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Weldpac -functional overview

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Mike Lewin

Weldpac is a new system for administering welding that provides improved traceability and documentation of welding and quality control processes. It revolves around weld process cards, NDT request cards, weld comprehensives, and PWHT stickers. The system expedites the welding process by printing cards with timestamps that are tracked through each stage from welding to NDT to heat treatment. Weldpac also provides management reports on welding progress, welder performance, and other key metrics to improve efficiency.

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Weldpac Functional & Operational Overview Weldpacisdesignedtomeetyourmanagerial, contractual, production andotherweld/QC requirements. ItisanISO3834 fundament. Itrevolvesaround three requestsandaform 1) WeldProcess card 2) NDT request card 3) Weld Comprehensive 4) PWHT sticker Weldpacisa new,completelydifferent wayof administeringwelding. The weldcard has multiple welddetails,upto4 weldersperweld. Ithasthe WPSdetailsanda consumable requisition. Printa weld card requestwithasystemdate and time stampand allocate itto the appropriate weldingsupervisor/foreman. He hasitcheckedoutuntil itis welded usuallywithin24 hours. The weldingisrecorded anddate andtime stampand if there isan NDT requestthatisprintedwiththe welder/weldingdetails withAGAIN adate andtime stamp. It goesonto the outstandingNDT list, and monitored everyday. So youcan see Weldpacexpeditesthe processandthe documentsrightontoanimpeccable comprehensive. Welpacalsokeepsuptodate withindividual welderperformance incheswelded and rejects. Choosingthe bestweldersall the time will have asignificantimpactonthe job. Cards are issuedin work sequence whenthe previouslinkis complete,andthe weldingdetailsare carriedforward from the weldcardtoall subsequent documents. A built-indocumentcontrol systemtracksall WeldProcesscardsandNDT Requests&PWHT to keep themmovingonschedule andidentifyanyrare late or missingdocuments. Everystage is timestamped sotheycanbe scheduledandtime controlled.The cardsall have serial numbers and can be reproduced. A detailedand accurate setof weldandNDT documentsis builtupwithfirstoffs, percentages, repairsare known. Because % NDT and repairs are tracked,the NDT requirementisalways obvious. It a case of fillinginthe missing ones, (2more thisclass thisweek),notblanketNDTing.Weldpac tracks and traces everything;acompanycan setup a dailyroutine, welding,andQCworking together. Knowingexactly whichweldshave tobe NDTd will drasticallyreduce the amountof NDT done. Weldpaccompressesandcompactsthe wayweldingworks:- Weldpac Day shift At 06:55 Weldingsupervisorscollecttheirprocesscards forthe day. These include detailsof the linestobe welded onthatday,grouped byWPS. It has the WPS detail printedon the cardon hand
for welderreview,aconsumable requisition withthe correctconsumable preprintedonit. Weldpac can track batchand use of consumablesi.e. full stockcontrol. At 07:00 am the overnightNDTandweldingcomesin.All iscaptured;repairsshow traceable backups. All backupsand repairs generate the correctrequest cards. At 2:09 pm the QC coordinatorpullsupdetailedreportsof recentwelding and testing,byline class, welderandfirstoffsandbackupNDT, his/hertheirneed for the detail thatmaybe required orhelp to selectNDT At 3:00 pm the last 24 hoursweldprocesscards are returned withthe NDTrequirementMARKEDUP From 15:00 to 16:00 Welding iscaptured,andthe NDTrequestsare printed (onlywelded) A listof all the outstandingRT isprinted asa planningtool anda reminderthattheydothe oldest firstand keepup PWHT labelsare printedincludingthe welddetail. The labels are included indocumentcontrol and mustcome back witha chart Whenthe line has beenwelded,printthe comprehensivesforsubmission Twice a week weldsby welderperformanceandndtrequirementvsprogress,overall job progress(withweldtocomplete) circulatedtothe client,departmental managersandperformance to projectmanagement. Reportsare deadaccurate as longas NDT is upwithwelding. Noexcuse withWeldpac. Notes. An upto date