FEDP-construction and Fabrication Procedure

8/12/2019 FEDP-construction and Fabrication Procedure

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INTENSIVE OIL AND GAS FACILITY ENGINEERIDEVELOPMENT PROGRAMME (FEDP)

CONSTRUCTION/FABRICATION PROC

This document is for exclusive use only, copying wit


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INTRODUCTION

Fabrication and installation of oil and gas facilities include the follow

operations;

CUTTING AND GRINDING

PIPE ALIGNMENT

SANDBLASTING

WELDING

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CUTTING PROCEDURE

STEP 1: Measure pipe

diameter

To determine if the pipe is suitable

for cutting, measure the pipe

diameter (or circumference) at the

location to be cut. Take this

measurement square with the

longitudinal axis of the pipe.

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STEP 2: Mark the location

of the cut pipe end

A line must be scribed or otherwise

marked on the circumference of the

pipe at the proposed cut location to

ensure that the cut is will be square.

Chalk is a good choice for marking

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CUTTING PROCEDURE


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CUTTING PROCEDURE

STEP 3: Cut the pipe

Cut the pipe to the desired length.

Make sure the pipe cut is square to

the pipe or joint assembly will be

difficult or impossible

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CUTTING PROCEDURE

STEP 4: Bevel the cut end

Bevel the cut end using grinder. The

outside of the field cut end should

match the bevel on a factory beveled

pipe. Round the leading edge of the

spigot and remove any sharp, round

edges which might cut or snag the

gasket

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OPERATIONS AND HANDLING SAFETY PRECAU

Perform a thorough Job Safety Analysis (JSA)

Be sure to wear Personal Protective Equipment

(PPE)- Hard Hat, Hearing Protection, Safety Booth,

Hand Gloves, Goggles, and Coverall

Gloves should be worn when cutting pipe to

prevent cut fingers and hands from sharp edgesafter pipe has been cut

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Avoid wearing loose items such as

earrings, rings, necklace, loose

clothing or long hair that could

catch on control or moving

machinery

Must read and understand the

Operation and Maintenance

Manuals of all equipment

The RPM of the machine must NOT

exceed the RPM of the wheel/disc

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Never use the grinder above chest height

Stand perpendicular to the plane of the cutting wheel

Ensure the cutting/grinding tool has the correct protective gua

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ALIGNMENT OF PIPE10

Proper alignment is important if a piping system is to be correctly

Poor alignment may result in welding difficulties.

The following alignment procedures commonly used in fabrication

Pipe-to-Pipe Alignment

45oElbow-to-Pipe Alignment

90o

Elbow-to-Pipe Alignment

Tee-to-Pipe Alignment

Flange-to-Pipe Alignment



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PIPE ALIGNMENT-continue

PIPE-TO-PIPE ALIGNMENT

Level one length of pipe using

spirit level Brings lengths together leaving

only small welding gap

Place spirit level over both pipesand maneuver unpositioned

length until both are level

Tack weld top and bottom

Rotate pipe900

Repeat Procedure

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45OELBOW-TO-PIPE

Level pipe using spirit level

Place fitting to pipe leaving small

welding gap

Place 45o spirit level on face of

elbow and maneuver elbow until

bubble

Tack weld in place

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900-ELBOW-TO-PIPE


Place fitting to pipe leaving small

welding gap

Place spirit level on face of elbow

and maneuver elbow until level

Tack weld in place

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TEE-TO-PIPE


Place tee to pipe leaving small

welding gap

Place spirit level on face of tee

and maneuver tee until level

Tack weld in place

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FLANGE-TO-PIPE

Bring flange to pipe end leavingsmall welding gap

Align top two holes of flange with

spirit level

Tack weld in place

Center square on face of flange

Tack weld in place

Check sides in same way

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SANDBLASTING

Four Basic Components of Sandblasting

The air source

The sandblasting cabinet

The dust collector

The blasting Medium

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SANDBLASTING-Safety Operation

