A 05.02.2014 ISSUED FOR INFORMATION M.C. Z.K. E.D.

Rev. Date Description Prepared Checked Approved

No.

ORIGINATOR

EDOPEC ENERJİ PETROL MÜHENDİSLİK SANAYİİ VE TİCARET LİMİTED ŞİRKETİ

Head Office : Palmiye Mah. Adnan menderes Bulv. Oktay Sitesi No: 9/8 PK = 33100 Yenişehir /Mersin –TURKEY P:+90 324 3260595 F:+90 324 3260596 Ankara Office : UĞUR MUMCU CAD(köroğlu cad) ERDİL APT 87/13 Gop-Çankaya -Ankara-TURKİYE P: +90 312 447 17 18 / 20 F:+90 312 447 17 21 İstanbul Office: Burhanıye Mahallesı Çamlıca Caddesi İhlamur villaları no 28 / 6^ŞRD3K Villa ^ Beylerbeyi –Üsküdar İstanbul / TURKEY P : +90 216 4220414 PBX F: +90 216 4220415 www.edopec.com. info@edopec.com

Document Title

WORK METHOD STATEMENT FOR CABLE CONNECTION WITH PIN BRAZING

Document No.

EDO WMS COE COR INT XXX 014 219 247 Rev

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DCC Seq.No Page 9

Page 2 of 10

Project: Proj. Identification:

Document Title: WORK METHOD STATEMENT FOR CABLE CONNECTION WITH PIN BRAZING

Document No.: EDO-WMS-COE-COR-INT-XXX-014-219-247-REV-A-WMS FOR CABLE CONNECTION WITH PIN BRAZING.DOC

Revision: A Date: 23.03.2014

Table of Contents

1  INSTALLATION METHOD .............................................................................................. 3 

2  KEEP THE TRIGGER DEPRESSED UNTIL THE BRAZE IS COMPLETED. ................. 6 

3  TECHNICAL REQUIREMENTS FOR COATING REPAIR .............................................. 8 

Page 3 of 10

Project: Proj. Identification:

Document Title: WORK METHOD STATEMENT FOR CABLE CONNECTION WITH PIN BRAZING

Document No.: EDO-WMS-COE-COR-INT-XXX-014-219-247-REV-A-WMS FOR CABLE CONNECTION WITH PIN BRAZING.DOC

Revision: A Date: 23.03.2014

1 INSTALLATION METHOD

All cable to pipe connections will be performed using the pin brazing technique. Edopec will use the pin brazing procedure and equipment.

Pin brazing is a jointing method, which is based on arc brazing where solder, is used whose fusing temperature is above 450°C.

Soldering is effected by means of a solder gun. The solder pin contained in the solder gun is raised several millimetres from the soldering point by means of an electro-magnet.

After approximately two seconds, the arc between the soldering point and the solder pin that results due to the power supplied causes the soldering temperature to increase to approx. 650°C.

The time wires at the solder pin fuses, and the solder pin hits the soldering point.

This method serves to braze connections, joints, threaded bolts, pins and soldering tags onto steel or other metal in order to obtain a high level of electrical conductivity.

The safety of staff must be of prime consideration on every occasion that work on or about the site is to be carried out, staff must comply with current safety requirements. Protective goggles must be used during grinding and brazing by the operator and any staff within 3m.

Page 4 of 10

Project: Proj. Identification:

Document Title: WORK METHOD STATEMENT FOR CABLE CONNECTION WITH PIN BRAZING

Document No.: EDO-WMS-COE-COR-INT-XXX-014-219-247-REV-A-WMS FOR CABLE CONNECTION WITH PIN BRAZING.DOC

Revision: A Date: 23.03.2014

The test procedure as presented in this documentation will be followed for pin brazing cable-to-pipe connections. The pin brazing areas the pipe coating will be removed by using knives or grinders. Approximate size of 10cm x 10cm. After the pin brazing operation the coating damaged area will be repaired in accordance with coating repair procedure. Brazing Pin – Each brazing pin is tipped with low temperature brazed alloy and the correct amount of flux, and has attached a copper fuse wire at the other end, which acts as a circuit breaker to control the breaking time. Ceramic Ferrules – For pin brazing the gun is loaded with one brazing pin and one insulating ferrule. The ferrule insulates the pin from the gun chuck; shields the molten braze metal from the air and protects the operator against spatter. Brazing Gun Loading/Preparation/Adjustment – Load the gun with a brazing pin and ceramic ferrule, ensuring that they are back fully home and tight. Do not straighten the kinked end of the pin fuse wire. The legs of the pin holder must be adjusted as necessary to ensure a firm grip while maintaining concentricity with the ferrule holder. Important: Under no circumstances should a brazing pin which has been inserted and then removed from the gun be re-inserted and used for brazing without checking the kinked end profile and fuse wire connection to pin. Before connecting the earth clamp to the steel, adjust the brazing pin “Lift Height” as follows: Hold the copper bond lug flat on the steel surface, Insert a loaded brazing pin into the hole in the bond lug and press the gun/ferrule against the surface of the lug evenly overcoming the internal spring. Turn the ferrule holder until the white adjustment indicator tube is flush with the gun’s rear face. The brazing gun should now be correctly set. Location of Connections – The desired position of the bonds required should be accurately marked on the steel. Do not use any oil-based marker as this will contaminate the grinder burr. Preparation of the Surface – If necessary the surface encompassing the pin braze area and adjacent earth connection shall be degreased before any grinding operation.

Scrape and clean the steel and grind an area for the earth clamp as near as

possible to the braze area. The surface must be ground to a bright finish to ensure a sound electrical connection between the work device and the work piece.

An area in excess of the cable lug must be located and cleaned to a bright finish.

All pits and marks must be removed.

Page 5 of 10

Project: Proj. Identification:

Document Title: WORK METHOD STATEMENT FOR CABLE CONNECTION WITH PIN BRAZING

Document No.: EDO-WMS-COE-COR-INT-XXX-014-219-247-REV-A-WMS FOR CABLE CONNECTION WITH PIN BRAZING.DOC

Revision: A Date: 23.03.2014

To prevent the ground from re-oxidizing, brazing must take place as soon as

possible, i.e. not more than 5 minutes.

Wear eye protection.

Pin Brazing – The magnetic lead attachment must be applied to the cleaned surface to ensure a sound electrical circuit. The brazing gun must be correctly adjusted with the correct pin and ferrule fitted. Locate the brazing pin so the brazing gun is in the center of the hole in the cable

lug. Apply sustained pressure on the brazing gun so that full contact is made between the ferrule and the bond attachment. When the operator is ready to braze he should look well to one side to protect his eyes from glare. The operator’s stance should be stable to enable this movement to be made without altering the critical positioning of the gun.

Hold the gun firm and close the circuit by squeezing the trigger.

Page 6 of 10

Project: Proj. Identification:

Document Title: WORK METHOD STATEMENT FOR CABLE CONNECTION WITH PIN BRAZING

Document No.: EDO-WMS-COE-COR-INT-XXX-014-219-247-REV-A-WMS FOR CABLE CONNECTION WITH PIN BRAZING.DOC

Revision: A Date: 23.03.2014

2 KEEP THE TRIGGER DEPRESSED UNTIL THE BRAZE IS COMPLETED.

After about 2 seconds the fuse wire should rupture, disconnecting the circuit. The

arc will extinguish and the pin will be shot forward into the molten filter. In the event of a fuse not rupturing after normal time, the gun must be withdrawn completely from the work keeping the trigger depressed.

After the fuse has ruptured, the gun must be held in place for a further 3

seconds to allow braze to set. Remove the gun by pulling straight off in line with the pin, then break out the

ferrule if this has remained in the gun only by levering against a suitable edge, beware, it mat be hot.

Hold the gun in a vertical position, and then depress the ejector button to expel

the remaining fuse wire. Catch the wire in your hand to ensure it has been ejected.

Page 7 of 10

Project: Proj. Identification:

Document Title: WORK METHOD STATEMENT FOR CABLE CONNECTION WITH PIN BRAZING

Document No.: EDO-WMS-COE-COR-INT-XXX-014-219-247-REV-A-WMS FOR CABLE CONNECTION WITH PIN BRAZING.DOC

Revision: A Date: 23.03.2014

Testing a completed bond – Direct pin braze attachments must be tested as follows: The shank of the pain pin must be carefully broken off with a hammer taken

care not to damage the lug. This must be done before another pin braze is made to the bond. After breaking off the shank the broken surface should be level or thereabouts with the outer surface of the lug. The lug shall be complete in all aspects.

