1 duties and responsibilities section 1

Duties and ResponsibilitiesDuties and ResponsibilitiesSection 1Section 1

Welding InspectorWelding Inspector

• Code complianceCode compliance

• Workmanship controlWorkmanship control

• Documentation controlDocumentation control

Main Responsibilities Main Responsibilities 1.11.1

Personal Attributes Personal Attributes 1.11.1

Important qualities that good Inspectors are expected to Important qualities that good Inspectors are expected to have are: have are:

• HonestyHonesty

• IntegrityIntegrity

• KnowledgeKnowledge

• Good communicatorGood communicator

• Physical fitnessPhysical fitness

• Good eyesightGood eyesight

Standard for Visual Inspection Standard for Visual Inspection 1.11.1

Basic RequirementsBasic RequirementsBS EN 970 - Non-destructive examination of fusion BS EN 970 - Non-destructive examination of fusion

welds - Visual examinationwelds - Visual examinationWelding Inspection Personnel should:Welding Inspection Personnel should:

• be familiar with relevant standards, rules and specifications be familiar with relevant standards, rules and specifications applicable to the fabrication work to be undertakenapplicable to the fabrication work to be undertaken

• be informed about the welding procedures to be usedbe informed about the welding procedures to be used

• have good vision have good vision (which should be checked every 12 (which should be checked every 12 months)months)

Welding Inspection Welding Inspection 1.21.2

Conditions for Visual Inspection (to BS EN 970)Conditions for Visual Inspection (to BS EN 970)Illumination:Illumination:• 350 lux minimum required350 lux minimum required• (recommends 500 lux - normal shop or office lighting)(recommends 500 lux - normal shop or office lighting)Vision Access:Vision Access:• eye should be within 600mm of the surfaceeye should be within 600mm of the surface• viewing angle (line from eye to surface) to be not less than viewing angle (line from eye to surface) to be not less than

30°30°

30°30°

600mm600mm


Aids to Visual Inspection (to BS EN 970)Aids to Visual Inspection (to BS EN 970)

When access is restricted may use: When access is restricted may use: a mirrored boroscopea mirrored boroscopea fibre optic viewing systema fibre optic viewing system

Other aids:Other aids:welding gauges welding gauges (for checking bevel angles, weld profile, (for checking bevel angles, weld profile, fillet sizing, undercut depth)fillet sizing, undercut depth)dedicated weld-gap gauges and linear misalignment (high-low) dedicated weld-gap gauges and linear misalignment (high-low) gaugesgaugesstraight edges and measuring tapesstraight edges and measuring tapesmagnifying lens magnifying lens (if magnification lens used it should have (if magnification lens used it should have magnification between X2 to X5)magnification between X2 to X5)

usually by usually by agreementagreement

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Welding Inspectors Equipment Welding Inspectors Equipment 1.31.3

Measuring devices:Measuring devices:• flexible tape, steel ruleflexible tape, steel rule

• Temperature indicating crayonsTemperature indicating crayons

• Welding gaugesWelding gauges

• VoltmeterVoltmeter

• AmmeterAmmeter

• Magnifying glassMagnifying glass

• Torch / flash lightTorch / flash light

• Gas flow-meterGas flow-meter

TWI Multi-purpose Welding GaugeTWI Multi-purpose Welding Gauge Misalignment GaugesMisalignment GaugesHi-Lo GaugeHi-Lo Gauge

Fillet Weld GaugesFillet Weld Gauges

G.A.L.

S.T.D.

10mm

12m

m

16mm

3mm

6mm

9mm

5mm4m

m

L

G.A.L.

S.T.D.

10mm

12mm

16mm

3mm

6mm

9mm5mm

4mm

T

Welding Inspectors Gauges Welding Inspectors Gauges 1.31.3

605040

0 1/4 1/2 3/41

05

1015

20

IN

MM

MM15

1/2MMIN

HI-L

O S

ingl

e Pu

rpos

e W

eldi

ng G

auge

1

2

3

4

5

6

Tong TesterTong Tester

AmmeterAmmeterVoltmeterVoltmeter

Welding Inspectors Equipment Welding Inspectors Equipment 1.31.3


Stages of Visual Inspection (to BS EN 970)Stages of Visual Inspection (to BS EN 970)Extent of examination and when required should be defined in Extent of examination and when required should be defined in the application standard or by agreement between the the application standard or by agreement between the contracting partiescontracting parties

For high integrity fabrications inspection required throughout For high integrity fabrications inspection required throughout the fabrication process: the fabrication process: Before weldingBefore welding

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

Typical Duties of a Welding Inspector Typical Duties of a Welding Inspector 1.51.5

Before WeldingBefore WeldingPreparation: Preparation:

Familiarisation with relevant ‘documents’…Familiarisation with relevant ‘documents’…

• Application Standard/Code - for visual acceptance Application Standard/Code - for visual acceptance requirementsrequirements

• Drawings - item details and positions/tolerances etcDrawings - item details and positions/tolerances etc

