This article is about Duties and Responsibilities of a Welding Inspector related to topic of Welding Inspection and questions can be asked in CBT Welding Test of Aramco or any CSWIP International Test.
DUTIES AND RESPONSIBILITIES OF A WELDING INSPECTOR
The Duties of Welding Inspector are to ensure that all operations concerning or related to welding are carried out in strict compliance with written, agreed practices or specifications. This includes monitoring and checking a number of welding operations and its associated actions as per the following stages:
A. BEFORE WELDING QC INSPECTION
The welding inspector has to ensure that all operations are carried out in complete compliance with local, company, or National safety legislations (i.e. permits to work are in place).
A.1 Before Fit-up
- The welding inspector has to check, review and verify;
- Applicable code, standard or specification to be implemented on the job is up-to-date with the latest revision or amendment.
- Correct fabrication or construction drawings to be issued and its revisions have been approved and the issuance number is marked.
- Procedures like Welding Procedure Specifications, Procedure Qualification Records, Weld Repair Procedure, Non Destructive Test (NDT) Procedure, etc. have been approved and are employed during the fabrication, construction or production process.
- Documents pertaining to the raw materials and consumables like Material Test Certificates (MTC), Material Traceability Record, etc. are available and in conformance with the applicable code and standards.
- List of equipments and other devices to be used were calibrated and calibration certificate has been provided so with calibration stickers or labels attached to it.
- List of qualified welders according to the process they are qualified are available. Approved welders/welding operators are provided with their identification card or I.D.
- The welding inspector has to check and verify the welding materials and consumables shall have proper storage or housekeeping according to their types and classifications.
- All above are Duties of Welding Inspector.
A.2 After Fit-up
A.2.1 The welding inspector has to check and verify;
1. Joints to be welded shall meet the requirement of the approved Welding Procedure Specifications (WPS) e.g. shapes and dimensions of the weld preparation as specified, fusion faces and adjacent surfaces are cleaned. Parts to be joined are fixed in relation to each other.
2. Pre-heating if required is in accordance with the specified and approved preheating procedure.
B. DURING WELDING QC INSPECTION
The welding inspector has to check, monitor and record the voltage, amperage and travel speed for each run of weld in order to control the heat inputs on the weld joint. Once the root bead is finished, he has to inspect the root penetration for possible imperfections or defects that may occur. He has to check that the surface of each run of weld is cleaned and particular attention to be paid off to the junctions between the weld metal and the fusion face. If imperfections are observed, it shall be reported so that remedial actions shall be taken before the deposition of further weld metal. He has to check that the transition between the runs and between the weld and the parent metal has such a shape that satisfactory melting can be accomplished when welding the next run.
C. AFTER WELDING QC INSPECTION
The welding inspector has to check the cleaning of the finished weld e.g. all slag has been removed by manual or mechanical means to avoid imperfections being obscured. He has to
check the profile of the weld face and the height of any excess weld or dimensions shall meet the requirement of the acceptance standards, the blending of the toe with the parent metal and the proper merging of the inter-runs. If a defect is detected, it shall be reported to the concerned personnel to go with the repairs in accordance with the approved Weld Repair Procedure. Area of defect shall be marked-out positively and clearly and full removal should be monitored with visual inspection and the applicable Non Destructive Test (NDT) process. Once the re-welding is finished, the welding inspector has to re-examine the weld with the applicable Non Destructive Test (NDT) process for further verification. If Post Weld Heat Treatment (PWHT) is required, it should be monitored and recorded.
MAIN RESPONSIBILITIES OF A WELDING INSPECTOR
The main responsibilities of a welding inspector are;
- To OBSERVE all relevant actions related to weld quality throughout the production. This will include a final visual inspection of the weld area.
- To RECORD, or log all production inspection points relevant to quality, including a final map and report sheet showing all identified welding imperfections.
- To COMPARE all reported information with the acceptance levels/criteria and clauses within the applied application standard.
