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Minimizing Weld Defects A Guideline 1591073113
Minimizing Weld Defects A Guideline 1591073113
Guideline for
Weld Reject Rate Reduction
Table of Contents
1. PURPOSE ......................................................................................................................................................................2
2. ACRONYMS .................................................................................................................................................................2
3. REFERENCE DOCUMENTS......................................................................................................................................3
4. WELD DEFECTS, WELD REJECTION RATE, AND WELD DEFECT CAUSES ..............................................4
5. PREVENTION OF WELD DEFECTS - REDUCTION ACTIVITIES ...................................................................9
6. WELD PRODUCTIVITY...........................................................................................................................................10
7. INSPECTION ..............................................................................................................................................................12
8. FIRST TEN PRODUCTION WELDS ......................................................................................................................13
9. QA SURVEILLANCE AND SYSTEM AUDITS .....................................................................................................14
1. PURPOSE
The purpose of this document is to provide a guideline to reduce the weld defect rates within an organisation. Ensuring a low
defect rate of welding on the project will also allow for the completion of the project within the scheduled time allowed within the
allocated budgets allocated.
2. ACRONYMS
Theses acronyms are included as a reference for general contract documentation as well as those directly
utilized within this guideline.
Acronym Description MMAW Manual Metal Arc Welding (same as
SMAW)
API American Petroleum Institute MSDS Material Safety Data Sheet
ASME American Society of Mechanical MT Magnetic Particle Testing
Engineers
ASNT American Society for Non‐Destructive‐ NACE National Association of Corrosion
Testing Engineers
ASTM American Society of Testing and NCR Non‐conformance Report
Materials NDE Non‐Destructive Examination
AWS American Welding Society NDT Non‐Destructive Testing
CR Criticality Rating NFPA National Fire Protection Association
CS Carbon Steel NOI Notification of Inspection
CUI Corrosion Under Insulation OSHA Occupational Safety and Health
DN Diameter Nominal (Pipe Material Size) Administration
DPT (PT) Dye Penetrant Testing Also Dye PT PAUT Phased Array Ultrasonic Testing
Penetrant Testing PMI Positive Material Identification
DWR Daily Welding Report PMT Project Management Team
ECA Equipment Criticality Analysis PQR Procedure Qualification Record
EPCC Engineering Procurement PH Preheat
Construction Commissioning PWHT Post Weld Heat Treatment
EPCM Engineering, Procurement, and
Construction Management RT Radiographic Testing/Examination
FCAW (GS) Flux Cored Arc Welding Gas Shielded SAW Submerged Arc Welding
FCAW (SS) Flux Cored Arc Welding Self Shielded SCC Stress Corrosion Cracking
GMAW Gas Metal Arc Welding (MIG, MAG) SMAW Shielded Manual Arc Welding
GTAW Gas Tungsten Arc Welding SME Subject Matter Expert
HIC Hydrogen Induced Cracking TOFD Time of Flight Diffraction
HSE Health Safety Environmental UT Ultrasonic Testing
ISO International Organization for WIM Welding & Inspection Manager
Standardization WPS Welding Procedure Specification
ITP Inspection and Test Plan WQR Welder Qualification Record
KOM Kick Off Meeting WQT Welder Qualification Test
KPI Key Performance Indicator WRR Weld Reject Rate
LOT Generic term ASME to define a specific
aligned group
3. REFERENCE DOCUMENTS
Document Title/Description
ASME B31.3 Process Piping
ASME B31.3 Interpretations Process Piping Interpretations for code
ASME V Non‐Destructive Examination
ASME Viii Rules for Construction of Pressure Vessels
ASME iX Qualification Standard for Welding
AWS D1.1 Structural Welding Code
AWS D1.6 Structural Welding Code ‐ Stainless Steel
API 650 Welded Tanks for Oil Storage
AWS 3.0 Welding Positions
AWS A2.4 Welding Symbols
AWS A5 Specification for Electrodes and Filler Wires (series)
4. WELD DEFECTS, WELD REJECTION RATE, and WELD DEFECT CAUSES
Every Defect found costs Schedule and Resources
Weld Defects lead to failure of systems and plant, it is for this reason that every action shall be taken
to eliminate their occurrence. Criticality of equipment is assessed, and on code / criticality
requirements a nominated percentage of testing will be required.
