Report Li (Bih)

8/10/2019 Report Li (Bih)

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INDUSTRIAL TRAINING REPORT

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In order to service BIHclients in the global economy BIHhave operating centers in

UK, Saudi Arabia, Canada & Malaysia. BIH also have regional offices throughout South

America. This enables the BIH team to understand the local cultures and requirements and

provide a ready service.

Utilizing this global approach we have unlimited capacity to assess each clients

requirement. We can then work to ensure that we plan our projects to work with suitable

global companies for the supply and fabrication of the equipment.

BIH are a total quality company with our quality department being pro-actively

involved with all aspects of our operation from design, through project management,

procurement and fabrication. We are fully accredited to BS EN ISO 9001, TS 29001, EN

1090 and PED 97/23/EC.

BIHs quality system is based on an international structure, organization and

procedures to ensure high levels of safety, control, reliability and efficiency of all areas of our

global operation. Quality is the cornerstone of all of our activities. The uncontrolled BIH

Quality Manual is available for review by prospective clients on request.

Following on from our global experience we have supplied heaters to countries where

compliance with national regulatory bodies is required. BIHhave successfully provided the

correct documentation and received the approvals. This has applied to Europe, Algeria,

Canada, Russia, South America, Middle East, China etc.

BIHare committed to designing, planning and running projects with Health, Safety

and the Environment as a priority. BIHhave established and implemented HSE Management

Systems to manage the risks associated with our premises and activities.

Above all BIH ensures compliance with all relevant HS&E legislation and regulation

together with customer requirements / specifications.


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1.1 Organizational Structure

BIH HEATERS MALAYSIA SDN.BHD.

ORGANISATION CHART


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1.2 BIH Heaters Mission Statements

BIH is aglobal supplier of direct fired process heaters (including high temperature

specialist furnaces), reformers, crackers, heat recovery steam generators (HRSG) and waste

heat recovery units (WHRU). Our aim is to be world market leader in our chosen field,

recognised by our clients for engineering excellence, quality, timely delivery, cost effective

solutions, the development of all staff to their full potential and for operating in an

environmentally conscious manner with health and safety as the highest priority.

1.3 BIH Heaters Quality Objectives

a. QUALITY Maintain the highest levels of quality on all aspects of contract

execution and to exceed customer expectations.

b. COSTbe mindful of cost position through duration and act diligently to deliver

projects within acceptable limits with full progress visibility to customer.

c. DELIVERYDeliver projects against agreed milestones through effective planning

and control mechanisms. Manage structured reviews with vendors and clients to close out

issues with minimal impact on schedule.

1.4 BIH Heaters Product and Services

BIH main products are design, supply and construction (EPC) of various types of

fired heaters andwaste heat recovery units (WHRUs) serving for the oil, gas, petrochemical

& energy industries.

Beside the above product BIH also provide service to the customer where covered as

below:-

a) Process design simulations

b) Evaluations of existing equipment including using process design models for new

applications on existing equipment and making recommendations for changes to meet

these new requirements.

c) Budget pricing to establish the viability and preparation of overall estimates forplants worldwide.
http://www.bihl.com/fired_heaters.htmlhttp://www.bihl.com/waste_heat_recovery.htmlhttp://www.bihl.com/waste_heat_recovery.htmlhttp://www.bihl.com/fired_heaters.html


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d) Project ManagementUtilizing BIHin house systems to ensure that the logistics

management of projects is undertaken on time and on budget.

e) Revamp, optimization work BIH offer cost effective innovative solutions to

increase the capacity, and / or efficiency of an existing unit perhaps with the addition

of a preheat system, installation of low NoX burners or a new convection section or

SCR system.

f) Spare partsBIHhave a complete record of heaters we have built and can supply

any spare parts requirements that you may have. We have a proven record of assistingClients across the world and even if the existing equipment was not supplied by BIH,

we can use our extensive knowledge and expertise to source your spare part

requirements.

g) Site ServicesProvision of experienced personnel to supervise the installation and

commissioning of new / revamped equipment.

h) Training Provision of specifically tailored classroom training courses for client

specific heaters and WHRUs.


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CHAPTER 2

WORK EXPERIENCE AND ACHIEVEMENTS

2.0 Chronology Services in BIH HeatersMalaysia Sdn. Bhd.

Chronologies of my services are as follows:

(i)

01stDecember 2012 jointed BIH Heaters as a position as QA/QC Engineer in

Quality department.

2.1 Achievement and success

The following is a list of projects Ivebeen involved:

Owner INPEX Operation Australia PTY. Ltd.

Client JKC Australia LNG PTY. Ltd.