Welderregister,WPSregisterandDrawingregister/weldtake off are includedin Weldpac,alongwithmany otherdetails,NDTrequirementand reasonforNDT to complete the above activities WeldingandQC departments have noreasonto disagree asthe cards have the available information such as date weldedandwelder. NDTrequests are tiedbackto the weldingandhave atime elastic.. Theyworktogetheronthe same mission aspart of a team. WeldersandWPSare stored ina separate database Theycanrun at different, connected,locations, offeringlotsof configurationoptions. Welderweldinginformationbecomesmanagementinformationon the site anda great tool to manage welding. The weldershave attentionfocusedonthemtheywill weld fasterandbetter. Shrewddistributionof welderstotheirbestprocedureswillhelpproductionanderrorsaswell as identifyingwelderswhoneedretraining. Youcouldhave the bestavailable welderswelding optimally. As NDT followswelding andtheyhave aweld/ndthistory andqcknow exactly whichweldtotest. Thisovercomes the unavoidable issueof overNDTingtogetadequate coverage. QCshouldalways run withinaprioritizedweekof welding,nodisassemblyrequired. ThisshouldreduceNDTcostby nearly 50%
Weldpacprovidesfull traceabilityincludingconsumable batchandbackupweldIDs The bestis that youhave a precise tothe nthdegree database of everyprocess. Anythingyouneed to know on welders,welding NDTetcetcshouldbe on the copioussystemreports,whichgo toemail and excel butif notwe will getitfor you. These are oftengoodfor claims, MLA has done weld volumetricanalysis,consumable use andweldersweldingperday anddayswhenweldersweldedin claimssupport. Whether you savethrough improved administration or using detailed Weldpac reports to shakeup field/shop operations, you can look forward to savings that make a big impact on your projects efficiency and cost with Weldpac.
MLA - Weldpac Functions 19/09/2014 Project data System/server Backup, exchange,support Change project/code (Unit) Change Unit,switch code etc. Exit Weld Management - find a weld fast Welders up for urgent requalification Consumables Consumables Register Consumables Requisition Drawing & Weld take off Drawing Register/take off 3D Weld pos in wall. Revision retains work done, progress incl.completion,WPS selected Spool Progress Fabrication Welders and Fitters Contact & qualifications/equivalences Weld maintenance BackupNDT Selection reject aid and tracability of backups Weld Deletions (secure) Reason for deletion required AssignWeldCards to supervisor Know where to get them KKS Assign Catch up for welds w/o KKS Mass Accept BulkNDT Setup Contract Contracts Projects Groups Sites Test Packs Lock out from change by QC, prep for hydro and submission NDT Requirements Code requirementfor NDT NDT NDT Defect Codes NDT Reasons NDT Types User can create own types - System Parameters Plate/pipe,unit defn, Progress % fit/weld/ndt Users accessrights Individual screen/report - Weld Weld Delete Reasons
Heat Treatment Repair Status Stages Weld Descriptions Weld Locations Procedure Qualification Record (Under development) Weld Processes Weld Reasons Weld Types WPS WPS Materials WPS Metals WPS Register Results Welding NDT Request NDT result Heat treatment Reports Weld Process Card (Filter) Weld request for a number of w elds with fillspec place for w elder, date and consumable recognition NDT Request Screen - HT Request Heat treatmentsticker Weld Comprehensive Report Weld Comprehensive Index Green Weld Heat Treatment Index All round document control (Indexes) WPS Register Report Requests for work (Forms eg Welder Register Record of Result References Sites Materials Test Packs NDTRequirements Weld Locations Weld Descriptions Weld Processes Weld Types Weld Reasons Heat Treatment NDTTypes NDTReasons Repair Status Defect Codes DocumentReferenceIndex Welder Defect Report
WeldingByWelder Report Fitting ByFitter Report NDT ByWelder ByPeriod Completed NDT NDT Distribution byNDT Required Consumable Usage NDT BackupReport Export Heat Treatment % weld complete/all welds system& overall (WIP) - Management Reports WeldingProgress Report Welder Performance Report DetailedProduction Report Scope of Work KPI Information KPI Summary Weld SummaryExport By System By Drawing By System (Completed) By Drawing(Complete) By System, Material QC Reports WPS By System Welders ByWPS QC DetailedProduction Data CollectionReports Indexes Weldingnot yet requested Weld Results Outstanding Weld Consumables Outstanding NDT Outstanding Defects Outstanding PWHT NEW - HT Request Outstanding Help

