Weld-Console

Weld-Console

Abstract

Weld-Console is a second-generation software developed in conjunction with LUCY Industrial Management Solutions that provides projects with vital data to help control welding and non-destructive evaluation (NDE) costs and schedule. The program is an intelligent database that performs validations of incoming weld data against project requirements, including welder qualification parameters and installed material specification and grade versus specified.

Weld-Console collects information in real time as a matter-of-routine weld tracking. Baseline weld data (weld numbers and weld details) are created in the design model (PDS/SP3D) and then imported into Weld-Console. The program evaluates each weld against pre-defined criteria to accurately apply NDE and other project requirements. It automatically selects welds for various NDE and PWHT in accordance with specifications and Code requirements, including individual welder lots to manage random radiography and progressive examination in accordance with ASME B31.3.

Weld-Console can produce the NDE selection reports that crews use to complete the work. Weld-Console is used to manage hydrotest package clearance by indicating that piping systems are complete and cleared of any outstanding NDE, repairs or invalid materials. Weld-Console also provides an easily employed system of traceability and record retrievability from hard copy records to the components they represent.

In addition to providing unparalleled traceability for welding activities, Weld-Console can also perform flange management activities such as those required by ASME PCC-1. Bolted connections are identified and tracked with essential variables such as size, flange rating, gasket type, bolt/stud information and torque or tension requirements. This information can then be utilized for planning and performing the work. Bolted connections are also incorporated into hydrotest package clearance to ensure that mechanical connections are completed with the same amount of confidence that is applied to welded joints.

These efforts are supported by Weld-Console’s configurability and reporting capabilities. Realizing that each project is unique, Weld-Console is highly customizable to easily address standard design codes and non-standard requirements. To ensure that the right information is delivered to the right personnel, Weld-Console boasts an ever-growing library of standard reports along with the functionality to design and create new reports at the project level. Reports can then be generated on an as-needed basis, or scheduled to be delivered to an email address or folder location on regular intervals in a variety of standard electronic formats.

Client Benefits

Confidence – The Weld-Console program provides the capability to achieve a high level of confidence in clients' systems. From managing the selection and recording of critical inspection and testing operations to validating materials, Weld-Console brings an array of tools to manage the job of ensuring that the project's systems have been verified to design.

Virtual inspection – The value of Weld-Console is in its validation. Weld-Console performs validation tasks such as:

  • Quantifying the number of welds produced per day to verify productivity goals are being met
  • Ensuring welder qualification is correct for the weld being made
  • Taking the correct percentage of NDE to comply with codes and specifications
  • Confirming weld repairs are completed and accepted prior to pressure testing
  • Ensuring PWHT is completed to comply with codes and specifications
  • Material validation including both base material and filler material, if needed, to the component (C)MTR's

Welder qualification – Every weld is compared to the welder's qualification parameters such as welding process, maximum thickness, minimum OD, open root qualification and base material to validate that the welder is qualified to make the weld. Reports detailing this information are available.

Material validation – Incorrect material is a leading cause of premature failure in process systems. Weld-Console was designed to combat this persistent dilemma. Each welded component being installed is validated to confirm it is the correct material for the system. This is possible due to the material heat numbers being recorded in MaterialManager® during material receipt. This information is then downloaded into Weld-Console. The heat numbers are recorded again while completing the daily welding report so that the system can then easily confirm if the correct material is installed in the system.

Applied project specifications – Every weld is tagged with inspection requirements and automatically selected once it is fabricated. Design specification requirements are preloaded into Weld-Console. As welds are loaded they are tagged with the requirements.

Verified traceability – In addition to the data collected and input daily, Weld-Console can also be utilized to store records of the activities, including daily weld reports, NDE reports, Welder Qualification Records and weld maps. These files are associated with the respective data and can be recalled as needed.