety standards are achieved through a dedicated Health, Safety and Environment program that includes:
35 programs / processes in place to maximize worker Safety
Our HSE program is registered and complies with ISNetworld
Daily Safety meetings are mandated to discuss potential hazards for the upcoming the day’s operations and supplemented with weekly safety stand downs
JSA’s are conducted for any complicated or potentially dangerous operations, including: lifting, hydro-testing, and load out
Work at offsite locations is monitored by an HSE representative to ensure compliance with our client’s offsite requirements
Incentive programs are in place to reward employees for meeting our safety goals
Quality Management Systems
Our project managers are experienced in Engineering, Design, and Construction throughout the Gulf of Mexico. We have systems in place for continuous improvement in our ISO 9001 compliant Safety, Quality, and Environmental Management Systems.
Our Quality Management System was developed on the ISO 9001 compliant format that subsea and drilling clientele demand. The ISO 9001 format includes:
1. Centralization of the documents register for consistent access.
2. Continuous improvement auditing functions.
3. Root cause analysis / corrective action tracking systems.
4. Supplier/customer performance.
Our quality management system allows for ease of transparency when clients audit our procurement, fabrication processes, proof testing methods, procedures, and data booklet records for traceability project retention. Our quality division and management are constantly looking ahead and strategizing for potential changes to customer regulation in compliance and certification with the American Petroleum Institute (API) Ql & Q2 management program requirements being considered for equipment and drilling rig services. Our QMS strategy goes beyond simple compliance with regulations and standards – reducing risk and improving performance.
Even though we have developed numerous offshore, marine, and subsea weld procedures over the years, we realize that weld procedures are never static. Especially under the stringent, post-Macondo – Gulf of Mexico regulations and other specifications as set out by the oilfield companies, API, BOEM, and other government agencies. Working in harmony with our client’s technical staff, we know that every subsea project requires our engineers to propose, perform, and qualify project specific weld procedures and other processes for witness and approval.
During initial tender and estimation of subsea components, welding procedure matrix and project specific testing plans are developed and submitted to our clients, indicating weld sequencing and welding applications.
Engineering: In-house engineering staff for support, design and build with projects like 3D laser scanning of offshore platforms for engineering load bearing analysis (prior to the arrival of our installation team). Structural, piping, and mechanical design to build capabilities.
Installation: Upgrades, conversions, and repairs. 3D laser scanning of offshore platforms for engineering load bearing analysis (prior to the arrival of our installation team). Electrical – Large service team available to support repairs. Large cable and component installation and power management. Hydraulic – Tubing, cylinders, and pump servicing. In-house fluid power engineering.
Testing: Within the project specifications for Welding Procedure Specification (WPS) and at the specified time schedule, third party Testing, Inspection and Certification (TIC) is carried out for material / filler metal (both NDE and destructive/hardness testing of welds for sweet or sour service applications) including Pull and Load Tests, . Our engineering and safety management teams perform third party witnessed and validated welding procedure and qualification tests with the most popular surveyors and classification societies in the world, including DNV (Det Norske Veritas), Bureau Veritas, API, ABS, ASME: (codes R, S, U, NB), NACE (industrial coatings), and AWS.
Nondestructive Weld Testing (NDT – NDI – NDE)
Radiography – Magnetic particle crack detection – Dye penetrant testing – Florescent penetrants – Ultrasonic flaw detection – Eddy current and – Electromagnetic testing – Pressure Testing
Destructive Weld Testing
Macro Etch Testing – Root and Face bend testing – Fillet Weld Break Test – Transverse Tension Test – Guided Bend Test – Load Testing – Pull Tests – Nick break tests
*All tests witnessed through either American Society of Mechanical Engineers, American Welding Society, American Petroleum Institute, Det Norske Veritas, American Bureau of Shipping, or Bureau Veritas
Subsea video from YouTube – public domain, by Aker Solutions – Houston, Texas
Over the past 25 years we have invested heavily in our engineering, fabrication, and project management teams for both our onshore and offshore fabrication clients. Specifically for our deep water projects (in accordance with DNV-F101 submarine pipeline standards, as witnessed by Det Norske Veritas (DNV) surveyors) our welding procedure qualification tests verified our capabilities in welding structural and pressure piping / vessels of API yield strength of 40 to 70 ksi. These specific fabrication capabilities enable us to construct sub sea structures such as Pipeline End Terminations (PLETS), Jumpers, Frames, Mudmats, Reels, Pullheads, Field Joint Coating, and many other subsea installation components.
Our code stamps and weld procedures are third party verified by the leading surveyors in Offshore, Marine and Subsea Fabrication. Including AWS, ABS, Det Norske Veritas (DNV), Bureau Veritas, NACE (industrial coatings) and ASME: R, S, U, NB – enabling us to handle any heavy structural or high pressure piping / vessel welding. We also have extensive machining capabilities including Super sized horizontal mills and lathes allowing us to machine to tolerance “after” fabrication.