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Welding Inspector Duties and Responsibilities Section 1

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Main Responsibilities

1.1

Code compliance

Workmanship control Documentation control2 of 691

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Personal Attributes

1.1

Important qualities that good Inspectors are expected to have are:

Honesty Integrity

Knowledge

Good communicator

Physical fitness

Good eyesight3 of 691

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Standard for Visual Inspection 1.1 Basic RequirementsBS EN 970 - Non-destructive examination of fusion Nonwelds - Visual examinationWelding Inspection Personnel should: be familiar with relevant standards, rules and specifications applicable to the fabrication work to be undertaken be informed about the welding procedures to be used have good vision (which should be checked every 12 months)

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Welding Inspection

1.2

Conditions for Visual Inspection (to BS EN 970) Illumination: 350 lux minimum required (recommends 500 lux - normal shop or office lighting)

Vision Access: eye should be within 600mm of the surface viewing angle (line from eye to surface) to be not less than 30 30600mm

30 30

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Welding InspectionWhen access is restricted may use: a mirrored boroscope usually by a fibre optic viewing system

1.3

Aids to Visual Inspection (to BS EN 970)

}

agreement

Other aids: welding gauges (for checking bevel angles, weld profile, fillet sizing, undercut depth) dedicated weld-gap gauges and linear misalignment weld(high(high-low) gauges straight edges and measuring tapes magnifying lens (if magnification lens used it should have magnification between X2 to X5)4/23/2007 6 of 691

Welding Inspectors EquipmentMeasuring devices:

1.3

flexible tape, steel rule Temperature indicating crayons Welding gauges Voltmeter Ammeter Magnifying glass Torch / flash light Gas flow-meter flow7 of 691

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Welding Inspectors Gauges10mm 10mm1 2

1.3

G.A.L.S.T.D. 16mm

G.A.L.

3 4

L

S.T.D. 16mm

5 6

Fillet Weld Gauges0 IN 1/4 1/2 3/4

TWI Multi-purpose Welding Gauge Multi-

Misalignment Gauges HiHi-Lo Gauge8 of 691

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HI-LO Single Purpose Welding Gauge

Welding Inspectors Equipment

1.3

Voltmeter

Ammeter

Tong Tester4/23/2007 9 of 691

Welding Inspection 1.3Stages of Visual Inspection (to BS EN 970)Extent of examination and when required should be defined in the application standard or by agreement between the contracting parties For high integrity fabrications inspection required throughout the fabrication process:

Before welding (Before assemble & After assembly) During welding After welding

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Typical Duties of a Welding InspectorBefore WeldingPreparation: Familiarisation with relevant documents Application Standard/Code - for visual acceptance requirements Drawings - item details and positions/tolerances etc Quality Control Procedures - for activities such as material handling, documentation control, storage & issue of welding consumables Quality Plan/Inspection & Test Plan/Inspection Checklist details of inspection requirements, inspection procedures & records required

1.5

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Typical Duties of a Welding InspectorBefore WeldingWelding Procedures: are applicable to joints to be welded & approved are available to welders & inspectors

1.5

Welder Qualifications: list of available qualified welders related to WPSs certificates are valid and in-date in-

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Typical Duties of a Welding Inspector 1.5Before WeldingEquipment: all inspection equipment is in good condition & calibrated as necessary all safety requirements are understood & necessary equipment available Materials: can be identified & related to test certificates, traceability ! are of correct dimensions are in suitable condition (no damage/contamination)4/23/2007 13 of 691

Typical Duties of a Welding Inspector 1.5Before WeldingConsumables: in accordance with WPSs are being controlled in accordance with Procedure Weld Preparations: comply with WPS/drawing free from defects & contamination Welding Equipment: in good order & calibrated as required by Procedure4/23/2007 14 of 691

Typical Duties of a Welding Inspector 1.5Before WeldingFitFit-up complies with WPS Number / size of tack welds to Code / good workmanship PrePre-heat if specified minimum temperature complies with WPS

