DUTIES OF WELDING INSPECTOR

DUTIES OF WELDING INSPECTOR.

Welding Inspectors are employed to assist with the quality control activities that are necessary to ensure that welded items will meet specified requirement and be fit for their operation.

STAGES WHEN INSPECTION IS REQUIRED:

For fabricated items such as Pressure vessels, piping and Large Structures inspection is required throughout the fabrication process namely:

• • BEFORE WELDING
  • DURING WELDING
  • AFTER WELDING

Inspection Activities at each stage of fabrication can be considered to be “DUTIES OF WELDING INSPECTOR”

DUTIES BEFORE WELDING:

SAFETY:

• • Be aware of all safety regulations for the work place.
  • Ensure that all operations are carried out in complete compliance with Local, Company (or) National Safety Regulations.
  • Ensure that all safety equipments required are available and in suitable condition.

DOCUMENTATION:

• • Check the specification is up to the date with latest revision and equipment.
  • Check that drawings are with correct revision number.
  • Check for approved W.P.S and its availability.
  • Valid calibration certificates for welding equipment and inspection material are present.
  • Check for material and consumable certificate.

MATERIAL:

• • Check material is according to W.P.S/drawing.
  • Material is in suitable condition and free from contamination.
  • Material Test Certificate is available.

EQUIPMENTS & CONSUMABLES:

• • Welding equipment is in suitable condition with valid calibration certificate.
  • Welding consumables are of correct type, size & are being stored as per the specification by W.P.S.

W.P.S:  Check that an approved W.P.S is available for Welder & Welding Inspector.

WELDERS QUALIFICATION: Check whether the welder is qualified according to W.P.S and welders Qualification Certificate is valid.

WELD PREPERATION & JOINT FIT-UP:

• • Weld preparation is in accordance with W.P.S with correct bevel angel, root face, root gap, root radius, alignment, land & free from contamination.
  • Joint fit-up are in accordance with W.P.S & all tack welds are to be monitored and inspected.

PRE-HEAT: Minimum required temperature is maintained according to W.P.S.

DUTIES DURING WELDING:

The presence of welding inspector during welding will almost reduce the number of weld defects and in-turn will reduce the over-all number of failures.

SITE (OR) FIELD WELDING: Ensure weather conditions are suitable for welding.

WELDING PROCESS & CONSUMABLES:

• • Welding Process is in accordance with W.P.S. Correct welding technique, direction & run sequence is being used.
  • Consumables are being used & stored accordance with W.P.S.

WELDING PARAMETERS: Current, Voltage& Travel speed are in accordance with W.P.S.

GAS FLOW: Check for the type, pressure, flow rate for welding and purging gas are I compliance with procedure.

ROOT RUN: It is visually inspected and accepted to code.

GOUGING/GRINDING & ITNTER-RUN CLEANING: It is by an approved method & to Good Workmanship Standards.

WELDER: Welders are approved according to W.P.S with valid Certificate.

DUTIES AFTER WELDING:

CLEANING: Ensure that the weld has been completely post cleaned and is suitable for all N.D.T methods.

VISUAL INSPECTION: It is being carried out to ascertain acceptability of appearance and defects like under-cut, Overlap, Surface Porosity, Incomplete Filled Grooves & Arc Strikes are inspected.

DIMENSIONAL SURVEY: Dimensional Accuracy must be checked accordance to drawing/code.

P.W.H.T: Inspect & Monitor for compliance with procedure.

N.D.T: Ensure all N.D.T is complete and reports are available

REPAIRS: Should be monitored in accordance with the procedure.

PRESSURE / LOAD TEST:

• • Test equipment is calibrated.
  • Monitor test to ensure compliance with procedure / code.
  • Ensure reports are available.

DOCUMENTATION RECORD: Ensure all reports / documents and records bare completed & collected as required.

M.C.Q IMPORTANT POINTS:

• 1. The minimum intensity of light required for visual inspection is 350 lux and recommended intensity is 500 lux.
  2. Inspection distance must be less than 600mm.
  3. Viewing angel should be more than 30 degree.
  4. Magnification must be 2-5 times.
  5. Inspection must be done Before, During and After welding.
  6. Welding process must be according to “WELDING PROCEDURE SPECIFICATION” and correct Welding Technique, Welding Direction and Welding Run Sequence should be maintained.
  7. Welding Parameters are:
     • Current
     • Voltage
     • Travel speed
     • Gas Flow Rate
     • Heat Input
  8. Back Gauging is a metal removal process.
  9. Post Welding Heat Treatment is a stress relieving operation.