All personnel subject to silica exposure from

sand-blasting operations shall be provided with

information about the adverse health effects,

safe work practices, and proper use and care of

all PPE

Sandblasting operators use appropriate

barricade methods and warning signs to warnunauthorized personnel of the sandblast area

of operation, and proper PPE is required to be

worn in this designated work area

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Appropriate PPE include the use of a full

sandblast outfit consisting of a rigid blasting

helmet with air-flow control valves and filters ,

disposable full-body protective clothing, leather

gloves and boot

Silicosis is characterized by shortness of

breath, fever. It could be diagnosed as

pulmonary edema (fluid in the lungs),pneumonia or tuberculosis. This is as a result

of exposure to silica dust. All employees

exposed to crystalline silica shall be subject to

a medical examinations

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sandblasting w


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Workers shall discard disposable clothing and change into clean

before leaving the work site

Used blasting agents shall be removed from the work area at the

blasting period in such a manner as to avoid dust dispersal

The blast nozzle shall be bonded and grounded to prevent the bu

static charges.

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WELDING OPERATION


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WELDING OPERATION

REFERENCE MATERIALS

1. American Petroleum Institute (API 1104)

2. American Welding Society (AWS)

a) AWS A05.1Specification for carbon steel electrodes for shielded metal a

b) AWS A05.18- Specification for carbon steel electrodes for gas shielded arc

c) AWS B2.1- Specification for welding procedure and performance qualifica

3. American Society of Mechanical Engineers (ASME) Boiler and Pressu

a) ASME BPVC Section II Part C- Specification for welding Rods, ElectrodesMetals

4. International Organization for Standardization

a. ISO 9692-1: Welding and allied processes recommendations for joint preSMAW, GMAW, and TIG

b. ISO 13847: Welding of pipeline

c. ISO 15607: Specification and qualification of welding procedures for meGeneral rules

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WELDING OPERATION

Weldingis a fabrication operation

by which two or more parts are

united by means of heat, pressure or

combination of both

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JOINT CONFIGURATION


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Butt Weld

1= Groove Face

2= Root Opening

3= Groove Angle

4= Root Face

5=Plate thickness

6=Bevel Angle 1 2

3

4

5

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JOINT CONFIGURATION

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JOINT CONFIGURATION


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Root OpeningA separation at the joint root between the two wo

Root FaceThe portion of the groove face adjacent to the joint ro

Groove FaceThe surface of a joint member included in the groo

Groove AngleThe total included angle of the groove between th

places

Bevel AngleThe angle formed between the prepared edge of a m

a plane perpendicular to the surface of the member

Groove weld sizeThe joint penetration of a groove weld

Plate thicknessThe thickness of the base metals to be welded

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JOINT CONFIGURATION


WELDING JOINT


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WELDING JOINT


Thi f j i i d


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This type of joint is used to conne

the same plane.

The joint is superior to all the oth

particularly under bending, cyclic

dynamic loadings, and is adopted

practicable for connecting structu

members


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WELDER TEST POSITIONS FOR PIPE


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1G- Pipe is horizontal and rotated, welding flat on or near top of p

2G- Pipe is vertical and not rotated during welding, welding is hor

3G- Plate is vertical, and axis of the weld is vertical. Weld position

4G- Plate is horizontal, weld position is overhead

5G- Pipe is horizontal fixed, and not rotated, weld is vertical, flat

6G- Pipe is inclined fixed at a 45 degree angle and not rotated du

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WELDER TEST POSITIONS FOR PIPE


PLATE AND PIPE WELDING POSITION


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PLATE AND PIPE WELDING POSITION


PLATE POSITIONS


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PLATE POSITIONS


PLATE POSITIONS ROTATED OR ROLLED


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WELDING DIRECTIONS OR POSITIONS


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TYPE OF WELD


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Bead

Groove

Fillet

Surfacing

Tack

Plug and Slot

TYPE OF WELD-continue


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Bead Weld

Produced by a single pass

Stinger Bead- which is made without

weaving motion.