Project Ichthys Onshore LNG Facilities Australia LNG (Dec.12 Nov.14)

Description EPC 4 of Waste Heat Recovery Units (WHRU) with ancillaries

equipments (Damper & Instrumentation)

Owner Canadian Natural Resources Limited (CNRL)

Client Snamprogetti Canada

Project Hydrotreaters Phase 2B, Fort McMurray Alberta, Canada (Dec.12-

Description EPC 1 Recycle Gas Heater & 1 HP Steam Drum with ancillaries

equipments (Burner, Fuel Skid, BMS & Instrumentation)

Owner INPEX Browse Limited.

Client GE Oil & Gas (Nuovo Pignone)

Project Ichthys Gas Field Development (FPSO) Australia (Dec 2012-Present)

Description EPC 3 of Waste Heat Recovery Units (WHRU). with ancillaries

equipments (Damper/Silencer/Instrumentation)

Owner Petronas Carigali Sdn. Bhd. (PCSB)

Client Technip/DSME

Project Petronas FLNG Malaysia(Dec 2012-Nov 2013)

Description EPC 2 of Waste Heat Recovery Units (WHRU). with ancillaries

equipments (Damper/Silencer/Instrumentation)

Owner Oil & Gas Development Company Ltd.(OGDCL)

Client SIEMENS Industrial Turbomachinery Ltd.

Project DAKHNI Expansion Project Pakistan (Dec 2012-Oct 2013)

Description EPC 1 of Waste Heat Recovery Units (WHRU). with ancillariesequipments (Duct Burner/Damper/Fuel Skid/Fan/Instrumentation)


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Owner Oil & Gas Development Company Ltd.(OGDCL)

Client SIEMENS Industrial Turbomachinery Ltd.

Project UCH-II Development Project Pakistan (Dec 2012-Oct 2013)

Description EPC 1 of Waste Heat Recovery Units (WHRU). with ancillariesequipments (Duct Burner/Damper/Fuel Skid/Fan/Instrumentation)

Owner Dow Chemical Company

Client Fluor Enterprise Inc.

Project USGC PDH-1 Propane De-Hydro generation USA (Dec 2012-Present)

Description EPC 4 of Fired Heaters with ancillaries equipments

(Damper/Fan/Burner/Ammonia Injection Grid/Instrumentation)

Owner YAMAL LNG

Client GE Oil & Gas/YAMGAZ

Project YAMAL LNG Project, Russia (Dec 2012-Present)Description EPC 6 of Waste Heat Recovery Units (WHRU) with ancillaries

equipments (Silencer/Instrumentation)

Owner Pertamina EP/ SKK Migas

Client Rekayasa Industries (REKIND)

Project Proyek Pengembangan Gas Matindok, Indonesia (Dec 2012-Present)

Description EPC 2 of Hot Oil Heaters with ancillaries equipments (Damper/Fuel

Skid/Burner/Instrumentation)

Owner Petroleos de Venezuela, S.A. (PDVSA)

Client Industrias Metalurgicas Van Dam (IMVD)

Project RPLC Deep Conversion, Venezuela (Dec 2012-Present)

Description EPC 1 of Fired Heaters with ancillaries equipments (Damper

/Burner/Instrumentation)


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CHAPTER 3

DUTIES AND RESPONSIBILITIES

3.0 Duties of QA/QC Engineer

The role and duties of QA/QC engineer, Quality Department is as the followings:

Direct reporting to Sr. QA/QC Engineer pertained all quality matters and ensuring

each project meet statutory, contractual and specification or code and standard applyon that project.

Preparation Project Quality Plan (PQP) and final dossier index accordance to

ITB/contract, project specification and agreement for client approval.

Review sub-vendor QA/QC procedure for each project inclusive Inspection Test Plan,

NDE procedure,WPS/PQR, WPQ and etc. as per ITB/contract, project specification,

codes and standard.

Perform, prepare an assesmnet audit to all sub-vendor and follow up any outstandingissue raise during audit.

Perform surviellance inspection to sub-vendors to ensure effective implementation of

relevant QA/QC procedure during project execution and comply to ITB/contract,

project specification, approved construction drawings code and standards and issue

inspection report for each visit done.

Review inspection report done by inspector to ensure the inspection was done based

on purchase order and compliance to project/contract requirements.

Review all sub vendor test certificate prior make any release to ensure compliance to

project/contract requirements and issue recommendations to inspection coordinator

for release.

Prepare pre-inspection meeting and agenda prior meeting take place for all major

fabrication to highlight applicable project requirements prior fabrication begin.