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Weldpac -functional overview

  • 1. Weldpac Functional & Operational Overview Weldpacisdesignedtomeetyourmanagerial, contractual, production andotherweld/QC requirements. ItisanISO3834 fundament. Itrevolvesaround three requestsandaform 1) WeldProcess card 2) NDT request card 3) Weld Comprehensive 4) PWHT sticker Weldpacisa new,completelydifferent wayof administeringwelding. The weldcard has multiple welddetails,upto4 weldersperweld. Ithasthe WPSdetailsanda consumable requisition. Printa weld card requestwithasystemdate and time stampand allocate itto the appropriate weldingsupervisor/foreman. He hasitcheckedoutuntil itis welded usuallywithin24 hours. The weldingisrecorded anddate andtime stampand if there isan NDT requestthatisprintedwiththe welder/weldingdetails withAGAIN adate andtime stamp. It goesonto the outstandingNDT list, and monitored everyday. So youcan see Weldpacexpeditesthe processandthe documentsrightontoanimpeccable comprehensive. Welpacalsokeepsuptodate withindividual welderperformance incheswelded and rejects. Choosingthe bestweldersall the time will have asignificantimpactonthe job. Cards are issuedin work sequence whenthe previouslinkis complete,andthe weldingdetailsare carriedforward from the weldcardtoall subsequent documents. A built-indocumentcontrol systemtracksall WeldProcesscardsandNDT Requests&PWHT to keep themmovingonschedule andidentifyanyrare late or missingdocuments. Everystage is timestamped sotheycanbe scheduledandtime controlled.The cardsall have serial numbers and can be reproduced. A detailedand accurate setof weldandNDT documentsis builtupwithfirstoffs, percentages, repairsare known. Because % NDT and repairs are tracked,the NDT requirementisalways obvious. It a case of fillinginthe missing ones, (2more thisclass thisweek),notblanketNDTing.Weldpac tracks and traces everything;acompanycan setup a dailyroutine, welding,andQCworking together. Knowingexactly whichweldshave tobe NDTd will drasticallyreduce the amountof NDT done. Weldpaccompressesandcompactsthe wayweldingworks:- Weldpac Day shift At 06:55 Weldingsupervisorscollecttheirprocesscards forthe day. These include detailsof the linestobe welded onthatday,grouped byWPS. It has the WPS detail printedon the cardon hand
  • 2. for welderreview,aconsumable requisition withthe correctconsumable preprintedonit. Weldpac can track batchand use of consumablesi.e. full stockcontrol. At 07:00 am the overnightNDTandweldingcomesin.All iscaptured;repairsshow traceable backups. All backupsand repairs generate the correctrequest cards. At 2:09 pm the QC coordinatorpullsupdetailedreportsof recentwelding and testing,byline class, welderandfirstoffsandbackupNDT, his/hertheirneed for the detail thatmaybe required orhelp to selectNDT At 3:00 pm the last 24 hoursweldprocesscards are returned withthe NDTrequirementMARKEDUP From 15:00 to 16:00 Welding iscaptured,andthe NDTrequestsare printed (onlywelded) A listof all the outstandingRT isprinted asa planningtool anda reminderthattheydothe oldest firstand keepup PWHT labelsare printedincludingthe welddetail. The labels are included indocumentcontrol and mustcome back witha chart Whenthe line has beenwelded,printthe comprehensivesforsubmission Twice a week weldsby welderperformanceandndtrequirementvsprogress,overall job progress(withweldtocomplete) circulatedtothe client,departmental managersandperformance to projectmanagement. Reportsare deadaccurate as longas NDT is upwithwelding. Noexcuse withWeldpac. Notes. An upto date Welderregister,WPSregisterandDrawingregister/weldtake off are includedin Weldpac,alongwithmany otherdetails,NDTrequirementand reasonforNDT to complete the above activities WeldingandQC departments have noreasonto disagree asthe cards have the available information such as date weldedandwelder. NDTrequests are tiedbackto the weldingandhave