Al Rushaid

Construction Co., Ltd.

FINDINGS

ROOT CAUSED

CORRECTIVE ACTION

PREVENTIVE ACTION

1
Based on the result of radiographic testing of our
welders the from 15 Sept 2015 to 03 Nov 2015
following are noted:
a. Twenty five (25) welders take the First
Three Production Joints requirement.
i. One (1) welder failed all First Three Production
Joints.
ii. Three (3) welders failed two (2) First Three
Production Joints.
iii. Four (4) welders failed one (1) First Three
Production Joints.
iv. One (1) welder on-going for First Three
Production Joints.
v. Two (2) welders for RT First Three Production
Joints.

2
3

b. Out of six (6) joints examined in Normal

Production Joints, two (2) joints failed.
i. First Three Production Joint which is equivalent to 20% rejection rate.
ii. Normal Production joints equivalent to 33.33%
rejection rate.
c. Common Causes
i. First Three Production Joints
Common defects found on First Three Production are Porosity (POR) and Incomplete Fusion
(IF)
iii. Normal Production Joints
All Incomplete Fusion (IF) found defect for
two joints failed in Normal Production.

1 Change of season. Weather condition(s) during those

days have been unpredictable. Heavy sandstorms have
always been encountered at site.
2 Overconfidence of Supervisor/In-Charge Person with the
welders who had passed the WPQT. They should properly
assess the capabilities these welders based on the skills
categorization, rate of rejection from previous project.

1 Re-train the welder on proper welding techniques

to minimize/eliminate common weld defects.

1 Conduct continuous training/seminar on welding techniques

and weld defects.

2 Supervisor/In-Charge of welders should check and

monitor sufficiency of wind barrier/tents to minimize
the entry of foreign particles that could affect the
result of weld process.

2 Monitor the Daily Welders Performance.

3 Assess welders previous qualification/background and
performance record to determine the type of monitoring to
be implemented before their First Three Production Joints.

3 Demobilized welder(s) that did not pass the First

Three Production Joint.
4 Closely monitor welder(s) who have minimal failures in the First Three Production Joint.

4 Welders who have minimal failures in the First Three

Production Joint and completed / passed penalty joints shall
be utilized as assist welder upon qualification. This to retrain them in adopting new techniques in minimizing the
defects that they have acquired.
5 Implement Welders Checklist to minimize common weld
defects by checking the equipment, gases and welding
consumables.