Issuance/reviewing Non-Conformance Reports (NCR) Corrective Action Reports

(CAR) upon having identified a process or procedural breach against the

ITB/contract, construction drawing, project specification, code and standard.


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Perform internal audit following audit schedule to ensure effectiveness of the quality

managements system and issue audit report to Quality Manager for review and

approval.

To monitor, review the arrangement and compilation of all sub vendor MDR and

compile as a final dossier before hand over to project engineer for client approval.

Review procedure commented by client and provide clarification if any required to

ensure its satisfied by all party involve.

Prepare discrepency log for each project involved and submitted to Quality Manager

for review and approval and also as a lesson learnt and continous improvements.

3.1 Quality Management System

Quality Management System (QMS) is a set of co-ordinated activities to direct and

control an organisation in order to continually improve the effectiveness and efficiency of its

performance.

These activities interact and are affected by being in the system, so the isolation and

study of each one in detail will not necessarily lead to an understanding of the system as a

whole. The main thrust of a QMS is in defining the processes, which will result in the

production of quality products and services, rather than in detecting defective products or

services after they have been produced.

The organization shall establish, document, implement and maintain a quality

management system and continually improve its effectiveness in accordance with the

requirements set within the international standard.

BIH Quality Management System for the Design and Project Management of the

equipment supplied by BIH is operated in accordance with all the elements of BS EN ISO

9001, TS 29001 and, in addition, has documented procedures for the Pressure Equipment

Directive (PED) 97/23/ECrequired under Modules H/H1, Construction Products Regulations

(CPR) CPR 305/2011/EU(EN1090) and applicable legislative requirements.


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The quality management system documentation shall include:-

a) Documented statements of a quality policy and quality objectives,

b) A quality manual,

c) Documented procedures and records required by international standard of

organization (ISO)

d) Documents, including records, determined by the organization to be necessary to

ensure the effective planning, operation and control of its processes.

a) Quality Policy & Quality Objective

Quality policy is document jointly developed by management and quality experts toexpress the quality objectives of the organization, the acceptable level of quality and the

duties of specific departments to ensure quality meeting company expectations.

The purpose of quality objectives is to determine conformity to (customer and

regulatory) requirements, and facilitate the effective deployment and improvement of the

quality management system (QMS).

Quality policy and objectives must be consistent with the scope of QMS and must

complement business objectives of organization such as those related to growth, finance,

profitability, the environment and occupational health and safety.

Quality policy must be appropriate to the purpose of the organization, a commitment

to comply with requirements and continually improve the effectiveness of the quality

management system, specified time framework for establishing and reviewing quality

objectives, communicated and understood within the organization, reviewed for continuing

suitability.

In order to achieve these objectives, the BIH operates a documented Quality

Assurance system, based on BS EN ISO 9001 and DO CEN ISO/TS29001 placing emphasis

on expert product design, Project Engineering, safety and continuous improvement. To

ensure that products and services comply with the needs and expectations of its customers,

BIH:

Uses quality plans, fabrication procedures and material specifications to identify the

requirements. BIH will then plan fabrication and manufacture, to ensure client

delivery of milestones are achieved.


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Uses inspection of product and certification to monitor compliance. Data dossiers

will provide documented evidence of compliance.

Ensures products meet all applicable client specifications and statutory regulation

requirements.

Ensures that products supplied to the European Economic Area shall be designed,

manufactured, final inspected and tested fully in accordance with the Pressure

Equipment Directive (PED) 97/23/EC, Construction Products Regulations (CPR)

CPR 305/2011/EU and all other applicable European Directives.

b) Quality ManualQuality Manual defines the Company's Management policies with regard to the

application of Quality Assurance systems in all areas of activity which have influence on the

quality of the product. The objectives are to:

Provide products with fitness for purpose at acceptable cost, in accordance with the

Contract Specifications

Identify and meet the needs and expectations of its customers and other interested

parties

Achieve, maintain and improve overall organisational performance and capability.

The functions of BIH Quality Manual are to:

a) Define the management policies with respect to Quality Assurance, and to enable

identification of the series of procedures, which specify the controls for the various

elements of the QA system.

b) Ensure uniformity of understanding and performance.

c) Provide a training document and to ensure continuity of the systems, when

personnel change.

d) Act as a reference base, against which the practices and procedures can be audited

both internally and externally and corrective action taken when non-conformance is

found.


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c) Documented Procedure and Records

Documented procedure or quality procedure is the written documents that require for

each department within the organization as assurance ensure the effective planning, operation

and control of its processes required by ISO which is a mandatory procedure to be developed.