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Typical Duties of a Welding InspectorDuring WeldingWeather conditions suitable if site / field welding

1.5

Welding Process(es) in accordance with WPS

Welder is approved to weld the joint

PrePre-heat (if required) minimum temperature as specified by WPS maximum interpass temperature as WPS

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Typical Duties of a Welding InspectorDuring WeldingWelding consumables in accordance with WPS in suitable condition controlled issue and handling Welding Parameters current, voltage & travel speed as WPS Root runs if possible, visually inspect root before single-sided singlewelds are filled up4/23/2007 17 of 691

1.6

Typical Duties of a Welding InspectorDuring WeldingInterInter-run cleaning in accordance with an approved method (& back gouging) to good workmanship standard Distortion control welding is balanced & over-welding is avoided over-

1.6

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Typical Duties of a Welding InspectorAfter WeldingWeld Identification identified/numbered as required is marked with welders identity

1.6

Visual Inspection ensure weld is suitable for all NDT visually inspect & sentence to Code requirements

Dimensional Survey ensure dimensions comply with Code/drawing

Other NDT ensure all NDT is completed & reports available19 of 691

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Typical Duties of a Welding InspectorAfter WeldingRepairs monitor repairs to ensure compliance with Procedure, ensure NDT after repairs is completed PWHT monitor for compliance with Procedure check chart records confirm Procedure compliance Pressure / Load Test ensure test equipment is suitably calibrated monitor to ensure compliance with Procedure4/23/2007

1.6

ensure all records are available

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Typical Duties of a Welding InspectorAfter WeldingDocumentation ensure any modifications are on as-built drawings asensure all required documents are available Collate / file documents for manufacturing records Sign all documentation and forward it to QC department.

1.6

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Summary of DutiesIt is the duty of a Welding Inspector to ensure all the welding and associated actions are carried out in accordance with the specification and any applicable procedures.

A Welding Inspector must:Observe To observe all relevant actions related to weld quality throughout production. Record To record, or log all production inspection points relevant to quality, including a final report showing all identified imperfections Compare To compare all recorded information with the acceptance criteria and any other relevant clauses in the applied application standard4/23/2007 22 of 691

Welding InspectorTerms & Definitions Section 2

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Welding Terminology & DefinitionsWhat is a Weld? A localised coalescence of metals or non-metals produced noneither by heating the materials to the welding temperature, with or without the application of pressure, or by the application of pressure alone (AWS) A permanent union between materials caused by heat, and or pressure (BS499) An Autogenous weld: A weld made with out the use of a filler material and can only be made by TIG or Oxy-Gas Welding Oxy-

2.1

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Welding Terminology & DefinitionsWhat is a Joint?The junction of members or the edges of members that are to be joined or have been joined (AWS) A configuration of members (BS499)

2.1

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Joint Terminology 2.2

Edge

Open & Closed Corner

Lap

Tee Cruciform4/23/2007

Butt

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Welded Butt Joints 2.2Butt A_________Welded A_________Welded butt joint

Fillet A_________Welded A_________Welded butt joint

Compound A____________Welded A____________Welded butt joint

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Welded Tee Joints 2.2

Fillet A_________Welded A_________Welded T joint

Butt A_________Welded A_________Welded T joint

Compound A____________Welded A____________Welded T joint

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Weld Terminology 2.3

Butt weld

Fillet weld

Spot weld

Edge weld

Plug weld Compound weld

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Butt Preparations Sizes

2.4

Partial Penetration Butt WeldActual Throat Thickness Design Throat Thickness

Full Penetration Butt WeldActual Throat Thickness

Design Throat Thickness

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Weld Zone Terminology 2.5AFace

B

Weld metal Heat Affected Zone Weld Boundary

CRoot

D

A, B, C & D = Weld Toes4/23/2007 31 of 691

Weld Zone Terminology 2.5Weld cap width

Excess Cap height or Weld Reinforcement

Actual Throat Thickness

Design Throat Thickness

Excess Root Penetration