This document discusses Weldpac, a construction management and control system for welding projects. It can manage all aspects of a project including fitting, welding, quality control, stores, and planning. It reduces costs by streamlining paperwork and improving efficiency across disciplines. Weldpac provides detailed reporting on project scope, progress, costs, and welding requirements to help ensure projects are completed safely, on time and on budget. It offers comprehensive management and control of welding operations from initial preparation through quality control and closeout.

1. MANAGEMENT
welding construction
SHOP AND FIELD C ONTROL SYSTEMS
Greatest Detail In Workshop And Field Management And Control

2. SHOP AND FIELD C ONTROL SYSTEMS
WELDING CONSTRUCTION MANAGEMENT
Weldpac (Fit, weld, QC, stores, management) is a multidiscipline construction control and management
system. Weldpac on Mossgass Onshore, by broad consensus, is estimated to have saved the contractor
R15 million rand.
Fourty technical QC clerks at the previous boiler job were replaced by five.
Testing rates were down. QA acceptance high.
These savings are available to your company.
page 1
DISCIPLINES:
• Project management
• Fitting
• Welding
• Stores
• Planning
• Quality
• Costing
The administration and management of welding is time consuming, people and paper intensive but also information
rich. Because it serves many disciplines it needs a wide range presentation.
Greatest Detail In Workshop And Field Management And Control
Weldpac reduces copying, transcription, duplications and analysis spreadsheets. It reduces the possibility of many
errors. Different disciplines update and independently share the benefit of each other’s updates – a very efficient process.

3. SHOP AND FIELD C ONTROL SYSTEMS
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WELDING CONSTRUCTION MANAGEMENT (continue)
Most construction managers measure and cost piping jobs in of weld inches. Weldpac is the weld inches
detective inspector for scope and progress.
“A general that knows where every enemy is will win.” Weldpac changes the way the job is managed for the
better. Welpac prevents slippage of work (up to the end of the job) and massive rework because of gaps between weld
completion and QC clearance. Documentation is printed with timely and accurate data.
• Fitting
• Welding
• Quality Control completion
KNOWING WELD INCHES IN TERMS OF:
The progress - as required every day is very powerful for the people concerned on the project.
Greatest Detail In Workshop And Field Management And Control

4. SHOP AND FIELD C ONTROL SYSTEMS
page 3
WELDING REQUIREMENTS
As welding forms such a substantial part of the project it must be managed to meet the same objectives as
the project. In other words, the welding administration must be professionally managed to be completed
within budget and on time, while meeting all of the contractual requirements to the principal.
In addition to the procedures and discipline necessary to achieve this, the contractor’s supervision and man-
agementmustreceivetheregularreportsnecessarytoevaluatethejobprogress.Thiswillenablehim totake
pre-emtive action to stop problems occurring and escalating.
• The welding work must all be completed by the agreed time.
• The operations must be cost controlled and must meet the contractual requirements in all respects.
• Documentation in respect of welder details, weld non-destructive testing (NDT) and heat treatment
charts numbers must be compiled.
• Welding operations must be managed in such a way that welding repairs are readily and
transparently handled.
• Errors and repairs increase costs and rework and have a negative impact on the project, so
prevention is crucial.
• Welder productivity and performance should be monitored as required on a daily, weekly or job
basis (or any other analytical period required). Welder can be optimally deployed.
• Measurement of welder performance and productivity is key to the management of the welding.
• Welder’s qualifications must be pre-certified and maintained with a minimum of cost and
unnecessary effort to the contractor.
THERE ARE MANY REQUIREMENTS THAT CAN COMBINE TO MAKE UP WELDING
CONTROL, THE FOLLOWING ARE BY NO MEANS THE SUM TOTAL:

5. SHOP AND FIELD C ONTROL SYSTEMS
page 4
CONTROL DURING WELDING
DURING CONSTRUCTION OPERATIONS THE FOLLOWING MUST BE ENSURED:
• Welders are only used for welds that they are qualified for.
• Consumables are correctly issued and used.
• The correct welding procedure is used for the weld.
• The fit-up and visual quality requirements are met.
This is achieved by checking that:
• Only issuing weld consumables against a requisition.
• The issue of the appropriate single consumable type to a welder at a time.
BASIC DISCIPLINES ARE ESTABLISHED AND ADHERED TO:
• No weld is done without a computer printed weld process card (WPC).
• No consumable is issued without the same card.
• No NDT is completed without a computer printed NDT request.
• WPC and Completed NDT requests are returned at the end of the shift so that the contractual
documentation can be updated.
• Progress records are brought up to date and outstanding work detailed.
• As built drawings can be progressively updated.
• Cancelled or superseded welds can be removed from the schedule.
REGISTERS TO BE KEPT:
• Chronolog by welder.
• Chronolog by line class.
• Backups.
• First off’s.
• NDT per welder per periods.
• Sockets per welder per period.
BY SPOOL PIECE:
• Materials.
• Fittings.