The procedure is to provide a guideline to the user or employee and or employer on

how the specific task to be carried out in general up to completion of the specific stages with

supplementary by additional documented procedure or work instruction.

Any records required by documented procedure to provide evidence of conformity to

requirements and of the effective operation of the quality management system shall be

controlled.

d) Supplementary Documented Procedure (Work Instruction)

Work Instruction is the fourth level of documented procedure which is act as

supplemental to mandatory required procedure. Typically work instruction specified more

detail on how each process being done from beginning up to finishing.


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3.2 Project Quality Plan (PQP)

PQP is a tool to ensure the end product and or services provided is meeting company

quality objective as well as customer expectations and needs. Contains of the PQP is

generally describing the activities, applicable procedure to be referred, acceptance of the

activities, record as verifying evidence and also responsible person for each activities.

Development of PQP is under QA/QC Engineer in conjunction with Quality Manager

in order to ensure all customer requirements are fully transfer and adhere to.

BIH PQP are divided by seven part covered for in house activities, pressure partmaterial, instrumentation and controls, non-pressure part components, refractory materials,

ancillaries equipment as well as minimum inspection and test required for the package

purchased items.

3.2.1 In-House Activities-part A

As in Tepat Teknik system, all the project being awarded to Tepat Teknik Sdn Bhd

will be given the contract number for company record and ease filing and the numbering

being made as to follow the order of the project being awarded. There are two type of

contract number being used in Tepat Teknik. One is the number with CT and another one is

the number with CTK. The different between both is CT where the jobs being awarded

direct to Tepat Teknik Sdn Bhd Shah Alam office while the job with contract number CTK is

the job that being awarded through Tepat Teknik (Kejuruteraan) Sdn Bhd located in

Kemaman, Terengganu.

3.2.2 Project Phase

Before the project being awarded to Tepat Teknik, a few phase need to be through

first. This is a phase where every project awarded to the company going to through:

1) Bidding


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-

This is the first stage of the job before it being awarded.

- Estimation Department and Marketing Department joined the invitation to bid

by client.

-

The job is being estimated, designed, planned, and sent for bid.

- Client carried out the Letter of Award once the project being awarded.

2) Project Hand Over

- After all the contract, estimation and documentation done and ready to be

execute, the project being hand over to Project Department to start the

execution.

- Project Department will have an internal meeting that being attended Project

Manager, Project Engineer, QA/QC and Design Engineer.

- Project Engineer will be the responsible person to execute the job and being

monitored by the Project Manager.

3) Planning & Preparing

-

Project Engineer starts planning the next step to be taken by preparing the

project schedule.The schedule will be mentioned the job to be done followed

the sequence:

(i) Engineering/Procurement.

(ii) Fabrication & QA/QC.

- Project Engineer preparing the budget by compared with Estimation Budget.

3.3 Engineering/Procurement

In one project, engineering is the most important part. Before a product going to

bidding or being produced, engineering will take the first part. The fabricator will prepare a

drawing together with the strength calculation based on suitable code and standard of


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fabricating such as ASME CODE, SHELL DEP, ANSI, ASTM, and etcetera to be use for

manufacturing. This will be done if the customer did not provide their drawing.

3.3.1 Drawing

The details of the items such as item designs, size, material specification, welding

process, orientation of the vessel, showed in the drawing.

3.3.2 Strength Calculation

Strength calculation purpose is to determine whether the product that being fabricate

can run smoothly during operation without any defect. It applies certain engineering

standards like ASME, API and sometime structural analysis.

With the strength calculation, all the information and calculation of stress, tensile,

allowable temperature, internal and external pressure of the vessel, materials specification,

process to be done, can be obtained.

3.3.3 D.O.S.H. Approval

All fabricated pressure vessel for local purpose required a certificate from Deputy

Safety and Health (DOSH) as to ensure that the pressure vessel is fit to be operated in this

country for the purpose of safety.

The strength calculation and drawing being submitted to DOSH as to get the approval

to fabricate the items. This will be done once the engineering section has done their job to

design the item according to the standard.

After the items completed fabrication, there will be held a hydrostatic test to helps

maintain safety standards and durability of a vessel over time.


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3.3.4 Procurement

Once Project Department received the drawing from Design, the Material Take Off

(MTO) will be executed. Project Engineer will reviewed and analyzed the drawing to take

out all materials required followed the requirement and specification. The drawing sometime

did not show the actual size of the material, especially size of a sheet of plate for the shell

course and formed dish head. Hence, to purchase the plate, it needs to have the length and

width. The material to be purchase shall be utilize the used material to avoid wastage

material.

