FEDP-construction and Fabrication Procedure

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INTENSIVE OIL AND GAS FACILITY ENGINEERING

DEVELOPMENT PROGRAMME (FEDP)

CONSTRUCTION/FABRICATION PROCEDURE

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INTRODUCTION
Fabrication and installation of oil and gas facilities include the following
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
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 PRECAUTIONS
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 edges
after 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 guard in place

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ALIGNMENT OF PIPE
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Proper alignment is important if a piping system is to be correctly fabricated.
Poor alignment may result in welding difficulties.
The following alignment procedures commonly used in fabrication:
Pipe-to-Pipe Alignment
45
o
Elbow-to-Pipe Alignment
90
o
Elbow-to-Pipe Alignment
Tee-to-Pipe Alignment
Flange-to-Pipe Alignment
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 pipes
and maneuver unpositioned
length until both are level
Tack weld top and bottom
Rotate pipe90
0
Repeat Procedure

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45
O
ELBOW-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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90
0
-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 leaving
small 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
Sandblasting is using compressed air
to propel abrasive media at a surface to
remove abrasive paints, rust, or grit
from metal object. This leave the metal
with a smooth finish for them to
powder coated, anodized or liquid
painted. Sand is used as the basic
material in the process.
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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 warn
unauthorized 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 without gloves
Workers shall discard disposable clothing and change into clean clothing
before leaving the work site
Used blasting agents shall be removed from the work area at the end of the
blasting period in such a manner as to avoid dust dispersal
The blast nozzle shall be bonded and grounded to prevent the build up of
static charges.

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WELDING OPERATION
REFERENCE MATERIALS
1. American Petroleum Institute (API 1104)
2. American Welding Society (AWS)
a) AWS A05.1 Specification for carbon steel electrodes for shielded metal arc welding
b) AWS A05.18- Specification for carbon steel electrodes for gas shielded arc welding
c) AWS B2.1- Specification for welding procedure and performance qualification
3. American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code
a) ASME BPVC Section II Part C- Specification for welding Rods, Electrodes, and Filler
Metals
4. International Organization for Standardization
a. ISO 9692-1: Welding and allied processes recommendations for joint preparation.
SMAW, GMAW, and TIG
b. ISO 13847: Welding of pipeline
c. ISO 15607: Specification and qualification of welding procedures for metallic material-
General rules
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WELDING OPERATION
Welding is a fabrication operation
by which two or more parts are
united by means of heat, pressure or
combination of both
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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
6
JOINT CONFIGURATION
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Root Opening A separation at the joint root between the two work pieces
Root Face The portion of the groove face adjacent to the joint root
Groove Face The surface of a joint member included in the groove
Groove Angle The total included angle of the groove between the two work
places
Bevel Angle The angle formed between the prepared edge of a member and
a plane perpendicular to the surface of the member
Groove weld size The joint penetration of a groove weld
Plate thickness The thickness of the base metals to be welded

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JOINT CONFIGURATION
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WELDING JOINT
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This type of joint is used to connect plates in
the same plane.
The joint is superior to all the other types,
particularly under bending, cyclic and
dynamic loadings, and is adopted wherever
practicable for connecting structural
members

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The welds that form a T joint are called Fillet
Welds.
These welds are the cheapest type of welds to
manufacture, because no edge preparation is
required
Single fillet T joints are preferred for smaller plate
thickness when subject to low or almost no-load
conditions, whereas, double T joints are
recommended for most severe loading conditions

1G- Pipe is horizontal and rotated, welding flat on or near top of pipe
2G- Pipe is vertical and not rotated during welding, welding is horizontal
3G- Plate is vertical, and axis of the weld is vertical. Weld position is vertical
4G- Plate is horizontal, weld position is overhead
5G- Pipe is horizontal fixed, and not rotated, weld is vertical, flat and overhead
6G- Pipe is inclined fixed at a 45 degree angle and not rotated during welding

