Presentation GMAW

GMAW

Mechanized Mechanized Gas Gas Metal Arc Metal Arc Welding (Auto GMAW) Welding (Auto GMAW) for for Qurayah Seawater Pipelines Qurayah Seawater Pipelines Before Start Welding Before Start Welding 1. Approval of GMAW Process from CSD. 2. Approval of WPS & PQR. 3. Inspection of Welding Consumables 4. Welder and welding Operator Qualification. 5. Welding Machine Calibration. 6. Approval of NDT Procedure. 7. Approval of NDT Personnel. Approval of GMAW Process from Approval of GMAW Process from CSD CSD SAES-W-012: 5.4.1 SAES-W-012: 5.4.1 d) Automatic/machine welding using the GMAW d) Automatic/machine welding using the GMAW process Requires approval by CSD. A process Requires approval by CSD. A computerized automated ultrasonic inspection computerized automated ultrasonic inspection system, approved by Inspection Department, system, approved by Inspection Department, must be used. must be used. Contractor has to submit complete details Contractor has to submit complete details about their GMAW process, controls like which about their GMAW process, controls like which are the parameters are controlled by M/c and are the parameters are controlled by M/c and by welders , Gas & gas mixtures to be used by welders , Gas & gas mixtures to be used etc. to CSD for approval. etc. to CSD for approval. Approval of WPS & PQR Approval of WPS & PQR . . SAES-W-012: 7  7.1.1 . All welding procedures to be used shall be submitted to Saudi Aramco as a complete package prior to the start of work. The package of welding procedures, qualification test records, and weld maps/tables shall be submitted for the technical approval by CSD.  7.1.5 . Welding shall not commence until the welding package has been approved for application by Saudi Aramco inspector and returned to the fabricator. Any welding prior to the approval of the welding package is subject to rejection at the sole option of Saudi Aramco inspector.  7.1.6 . After approval by Saudi Aramco inspector, the fabricator shall issue copies of the approved Welding Procedures and Weld Table to the Saudi Aramco Inspector and PMT prior to the start of fabrication.  7.2.1. All WPSs and PQRs shall conform to the latest edition of the relevant Code (API STD 1104 or ASME SEC IX, as appropriate). Procedures that comply with a previous edition but not the current edition of the relevant Code are not acceptable, Procedures no longer conforming to the latest Code edition shall be revised and requalified. Inspection of Welding Consumables Inspection of Welding Consumables SAES-W-012 :6.7  Shielding gases shall conform to the following requirements:  6.7.1 Carbon dioxide (CO2): Federal Specification BC-C- 101, Type B or Compressed Gas Association CGA G-6.2, Type F.  6.7.2 Argon (Ar): Compressed Gas Association CGA G- 11.1, Grade A.  6.7.3 The requirements for other gases and gas mixtures shall be submitted to CSD for approval.  So contractor has to submit the certificate of shielding gases to comply with above requirements. Welder and welding Operator Welder and welding Operator Qualification Qualification SAES-W-012: 8  8.1 All welders, welding operators, shall be qualified in accordance with either ASME SEC IX or API STD 1104 and SAEP-321, SAEP-322, SAEP-323, and SAEP-324, as applicable, for all welding, including tack, temporary, and repair welds.  8.3 Performance qualification tests shall not be performed on production joints on Saudi Aramco work Welding Machine Calibration Welding Machine Calibration . . SAES-W-012: 18 18.2 Welding power supplies shall be calibrated in accordance with BS 7570 or an approved equivalent if impact toughness test is required by the applicable company or industry specifications or codes. Calibration records shall be available to Saudi Aramco Inspection upon request. Approval of NDT Procedure and NDT Personnel Approval of NDT Procedure and NDT Personnel  SAES-W-012: 16 16.1.1. Nondestructive Testing (NDT) inspection procedures shall be established in accordance with ASME SEC V. A written procedure for each inspection method and technique, including acceptance criteria, to be used shall be submitted to Inspection Department for approval. Qualification of the procedure by the contractor may be required, as determined by Saudi Aramco Inspection. Inspection procedures in conformance with other standards are acceptable only with the approval of Inspection Department. NDT performed without approved procedures shall be considered unacceptable. 16.1.6 All NDT personnel shall be qualified in accordance with SAEP-1140 or SAEP- 1142, as applicable.  