After the Material take Off (MTO) finished, Material Requisition or in the short name

called MR, being raised to Procurement Department to source and purchase the materials. If

the materials are hard to be find or got any balanced materials from other project, buyer will

come back with Approval Requisition (AR) form to offer other material identical with the

required and to confirmed if the price could be appropriate price.

Once the buyer (Procurement Department) purchased the material, a copy of Purchase

Order (P.O) will be give to Project Engineer as a record for project filing. This going to be

needed to be the reference if there will happen something unexpected such as wrong material

received, or late delivery of the material.


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CHAPTER 4

PROCESS MANUFACTURING

4.0 Fabrication

Once the materials received, the fabrication job could be start. Usually, plates and

forging materials should be comes first because plate need to be roll to be the shell course

and forging material such as flange need to be pre-fabricate before being fit-up to the shell.

4.1 Activity

The fabrication activities include:

1.

Mark & cut


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All the received plates being marked followed the size as shown in the

drawing. QC Inspector then did the dimension check after marking. Once the

marking activity had done, the plate being cut into the size.

Fig. 4.1.1 Plate marking Fig. 4.1.2 Plate cutting

The plates meant to be the shell course being rolled to the I.D required after

cut.

Fig. 4.1.3 Plate rolling

As for the dish head, after being marked and cut, the plates being delivered to

Soon Lien Fatt, to performed dish head forming.

Fig. 4.1.4 Formed dish heads


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2.

Pre-fabrication.

All nozzles and leg support being pre-fab before being attached to the shell.

Pre-fab means, for the nozzle, the flange and nozzle neck (rolled plate or pipe)

being fit-up and weld.

Fig. 4.1.5 Pre-fab

Nozzle opening being done on the shell and formed head.

Fig. 4.1.6 Nozzle opening

3. Fit-up & welding.

After all the marking, cutting, rolling, edge preparation and nozzle pre-

fabrication finished, the vessel being fit-up and weld.

First, fit-up and weld top shell and lower shell

Then, fit-up and weld the nozzle plate and vortex breaker inside the vessel (as

required in the drawing).

Next, fit-up and weld top head and lower head with shell

Then, fit-up and weld nozzles on the dish head and shell.

Next, fit-up and welding 2 unit of sight glass on the shell course.

Finally, support leg being attached and weld on lower head since the vessels

were vertical vessel.


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Fig. 4.1.7 Fit-up & welding lower head Fig. 4.1.8 Nozzle fit-up on upper head

Fig. 4.1.9 Nozzle Pad fit-up Fig. 4.1.10 Sight glass attachment

There were five types of welding process that have been used in this project include:

1.

GTAW

Gas tungsten arc welding (GTAW), also known as tungsten inert gas

(TIG) welding, is anarc weldingprocess that uses a nonconsumabletungsten

electrode to produce the weld.The weld area is protected from atmospheric

contamination by a shielding gas (usually an inert gas such as argon), and a

filler metal is normally used, though some welds, known as autogenous welds,

do not require it. A constant-current welding power supply produces energy

which is conducted across the arc through a column of highly ionized gas andmetal vapors known as plasma.
http://en.wikipedia.org/wiki/Arc_weldinghttp://en.wikipedia.org/wiki/Tungstenhttp://en.wikipedia.org/wiki/Electrodehttp://en.wikipedia.org/wiki/Weldinghttp://en.wikipedia.org/wiki/Shielding_gashttp://en.wikipedia.org/wiki/Inert_gashttp://en.wikipedia.org/wiki/Argonhttp://en.wikipedia.org/wiki/Filler_metalhttp://en.wikipedia.org/wiki/Current_sourcehttp://en.wikipedia.org/wiki/Welding_power_supplyhttp://en.wikipedia.org/wiki/Welding_power_supplyhttp://en.wikipedia.org/wiki/Current_sourcehttp://en.wikipedia.org/wiki/Filler_metalhttp://en.wikipedia.org/wiki/Argonhttp://en.wikipedia.org/wiki/Inert_gashttp://en.wikipedia.org/wiki/Shielding_gashttp://en.wikipedia.org/wiki/Weldinghttp://en.wikipedia.org/wiki/Electrodehttp://en.wikipedia.org/wiki/Tungstenhttp://en.wikipedia.org/wiki/Arc_welding


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GTAW (WPS No. TT-A-O-N-1) has been applied to all the nozzles with size

less than DN 50.

2. SMAW

Shielded metal arc welding (SMAW), also known as manual metal arc

(MMA) welding or informally as stick welding, is a manual arc welding

process that uses a consumableelectrode coated in flux to lay the weld. An

electric current, in the form of either alternating current or direct current from

a welding power supply, is used to form an electric arc between the electrode

and the metals to be joined. As the weld is laid, the flux coating of the

electrode disintegrates, giving off vapors that serve as a shielding gas and

providing a layer of slag, both of which protect the weld area from

atmospheric contamination.

