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Control of Welding Rejection Rate and NDT Backlog in MEGA Project

Picture for Control of Welding Rejection Rate and NDT Backlog in MEGA Project
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This paper provides a real case study in regard to controlling the welding repair rate and NDT backlog in a company mega-project assigned to a new contractor. This case study shows the improvements in both KPIs, through the utilization of various quality and improvement tools, such as root cause analysis (Fishbone and Pareto chart), brainstorming, and PDCA cycle. The collaborative efforts between the client and contractor, including the welding and NDT subcontractors, resulted in reducing the WRR from 11.04% to below 5% (the set KPI). The NDT backlog was also controlled and reduced from 2500 joints to below 600 joints (less than one week production).

Product Number: MPWT19-15302
Author: Abdullah H. Shaiban, Saad A. Aldossari, Yahya M. Haydar, Naif S. Alrasheedy
Publication Date: 2019
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Picture for Influence of Repeated Welding Thermal Cycle on The Mechanical Properties of SA516 Steel Weldment
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Influence of Repeated Welding Thermal Cycle on The Mechanical Properties of SA516 Steel Weldment

Product Number: MPWT19-14345
Author: Sandeep Kumar, Abdulla Ali Juma
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This study investigates the influence of thermal cycle as a result of repeated welding heat input on the mechanical and microstructural properties of the SA516 Gr 65 steel plates weldment in as-welded condition. The test specimens used were having an identical joint design, welded with submerged arc welding (SAW) process. Three different heat inputs of 0.96kJ/mm (low heat input), 1.5kJ/mm (medium heat input) and 3.58 kJ/mm (high heat input) were used for welding three individual specimens. All weld longitudinal tensile testing, Charpy V-notch impact test and weld metal & heat affected zone (HAZ) microstructural testing were done. The work shows that low heat input (LHI) produced welds with highest yield, tensile strength and toughness in the weld metal whereas high heat input (HHI) resulted in decrease in yield, tensile strength and toughness in the weld metal. Increased level of acicular ferrite and a fine grain structure in weldment were achieved with LHI, while the HHI produced coarse grain structure in the weldment and in the HAZ.
Picture for Design Consideration for Internal Welding Attachments in Clad Pressure Vessels
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Design Consideration for Internal Welding Attachments in Clad Pressure Vessels

Product Number: MPWT19-14326
Author: Olivier Sarrat
Publication Date: 2019
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Process equipment which employs a corrosion resistant alloy (CRA) layer cladded to steel is common in refineries, petrochemical plants and other plants processing highly corrosive media. There are two regularly employed methods for welding attachments and internals to clad process vessels. One is to remove the CRA cladding for welding the attachment to the steel base metal assuming dissimilar welds and restoring CRA by weld overlay. The other eliminates the step of removing the cladding, simplifying the attachment process by direct welding of the internals onto the clad layer. With the lack of data to prove the integrity of direct welding attachment onto the clad layer, designers frequently demand the cladding be removed or allow only a conservatively low stress limit for what can be attached directly to the clad surface. It is well understood that eliminating the step of removing clad increases the simplicity, improves the lead-time, and reduces the cost of making these attachments for trays or other internals, but there are concerns about clad disbonding risks. With the aim to provide data around the integrity of direct welding attachments for better risk assessments, a technical study was undertaken. In this study, it will be shown that the bond between clad material and the base steel is robust enough to withstand the heaviest attachments and harshest conditions. The theory behind the technical study will be presented along with the results of this study
Picture for 00573 Special Alloys and Overmatching Welding
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00573 Special Alloys and Overmatching Welding Products Solve FGD Corrosion Problems

Product Number: 51300-00573-SG
ISBN: 00573 2000 CP
Author: J. R. Crum, L. E. Shoemaker, S. D. Kiser, P.E.
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