Careful consideration should be given to ensuring the brazing time is short. A long braze time may result in insufficient current being drawn. Insufficient current is usually the result of a poor battery condition which results in an improper braze. If it is known that the battery is good then the cause for an improper braze may be incorrect setting of the gun “lift height”.

If the ferrule is not held against the copper lug and is in partial contact then the

arc can escape out of the gap and that will result in the side of the copper lug burning away.

Note: Repeated bond attempts must not be made at the same position as this may cause structural/metallurgical damage to the base of the steel. Equipment Check – When the equipment is in use time must be allowed during a working period to carry out the necessary checks as recommended by the manufacturer and servicing required. Carrying out these procedures will prevent time wasted on site, when work is aborted due to faulty equipment. Refer to brazing gun loading/preparation section.

Page 8 of 10

Project: Proj. Identification:

Document Title: WORK METHOD STATEMENT FOR CABLE CONNECTION WITH PIN BRAZING

Document No.: EDO-WMS-COE-COR-INT-XXX-014-219-247-REV-A-WMS FOR CABLE CONNECTION WITH PIN BRAZING.DOC

Revision: A Date: 23.03.2014

3 TECHNICAL REQUIREMENTS FOR COATING REPAIR

3.1 GENERALITIES

3.1.1 Safety

The operator uses appropriate individual protection equipment:

Minimum: helmet, safety goggles, safety shoes, work garment, gloves

As needed: hearing protection, high temperature gloves, mask,

He ensures that working conditions do not present any danger, neither for him, nor for others (proximity of traffic, stacking conditions, fire precautions...)

3.2 METHODS

3.2.1 Work Instruction for repairs

Equipment used

Equipments

Gas torch with nozzle approximately 50 mm wide, spatula, high-temperature gloves, scraper, abrasive paper or grater, knife or cutter, roller, file.

Instruments

Thermometer with temperature probe or temple stick, holiday detector.

Products

Adhesive and filler following service temperature, patch (band PERP).

Methodology

The repair environment must permit the repair surface to be dry.

The surface that the repair will be applied must be roughen by sand paper and brushed with steel brush.

The edges of the pin brazing hole coating must have 45 degrees of slope for repair.

Cut a piece of mastic the size of the hole. Fully fill the hole with mastic.

Page 9 of 10

Project: Proj. Identification:

Document Title: WORK METHOD STATEMENT FOR CABLE CONNECTION WITH PIN BRAZING

Document No.: EDO-WMS-COE-COR-INT-XXX-014-219-247-REV-A-WMS FOR CABLE CONNECTION WITH PIN BRAZING.DOC

Revision: A Date: 23.03.2014

Prepare the piece of PERP: corners are rounded with scissors. The piece must overlap at least 50 mm on all sides of the defect. Also put a small X on the prep to let the cable out easily.

Preheat the steel surface inside the defect area to the temperature recommended by the supplier. Adjustment of the flame: approximately 200 mm.

IN ALL APPLICATIONS WITH GAS TORCH BE CAREFUL ABOUT THE NOT BURNING THE COATING OF THE CABLE ATTACHED TO CABLE LUG WHERE THE LUG IS PIN BRAZED TO PIPE.

Put on the gloves and apply the filler in the hole smooth the filler with the spatula heated with the gas torch. Eliminate excess filler overlapping the adjacent coating.

Heat approximately 2 seconds the underside of the piece of PERP prepared previously, as well as the surface where it is to be applied. Put the cable out from the X.

Page 10 of 10

Project: Proj. Identification:

Document Title: WORK METHOD STATEMENT FOR CABLE CONNECTION WITH PIN BRAZING

Document No.: EDO-WMS-COE-COR-INT-XXX-014-219-247-REV-A-WMS FOR CABLE CONNECTION WITH PIN BRAZING.DOC

Revision: A Date: 23.03.2014

Apply the piece and heat it until adhesive appears at the edges.

Pass the roller to eliminate all bubbles.

The adhesive must overflow onto the periphery of the piece.

After cooling, file edges of the patch, if needed.

Cut a piece of mastic and cover the part of cable on the patch.

Also stick the cable with a piece of mastic at least 10 mm. from the edge of the patch. Do not roughen the surface.

Inspection after repair

Inspect surface condition visually.

Inspect to the holiday detector (tension conform to the SQP).