6. SHOP AND FIELD C ONTROL SYSTEMS
page 5
WELDPAC OPERATIONS
Each operation is updated so the information is carried forward to the next operation. Dates and names
are accurately recorded and the operator has all the information he needs to complete the job. There is
very little transcription accuracy is improved.
Greatest Detail In Workshop And Field Management And Control
PHASE 3 - REWARD
C Operational & management reports
PHASE 2 - PROCESS
Drawings
Welds
Weld process card and welding record
Consumable requisition and issue
NDT request and results
PWT, other test and chart records
B
PHASE 1 - PREPARATION
Contract Details
Welders DB
Welders Qualifications
Fitters
Consumable types
batches & receipts
A
Weld procedures

7. SHOP AND FIELD C ONTROL SYSTEMS
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WELDPAC OPERATIONS - QC CLEARANCE
Each plant design has a structured quality requirement. QC clearance is the last step in the construction
process, so the job is in suspense until the QC is complete. The documentation should follow immediately
after the each process and should never hold up the job itself or the completion of the job. The paperwork
should never accumulate through the course of the project. The final documentation should be ready for
hand over the moment the last test has been completed. Weldpac makes certain of this. On large welding
projects this can be very complex to calculate and always be argued against if done manually.
Greatest Detail In Workshop And Field Management And Control

8. SHOP AND FIELD C ONTROL SYSTEMS
page 7
WELDPAC OPERATIONS - QC CLEARANCE
PERCENTAGE OF WORK COMPLETED
A certain percentage of NDT is required to prove the quality of welding. This is expressed as a percentage by ISO,
line, line class, unit etc. as contracted with the client. To control the percentage of NDT required and completed
a date-sequenced list of welds completed is maintained per drawing, test pack, unit, system i.e. the basis agreed
in the contract. Depending on the percentage of each type of NDT required, every tenth (for a 10% requirement),
fourth (for a 25% requirement) must be selected for NDT. NDT must be completed at least once a day.
WELDER QUALITY
NDT is also required to monitor the quality of the work performed by welders.
This is expressed as “first-off’s” per welder followed by a specified number of NDT’s per welder per week, monthly
or as agreed with the client. To control the NDT per welder a chronological list of welds per welder is maintained.
“First-off” and regular NDT is selected and performed as soon as is practical after completion of the required welds.
REPAIRS
Rejected and repaired welds must be NDT’d in the same way as the original weld was. In addition to this NDT, two
similar welds from the same period must be NDT’d. Further back up NDT’s may be done in accordance with the
specification. Registers must be kept of all rejects and repairs and must document the backup done for each reject.
WELD HEAT TREATMENT
Heat treatment chart numbers must be recorded in the welding documentation record.
WELDING CONSUMABLES
Welding consumables are expensive to purchase and difficult to control. They are often issued in bulk and not all
accounted for. Weldpac has a stores system built into it. Batch and type of consumable is entered into the Weldpac
and a requisition is attached to the Weld process card.
The weld process card is designed to represent one days work for one welder on the same consumable type.
This passes the accountability from the store man onto the welder.

9. • Control your fitters.
• Monitor fitting progress.
• Control your welders.
• Manage welder qualifications.
• Detail procedures.
• Control welder’s welding (proc details, time, success, consumables.
• Control your quality control progress NDT by NDT.
• Manage and control the expensive weld consumables.
• Get the highest possible definition on job scope – job down to every weld.
• Get the most accurate detailed progress reports on anything– regularly and with no
extra effort and with accurate dates.
• Accelerate weld quality control processes.
• Impress your client and third party inspectors with speed of processing and quality
of documentation.
SHOP AND FIELD C ONTROL SYSTEMS
PROJECT MANAGEMENT
ALL FROM ONE SYSTEM - WELDPAC
At the true guts of a piping project.
Gut level project control at a tiny, tiny fraction of the cost – Can there be any better offer?
MLA & WELDPAC
Started in 2000, MLA specialises in designing and building field systems. These systems are built using common
or mainstream technology and is very user friendly. Over the years we have built Weldpac material control and a
variety of man-hour controls systems with various levels of integration and costing.
We subscribe to the theory that construction information starts on site and not on the ninth floor of a remote head
office. MLA seems to be the only company in the world that exclusively builds and sells field systems. We have the
knack of extracting common information across disciplines when it is hard to imagine that the QC manager, paller
and accountant are working on the same project. We are quite good at it to.
Our clients include:
• Controlware
• Murray & Roberts
• Katanga Mining
• Redis Construction
• Sapref
• Engen
• Babcock
• Bateman
Our systems run on Microsoft Windows and Microsoft Server. We require internet access for support but our
clients don’t require many visits to our installations.
Impress your client and third party inspectors with speed of processing and quality of documentation.
CONTACT US:
Mike Lewin, MLA
Tel: +27 11 880-5500
Fax: +27 82 896-0331
E-mail: mike@mla.co.za
Website: www.mla.co.za