Doc Title: Document No : SP12-20-D-04-1-021/D1
Date : 24-Nov-08
Gouging Procedure
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Doc Title: Document No : SP12-20-D-04-1-021/D1
Date : 24-Nov-08
Gouging Procedure
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Table of Contents Page
1.0 INTRODUCTION 4
2.0 SCOPE OF WORK 4
3.0 DEFINITIONS 4
4.0 REFERENCED STANDARD AND SPECS
5
5.0 PROCEDURES
5
5.1 Electrodes 7
5.2 Operating techniques 7
5.3 Inspection 11
Table 1 - Suggested Current Ranges for Commonly Used Electrode Types and Sizes 8
Figure 1 - Typical Arrangement for the Carbon Arc Gouging (CAG) 6
Figure 2 - How a Standard CAG Torch Works 6
Figure 3 - Flat Position Gouging 7
Figure 4 - Vertical Position Gouging 9
Figure 5 - Horizontal Position Gouging 9
Figure 6 - Overhead Position Gouging 10
Figure 7 - Gouging Electrode push angle 10
Figure 8 Cutting with CAG 11
Doc Title: Document No : SP12-20-D-04-1-021/D1
Date : 24-Nov-08
Gouging Procedure
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1. INTRODUCTION
The offshore development shall consist of three identical wellhead platforms SPD12A, B, C
each with 15 slots for field exploration located in approximately 70 m water depth, each
linked to a remote flare platform through a two span bridges. Topsides design features shall
be according to minimum production facilities concept consisting of fluid gathering,
chemical injection, well testing, condensed and saturated water separation and oily water
treatment. The platforms shall be designed for drilling through jack-up operations. All the
three platforms shall be unmanned and personnel from shore shall perform major
operations, whereas routine and emergency operations shall be carried out from nearby
offshore complexes built within NIOC South Pars Phase-1 development. Personnel will
come on board by boat or by helicopter on temporary basis and as such a shelter to
accommodate 6 people on a temporary basis shall be included. Each wellhead platform
shall be designed for maximum production capacity of 1200MMSCFD although the planned
production shall be 1000 MMSCFD of equivalent well fluid.
Each of the wellhead platforms shall have HP/LP flare systems. The flare system shall
include collecting headers, KO drums, elevated flare stack and HP/LP flare tips.
2. SCOPE OF WORK
The purpose of this procedure is to set guidelines for excavation and cutting with gouging
process. This procedure describes the recommended practices of Carbon Arc Gouging
(CAG) and cutting, and provides a general description of components used for the process,
and process consumables.
3. DEFINITIONS
Project South Pars Gas Field Development Phase 12, Topsides.
Company Petro Pars Limited
Contractor Iranian Offshore Engineering and Construction Company
(IOEC) responsible for engineering, procurement, construction
of topsides.
Subcontractor The company selected by the Contractor and approved by
Company for performance of the part of the work.
Third Party Agency Fabrication certifying authority (TPA).
Inspection Agency Designated Third Party Inspection agency carrying out
Inspection.
Inspector The Company's/Contractor's representative and member(s) of
inspection agency appointed for inspection of fabrication works.
Approval the authorization in writing given by the Company and/or TPA to
the Contractor to proceed with the performance of a specific
Doc Title: Document No : SP12-20-D-04-1-021/D1
Date : 24-Nov-08
Gouging Procedure
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part of the work without releasing in any way the Contractor
from any of its obligations or liabilities under the contract or at
law: Approve, Approved and Approval shall be construed
accordingly.
May Used to indicate that a provision is optional
Shall Used to indicate that a provision is mandatory.
Should Used to indicate that a provision is not mandatory but is
recommended as good practice.
4. REFERENCED STANDARDS AND SPECS.
4.1 Company Specifications
Document/ Specification Rev. Description
SP12-20-D-23-4-003 Latest General Technical Specification - Structural
Fabrication
SP-12-20-D-04-1-013 Latest Welding procedure
SP-12-20-D-04-1-022 Latest Welding repair procedure
4.2 International Standards
Document/ Specification Rev. Description
AWS D1.1 2002 Structural Welding Code - Steel
AWS C5.3 2000 Recommended Practice for Air Carbon Arc
Gouging and Cutting
5. PROCEDURE
The CAG process requires a welding power source, a source of compressed air, carbon
electrode, and cutting torch. Compressed air is introduced to blow away the molten metal.
Figure 1 shows the typical arrangement for using this process.
CAG is used with DCEP (reverse polarity). The electrode should have a maximum
extension of 180 mm from the cutting torch, with the air jet between the electrode and the
workpiece. Although there is no minimum extension, care should be taken to prevent
damage to the torch. Therefore 38 to 51 mm minimum extension is recommended.