Generally, the welding inspector has to make a final inspection report which is signed off along with the updated as-built drawing or weld maps and to be submitted to the concerned Quality Assurance/Quality Control (QA/QC) personnel or higher authority for record analysis and for any remedial actions.
VISUAL INSPECTION
At any time point in the course of welding, i.e. tacking, root pass, filler pass or capping, but particular for the root and cap, a detailed inspection may be required. British Standard 5289: 1976 gives guidance to tools and responsibilities together with sketches of typical defects.
The inspector at this point must –
- Observe, identify and perhaps record (measure) the features of the weld.
- Decide whether the weld is acceptable in terms of the particular levels that are permitted; defects levels maybe in-house or national codes of practice. When the defect size is in excess of the permitted level then either a concession must be applied for (from a competent person) or the weld rejected.
AIDS OF VISUAL INSPECTION
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- Illumination: Good lighting is essential.
- Inspection Lenses: The magnification should not exceed 2-2.5 diameters. If higher magnification is required use a binocular microscope. Optical viewing can progressively develop from eyesight, to use a hand torch and mirror, to the addition of a magnifier and light source.
In order to achieve accessibility, remote probe units are available which must have the following properties:
- Large field of vision.
- Freedom from distortion of image.
- Accurate preservation of color values.
- Adequacy of illumination.
CODE OF PRACTICE QC WELDING INSPECTOR
A code of practice for an inspection department should take from outlined below. It is appreciated that full implementation of the code would be extremely costly and therefore it may be necessary to reduce the amount of inspection to less than is theoretically required. The inspector should be familiar with the following:
- All applicable documents
- Workmanship standards
- All phase of good workshop practice
- Tools and measuring devices
INSPECTION BEFORE WELDING
Before Assembly:
Check:
- All applicable documents.
- Quality plan is authorized and endorsed with signature, date and company stamp.
- The drawing are clear, the issue number is marked and the latest revision or amendment.
- Welder qualification with identification and the range of approval are verified and that only approved welders as required are employed in production.
- Calibration Certificates, Material Certificates (mill sheets) and consumer certificates are available and valid.
- Parent material identification is verified against documentation and markings.
- Material composition, type and composition.
- Identification of welding consumables such as electrodes, filler wire, fluxes, shielding and backing gases and any special requirements (e.i. drying) are met.
- Plant and equipment are in safe condition and adequate for the job.
- Safety permits e.g. hot works permit, gas free permit, enclosed space certificate are available and valid.
After Assembly
Check:
- Dimensions, tolerances, preparation, fit-up and alignment are in accordance with the approved drawings and standards
- Tack welds, bridging pieces, clamping and type of backing – if any used are correct
- Cleanliness of work area is maintained
- Preheat in accordance with procedure
Note: Good inspection prior to welding can eliminate conditions that lead to the formation of defects.
INSPECTION DURING WELDING
Check:
- The welding process must be monitored.
- Preheat and interpass temperatures must be monitored.
- Interpass cleaning – chipping, grinding, gouging must be monitored.
- Root and subsequent run sequence.
- Essential variables such as current, voltage, travel speed to be monitored.
- Filler metals, fluxes and shielding gases are correct.
- Welding is in compliance with the weld procedure sheet and application standard.
INSPECTION AFTER WELDING
Check:
- Visual inspection to be carried out to ascertain acceptability of appearance of welds.
- Dimensional accuracy o be ascertained
- Conformity with drawing and standards requirements
- Post weld heat treatment, if any, monitored and recorded
- NDT carried out and reports assessed
- Assess defects as to either repairing or application for concession
- Carry out any necessary repairs
- Control of distortion
WELDING REPAIRS
- Repair procedure and welding code should be authorized.
- Defect area should be marked positively and clearly.
- Check when partiality removed and fully removed (Visual and NDT).
- Re-welding should be monitored.
- Re-inspect complete repair.
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