SMAW (WPS No. TT-A-O-N-2) has been applied on all attachment to

pressure parts, longitudinal weld (LW) and circumferences weld (CW).

3. FCAW

Process that joint two or more material using flux cored wire consists of metal

sheath containing a granular flux

FCAW (WPS No. TT-A-O-N-8A) has been applied on all non-pressure part of

the vessels.

4. GTAW/SMAW

GTAW/SMAW is a combined process between GTAW and SMAW process

that made GTAW as a root, thickness of weld more or less of 6mm and

SMAW became the caping.
http://en.wikipedia.org/wiki/Arc_weldinghttp://en.wikipedia.org/wiki/Electrodehttp://en.wikipedia.org/wiki/Electrodehttp://en.wikipedia.org/wiki/Arc_welding


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This combination happened when the gap between welding edge that required

SMAW process is small. SMAW using a rod as the arc which having a big

diameter while GTAW using a wire to perform as the arc which the diameter

smaller than a rod.

This process (WPS No. TT-A-O-N-4B) being applied on all nozzles with size

greater than DN 50.

5. SAW

Submerged Arc Welding (SAW) is a common arc welding process. It

requires a continuously fed consumable solid or tubular (flux cored) electrode.

The molten weld and the arc zone are protected from atmospheric

contamination by being submerged under a blanket of granular fusible flux.

When molten, the flux becomes conductive, and provides a current path

between the electrode and the work.

SAW (WPS No. TT-A-O-N-3A) has been applied to longitudinal weld (LW)

and circumferences weld (CW) and welding on nozzle plate.

The welding location and process used in the project showed in a weld map as

a guide to welder to perform the welding.

4.2 Blasting & Painting

Blasting & painting being applied according to the Client Specification and

Applicable Code and Standard and the process being made after all the fabrication

activities including rubber lining and hydrostatic test have been done.

Blasting to be applied once the surface has been cleaned before proceed with

the painting to clear all the contamination.


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Paint materials being prepared and applied according to the paint

Manufacturers recommendations after the surface being cleaned with oxygen

free compressed air once the grift blasting being applied.

4.3 Packing & Delivery

Once the 2 units of vessels finished blasting and painting, the items ready to be

deliver to site.

Packing

Before the items being delivered, they need to be pack as to maintain the

appearance and to avoid unexpected thing happened on their way to the site.

Fig. 4.3.1 Bare packing, saddle type

Delivery

The items being delivered after the packing job finished. All the delivered

items being mentioned in the packing list and ship invoice that will be send

together with the items.


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4.4 QA/QC

In QA/QC section, the welding, hydrostatic test, non-destructive examination (NDE)

and all the procedures and documentation are under QA controlled as to assure everything

being prepared according to appropriate standard and code. Whereas QC is to ensure that the

quality being achieved by carrying out the inspection on the appropriate matter such as the

inspection on NDE, material inspection, etc according to the standard and specification.

1.4.1 NON-DESTRUCTIVE TESTING

NDE or Non Destructive Examination is used to assess the quality of a component

without destroying it.

There are many methods of NDE some of which require a very high level of skill in

both application and analysis.

The four basic methods of NDE are:

1.

Liquid Penetrant testing (LPT)

2. Ultrasonic testing (UT)

3. Radiographic testing (RT)

4.

Magnetic particle testing (MPT)

As for this project, all four methods being used during the fabrication activity

to detect any defect.

1. Liquid Penetrant Test (LPT)

The liquid penetrant examination method is an effective means for detecting

discontinuities which are open to the surface of nonporous metals and other materials.

Typical discontinuities detectable by this method are cracks, seam, laps, cold shuts,

laminations, and porosity.


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In principle, a liquid penetrant is applied to the surface to be examined and allowed to

enter discontinuities. All excess penetrant is then removed, the part is dried, and a developer

is applied.

The developer functions both as a blotter to absorb penetrant that has been trapped in

discontinuities, and as a contrasting background to enhance the visibility of penetrant

indications. The dyes in penetrants are either color contrast (visible under white light) or

fluorescent (visible under ultraviolet light).

Procedure:

1.

Surface preparation

- the component being thoroughly cleaned by grinding, machining and detergents.

- the surface then being dried by normal evaporation and being applied ELY S-72

Remover for pre-examination cleaning by spraying the entire area being tested.

- the dirt being wiped out by clean, lint-free cloth, repeating the operation until all

the dirt has been removed.