Every Defect not found is an increased Risk to Project
Where only a low percentage of testing is required it becomes even more critical that the quality of
workmanship is at professional levels, for this reason weld rejects are recorded and their data
analysed. The subsequent defect rate becomes the basis for risk assessment of that weld quality.
4.1 Proof Testing
All engineering and RISK ASSESSMENT is based upon the principle of good quality fabrication.
Proof Testing (Hydro, Pneumatic, Sensitive leak etc.) is only a once off test and does not
consider real world conditions/stresses during the life of the plant including ‐
• Heat cycling • Corrosion
• Pressure cycling • Erosion
• Effects of transported media • Shock loading from “issues”
• Weight transfer as product flows
4.2 Weld Reject Rate ‐ WRR
For weld defect rates the ideal repair rate would be zero. Zero in measured units and Zero in
percentage of all categories. In the real world it is however important to allow for the practical reality,
welding is a highly skilled operation that has many variables that can lead to failure of parts of the
weldment.
Understanding that there will be an amount of rejects, it is then critical to determine a benchmark to
compare the quality of workmanship. This KPI Key Performance Indicator becomes the benchmark for
comparison, the environment and type of welding needs to be considered also. Further to this,
analysis of the defect type and the root cause of them can then be systematically utilized to prevent or
reduce re‐occurrence.
4.3 Percentage Tested
In relation to the percentage tested, it is important to look at the percentage of defects. It is a
common misconception that when testing at a higher percentage (due to criticality of the line or
specification requirements) that it will have a higher defect rate. That is only true of there is an
inherent poor quality of workmanship. If higher rates of defects are presented when the only change
is the percentage of testing then what is actually revealed is a much higher number of defects that
remain unidentified that pose a continued unacceptable risk to the project.
Example only ‐ Represented below are results of a line that was changed from spot inspection to
complete testing; the contractor was required to complete 100% testing on sections of pipe that
would become inaccessible for inspection during hydro testing. This was completed to minimize the
risk of testing failure and the inability to visually inspect the welds after the delayed hydro test. This
clearly shows that on similar lines welded by the same work teams that the quality of welds that
remain untested remain a risk to project (regardless of proof testing that was subsequently
Intended/Completed.)
These activities include
Weld Defect Recognition training
Visual Weld Inspection training
Training in the use of inspection tools
Tack Welding of Pipe training
Understanding Weld and NDE data
Direct support from welding engineers and NDE SME’s in review of procedures and
contractor improvement programs including ‐
Competency assessment of welders to be completed before welding to be started ‐
theory testing on
o Importance of factors that can reduce defects (specific to work to be
completed)
o Pre‐heat measurement and requirements
o Requirement to adhere to Procedures
o Identification of equipment shortfalls
WQT Welder Qualification Testing that is relevant to the work being completed
o Same P number
o Same weld geometry
o Same machine type
On site welder training for welders that
o Fail First Ten Production weld requirements
o Exceed the stated KPI’s during works
On site coaching by welding supervisors, this assistance in set up and detailing where
difficulties have been experienced by other welders is beneficial for all concerned.
Electrode control
Improve quality weld supervisor
Preheat procedures
Control of inter‐pass temperature
Bonus scheme and recognition of best welders
Quality inert gas to be ensured
Earlier identification of poor performing welder quick turnaround time on RT and
reduce RT backlog
Recognition that the welder has the right to refuse poorly fitted up joints (it is
strongly recommended that welders fit their own joints.
