Client

Confidential – Offshore Oil & Gas Operator

Project Overview

Carbon Arc was engaged to support the fabrication and qualification of pressure-retaining components for an offshore oil and gas installation. The project involved complex welding operations on high-integrity systems subject to ASME Section IX and the Pressure Equipment Directive (PED). Given the critical nature of the equipment, a HAZOP (Hazard and Operability Study) was integrated into the welding engineering scope to proactively identify and mitigate risks.

Our Role

Carbon Arc led the development and execution of a welding-focused HAZOP study, which was embedded into the broader engineering assurance framework. Key activities included:

• Identifying potential deviations in welding processes using HAZOP guide words (e.g., “no weld,” “more heat,” “wrong filler”)

• Evaluating risks associated with material selection, joint design, and environmental conditions

• Reviewing welding procedure specifications (WPS) and qualifications (WPQR) for compliance and robustness

• Assessing NDT protocols and inspection readiness

• Documenting safeguards and corrective actions to ensure operability and safety

Execution & Oversight

Carbon Arc facilitated cross-disciplinary HAZOP workshops involving welding engineers, quality managers, and client representatives. The study focused on:

• Aluminium and carbon steel weldments used in pressure systems

• Process deviations that could lead to weld failure, distortion, or non-compliance

• Inspection gaps in radiographic and ultrasonic testing

• Operational risks such as delayed preheat, incorrect shielding gas, or post-weld heat treatment errors

Outcome

The HAZOP-led approach resulted in:

• Early identification of critical welding risks

• Enhanced documentation and traceability for regulatory audits

• Improved weld quality and reduced rework

• Successful certification of pressure systems under ASME IX and PED

Carbon Arc’s integration of HAZOP methodology into the welding engineering scope set a new benchmark for proactive risk management in oil and gas fabrication projects.