A refinery shutdown (TAR — turnaround) is the most demanding industrial exercise there is: 15 to 30 days where every hour is worth tens of thousands of euros. Sizing the welding wrong means delaying restart, and that is margin evaporating.
The ratios that matter
At the petrochemical sites of Cartagena, Tarragona and Algeciras we start from these references:
- 1 UNE-EN ISO 9606-141 (TIG) welder closes 8-12 joints/day on 2"-6" 316L stainless piping.
- 1 UNE-EN ISO 9606-111 (stick) welder handles 5-8 joints/day on high-thickness piping.
- 1 pipefitter feeds 2 welders in pre-assembly.
- 1 boilermaker per 4-5 welders for structural repair.
- 1 supervisor per 8-10 operatives.
Classify by criticality
Not every joint weighs the same. Pre-classify: A (high pressure, acid service, high temperature — requires UNE-EN ISO 9606 6G and 100% radiography), B (utilities, low pressure — 1G/2G), C (supports and structure — minimum qualification).
The buffer is not optional
Add 15-20% margin to the calculated headcount. A welder falls ill, a certificate is failed by the inspector, a joint is rejected and must be redone. Whoever plans at zero runs late — every time.
Checklist before mobilizing
- WPS and WPQR approved for every process + material + thickness combination.
- Valid UNE-EN ISO 9606 homologations (mind the six-month confirmation).
- Level 2 welding inspector (VT, ISO 9712) accredited on site.
- Lodging, transport and PPE locked in before arrival.
- Contingency plan: 2 extra welders on remote stand-by.
What Iron Pulse delivers
On the shutdowns we cover —Cartagena, Tarragona, Algeciras, Huelva— we deliver the crew with a traceable dossier, PPE, lodging and transport. Meet our UNE-EN ISO 9606 welders or request deployment.
