Shop 26 completes fourth RCD package with zero rejectable conditions on all inspected weld joints

Shop 26 completes fourth RCD package with zero rejectable conditions on all inspected weld joints

By Max Maxfield, PSNS & IMF Public Affairs

BREMERTON, Wash. -

The Shop 26 welders who assemble Reactor Compartment Disposal packages recently completed their fourth RCD package with zero rejectable conditions on all volumetrically inspected weld joints, at Puget Sound Naval Shipyard & Intermediate Maintenance Facility.

According to Torey Hansen, general foreman, Shop 26, volumetrically-inspected welds are critical welds used on submarines and aircraft carriers that are inspected using ultrasound or radiographic equipment.

"The equipment is very similar to what hospitals use with pregnancies to view an unborn baby," Hansen said. "The inspectors can look inside the weld to ensure that it is of good quality and there are no defects that would make the weld weak, or that could compromise the integrity of the weld."

Hansen said this type of welding on the fore and aft ends of RCD packages can be as challenging as it is critical.

"All the welding is done by hand, with the exception of the 33-foot horizontal joint on the middle of the forward bulkhead," he said. "This weld is accomplished using a mechanical track welder. Bulkheads are then installed onto the package. The circumference weld of each bulkhead is approximately 104 feet, and each bulkhead weld encompasses all welding positions using Gas Metal Arc Welding, known as GMAW. This requires overhead welding, which transitions to vertical welding, to finally flat position welding along the top of the package.

"Ergonomics, body positioning combined with the use of strip heaters to preheat all the metal being welded to 200 degrees makes the job extremely challenging. This same hand-held wire feed welding process is used on the inner bottom tanks of aircraft carriers."

Hansen said his team is proud of their string of recent successes. Accomplishing quality work the first time is easier on his welders, and saves the Navy resources.

"First-time quality is something Shop 26 strives for," Hansen said. "We set a very high standard for the work we accomplish. Just one 7/8" welding reject can add a shift or two to the undocking schedule, increasing costs, including additional resource hours for prep time, welding, then re-inspection."

Shop 26 utilizes validation processes to ensure all welders doing this critical work are up to the challenge.

"The welders who are selected for this work go through Advanced Continuous Training and Development, which includes mock-up training," Hansen said. "When they are in training they are evaluated by welding a mock up 'coupon' that mimics the work to be performed on an RCD package. With the newer workforce this helps to develop the skills and techniques of our people."

Hansen said Shop 26 has a training and career path that can take someone with no civilian welding experience and grow them into a skilled tradesperson who can perform the most difficult and critical welding tasks the U.S. Navy needs.

"A brand new employee who comes to the shop with little to no experience comes in as a helper," he said. "After helper school the employee has two options. They can apply for the apprenticeship program, or they can take the Position Development Plan route. After successful completion of the four-year apprenticeship program, the employee will now be a journey-level welder.

The PDP program enables a new employee to progress and gain the experience required to attain a journeyman-level welder at their own pace. Both career paths will teach welders to master a variety of welding processes and techniques.

"We use many different types of welding processes for the construction of the RCD packages in the shop, as well welding projects in dry dock," Hansen said. "We use carbon arc gouging, known as air arc gouging, for removing service material that is used to hold everything together to achieve fit up prep for welding. We use Shielded Metal Arc Welding, which is referred to as SMAW or 'stick welding,' for the root passes during bulkhead construction in the shop."

"A sub-arc tractor on a track spanning the bulkhead is then used to fill up the weld joint," he continued. "The support fixtures are welded in the shop using wire feed pulse welders, or GMAW Pulse welding. All the welding in the dock for the package construction uses approximately 5,000 pounds of GMAW weld wire."

Despite the challenges and the wide variety of welding skills needed to complete and RCD package, Hansen said his team understands the importance of what they are doing for PSNS & IMF, and the U.S. Navy.

"Welding and first-time quality is very important to the Navy and important to all of us," he said. "As we follow the shipyard's mission to maintain, modernize, and retire our navy's fleet, we also strive to perform it in the most cost-effective way possible, while maintaining critical schedules."

"Above and beyond the RCD success is our employee development here at PSNS and also Detachment Everett," he continued.

Hansen and other leaders in Shop 26 also work with Sailors at PSNS & IMF Everett Detachment to provide training to qualify Sailors to be active participants in the welding work needed there. The goal is for them to become expert welders to help get the destroyers homeported at Everett Naval Station back to sea as quickly as possible, in the best possible condition.