Fletcher welding program progresses

As economic developers take a look at the importance of skilled trades for the Tri-parish region, Fletcher Technical Community College’s welding program is making its mark on the industry by upgrading equipment and preparing plans for an expanded training facility.

Fletcher welding instructor Tony Callais took time to demonstrate a new Prepzilla Millhog tool, financed with an $11,000 grant from ConocoPhillips, and revealed that plans are in the beginning stages to build a new welding training facility at Fletcher’s Louisiana Marine and Petroleum Institute at 311 Dickson Road in Houma.

“I have no idea where the name [for the Prepzilla mill tool] came from,” Callais said.

“The Prepzilla Millhog is an air-powered pneumatic machine,” Callais said. “It is kind of a portable air lathe. What we do is we set the millhog in a vice and put pieces of pipe on it. Then we actually machine a perfect bevel on it.”

With regular torches such a project would require multiple steps of preheating, squaring, beveling, cutting, grinding, fitting, cooling and cleaning the pipe for welding. Traditional methods require preparation of a 6-inch schedule 80 pipe to take 90 minutes to 2 hours. With the Prepzilla, the procedure is reduced to less than 15 minutes, including setup time.

Callais said that usage of this equipment enhances the students’ skills and prepares them for yards where the new equipment is already being used. “The amount of time ConocoPhillips saved us in donating the money for this equipment is unbelievable,” he said. “We can set it up and cut in about a minute and a half. Put it on the millhog and bevel a 4-inch pipe in 56 seconds. It’s a tremendous asset for us. It gives the students more actual welding time.”

“ConocoPhillips has always been a huge supporter of the college,” Fletcher Public Relations Director Elmy Savoie said. “We were very excited that they were able to give us the donation. They were impressed with [the mill machine] and what we were doing with it.”

While demonstrating the welding preparation equipment, Callais said that plans are being made for a new building at the LaMPI campus with an enlarged welding training facility.

“We’re looking at brand new machines,” Callais said. “We’re going to do stick welding, flux-cored welding, shore-up welding and TIG welding all with the same machine. Now different machines do different things. So this will be great.”

In addition to moving Prepzilla to the expanded location, a new virtual reality welding simulator will be used as a teaching tool. “The only thing it doesn’t do is burn you,” Callais said.

Detailed plans for the new welding facility have not been established, but Callais said that technology should set the new work center apart from Fletcher’s current shop.

Callais has been working with the Fletcher welding program for 16 years. “What we do is based on a one-year program [on average],” he said. “Once we do safety in the classroom and get in the shop, everything is individualized. Everybody moves at their own pace and we take as much time as we need.”

With 20 students in his day class and another 20 at night, the Fletcher welding program covers all aspects of the trade from safety to skills on various torches and all forms of welding. Upon completion of the welding program, students receive a diploma and are prepared to become American Welding Society certified in the trade.

“We offer the night class during the year, but it is not a diploma class. It is strictly an upgrade or a skills class,” Callais said. “It is for people who are working already, but cannot afford to quit their job and come and upgrade.”

Callais said that those in welding training are finding more work opportunities. “What I’m hearing from most of the companies is they are having trouble getting skilled employees,” he said. “From what I’m seeing [the need for skilled trades] is picking up.”

Fletcher Technical Community College welding student Kenric Ware, left, receives personal guidance from instructor Tony Callais on the school’s new Prepzilla Millhog tool. MIKE NIXON I TRI-PARISH TIMES