SAEP-1142  4.2 Any organization supplying, employing, or delegating NDT personnel shall have a written practice or procedure covering NDT personnel training, experience, qualification, and certification. This written practice shall meet or exceed the minimum requirements of ANSI/ASNT CP-189 (latest edition) plus the additions and clarifications outlined in this SAEP. The organization's NDT personnel qualification and certification procedure shall be submitted to the Saudi Aramco Inspection Department, Dhahran, for review and approval prior to the commencement of any NDT operations.  4.4 Personnel responsible for interpretation of or affecting the results of NDT operations shall be certified to a minimum of Level II per the certifying organization's written practice.  Schedule ‘Q’ Attachment VI (Replace Table of Attachment IV) Personnel qualification procedure approval and Personnel qualification approval not required when NDT is subcontracted to an approved in-kingdom sub contractor. NDT technician performance shall be monitored by Contractor on all projects. Comparison of SMAW Comparison of SMAW ( ( Shield Metal Arc Welding , Shield Metal Arc Welding , Manual welding Manual welding ) with Auto ) with Auto GMAW GMAW Note: Applicable only in Qurayah Seawater pipelines Note: Applicable only in Qurayah Seawater pipelines Major Points Major Points  Purpose or Use in Qurayah Pipelines  Joint Design  Fitup or Joint preparation  Clamps for Fitup  Preheating  Shielding Gas  Electrode / Filler wire  Control  Production  Defects  NDT [...]... crossing sections  GMAW Mainline welding (Long sections) Joint Design  SMAW Single ‘ V ‘ with Root Gap Groove Angle = 60º (+10º, - 0º) Bevel Angle = 30º Root Face = 1.6mm Root Gap = 2-3 mm  GMAW Single ‘ U ‘ without Root Gap Bevel preparation   SMAW By gas cutting and grinding GMAW Using Beveling Machine Beveling Machine Clamps for Fitup   SMAW:  Internal Clamp Using external GMAW: External clamp... Top to Down) Preheat - By Induction heating and Torch Control & Production  SMAW:  Completely Manual, all parameters to be adjusted by welders  Slow process and production also less compared with GMAW   GMAW:  Filler wire feed automatically  All parameter fixed in m/c and Operator can adjust a bit of oscillation and stick out  High speed process, weld deposition less and production very high SAES... the actual PQR value Auto GMAW welding head Defects & NDT  SMAW Defects : Most common defects are Slag, Porosity, Lack of root fusion and penetration NDT : 100% Radiography SAES-W-012, 10.4.2: External line-up clamp may be used for pipe diameter 16 inches or larger if approved by CSD Welding Engineer with a condition that 100% radiography is performed to the production welds  GMAW Defects: Common defect... Filler wire  SMAW: Shielding gas – Nil Electrode – Flux coated electrode E6010- Root welding, E8018C3 – Hot, Fill & Cap pass Direction of Welding – Uphill ( from Down to Up) Preheat – By Gas Torch  GMAW: Shielding gas – 100% CO2 - for Root, hot & Fill pass1 welding 70% CO2+ 30% Argon – for Fill 2 & Cap pass Electrode: Bare Filler wire, ER 70 S6 – for All passes Direction of Welding – Down hill (... Side wall lack of fusion Due to high rejection, it may affect project repair rate NDT : 100% Automatic- Ultrasonic Testing SAES-W-012, 16.6: Exception: For girth welds made with an automatic/mechanized GMAW process using the shortcircuiting mode, 100% inspection using a computerized automated ultrasonic inspection system is required 16.6.1.1.3 Additional radiography The following weld joints are also... shall include a band of base metal at least 25.4 mm wide on each side of the weld  16.3.2 A computerized automatic ultrasonic system must be used for all welding performed with an automatic/mechanized GMAW welding system operating in the short-circuiting mode The system must be approved by Inspection Department  16.3.3 When a computerized automatic ultrasonic system is used, it shall be operated within... shall not be less than 900 mm all around the pipe For pipelines greater than 16 inch diameter, at least two welders shall be used, operating simultaneously and in opposite quadrants    Some pictures of GMAW Machine (Saipem) Control unit Thank You . (Auto GMAW) Welding (Auto GMAW) for for Qurayah Seawater Pipelines Qurayah Seawater Pipelines Before Start Welding Before Start Welding 1. Approval of GMAW. Approval of GMAW Process from Approval of GMAW Process from CSD CSD SAES-W-012: 5.4.1 SAES-W-012: 5.4.1 d) Automatic/machine welding using the GMAW d)