SERVICES - WELD REPAIR DEVELOPMENT & OVERSIGHT

Field weld engineering and QA/QC for industrial weld repairs on existing plant equipment and structures is a specialty of Advanced Welding Solutions. Quality assurance (QA) is defined as any systematic process of determining whether a product or service meets specified requirements. Quality control (QC) on the other hand is the process of confirming that the product meets the specifications.  QC will often include in-process checks during manufacturing or repair to identify defects in a timely manner. Once a flaw is identified an appropriate action plan is formulated and/or implemented allowing for process optimization and/or rework. 

Repair Quality Assurance Plans (QAP) start with a project specific plan that meets all the necessary welding and inspection requirements (drawing, customer specifications, jurisdictional, regulatory). These weld repair development plans contain all the technical details including WPS selection, heat treatment, NDT methods, drawings, datasheets and hold point requirements with acceptance criteria. Almost always, the QC phase includes on-site travel to oversee every aspect of the job from cradle to grave, generating a detailed report upon completion. All too often short cuts are unintentionally (or sometimes intentionally) taken to cut cost and save time, all while compromising quality of the weldment. In the end, the equipment owner is left with unnecessary risk and the potential for component failure with additional downtime. These issues or concerns could be brought up or addressed immediately with the help of a watchful eye on all minute details of the process. In a manufacturing environment, thorough QA/QC document packages can counter claims of defective products.

We have experience overseeing weld repairs on turbine casings, valve bodies, piping systems, pump casings, pump impellers and plant structures, to just name a few. Give us a call to discuss your specific project details.

Basic Weld Repair Quality Assurance Plan Elements

Pre-Job

• Method(s) for defect removal if repair (grinding, arc gouging, machining)
• NDT methods and requirements
• WPS selection including details of post-weld heat treatment, if necessary
• Hold points established
• Material confirmation including base material, filler, backing, etc.
• Joint design and preparation 
• Joint fit-up
• Welder qualification
• Location of thermocouples or heating elements (if used)

During Welding

• Ensure 100% compliance with the repair plan including WPS variables (preheat, interpass temperature, filler, etc.), NDT and hold points

Post-Welding

• Ensure post-weld heat treatment (PWHT) compliance
• NDT