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A
contractor's main experience was producing steelwork for the building and civil
engineering markets, however due to economic pressures it was decided to look
at entering alternative markets.
Mitchell Services identified the various
industrial sectors that could be supplied and the improvements necessary to facilitate
market entry.
A review of existing capabilities was completed and potential
markets with growth potential identified. Various proposals were presented and
the associated barriers to market entry identified. Barriers included existing
working methods and internal systems, unsuitable control procedures and associated
method statements. The contractor had no previous track record in the selected
market.
Method statements, associated controls and working methods were
prepared and implemented in accordance with the codes and standards used by the
selected industrial market. Weld procedures and welders were qualified in accordance
with the applicable specifications codes and standards.
The introduction
and implementation of improved working methods and procedures satisfied the requirements
of the selected industrial market resulting in the contractor successfully securing
their first order.
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A
fabricator lost a long standing client and required to secure orders from another
client. An alternative client from Europe was located which in turn resulted in
commercial, technical and quality audits. The fabricator complied with the commercial,
technical and quality requirements, however the client required a welding engineer
qualified European Welding Engineer status before the fabricator would be entered
on the approved global supplier list.
Mitchell Services provide welding
engineering support services resulting in the fabricator securing a place as a
global supplier and securing ongoing repeat orders.
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A
number of assignments have required project documentation to be reviewed for compliance
with project specifications on behalf of main contractors.
One project
involved the main contractor completing design and engineering from their UK offices
for a multi-million dollar grass roots petrochemical facility located in the Middle
East. Mitchell Services provided the welding engineering capability on behalf
of the main contractor.
Main contractor specifications for fabrication,
heat treatment, materials, and welding were prepared and approved for construction.
All vendor method statements including assembly, fabrication, heat treatment,
materials, welding procedures and associated documentation was reviewed for compliance
with project specifications.
In addition to this project Mitchell Services
has provided welding engineering support services on various new build and refurbishment
projects for the oil, gas, nuclear and process industries.
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A
contractor secured an order for the site construction of three large storage tanks
in accordance with API 620 & API 650. Two tanks were constructed using carbon
manganese steels and one tank was constructed using corrosion resistant alloys.
Prior to project commencement the contractor required existing weld procedures
to be reviewed for compliance. Many of the procedures had been qualified in the
mid 1970's and contained omissions, errors and mechanical testing results were
at the limit of the operating envelope. Some of consumables specified in the existing
weld procedures were considered unsuitable for the application.
Project
specifications were reviewed, weld procedure proposals and associated documentation
required to cover the scope of work were prepared. All aspects of the weld procedure
and welder qualifications were co-ordinated including consumable procurement,
material preparation, monitoring, non destructive examination, post weld heat
treatment, third party witness and detailed certification records. Weld procedures
and welder qualifications were successfully completed in accordance with the project
specifications.
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Companies
usually have weld procedures available that were previously qualified for particular
applications or projects. Companies can have large numbers of procedures and may
believe at the tender stage that they will cover the scope of work. These procedures
may contain errors and omissions that are only identified when submitted for project
acceptance. These assumptions that procedures will be considered acceptable in
our experience have led in to delays at project commencement.
Existing
weld procedure documentation has been reviewed for various companies in order
to identify and withdraw unsatisfactory or duplicate procedures. In addition the
production weld procedure specifications have been rationalised to present a co-ordinated,
professional appearance.
A large diameter subsea pipeline end manifold had sustained damage and
required a replacement Y piece to be manufactured and installed. The manufacture
and installation of the replacement Y was urgently required to enable the pipeline
to be returned back into operation.
This required the fast track preparation
of all the method statements, the qualification of weld procedures and welders.
All the activities for the successful completion of the repair were co-ordinated
and resulted in the repair being completed on schedule.
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Compliance
with ISO 3834 is increasing requirement of application specifications particularly
in the rail and structural steelwork sectors.
Steelwork contractors completing
projects in accordance with NSSS 5th Edition are required to comply with ISO 3834
which in turn requires the installation of factory production control system.
It is also a requirement to appoint a Responsible Welding Co-ordinator and supporting
Welding Co-ordination personnel. In addition control procedures including qualified
weld procedures and welders are required.
Mitchell Services has provided
Responsible Welding Co-ordinator qualified to European Welding Engineer status
to steelwork contractors. Factory production control systems have been installed
at steelwork contractors together with full weld procedure and welder qualification
documentation.
The implementation of these factory production control systems
has assisted in contractors being awarded various contracts.
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A
fabricator experienced failures during the qualification of weld procedures using
the MIG process for welding S355 steels. Existing weld procedures were reviewed
and found to specify incorrect consumables and welding parameters for the application.
Alternative procedures were qualified with the correct consumables and improved
parameters.
The alternative procedure provided an improvement in mechanical
properties and increased deposition rates. The weld procedures have been successfully
implemented into production operations and the overall weld repair rates declined.
Welding Engineering Solutions