Progression should only be in the direction of air flow. The electrode push angle will vary,
depending on the operation being performed. The cutter should maintain the correct arc
length to allow the air jet to properly remove the molten metal (see Figure 2).
Gouging process shall be done by skill person, approved by Company or TPA.
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Date : 24-Nov-08
Gouging Procedure
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Figure 1 - Typical Arrangement for the Carbon Arc Gouging (CAG)
Figure 2 - How a Standard CAG Torch Works
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Date : 24-Nov-08
Gouging Procedure
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5.1 Electrodes
There are three basic types of electrodes:
a. DC copper coated electrodes. This type is most widely used because of its
comparatively long electrode life, stable arc characteristics, and groove uniformity.
These electrodes are available in the following diameters: 3, 4, 5, 6, 8, 10, 12, 16 and
19 mm. The copper coating improves electrical conductivity providing more efficient,
cooler operation and helps maintain electrode diameter at the point of the arc.
b. DC uncoated electrodes. This type has limited use. These electrodes are generally
used in diameters of less than 10 mm. During cutting these electrodes are consumed
more rapidly than the coated electrodes. They are manufactured the same as the
coated electrodes without the copper coating.
c. AC copper coated electrodes. These electrodes are made from a special mixture of
carbon and graphite with a suitable binder. Rare-earth materials are incorporated to
provide arc stabilization for cutting with an alternating current. These electrodes,
coated with a controlled thickness of copper.
5.2 Operating techniques
a. Gouging. Table 1 shows suggested current ranges for various electrode types and
sizes. The electrode is gripped, so that a maximum of 180 mm extends from the
cutting torch. The air jet should be turned on before striking the arc, and the cutting
torch should be held as shown in Figure 3. The torch should always be operated using
the forehand technique, i.e., the electrode and air jet pointed in the direction of travel.
Under proper operating conditions, the air jet is expected to sweep beneath the
electrode end and remove all molten metal.
The steadiness of progression controls the smoothness of the resulting cut surface.
Figure 3 - Flat Position Gouging
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Gouging Procedure
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Table 1 - Suggested Current Ranges for Commonly Used Electrode Types and Sizes
Electrode Diameter
(mm)
DCEP Polarity
(amperes)
AC Electrode
(amperes)
3 30 60
4 90 150
5 200 250 200 250
6 300 400 300 400
8 350 450 325 425
10 450 600 350 450
13 800 1000 500 600
16 1000 1250
19 1250 1600
25 1600 2200
For gouging in the vertical position, the cutting torch should be held as shown in
Figure 4. Gouging should be done in a downhill direction, which permits gravity to
assist in removing the molten metal.
Gouging in the horizontal position may be done either to the right or to the left, but
always with forehand gouging. In gouging to the left, the cutting torch should be held
as shown in Figure 5. In gouging to the right, the cutting torch will be reversed to locate
the air jet behind the electrode.
When gouging in the overhead position, the electrode and torch should be held at an
angle that will prevent molten metal from dripping on the cutter's glove, as shown in
Figure 6.
The depth of the groove produced is controlled by the travel speed. Grooves up to
25 mm deep may be made. Slow travel speeds produce a deep groove. Fast speeds
will produce shallow grooves. The width of the groove is determined by the size of the
electrode used and is usually about 3 mm wider than the electrode diameter. Wider
grooves may be made with an electrode that is oscillated with a circular or weave
motion.
When gouging, a push angle of 65 degrees from the surface of the workpiece is used
for most applications (Figure 7). A steady rest is recommended in gouging to ensure a
smoothly gouged surface. It is particularly advantageous for use in the overhead
position.
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Gouging Procedure
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Figure 4 - Vertical Position Gouging
Figure 5 - Horizontal Position Gouging
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Gouging Procedure
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b. Cutting. Figure 8 shows the electrode in position for cutting. In general, the cutting
technique is the same as for gouging, except that the electrode is held at a steeper
angle; that is, with a push angle between 10 and 20 degrees.
With the electrode in this position, the metal may then be cut by moving the arc up and
down through the metal with a sawing motion.
Figure 6 - Overhead Position Gouging
Figure 7 - Gouging Electrode push angle
65
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5.3 Inspection
The free carbon particles are rapidly absorbed by the melted base metal. Increased carbon
can lead to increased hardness and possible cracking. Since this absorption cannot be
avoided, to avoid difficulties with carburized metal it is important that all carburized molten
metal be removed from the cut surface. Thus, gouging area shall be cleaned by grinding
and brushing. After grinding, these areas shall be inspected visually for recognize removal
all carburized metal.
Following grinding, the preparation shall be fully inspected visually before the
commencement of welding. Where there are visual indications, PT or MPI shall be applied
to ensure that the gouging areas are free from defects before welding.
Figure 8 Cutting with CAG
