SLIDE SHOW

ORGANIZATION CHART

CORE BUSINESS

BUSINESS CLIENT

SHELL

PERSONAL PROTECTIVE EQUIPMENT ( PPE )

QUALITY CONTROL INSPECTOR EQUIPMENT

VOLTMETER & AMMETER

READING

TEMP. INDICATOR

MEASURING TAPE

TORCH LIGHT

STOP WATCH

MARKER

WELDING

PROCEDURES

1.PWPS: Preliminary Welding Procedure Specification

reference document to be used by the welder to complete a welding procedure qualification test

piece. Normally using the same format as that to be used for the WPS, the pWPS contains the key variables of the welding procedure to be qualified. Along with the dimensions, joint configuration,

consumable type etc. it gives the suggested welding parameters to be used (i.e. Current, Voltage,

travel speed) based on the welders knowledge and past experience.

2.WPS: Welding Procedure Specification

formal written document describing welding procedures, which provides direction to the welder

or welding operators for making sound and quality production welds as per the code

requirements . The purpose of the document is to guide welders to the accepted procedures so

that repeatable and trusted welding techniques are used. A WPS is supported by a Procedure Qualification Record (PQR or WPQR).

WELDING

PROCEDURES

3.WPQR: Welding Procedure Qualification Record

A WPQR is a record of a test weld performed and tested to ensure that the procedure will produce

a good weld. Individual welders are certified with a qualification test documented in a Welder Qualification Test Record (WQTR) that shows they have the understanding and demonstrated

ability to work within the specified WPS. The WPQR is supported by a number of documents (eg,

a record of how the weld was made, NDT, mechanical test results) which together comprise with

WPS document.

• SAMPLE COMPLETE FILE THAT HAVE BEEN COMPILE

WPQR

WPS sample

cover page

WELD DATA RECORD

WELDING PROCEDURE

FLOW

WORKSHOP

ACTIVITY

TAKING PARAMETER &

CALCULATION

WELDING STEP &

PROCESS

OXYFUEL GAS CUTTING

5 STEP OF A 6G WELD

There were 5 parameter that have been take by welding inspector during the welding process:

Oxy-fuel cutting is a chemical reaction between pure oxygen and steel to form iron oxide. It can be described as rapid, controlled rusting. Preheat flames are used to raise the surface or edge of the steel to approximately 1800°F (bright red color). Pure oxygen is then directed toward the heated area in a fine, high pressure stream. As the steel is oxidized and blown away to form a cavity, the preheat and oxygen stream are moved at constant speed to form a continuous cut.Only metals whose oxides have a lower melting point than the base metal itself can be cut with this process.

• The first “pass” or weld that you must do is considered a root pass. With root pass it make weld to slightly penetrate through the steel so that it come through on the inside completely sealing it.

• Length, Tempertaure, Voltage, Current, Time.

TAKING PARAMETER

&CALCULATION

2 calculation, to find heat input and travel speed:

• After your first pass and usually after every pass you have to clean and grinding the welding surface so that you do not get any slag inclusions. Slag inclusions are when piece of slag (the shielding component of the electrode that melts and protect the weld from the environment as it is being welded) get trapped within the weld and cause a weak spot where the metal is not actually bonded together.

• Next, the 2nd pass is hot pass, exactly what it sounds like a hotter pass at a higher amperage that bond the root pass and both pieces together. By going over the first weld hotter and usually with a heavier electrode that hot pass begins to fill the bevel more and more securely bonds the metal together.

• Third, is fill pass, exactly same like hot pass layer. By changing the electrodes and amperage of the machine welders can fine tune the amount of metal flowing into the weld and how hot the metal is getting. But, If the metal gets too hot on any of the pass, there is the potential for over penetration and just melting a hole through the material.

• The final cap cover the entire bevel or only a portion of it again depending on the thickness. The cap pass ensures a seamless seal on the outside of the finished weld. By making sure that there are no defects in the final weld there is less of a chance that the elements that the pipe is exposed to will damage the joint or effect the weld.

NON-DESTRUCTIVE

TESTING.

