FEDERAL UNIVERSITY OF TECHNOLOGY OWERRI
P.M.B. 1526, OWERRI
IMO STATE
A TECHNICAL REPORT ON
STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME
200 LEVEL
STEVE-INTEGRATED TECHNICAL SERVICES
LIMITED
BY
NWAKPU GERALD EMENIKE
20121796593
DEPARTMENT OF PETROLEUM ENGINEERING
SCHOOL OF ENGINEERING AND ENGINEERING
TECHNOLOGY (SEET)
SUBMITTED TO
THE SIWES COORDINATOR
DEPARTMENT OF PETROLEUM ENGINEERING
IN PARTIAL FULFILLMENT OF THE REQUIREMENT
FOR THE AWARD OF BACHELOR OF ENGINEERING (B.ENG) IN PETROLEUM ENGINEERING
JANUARY, 2015.
DEDICATION
This work is dedicated to Steve-Integrated Technical
Services, my lecturers, my family and my fellow students.
ACKNOWLEDGEMENT
This work reflects the effort of
various people who have in one way or the contributed to its success.
My immense gratitude goes to the likes
of Gbenga, Saviour whose efforts and guidance has endeared me towards ensuring
that this work was successful.
Above all, my indebt appreciation goes
to God almighty who is the master of the universe, both everything above and
beneath the earth.
CHAPTERN
ONE
HEALTH,
SAFETY AND ENVIRONMENT
1.1 INTRODUCTION
Health,
safety and Environment (HSE) departments
also called SHE or HSE departments, are entities commonly found
within companies that consider environmental protection, occupational health
and safety at work as important as providing quality products, and which
therefore have managers and departments responsible for these issues. EHS
management has two general objectives: prevention of incidents or accidents
that might result from abnormal operating conditions on the one hand and
reduction of adverse effects that result from normal operating conditions on
the other hand.
For
example, fire, explosion and release of harmful substances into the environment
or the work area must be prevented. Also action must be taken to reduce a
company’s environmental impact under normal operating conditions (like reducing
the company’s carbon footprint) and to prevent workers from developing work
related diseases. Regulatory requirements play an important role in both
approaches and consequently, EHS managers must identify and understand relevant
EHS regulations, the implications of which must be communicated to top
management (the board of directors) so the company can implement suitable
measures.
1.2 HAZARDS:
A hazard
is a situation that poses a level of threat to life,
health,
property,
or environment.
Most hazards are dormant or potential, with only a theoretical risk
of harm; however, once a hazard becomes "active", it can create an emergency
situation. A hazardous situation that has come to pass is called an incident.
Hazard and possibility
interact together to create risk.
1.3
MODES OF A HAZARD
Hazards are sometimes classified into three modes;
- Dormant—the situation presents a potential hazard,
but no people, property, or environment is currently affected. For
instance, a hillside may be unstable, with the potential for a landslide, but there is nothing below or on the
hillside that could be affected.
- Armed—People, property, or environment are in
potential harm's way.
- Active—a harmful incident involving the hazard has
actually occurred. Often this is referred to not as an "active
hazard" but as an accident, emergency, incident, or disaster.
1.4 TYPES OF HAZARD
Hazards are generally labeled as one of five types:
Physical hazards are conditions or situations that can cause the body physical harm or
intense stress. Physical hazards can be both natural and human made elements.
Chemical hazards are substances that can cause harm or damage to the body, property or
the environment. Chemical hazards can be both natural and human made origin.
Biological hazards are biological agents that can cause harm to the
human body. These some biological agents can be viruses, parasites, bacteria,
food, fungi, and foreign toxins.
1.5 CLASSIFICATION OF HAZARDS
By its nature, a hazard involves something that could potentially be
harmful to a person's life, health, property, or the environment. One key
concept in identifying a hazard is the presence of stored energy that, when
released, can cause damage. Stored energy can occur in many forms: chemical,
mechanical, thermal, radioactive, electrical, etc. Another class of hazard does
not involve release of stored energy, rather it involves the presence of
hazardous situations. Examples include confined or limited egress spaces,
oxygen-depleted atmospheres, awkward positions, repetitive motions, low-hanging
or protruding objects, etc.
There are several methods of classifying hazard, but most systems use
some variation on the factors of "likelihood" of the hazard turning
into an incident and the "seriousness" of the incident if it were to
occur.
A common method is to score both likelihood and seriousness on a
numerical scale (with the most likely and most serious scoring highest) and
multiplying one by the other to produce a comparative score.
