CASE STUDY / 2023

Petrochemical Turnaround — Weld Program Audit

REGION

US Gulf Coast

YEAR

2023

SCOPE

Welding audit · NDT witnessing · Expert witness (subsequent)

SCHEMATIC

What PSG covered

PROJECT SCOPE / SECTION VIEW

THE BRIEF

What the client needed

A petrochemical owner experienced a flange-weld failure during a unit turnaround, with consequential downtime and a dispute opening between the owner and the maintenance contractor. PSG was retained to audit the welding program in the affected unit and, subsequently, to serve as the owner-side expert in the contractor dispute.

PSG'S APPROACH

What we did, in order

01
Two-week on-site audit of WPS/PQR documentation, welder qualification records, and NDT records for the affected unit.
02
Witnessing of repair welds and qualification re-tests for two welders flagged during the audit.
03
Expert report written to the form required for the subsequent commercial dispute, with code citations and photographic evidence.
04
Deposition testimony delivered the following quarter; the dispute settled before trial.

OUTCOMES

What the engagement delivered

14
WELDER REQUALIFICATION CYCLES WITNESSED
3
PROCEDURAL DEFICIENCIES IDENTIFIED AND CORRECTED
1
EXPERT REPORT LEADING TO NEGOTIATED SETTLEMENT

SERVICE PILLARS

INDUSTRIES

Petrochemical

VERIFIED BY

Manisha Sharma, Project Lead · CWI AWS · expert witness qualifying matter

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