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WELDER TEST POSITIONS FOR PIPE
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PLATE AND PIPE WELDING POSITION
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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
Bead
Groove
Fillet
Surfacing
Tack
Plug and Slot
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TYPE OF WELD-continue
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 simply welds made
in the groove between two members
to be joined.
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Surfacing welds
A surfacing weld is composed of
one or more stringer or
weave beads. Surfacing,
sometimes known as hardfacing or
wearfacing is often used to build up
worn shafts, gears, or cutting edges.
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Fillet weld
This weld is used to join two surfaces
that are at approximately right angles
to each other in a lap, tee, or corner
joint
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Tack weld
Tack weld is a short weld made to hold
the plates in perfect alignment with
uniform root gap prior to final welding.
Tack welds are made at regular intervals
along the joint
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Plug and Slot weld
Are welds made through holes or
slots in one member of a lap joint.
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1. Shielded Metal Arc Welding (SMAW)
Shielded Metal Arc Welding uses the heat of an electric arc between a covered
metal electrode and the work (pipe, plate, etc.). Shielding comes from the
decomposition of the electrode flux coating. Filler is supplied by the electrode
core wire and covering (iron powder and alloy). SMAW is performed by striking
an arc between a coated- metal electrode and the base metal.
The basic equipment is a work clamp, an electrode holder, arc welding
machine and the electrode
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Types of Arc Welding

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Arc Welding Machines
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Electrode and Holder
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Shielded Metal Arc Welding
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Strength- Tensile strength (I.E. 70, or 60) 70,000 psi / 60,000 psi
Position: 1= all positions. 2= flat and horizontal fillet position only
Example: E-7018, E-6010
SMAW ELECTRODE IDENTIFICATION SYSTEM

E X X X X
STRENGTH
POSITION
COATING / OPERATING
CHARACTERISTICS
2. Gas Metal Arc Welding (GMAW or MIG)
Gas Metal Arc Welding (GMAW or MIG) uses the heat of an electric arc
between a continuous bare wire filler metal electrode and the work.
Shielding is obtained entirely from an externally supplied inert gas (argon
or helium) or reactive gases (C0
2
or 0
2
) or a combination thereof. This
process can be semi-automatic or automatic. Shielded gases protect gas
metal arc welds from the atmosphere. Fluxes are not used in this process.
All deoxidizers and alloying elements are incorporated into the electrode
wire. GMAW process deposits the weld metal in the joint by one of the
following modes: spray transfer, globular transfer and short circuiting
transfer.

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Gas Metal Arc Welding (GMAW or MIG)
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GMAW ELECTRODE IDENTIFICATION CHART

E R X X S - X
ELECTRODE ROD
STRENGTH
SOLID
WIRE
CHEMICAL
COMPOSITION
Gas Metal Arc Welding (GMAW or MIG)
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MIG Machine with Spool Feeder
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GUN used in GMAW
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MIG Torch
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GMAW Weld Diagram
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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 obtained from an
inert gas or inert gas mixture. Welds may be made with or without filler metal
as required. The most significant feature in GTAW is that the electrode
(tungsten) used is not intended to be consumed. Only the filler metal is
consumed.

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Gas Tungsten Arc Welding or Tungsten Inert Gas (GTAW or TIG)
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The tungsten electrode contributes neither deoxidation nor fluxing, so it is
fortunate that the melting is essentially slow and that most of the gases can
escape from the weld pool before it freezes. The filler rod contains the needed
deoxidizers. The slow heating and lower temperatures combined with slower
cooling rates in GTAW will result in improved weld metal and heat affected
zone mechanical properties. The outstanding factor of GTAW is the exceptional
cleanliness that can be obtained in the weld, producing crack free welds in
alloys that are difficult to weld in other process
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TIG Welding
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GTAW or TIG Process
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GTAW Welding Equipment
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TIG Welding Machine
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TIG Torch
END OF TASK
QUESTIONS
AND
ANSWERS
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INTENSIVE OIL AND GAS FACILITY ENGINEERING

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