Welder Re-qualification / Previous Welds
Welder Re-qualification / Previous Welds
(OP)
We are fabricating offshore jackets to AWS D1.1 and are having quality issues with welding (this is in a W. Africa fab shop). Due to a high repair rate, we are going to ask for some welders to be re-qualified. Question, if a welder fails his re-qualification, does that call in to question the welds he has welded on previously.
The question seems a bit ridiculous on one hand because if the weld passes NDT, then what's the problem? On the other hand, taken to its logical conclusion, then why have any qualification standards at all, WPS's, PQR;s etc, just let the guy weld and if it passes NDT great.
I have looked thru AWS D1.1 Sections 3 and 4 and don't find any direction.
I would like to get some thoughts on the matter.
The question seems a bit ridiculous on one hand because if the weld passes NDT, then what's the problem? On the other hand, taken to its logical conclusion, then why have any qualification standards at all, WPS's, PQR;s etc, just let the guy weld and if it passes NDT great.
I have looked thru AWS D1.1 Sections 3 and 4 and don't find any direction.
I would like to get some thoughts on the matter.
Greg Lamberson, BS, MBA
Consultant - Upstream Energy
Website: www.oil-gas-consulting.com





RE: Welder Re-qualification / Previous Welds
RE: Welder Re-qualification / Previous Welds
Unfortunatley I do not have them electronically. We are doing UT, MPT, and radiography.
This is a situation of coming in to the project at the tail end and finding some quality deficiencies and trying to make the best out of a bad situation. One thing we have started doing is classifying welds for criticality.
And while we've asked for some welder re-qualifications, it's kind of like the dog chasing the car, you catch it and what do you do with it. I understand from D1.1 (4.32.1.4) that once a welder fails a re-qualification, he must undergo re-training prior to attempting again.
But again, what I am not sure of is how to handle the welds he did work on. Can we accept them without exposing the company to risk?
Greg Lamberson, BS, MBA
Consultant - Upstream Energy
Website: www.oil-gas-consulting.com
RE: Welder Re-qualification / Previous Welds
Yes, I believe it does. You have uncovered a quality problem or nonconformance that requires a disposition. Regardless, of when it was found it needs to be dispositioned.
If I was the customer, I would require the fabricator to go back and re-examine a percentage of the welds (say 10% to begin) that were deposited by this welder (if traceable). If you cannot trace the welds, I would go back and examine a 10% sample for starters. If during this production inspection any of the welds did not pass NDT, all of the welds would be suspect, and need to be examined and repaired by a qualified welder.
RE: Welder Re-qualification / Previous Welds
You don't know how much I appreciate your input. I know this is a forum and the idea is to exchange information, but I owe you.
Greg Lamberson, BS, MBA
Consultant - Upstream Energy
Website: www.oil-gas-consulting.com
RE: Welder Re-qualification / Previous Welds
Finally, check the contract. Most oil company's contracts give them the right to reject any welder for whatever reason.
The aim of qualification is to demonstrate that a welder is capable of making satisfactory welds. The aim of quality control is to ensure that the welder's resolve to make satisfactory welds doesn't lapse!
Good luck with sorting out the radiographs and the UT reports!
Steve Jones
Materials & Corrosion Engineer
http://www.pdo.co.om/pdo/
RE: Welder Re-qualification / Previous Welds
RE: Welder Re-qualification / Previous Welds
Greg - whilst you are worrying about the welders did anyone think of cross-checking the NDT?!!!
Steve Jones
Materials & Corrosion Engineer
http://www.pdo.co.om/pdo/
RE: Welder Re-qualification / Previous Welds
We are in the process of doing that now, allot of things going on in parallel.
We arrived to site as a new team on Week 33 of the project (this is a sub-project within the project, I also have 3 other sub-projects, all challenging but not quite so much so as this one), so to say we have stepped into a situation is putting it mildly.
We do not yet have all of the PQR's done (load out is scheduled for early January!), some repair procedures have not been run yet, traceability of the welders is spotty. We have welds that are filled and capped and the welder matrix is only filled out for the bead & HP. UT contractor is suspect, we are running some traps on him at the moment.
But you know what - that's part of it, got to look for solutions rather than dwelling on the problems.
Metengr
Agree 100% on the criticality assessments, however, as per the above, that was not done. So the only option I have is to evaluate the criticality now so as to be able to focus minimal resources and little time to get the biggest bang for the buck. At the end of the day the client will have to decide if we sailaway or not.
I really do appreciate the input
Greg Lamberson, BS, MBA
Consultant - Upstream Energy
Website: www.oil-gas-consulting.com
RE: Welder Re-qualification / Previous Welds
Steve Jones
Materials & Corrosion Engineer
http://www.pdo.co.om/pdo/
RE: Welder Re-qualification / Previous Welds
As mentioned by "Metengr", it is best if these contingencies are addressed in the project specifications before the project starts.
Best regards - Al
RE: Welder Re-qualification / Previous Welds
RE: Welder Re-qualification / Previous Welds
Greg Lamberson
Consultant - Upstream Energy
Website: www.oil-gas-consulting.com
RE: Welder Re-qualification / Previous Welds
As for the AWS D1.1 Code, there are no requirements to go back and re-inspect the other welds that were done prior to the request for "Requalification". I must add now in my opionion and not of the AWS or AWS D1 committee.
The AWS D1.1 Code does not require NDT unless a specific splice in a beam.
Therefore any other NDT, other than visual, must be specified in the contract. As such, terms like Spot, which can become progressive evaluations due to the lot evaluation being un-acceptable, would force additional NDT of the prior welds.
Regards,
Allen
Sindel & Associates
www.consulting.awsindel.org