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INTENSIVE OIL AND GAS FACILITY ENGINEERIDEVELOPMENT PROGRAMME (FEDP)
CONSTRUCTION/FABRICATION PROC
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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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OPERATIONS AND HANDLING SAFETY PRECAU
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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OPERATIONS AND HANDLING SAFETY PRECAU
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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PIPE ALIGNMENT-continue
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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PIPE ALIGNMENT-continue
900-ELBOW-TO-PIPE
Level pipe using spirit level
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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PIPE ALIGNMENT-continue
TEE-TO-PIPE
Level pipe using spirit level
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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PIPE ALIGNMENT-continue
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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SANDBLASTING-Safety Operation
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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SANDBLASTING-Safety Operation
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
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WELDING JOINT
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WELDING JOINT
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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
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PLATE AND PIPE WELDING POSITION
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PLATE AND PIPE WELDING POSITION
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PLATE POSITIONS
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PLATE POSITIONS
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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
TYPE OF WELD-continue
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Groove weld
Groove welds are simp
in the groove between
to be joined.
TYPE OF WELD-continue
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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
TYPE OF WELD-continue
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Fillet weldThis weld is used to join tw
that are at approximately
to each other in a lap, tee,
joint
TYPE OF WELD-continue
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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
TYPE OF WELD-continue
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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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Types of Arc Welding
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Arc Welding Machines
Types of Arc Welding
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Electrode and Holder
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Types of Arc Welding
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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
Types of Arc Welding
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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)
Types of Arc Welding
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Gas Metal Arc Welding (GMAW or MIG)48
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MIG M hi ith S l F d
Types of Arc Welding
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MIG Machine with Spool Feeder49
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GUN d i GMAW
Types of Arc Welding
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GUN used in GMAW50
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GMAW Weld Diagram
Types of Arc Welding
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GMAW Weld Diagram52
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3 G T t A W ldi T t I t G (GTAW TIG)53
Types of Arc Welding
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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
Types of Arc Welding
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Gas Tungsten Arc Welding or Tungsten Inert Gas (GTAW or TIG)54
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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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Types of Arc Welding
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55TIG Welding
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Types of Arc Welding
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56GTAW or TIG Process
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58 TIG W ldi M hi
Types of Arc Welding
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58 TIG Welding Machine
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59 TIG T h
Types of Arc Welding
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59 TIG Torch
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