2. Penetrant application

- penetrant being applied by spraying to the entire surface to be inspected. The

excess penetrant being allowed to drain from the after application, while allowing

for proper penetrant dwell time of 5 to 10 minutes.

3. Removal of excess penetrant

- excess penetrant then being wiped out by clean, lint-free cloth, repeating the

operation until most traces of penetrant have been removed. The remaining tracesbeing removed by lightly wiping the surface with cloth or absorbent paper

moistened with solvent.

- the excess penetrant removal being dried by normal evaporation.

4. Application of developer

- non-aqueous wet developer being sprayed to the part once the excess penetrant

being dried.

5. Inspection


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- inspection being performed on the parts within 5 to 10 minutes of development

time as to assure the penetrant properly bleed-out from discontinuities onto the

developer coating.

Method : Color contrast and solvent removable.

Advantages & Disadvantages

Advantages

i.

low operator skill levelii.

applicable to non-ferromagnetic materials

iii.

low cost

iv. simple, cheap and easy to interpret

v. portability

Disadvantages

i. careful surface preparation required

ii.

surface breaking flaws only

iii. not applicable to porous materials

iv. no permanent record

v.

potentially hazardous chemical

Fig. 4.4.1.1 LPT on circ seam (CW)


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Fig. 4.4.1.2 LPT on dish head

2. Ultrasonic Testing (UT)

In ultrasonic testing, very short ultrasonic pulse-waves with center frequencies

ranging from 0.1-15 MHz and occasionally up to 50 MHz are launched into materials to

detect internal flaws or to characterize materials. It is also commonly used to determine the

thickness of the test object - monitoring pipework corrosion being a good example.

Ultrasonic Inspection is often performed on steel and other metals and alloys, though

it can be used on concrete and other materials such as composites.

Method

Atransducerbeing connected to a diagnostic machine is passed over the object being

inspected. In reflection (or pulse-echo) mode, the transducer sends pulsed waves through a

couplant (such as water or oil) on the surface of the object, and receives the "sound" reflectedback to the device. Reflected ultrasound comes from an interface - such as the back wall of

the object or from an imperfection. The screen on the calibrated diagnostic machine displays

these results in the form of a signal with an amplitude representing the intensity of the

reflection and the distance taken for the reflection to return to the transducer. In attenuation

(or through-transmission) mode, a transmitter sends ultrasound through one surface, and a

separate receiver detects the amount that has reached it on another surface after travelling

through the medium. Imperfections or other conditions in the space between the transmitter

and receiver reduce the amount of sound transmitted thus indicating their presence.

Couplant applied Sound wave applied Result displayed

Procedure

1.

Component being cleaned by light grinding to remove spatter, pitting, etc in order

to obtain a smooth surface.
http://en.wikipedia.org/wiki/Ultrasoundhttp://en.wikipedia.org/wiki/Ultrasonic_sensorshttp://en.wikipedia.org/wiki/Amplitudehttp://en.wikipedia.org/wiki/Amplitudehttp://en.wikipedia.org/wiki/Ultrasonic_sensorshttp://en.wikipedia.org/wiki/Ultrasound


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2.

Couplant is then being applied to the test surface. (water, oil, grease, etc)

This enable the ultrasound to be transmitted from the probe into the component

under test.

3.

A range of angle probes being used to examine the weld root region and fusion

faces.

(Ultrasound must strike the fusion faces or any discontinuities present in the weld

at 90 in order to obtain the best reflection of ultrasound back to the probe for

display on the cathode ray tube).


Advantages

i.

Can easily detect lack of sidewall fusion

ii.

Ferrous & Non-ferrous alloy

iii. No major safety requirements

iv.

Portable with instant result

v. Able to detect sub-surface defects.

Measures depth and through wall excellent

Disadvantages

i.

High operator skill level

ii. Difficult to interpret

iii. Requires calibration

iv. No permanent record

v. Not easily applied to complex geometry


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Fig. 4.4.1.3 UT on side drilled hole

3. Radiographic Testing (RT)

Radiographing is a process of passing electronics radiation through an object and

obtaining a record of its soundness upon a sensitized film.

Radiographic Testing is:

A highly effective and sensitive method for thick wall welded pipe

Only capable of defecting defects which extend in the direction of the

radiographic beam.

Also confined to the actual weld and the immediately adjacent area.

The base for welding factor 1.0 according to European and ASME rule

Fig. 4.4.1.4 RT arrangement sketch


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In principle, there are no limitations to this method when it comes to sizes and

consequently radiographic testing constitutes the normal non-destructive method of testing

for tubes with wall thickness greater than 3-4mm.

