CASE STUDY 5:
HCS was invited to work with a major client on a large-scale project which involved the manufacture, assembly and testing of 3 x SSIV units, 14 x CDA units, 2 x DUTA units and 2 x manifolds. This 2 year project was undertaken at the client’s site. The size and scale of this project tested our project management and quality control processes. The detailed work scope demanded a highly collaborative working partnership between HCS and the client’s own internal teams.
First we appointed a core project team. The team consisted of functional experts from across our business but primarily projects, quality and operations.
Validation of new weld procedures was a priority undertaken by our quality team with the support of our welding engineer and technicians proficient in working with inconel 625, 6mo, duplex, super duplex and hastelloy c276.
Initially the project team worked 5 days a week on-site, however, as the project scaled-up, construction split across two sites operating a 7 day/12-hour shift schedule. Additional technical staff were appointed to accommodate the increased working hours and additional personnel were appointed to support the core project team.
Midway through the project, HCS was asked by the client to commit further resources to support another aspect of the project. Two additional welder/pipefitter crews were appointed and supported by another NDT inspector.
This project proved our capability to deliver quality workmanship and also showcased our quality management and project management expertise. All HCS input to the client’s project met their timeline. Our contribution to this project involved over 5,000 orbital welds – 100% NDT and pressure tested. Topline statistics on this project for HCS were:
- 80,000-man hours (labour and management)
- 73 project variations
- 282 evidenced invoices for client’s auditors
- 12 weld procedures developed and qualified