Highly-skilled welders and low redirection rates are hard to find in the oil and gas industry. Unless you’re Timec.
In an industry where welding redirection [or failure] rates generally run 5 to more than 10 percent, Timec rises to the top with a 2018 overall rate of 2.4 percent. That’s below Timec’s yearly target rate of 3 percent or less, a rate it has successfully met for the last 10 years.
The industry benchmark for world class welding performance is in the 5 to 6 percent reject rate. Timec’s rate is half that.
“First and foremost, I would say our success has been a result of a quality group of welders,” says Rick Johnson, Corporate Quality Control Manager. “We can have the best procedures and inspectors in the industry, but once that hood goes down it’s all in the welders’ hands.”
The consequences of failed welds can be deep and wide, including cost overruns, schedule impacts and lowered confidence in our services. For this reason, Timec holds its welders to more stringent standards. “Our welder testing tends to be a little stricter. We require specialty welders to pass multiple tests including a standard Ni alloy that requires a bit higher skill set,” says Rick.
He also attributes Timec’s success to its policy of real-time monitoring by quality control teams and flagging welders who might be struggling to complete sound welds. “This allows us to identify problems as they happen and take action to minimize their overall impact. The strong working relationship between our inspection and production personnel allows them to work as a team. This stands out, and it’s recognized by our clients.”
Within the petrochemical industry, the key KPI is a reporting of welds that receive some type of volumetric examination. These inspections, performed by third-party contractors, include techniques that result in a complete test of a weld’s integrity throughout its entire cross-section. Any weld found not in compliance must be removed, re-welded and re-examined using the same inspection technique that identified the original defect.
[photo credit: Rich Johnson]