It was intended to finish
the work by 2 months, and therefore it was planned to build the structures by
two methods of welding i.e. Butt-welding for connecting the plates of platform
and Fillet welding for all the beam connections. All the four positions of
welding had to be engaged here i.e. Flat, Horizontal, Vertical and the most
difficult Overhead position.  Upon
discussion, the project was planned to be completed by three processes of
welding according to the locations and circumstances. The selected processes
were SMAW (Shielded Metal Arc Welding), GMAW (Gas Metal Arc Welding) and GTAW
(Gas Tungsten Arc Welding).

CE3.4
My
job was to confirm the integrity of all the welded parts by performing a series
of Non Destructive Examinations in various courses of the welding process. I
put into practice Visual Testing, Magnetic Particle inspection, Ultrasonic
Shear wave inspection and Hardness Testing. Since it was a marine environment
and the wind speed was high, the welding company took into consideration all
the critical factors to plan the procedures accordingly. I made sure that all
chores involved in the construction of the intended platform were executed as
per the standards and by following procedural outlines.

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CE3.5
I
was performing a callout job at Rig for the supervision of the welding
activities on the behalf of my company. I had a regular telephonic conversation
with my inspection supervisor and shared project updates with my immediate
seniors as and when needed. Organization of my project position is shown below:

Project
Manager

 

 

QA QC
Superintendent

 

Inspection
Supervisor

 

Inspection
Engineer

 

 

                                              Figure
1: My project position

CE3.6
The
roles I performed in this project had the below listed responsibilities:

·        
Reviewing of all the NDT inspection
requirements in conjunction with the Welding Inspectors and Welders. 

·        
Conducting regular examination of the
welding in association with the Welding Inspectors at all the welding locations
for resolving problem areas and assured consistency and accuracy of work
quality.

·        
Identifying all the Non-Compliances
noticed in welds according to the results of NDT tests as applicable
specifications and standards and suggested preventive measures of reoccurrence
of such defects.

·        
Coordinated with the Welding Supervisor
for the daily NDT diagnosis of Repair and Cut-out Welds to ensure satisfactory
quality standards of all cut-out and repaired welds.

·        
Assuring proper remedial action in
confirmation with all non-compliances and work procedures.

·        
Formulating of all necessary reports
associated with the Non-Compliances followed by their filling and distribution.

·        
Documenting Daily Welding, NDT Production
and Quality Reports for effective communication with the Rig Engineer.                                                                     

 

Personal
Engineering Activity

CE3.7
I
attended an official project meeting as the first step of this project work. The
meeting was attended by all the stakeholders involved in the work, including
engineers, client representatives and senior management of the company. In this
meeting, I was given all the technical details of the work along with a formal
time schedule of all the milestones of the work. I also got directions of the quality
required in the activities with the total budget of the entire project. My
senior gave me a list of task responsibilities as per the company set of
protocols.

CE3.8
As
a first activity, I positioned the welders on the welding structures for the
welding processes. I kept in mind Saudi Aramco welding process standards that
did not permit welding above 8 km/hr.-wind speed. I took into consideration the
economy factor to do the root pass of both kinds of welds by GTAW and further
passes by SMAW and GMAW. I decided to use GTAW to minimize all the initial
defects in the processes. However, I noticed that it increased the total budget
due to the gases used in the process. I also assured the quality of weld by using
GMAW process for Fillet welding and applying SMAW for Butt welding in the cases
of all the Hot Passes, Fillet passes and the final caps.

CE3.9
I
supervised the tasks of the workmen by welding the vertical beams on to the
Main Deck plates along with the diagonal braces between the columned beams.
There were 12 columns with 24 diagonal braces for the support. These columned
beams were then welded to beneath I-beams to form the structure of platform. I
made sure that the steel plates forming the platform were welded in between
those I beams. There were 20 pieces of such plates, including the ones for
walkway and the joining of plates were to be started from one end.