1.6 RISK
= Hazard × Vulnerability /
Capacity
This score identifies hazards that require mitigation. A low score on
likelihood of occurrence may mean that the hazard is dormant, whereas a high
score indicates it may be an "active" hazard.
An important
component of "seriousness if incident occurred" is "serious to
whom?" Different populations may be affected differently by accidents. For
example, an explosion has widely differing effects on different populations,
depending on the distance from the explosion. These possible effects range from
death from overpressure or shrapnel, to inhalation of noxious gases to exposure to a loud noise.
1.7 PRIORITIZATION OF HAZARDS
Hazards can
be identified and prioritized using the SMUG model. The SMUG model provides a
means for prioritizing hazards based on the risk they present during an
emergency. The SMUG model stands for Seriousness, Manageability, Urgency, and
Growth.
1.8 ACCIDENTS
An
accident or a mishap is an incidental and unplanned event or
circumstance, often with lack of intention or necessity.
It usually implies a generally negative outcome which might have been avoided
or prevented had circumstances
leading up to the accident been recognized, and acted upon, prior to its
occurrence. Injury
prevention refers to activities
designed to foresee and avoid accidents.
Accidents
of particularly common types (crashing of automobiles,
events causing fire, etc.) are investigated to identify how to avoid them in
the future. This is sometimes called root cause analysis,
but does not generally apply to accidents that cannot be deterministically
predicted. A root
cause of an uncommon and purely random
accident may never be identified, and thus future similar accidents remain
"accidental."
1.9 TYPES OF ACCIDENTS
Physical
and non-physical
Physical
examples of accidents include unintended collisions or falls, being injured by
touching something sharp, hot, or electrical, or ingesting poison. Non-physical
examples are unintentionally revealing a secret
or otherwise saying something incorrectly, forgetting an appointment, etc.
1.10 SAFETY EQUIPMENT
A critical part of welding safely
is having, and knowing how to use, the correct safety equipment for the job.
Here are some typical items that are required for welding safely.
§
Welding shield (hood). This is the mask which is worn to protect the
person welding from the bright flash of the arc, and from sparks being thrown
during welding. Standard arc welding lenses are tinted very darkly, since
exposure to the arc flash can cause flash burns to the retina of the eye. A
level 10 darkness is the minimum for arc welding. Welding hoods with a flip
up lens was once preferred, as the dark lens can be lifted up, and a
separate clear glass lens will protect the welder from bits of slag while the
weld is chipped. The newer self-darkening welding shields are the most
desirable welding shield now sold. These welding shield lens are very light
colored for grinding and torch cutting. When an arc is struck the automatic
self-darkening lens will change to a preset #10 shade. Even newer on the market
are the variable shade automatic self-darkening lens.
§
Welding gloves. These are special, insulated leather gloves that reach
about 6 inches (15.2 cm) above the wrists, and protect the hands and lower
arms of the welder (the person welding). They also provide limited protection
from accidental shock if the person welding comes into contact with the
electrode accidentally.
§
Welding leathers. This is an apron like leather jacket that covers the
shoulders and chest of the welder, used for overhead work where sparks might
ignite the welder's clothing, or cause burns.
§ Work boots. The person welding should wear at least
a 6 inch (15.2 cm) lace-up type boot to prevent sparks and hot slag from
burning his feet. These boots should have insulating soles made from a material
which does not melt or burn easily.
CHAPTER TWO
2.1
IDENTIFICATION
OF MATERIALS
1.) PIPES: a hollow cylinder or tube of metal, plastic, or
other material used to convey water, gas, oil, or other fluid substances.
Pipes are
usually classified according to thickness which are usually inscribed on the
body.
2.) 24 inch flange
3.) 24 inch T: Used in joints especially in joining three pipes
of the same diameter.
4.) 90
degree elbow: Used in joining two pipes.
Ø Spooletc.
5.) U-channel: Used in fabrication of platforms
6.) Beams
7.) Grinder:
8.) Electrodes: There are many specialized welding
electrodes, used for specific alloys and types of metals, such as cast or
malleable iron, stainless or chromoly steel, aluminum, and tempered or high
carbon steels. A typical electrode consists of the wire rod in the center
covered with a special coating (flux)which burns as the arc is maintained,
consuming oxygen and producing carbon dioxide in the weld area to prevent the
base metal from oxidizing or burning away in the arc flame during the welding
process.