atime elastic.. Theyworktogetheronthe same mission aspart of a team. WeldersandWPSare stored ina separate database Theycanrun at different, connected,locations, offeringlotsof configurationoptions. Welderweldinginformationbecomesmanagementinformationon the site anda great tool to manage welding. The weldershave attentionfocusedonthemtheywill weld fasterandbetter. Shrewddistributionof welderstotheirbestprocedureswillhelpproductionanderrorsaswell as identifyingwelderswhoneedretraining. Youcouldhave the bestavailable welderswelding optimally. As NDT followswelding andtheyhave aweld/ndthistory andqcknow exactly whichweldtotest. Thisovercomes the unavoidable issueof overNDTingtogetadequate coverage. QCshouldalways run withinaprioritizedweekof welding,nodisassemblyrequired. ThisshouldreduceNDTcostby nearly 50%
  • 3. Weldpacprovidesfull traceabilityincludingconsumable batchandbackupweldIDs The bestis that youhave a precise tothe nthdegree database of everyprocess. Anythingyouneed to know on welders,welding NDTetcetcshouldbe on the copioussystemreports,whichgo toemail and excel butif notwe will getitfor you. These are oftengoodfor claims, MLA has done weld volumetricanalysis,consumable use andweldersweldingperday anddayswhenweldersweldedin claimssupport. Whether you savethrough improved administration or using detailed Weldpac reports to shakeup field/shop operations, you can look forward to savings that make a big impact on your projects efficiency and cost with Weldpac.
  • 4. MLA - Weldpac Functions 19/09/2014 Project data System/server Backup, exchange,support Change project/code (Unit) Change Unit,switch code etc. Exit Weld Management - find a weld fast Welders up for urgent requalification Consumables Consumables Register Consumables Requisition Drawing & Weld take off Drawing Register/take off 3D Weld pos in wall. Revision retains work done, progress incl.completion,WPS selected Spool Progress Fabrication Welders and Fitters Contact & qualifications/equivalences Weld maintenance BackupNDT Selection reject aid and tracability of backups Weld Deletions (secure) Reason for deletion required AssignWeldCards to supervisor Know where to get them KKS Assign Catch up for welds w/o KKS Mass Accept BulkNDT Setup Contract Contracts Projects Groups Sites Test Packs Lock out from change by QC, prep for hydro and submission NDT Requirements Code requirementfor NDT NDT NDT Defect Codes NDT Reasons NDT Types User can create own types - System Parameters Plate/pipe,unit defn, Progress % fit/weld/ndt Users accessrights Individual screen/report - Weld Weld Delete Reasons
  • 5. Heat Treatment Repair Status Stages Weld Descriptions Weld Locations Procedure Qualification Record (Under development) Weld Processes Weld Reasons Weld Types WPS WPS Materials WPS Metals WPS Register Results Welding NDT Request NDT result Heat treatment Reports Weld Process Card (Filter) Weld request for a number of w elds with fillspec place for w elder, date and consumable recognition NDT Request Screen - HT Request Heat treatmentsticker Weld Comprehensive Report Weld Comprehensive Index Green Weld Heat Treatment Index All round document control (Indexes) WPS Register Report Requests for work (Forms eg Welder Register Record of Result References Sites Materials Test Packs NDTRequirements Weld Locations Weld Descriptions Weld Processes Weld Types Weld Reasons Heat Treatment NDTTypes NDTReasons Repair Status Defect Codes DocumentReferenceIndex Welder Defect Report
  • 6. WeldingByWelder Report Fitting ByFitter Report NDT ByWelder ByPeriod Completed NDT NDT Distribution byNDT Required Consumable Usage NDT BackupReport Export Heat Treatment % weld complete/all welds system& overall (WIP) - Management Reports WeldingProgress Report Welder Performance Report DetailedProduction Report Scope of Work KPI Information KPI Summary Weld SummaryExport By System By Drawing By System (Completed) By Drawing(Complete) By System, Material QC Reports WPS By System Welders ByWPS QC DetailedProduction Data CollectionReports Indexes Weldingnot yet requested Weld Results Outstanding Weld Consumables Outstanding NDT Outstanding Defects Outstanding PWHT NEW - HT Request Outstanding Help