Weave Bead- made by side-side

oscillation



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Groove weld

Groove welds are simp

in the groove between

to be joined.



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Surfacing welds A surfacing weld is co

one or more stringer or

weave beads. Surfacinsometimes known as h

wearfacing is often use

worn shafts, gears, or c



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Fillet weldThis weld is used to join tw

that are at approximately

to each other in a lap, tee,

joint



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Tack weldTack weld is a short weld

the plates in perfect align

uniform root gap prior to

Tack welds are made at r

along the joint



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Plug and Slot weld

Are welds made throslots in one membe


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Types of Arc Welding


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1. Shielded Metal Arc Welding (SMAW)

Shielded Metal Arc Welding uses the heat of an electric arc betwe

metal electrode and the work (pipe, plate, etc.). Shielding comes f

decomposition of the electrode flux coating. Filler is supplied by t

core wire and covering (iron powder and alloy). SMAW is performe

an arc between a coated- metal electrode and the base metal.

The basic equipment is a work clamp, an electrode holder, arc we

machine and the electrode

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Arc Welding Machines



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Electrode and Holder


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Strength- Tensile strength (I.E. 70, or 60) 70,000 psi / 60

Position: 1= all positions. 2= flat and horizontal fillet pos

Example: E-7018, E-6010

SMAW ELECTRODE IDENTIFICATION SYSTEM

E X X X X

STRENGTH

POSITION

COATING / OPERATING

CHARACTERISTICS



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2. Gas Metal Arc Welding (GMAW or MIG)

Gas Metal Arc Welding (GMAW or MIG) uses the heat of an electr

between a continuous bare wire filler metal electrode and the wor

Shielding is obtained entirely from an externally supplied inert ga

or helium) or reactive gases (C02or 02) or a combination thereof.

process can be semi-automatic or automatic. Shielded gases prot

metal arc welds from the atmosphere. Fluxes are not used in this

All deoxidizers and alloying elements are incorporated into the ele

wire. GMAW process deposits the weld metal in the joint by one o

following modes: spray transfer, globular transfer and short circu

transfer.

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G M t l A W ldi (GMAW MIG)



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Gas Metal Arc Welding (GMAW or MIG)48


MIG M hi ith S l F d



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MIG Machine with Spool Feeder49


GUN d i GMAW



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GUN used in GMAW50



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GMAW Weld Diagram



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GMAW Weld Diagram52


3 G T t A W ldi T t I t G (GTAW TIG)53



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3. Gas Tungsten Arc Welding or Tungsten Inert Gas (GTAW or TIG)

Gas Tungsten Arc Welding (TIG) uses an electric arc between a non

consumable electrode (tungsten) and the work. Shielding is obtaine

inert gas or inert gas mixture. Welds may be made with or without

as required. The most significant feature in GTAW is that the electr

(tungsten) used is not intended to be consumed. Only the filler met

consumed.

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G T g t A W ldi g T g t I t G (GTAW TIG)54



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Gas Tungsten Arc Welding or Tungsten Inert Gas (GTAW or TIG)54


The tungsten electrode contributes neither deoxidation nor fluxing

fortunate that the melting is essentially slow and that most of the

escape from the weld pool before it freezes. The filler rod contains

deoxidizers. The slow heating and lower temperatures combined w

cooling rates in GTAW will result in improved weld metal and heat

zone mechanical properties. The outstanding factor of GTAW is th

cleanliness that can be obtained in the weld, producing crack free

alloys that are difficult to weld in other process

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55TIG Welding


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56GTAW or TIG Process



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58 TIG W ldi M hi



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58 TIG Welding Machine


59 TIG T h



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59 TIG Torch



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Documents

FEDP-construction and Fabrication Procedure