RADIOGRAPHIC TESTING

ULTRASONIC TESTING

RADIOGRAPHIC TESTING

ULTRASONIC TESTING

- RADIOGRAPHIC TESTING (RT) IS A TECHNIQUE THAT INVOLVES THE USE OF EITHER X-RAYS OR GAMMA RAYS TO VIEW THE STRUCTURAL COMPONENT SUCH AS PIPELINE, PRESSURE VESSELS AND VALVES, TO DETECT FOR FLAWS.

- USE HIGH FREQUENCY SOUND WAVES ( RANGE BETWEEN 0.5 - 15 MHZ ) TO CONDUCT EXAMINATIONS AND MAKE MEASUREMENT. CAN BE USE FOR FLAW DETECTION, DIMENSIONAL MEASUREMENTS, MATERIAL CHARACTERIZATION AND ETC. ULTRASONIC TESTING IS BASED ON THE CAPTURE AND QUANTIFICATION OF EITHER THE RELFECTED WAVES (PULSE-ECHO) OR THE TRANSMITTED WAVES (THROUGH-TRANSMISSION).

TYPE OF RADIOGRAPHIC 'TECHNIQUES'

ADVANTAGES & DISADVANTAGES

ADVANTAGES: - RAPID RESULTS

- BOTH SURFACE & SUBSURFACE DETECTION

- SAFE

- PORTABLE

ADVANTAGES & DISADVANTAGES

DISADVANTAGES: - SKILLED OPERATOR REQUIRED

- GOOD SURFACE FINISH REQUIRED

- NO PERMANENT RECORD

- CALIBRATION REQUIRED

DISADVANTAGES:

- EXPENSIVE CONSUMABLE

- HARMFUL RADIATION

- SLOW RESULTS

- BULKY EQUIPMENT

ADVANTAGES:

- PERMANENT RECORD

- NOT SO RELIANT UPON OPERATOR SKILL

- DEFECT IDENTIFICATION

- NO MATERIAL TYPE LIMITATION

WELDING IMPERFECTION ( RADIOGRAPHY TESTING)

CAUSES OF IMPERFECTION

TYPICAL CAUSES OF WELDING IMPERFECTION:

• Welding current too low

• Bevel angle too steep

• Root face too large/small

• Incorrect electrode angle

• Linear misalignment

• Welding speed too high

• Damp electrode

• Poor welder skill

• Incorrect inter-run cleaning

MECHANICAL TESTING

• Mechanical testing or engineering tests are performed to determine various mechanical properties of materials such as strength, hardness, ductility, toughness, brittleness, etc. There are several types of test to determine various mechanical and physical properties of material. The precision results of these tests is utilised to determine suitability of materials for the field application.

• The realistic meaning of mechanical testing in testing laboratories is to perform various strength test such as tensile test, compression test, shear test, flexural test, bend (ductility) test, impact (toughness) test, weld fracture test, Rockwell hardness test, Vickers Hardness test, Brinell hardness test, macro test etc.

MECHANICAL TEST SAMPLE

TENSILE TEST

CTOD TEST

CHARPY TEST

BEND TEST

• Bend tests deform the test material at the midpoint causing a concave surface or a bend to form without the occurrence of fracture and are typically performed to determine the ductility or resistance to fracture of that material..

• The Charpy impact test, also known as the Charpy V-notch test, is a standardized high strain-rate test which determines the amount of energy absorbed by a material during fracture. This absorbed energy is a measure of a given material's notch toughness and acts as a tool to study temperature-dependent ductile-brittle transition.

• Tensile testing also known as tension testing, is a fundamental materials science and engineering test in which a sample is subjected to a controlled tension until failure. Properties that are directly measured via a tensile test are ultimate tensile strength, breaking strength, maximum elongation and reduction in area.

• The Crack Tip Opening Displacement or CTOD Test measures the resistance of a material to the propagation of a crack. CTOD is used on materials that can show some plastic deformation before failure occurs causing the tip to stretch open. Accurate measurement of this displacement is one of the essentials of the test.

Tensile specimens made from an aluminum alloy. The left two specimens have a round cross-section and threaded shoulders. The right two are flat specimens designed to be used with serrated grips.