Radiographic testing frequently used as partial inspection, for instance with one film

per tube or one film from each end of each tube.

Procedure

1. X or gamma radiation is imposed upon a test object.

2. Radiation is transmitted in varying degrees dependent upon the density of the

material through which it is travelling.

3.

Variations in transmission detected by photographic film or fluorescent screens.

(Film placed between lead screens then placed inside a cassette)

4. An IQI (image quality indicator) should always be placed on top of the specimen

to record the sensitivity of the radiograph.

Method

a. Load film cassette

b. Exposure to radiation

c.

Developed graph

Advantages and Disadvantages

Advantages

i. Permanent record

ii. Most materials can be tested

iii. Detects internal flaws.

iv. Gives a direct image of flaws

v. Fluoroscopy can give real time imaging

Disadvantages

i. Skilled interpretation required.


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ii.

Access to both sides required

iii. Sensitive to defect orientation

(Possible to miss planar flaws)

iv.

Health hazard

v. High capital cost

4. Magnetic Particle Testing (MPT)

The magnetic particle examination method being applied to detect cracks and other

discontinuities on or near the surfaces of ferromagnetic materials. The sensitivity is greatest

for surface discontinuities and diminishes rapidly with increasing depth of subsurface

discontinuities below the surface.

Typical types of discontinuities that can be detected by this method are cracks, laps,

seams, cold shuts, and laminations.

In principle, this method involves magnetizing an area to be examined, and applying

ferromagnetic particles (the examinations medium) to the surface. The particles will form

patterns on the surface where cracks and other discontinuities cause distortions in the normal

magnetic field. These patterns usually characteristic of the type of discontinuity that being

detected.

Method

Contrast paint applied Magnet & ink applied Result achieved

Procedure

1. Method being test to detect surface and sub-surface defects in ferromagnetic

materials.

2. Magnetic field being induced in component (permanent magnet)

3. The magnetic flux being disrupted by defects.

4.

Ferromagnetic particles being applied to revealed defects.


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Advantages

i. Pre-cleaning not as critical as with DPI

ii. Will detect some sub-surface defects

iii.

Relatively low cost

iv. Simple equipment

v. Possible to inspect through thin coatings

Disadvantages

i. Ferromagnetic materials only

ii. Demagnetization may be required

iii. Direct current flow may produce Arc strikes

iv.

No permanent record

v. Required to test in 2 directions

Fig. 4.4.1.5 Contrast paint applied (left)

Fig. 4.4.1.5 Black magnetic particle &

magnet applied (left)


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Fig.4.4.1.6 White Contrast Paint & Fig. 4.4.1.7 MPT Magnet (left)

Black Magnetic Particle (right)

4.5 HYDROSTATIC TEST (HT)

A hydrostatic test is the common way in which leaks can be found in pressure

vessels such aspipelines andplumbing. Hydrostatic tests, on the other hand, performance

verify fluid pressure vessels. Using this test helps maintain safety standards and durability

of a vessel over time. Newly manufactured pieces are initially qualified using the hydrostatic

test and continually re-qualified at regular intervals using the proof pressure test, which is

also called the modified hydrostatic test. Hydrostatic testing is also a way in which a

gas pressure vessel such as agas cylinder or aboiler is checked forleaks or flaws. Testing is

very important because such containers can explode if they fail when containing

compressed gas.

The completed vessel filled with water shall be subjected to a test pressure

which is equal to 1 times the maximum allowable working pressure to be marked on

the vessel or 1 times the design pressure by agreement between the user and the

manufacturer.
http://en.wikipedia.org/wiki/Pipeline_transporthttp://en.wikipedia.org/wiki/Plumbinghttp://en.wikipedia.org/wiki/Gas_pressurehttp://en.wikipedia.org/wiki/Gas_cylinderhttp://en.wikipedia.org/wiki/Boilerhttp://en.wikipedia.org/wiki/Leakhttp://en.wikipedia.org/wiki/Leakhttp://en.wikipedia.org/wiki/Boilerhttp://en.wikipedia.org/wiki/Gas_cylinderhttp://en.wikipedia.org/wiki/Gas_pressurehttp://en.wikipedia.org/wiki/Plumbinghttp://en.wikipedia.org/wiki/Pipeline_transport


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CHAPTER 5

CONCLUSION

Experiences in Tepat Teknik Sdn Bhd, the job of project management in the field of

oil & gas fabricator are challenging task. This required a very high commitment and self-

confident, willing to learn to complete all the job being given which might facing a lot of

problems and difficulties.


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Report Li (Bih)

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