5.1 Understanding Weld Defect Costs
The cost of Weld defects includes the following ‐
• Loss of original planning, labour, and consumables
• Defect detection and identification
• Defect removal
• Testing to determine if all of the defect is removed and no residual issues that will
impact subsequent repairs
• Actual Repair, Preheat, welding, Post Weld Heat treatment
• Retesting to confirm integrity,
– may involve setting up scaffolding again, moving other equipment, disruption to other
activities etc.
– Increases NDE Backlog
• Delay to other work, either work that cannot be completed until the defect is
remedied or by the use of resources for the repair, the inability to complete work that
was scheduled for completion
• Delays to Proof testing program
• Additional testing required (penalty shots)
• Weld defects can cost as much as ten times the original placement of the weld and
affect schedule negatively
6. WELD PRODUCTIVITY
The reality of project work is that contractors that are efficient and effective in their work can plan
for the required activities to complete quality welding on schedule. Unprofitable contractors will not
invest time in completing work to their contract required conditions.
6.1 Process Deposition Efficiency
Utilizing weld processes and procedures that effectively deposit weld material is essential for both
client and contractor, this enables schedules to be met and quality objectives attained. Critically also
is the wastage of those consumables.
Recovery Rate of consumables
6.2 Weld Labour
Weld Labour costs are a key contributor to overall costs, as the amount of labour involved directly
affects schedule it is critical that welding processes and procedures are utilised that utilize the
minimum amount of labour possible
6.3 Defect Propensity
The more likely that a process or procedure is likely to create defects the greater the delays and costs
that will result from the subsequent weld defects created. Utilising weld processes and procedures
that have the lower likelihood of weld defects will have a positive effect in the ability to meet
schedule and cost constraints.
7. INSPECTION
7.1 Timely Inspection of weldments is the key to minimizing the effects of weld defects; the inspection
process should include the following as a minimum ‐
QC department verifying that the materials to be utilized for construction meet project specifications and are fit for
the purpose they are intended
Storage is controlled to ensure that the materials remain in a suitable condition for use
Transport and movement of the materials conducted as so that they are not damaged or compromised
Consumables issued in a controlled manner so that batch recording and full Positive Material Identification (PMI) can
be recorded and conducted as required (subject to the criticality of the equipment)
Consumables taken into work environment and stored / fitted appropriately
Verification of required fit up and geometry
Inspection of welding equipment, including all leads, hoses, welding torches, flow meters, equipment gauges,
calibration stickers and logs
Final cleanup of parts to ensure that there are no traces of oxides or contaminants that could affect the weldment
Fit up and tacking performed by Qualified and Competent personnel (or ideally positioned within equipment that
does not requiring tacking (Ref “Tacking of Pipe” training presentation)
Verification of dimensional accuracy of fit up and conformance to that of the WPS requirements for the weld
geometry
Clean up and feathering of tacking (ensuring that no residue from grinding or tacking process remains (blow out with
clean dry compressed air)
Complete welding as per approved welding procedure (verifying correct usage of welding parameters) Inspection
after root, hot pass and filler and capping
Close visual inspection as per code requirements
Ensure correct selection for PWHT, NDE as required
Spot review of reporting of PWHT and NDE
Inspection is the responsibility of all concerned in all levels within a manufacturing and quality
sphere, the welding first shall always be inspected by the operator. Operators who do not take
enough interest and pride in their work to inspect should be encouraged to work elsewhere.
Structured QC inspection shall be documented and at a minimum be based upon comprehensive,
complete, reviewed and approved Inspection and Test Plans (ITP’s)
7.2 Inspection Tools –
Contractor QC Shall check that measurement tools are available and being used by contractors in their
QC activities and these include –
Codes 8m Tape Measure Gas flow meter
Specifications Good torch Chalk
NAKA gauge Vernier’s Marking ink pen
Fillet Gauge Engineers square Chalk line
Pit Gauge Volt Metre Clamp
150mm Rule Amp Metre Inspection mirror
300mm Rule Temperature gun Stop Watch
8. FIRST TEN PRODUCTION WELDS
The Testing of First Ten Production joints are required to establish the quality of the new welder. This
program enables the contractor to observe and understand the likelihood of the welder to produce
welds that could disrupt their ability to meet schedule.