2.2 PRE-HEAT TREATMENT
Preheating is the process applied to raise the
temperature of the parent steel before welding. Gas torches, electric heaters, or
infra-red radiant pane heaters can all be used to apply preheat, which
decreases the weld cooling speed and thereby prevents cold cracking in welds. It is used for
the following main reasons:
To slow the cooling rate of the weld and the base
material, resulting in softer weld metal and heat affected zone microstructures
with a greater resistance to fabrication hydrogen cracking.
The slower cooling rate encourages hydrogen diffusion
from the weld area by extending the time period over which it is at elevated
temperature (particularly the time at temperatures above approximately 100°C)
at which temperatures hydrogen diffusion rates are significantly higher than at
ambient temperature. The reduction in hydrogen reduces the risk of cracking.
Preheat can be
applied through various means. The choice of method of applying preheat will
depend on the material thickness, weldment size and the heating equipment
available at the time of welding. The methods can include furnace heating for
small production assemblies or, for large structural components, arrays of
torches, electrical strip heaters, induction heaters or radiation heaters.
It is important
to apply preheat correctly, with appropriate monitors and controls, and also to
monitor the interpass temperature (the temperature of the work piece between
welding the first and subsequent passes), to ensure that it does not fall below
the preheat temperature.
Common
techniques for monitoring preheat are temperature indicating crayons and
thermocouples or contact thermometers. Preheat should be monitored at a
distance of 4t (where t is the thickness of the material to be joined) away from
the longitudinal edge of the groove for t<50mm [1] or at a
minimum distance of 75mm from the joint preparation for t>50mm and on the
reverse side of the plate to the heat source.
2.3 ROOTING
This
involves welding round the pipe before hot passing.
2.4 HOT PASS
Hot pass is the pass after the root to clean out any
slag that may be left in the root pass.
2.5 FILLING
This follows immediately after hot pass using filler
materials.
2.6 CAPPING
The final part of the welding process which proceeds
filling.
2.7 POST-WELD HEAT TREATMENT
This is a
special heat treatment which depends on the thickness, usually above i6mm or
18mm depending. The essence is for stress relief of the materials, beforethis,
radiography is carried out.
2.8 RADIOGRAPHY
This is
usually a test,
The essence
is to ensure quality of the weld in accordance with the client’s specifications.
2.9 FITTING OPERATIONS
The essence
of this is to enable the i-load to fit in very well.
2.10 TOOLS/DEVICES USED IN FITTING OPERATIONS
Ø Grinding machine:
This is used in grinding the edge of the hollow
pipe where the fitting is to occur.
Ø Measuring tape: for general measurements during the
fitting operations especially to determine the length at which the operation
will extend.
Ø Square: also for measurement.
Ø Straight gauge level: this is used to ensure the
fitted pipes are in uniform.
2.11 OPERATIONS INVOLVED
1.
Grinding operation: usually carried out using the grinding machine.
2.
Measurement of the grinded zone: this is to ensure it is up to the
required depth before fitting.
3.
The fitting of the pipes: this is carried out using lifting devices such
as cranes.
4.
Final cross-checking: this is usually carried out to check for
alignment.
5.
Welding: after the final cross-checking, welding of the fitted pipes
then commences.
CHAPTER THREE
3.1 INTRODUCTION
TO LIFTING SYSTEM
These are
various means or system by which lifting operations are usually carried out
especially during fitting of the pipes or during loading for transportation of
the pipes, etc. The lifting system is very essential in the oil and gas
pipeline welding industries as most of the materials used are usually very heavy,
hence cannot easily be carried by humans.
3.2 TYPES OF LIFTING EQUIPMENT AND DEVICES
1.
Cranes;
The crane
system is of various types, they include;
Ø Rough-terrain crane; this type of cranes uses very
strong and massive tires and can be used to work in places that are rough due
to the fact that it can withstand the harsh environment.
Ø The crawler; this kind of crane works on a steel
track or terrain.
Ø The stationed crane; this kind of cranes are
usually non-mobile, that is it is immoveable.
2.
The chain blocks; this is a lifting device for carrying heavy loads
efficiently.it comes in various forms based on the capacities, such as
1.5tons,5tons,10tons,etc
Other lifting devices includes;
3.
Come-alongs; a hand operated winch with a ratchet used to pull objects.
4.
Tirfor jacks;
5.
Monkey jacks;
3.3 CONCLUSION
Oil and gas
pipeline welding involves so many activities, ranging from gathering of the
materials, drawing of plans, design of the projects, the welding etc. up to the
finishing stage like painting and sandblasting, depending on the requirements
of the clients. Such clients are usually the oil firms like Chevron, Shell and
Total.
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