CE3.10
I
carried out preheating of all the areas to be welded for the removal of minute
moisture contents and to provide an initial temperature for the base metal to
achieve proper fusion. I assured that Post Welding Heat Treatment (PWHT) was
applied to the areas at least 3 times the thickness of the metal being welded
to relieve stress. I carried out the PWHT by electrical resistance heater for a
minimum soak time of 1 hr. I marked all weld joints for identification by a
weld number and a weld symbol. I thoroughly inspected all the welds visually
and tested with the magnetic particle inspection. Considering the critical load
bearing points, Ultrasonic inspection and Hardness testing were limited to the
welds connecting Columned beams to the deck as well as to I beams and all welds
that connect the steel plates to main I-beams. I recognized four types of
defects but rectified them by the first three methods of NDT.

CE3.11
I
visually inspected all the welds and effectively examined the joint preparation,
condition of electrodes, current used, weather conditions and slag removal. I
noticed some undercuts at the 7 overhead points at which Fillet welding was
done. It was not a tough task for me to understand that they came up due to
incorrect electrode angles. To prevent the further formation of undercuts, I
instructed the welders to use proper electrode angles and pause at sides of
weld beads when using weaving method.

CE3.12
I
performed Magnetic particle inspection on the welds to recognize other defects
disrupting the magnetic field. I observed some longitudinal cracks on the surface
welds at 11 points in the Heat Affected Zone (HAZ) parallel to weld beads. The
reason for these cracks was the comparatively small groove angles while
maintaining the same large welding current. Again, I made an effective use of
my engineering knowledge to overcome this issue by selecting proper combination
of grove angle and current. Proper repair and re-welding was done on these
cracked areas.

CE3.13
While
conducting ultrasonic testing, I found lack of penetrations and slag inclusions
in 6 welds. Lack of fusions and inclusions were clearly found because they were
very good sound reflectors. Slag inclusion occurs due to incomplete slag
removal from previous bead and too large weaving widths while incomplete fusion
occurs from small root gaps and groove angles. As these defects may act as
stress risers, I insisted the welders to pay attention so that they were
prevented from reoccurrence.

CE3.14
As
the final testing procedure, I performed hardness testing on the welds in the
project. I kept a strict adherence to the standards of ASTM A833 for testing
indentation hardness of metallic materials and Saudi Aramco procedure. I
applied the Vickers Methods in the process by applying a load of 10 kg using
pyramidal diamond into the test welds. I noted the results and reported the
hardness values to create the indentation. Though I had only little experience
with this method, I got hardness levels from 290 to 330 HV which were the
acceptable range.

CE3.15
Technical Problem

I knew that Saudi Aramco
welding process standards did not permit welding above 8 km/hr.-wind speed. It
was a major challenge and thus to overcome this, I used wind shields and also
dried the surfaces prior to welding. After finishing all the passes and the
welds gets cooled, I coordinated with the NDT inspectors to conduct all
aforementioned testing procedures. I interpreted and evaluated key parameters
without any discrepancies and shared them with the welders and their
supervisor. After analyzing the discontinuities, I decided their acceptability
or repairing level on the basis of the specification AWS D1.1 (American Welding
Society). I made preventive guidelines for the reoccurrence of those defects.
Then, the welders would make the necessary repairs followed by re-inspection by
Inspectors. Further, I prepared a detailed Non-Compliance report about these
defects and discussed it with the Rig Engineer. In this way, my mechanical
engineering concepts aided to provide efficient solutions to the problems met
in the project.

Summary

CE3.16
In
this project, I led and supervised a big team of professionals. I also faced a
series of technical problems; but all were resolved skillfully. My professional
expertise helped me to achieve trust and respect among my team members. I conducted
interactive sessions regarding the challenges faced in the projects and their
remedial or precautionary measures. I was approachable to the team for their
queries that were in my competence. I consulted with other specialists
concerned with this project to solve various complications above my competency,
especially in the case of hardness testing. Also, the job in Almansoori gave me
an opening and wide exposure to the Oil and Gas industry.

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