As code weld testing percentages are based upon an acceptable quality of welding, this is the
opportunity to ensure that the operators conducting this work are capable of doing so. The
importance of the original Welder qualification testing is not to be underestimated; however, there is
a large difference between welding in a controlled welding environment of a test bay and that of
completing in‐situ work. It is for this reason that the program of First Ten Production Weld testing is
critical to contractor and project risk. This enables workmanship deficiencies to be corrected; it allows
for training and assistance for the welder to complete their tasks and confirms to the operator the
level of quality that is expected for the project.
First Ten Production testing is critical to maintain schedule requirements (prevents / reduces defects
within general production program by identifying welders that are likely to have unacceptable defect
rates.
8.1 Provision for Equivalent value for Joint
Permit 1000mm of welding (equivalent to 12” pipe joint) as substitute for “joint” to allow for large
bore pipes, and tank work as current “joint” I.e. 10m welding being equivalent to 10 joints.
8.2 Provision for continuance of welding when testing is not completed and reported
Allowance for welders to continue welding with the condition that any defects found within the First
Ten Production Welds would necessitate testing of all subsequent welding until it is confirmed that
the weld quality is consistent with project KPI’s). This allows the productivity for the contractor and a
guarantee of quality that if the welder is found to be deficient that any work so completed would be
checked adequately.
8.3 First ten Production weld failure
When a new operator is completing their First Ten Production Welds it is expected that this will result
in ten welds that conform to code and specification. Where any of the welds fail, i.e. containing
defects that are beyond the acceptance of the acceptance criteria as stated for the applicable code it
is recorded as a joint defect. A single failure represents a 10% defect rate and as that is 3 times the
established KPI this should then require the welder to be continually tested until such time as they can
prove to consistently weld at an acceptable quality level.
9. QA SURVEILLANCE AND SYSTEM AUDITS
9.1 Quality Assurance
The CONTRACTOR is the main focal point and execution of the work scope. It is incumbent on the
CONTRACTOR to monitor the CONTRACTOR’s execution of their welding activities and Procedures.
CONTRACTOR Quality shall examine and document through surveillance reporting,
ITP’s
Welding and NDE Documentation and Records
The CONTRACTOR shall establish a surveillance schedule that ensures CONTRACTOR’s implementation
of their welding Program is being effectively managed. The surveillance schedule shall be managed by
the CONTRACTOR Quality Manager and coordinated with the Client.
9.2 Client Construction Walkabouts and Spot inspections
The WIM and NDE SME’s will coordinate with each contractor Head of Quality to engage with the
CONTRACTOR walkabout with a focus in the following areas:
Receipt and storage of Equipment, Consumables, and Materials of construction
Inspection and Examination activities on received, work in progress and stored items
Documentation requirements
The WIM and NDE SME’s will coordinate with each Head of Quality to engage with the CONTRACTOR
spot inspections with a focus on areas that are highlighted within exception reporting from
CONTRACTOR monthly reports, from observations within Scheduled Audits in the following areas:
Receipt and storage of Equipment, Consumables and Materials of construction
Inspection and Examination activities on received, work in progress and stored items
Documentation requirements
Written by Chris Wylie 31st May/2020
Published on LinkedIn Monday, 1 June 2020
Guideline for Reduction in Weld Rejection Rates.
This guideline is intended to provide the basic information for a welding contractor or as a guide for a client to
assist their contractors in improving weld quality with the aim of Project risk minimisation.
The information has been assembled from many different projects and contractors I have worked with over
my career.