• Quality Control Procedures - for activities such as material Quality Control Procedures - for activities such as material handling, documentation control, storage & issue of handling, documentation control, storage & issue of welding consumableswelding consumables

• Quality Plan/Inspection & Test Plan/Inspection Checklist - Quality Plan/Inspection & Test Plan/Inspection Checklist - details of inspection requirements, inspection procedures details of inspection requirements, inspection procedures & records required& records required


Before WeldingBefore WeldingWelding Procedures:Welding Procedures:

• are applicable to joints to be welded & approvedare applicable to joints to be welded & approved

• are available to welders & inspectorsare available to welders & inspectors

Welder Qualifications:Welder Qualifications:

• list of available qualified welders related to WPS’slist of available qualified welders related to WPS’s

• certificates are valid and ‘in-date’certificates are valid and ‘in-date’


Before WeldingBefore Welding

Equipment:Equipment:

all inspection equipment is in good condition & calibrated as all inspection equipment is in good condition & calibrated as necessarynecessary

all safety requirements are understood & necessary all safety requirements are understood & necessary equipment availableequipment available

Materials:Materials:

can be identified & related to test certificates, traceability !can be identified & related to test certificates, traceability !

are of correct dimensionsare of correct dimensions

are in suitable condition (no damage/contamination)are in suitable condition (no damage/contamination)



Consumables:Consumables:

in accordance with WPS’sin accordance with WPS’s

are being controlled in accordance with Procedureare being controlled in accordance with Procedure

Weld Preparations:Weld Preparations:

comply with WPS/drawingcomply with WPS/drawing

free from defects & contaminationfree from defects & contamination

Welding Equipment:Welding Equipment:

in good order & calibrated as required by Procedurein good order & calibrated as required by Procedure



Fit-upFit-up

complies with WPScomplies with WPS

Number / size of tack welds to Code / good Number / size of tack welds to Code / good workmanship workmanship

Pre-heatPre-heat

if specified if specified

minimum temperature complies with WPSminimum temperature complies with WPS


During WeldingDuring WeldingWeather conditionsWeather conditions

• suitable if site / field weldingsuitable if site / field welding

Welding Process(es)Welding Process(es)

• in accordance with WPSin accordance with WPS

WelderWelder

• is approved to weld the jointis approved to weld the joint

Pre-heat (if required)Pre-heat (if required)

• minimum temperature as specified by WPSminimum temperature as specified by WPS

• maximum interpass temperature as WPSmaximum interpass temperature as WPS


During WeldingDuring Welding

Welding consumablesWelding consumables

in accordance with WPSin accordance with WPS

in suitable conditionin suitable condition

controlled issue and handlingcontrolled issue and handling

Welding ParametersWelding Parameters

current, voltage & travel speed – as WPScurrent, voltage & travel speed – as WPS

Root runsRoot runs

if possible, visually inspect root before single-sided welds are if possible, visually inspect root before single-sided welds are filled upfilled up


During WeldingDuring Welding

Inter-run cleaningInter-run cleaning

in accordance with an approved method (& back gouging) to in accordance with an approved method (& back gouging) to good workmanship standardgood workmanship standard

Distortion controlDistortion control

welding is balanced & over-welding is avoidedwelding is balanced & over-welding is avoided


After WeldingAfter WeldingWeld IdentificationWeld Identification

• identified/numbered as requiredidentified/numbered as required

• is marked with welder’s identityis marked with welder’s identity

Visual InspectionVisual Inspection

• ensure weld is suitable for ensure weld is suitable for allall NDT NDT

• visually inspect & ‘sentence’ to Code requirementsvisually inspect & ‘sentence’ to Code requirements

Dimensional SurveyDimensional Survey

• ensure dimensions comply with Code/drawingensure dimensions comply with Code/drawing

Other NDTOther NDT

• ensure all NDT is completed & reports availableensure all NDT is completed & reports available


After WeldingAfter Welding

RepairsRepairs

monitor repairs to ensure compliance with Procedure, ensure monitor repairs to ensure compliance with Procedure, ensure NDT after repairs is completedNDT after repairs is completed

PWHTPWHT

monitor for compliance with Proceduremonitor for compliance with Procedure

check chart records confirm Procedure compliancecheck chart records confirm Procedure compliance

Pressure / Load TestPressure / Load Test

ensure test equipment is suitably calibratedensure test equipment is suitably calibrated

monitor to ensure compliance with Proceduremonitor to ensure compliance with Procedure

ensure all records are availableensure all records are available


After WeldingAfter Welding

DocumentationDocumentation

ensure any modifications are on ‘as-built’ drawingsensure any modifications are on ‘as-built’ drawings

ensure all required documents are availableensure all required documents are available

Collate / file documents for manufacturing recordsCollate / file documents for manufacturing records

Sign all documentation and forward it to QC department. Sign all documentation and forward it to QC department.

Summary of DutiesSummary of Duties

A Welding Inspector must: A Welding Inspector must: ObserveObserveTo observe all relevant actions related to weld quality throughout To observe all relevant actions related to weld quality throughout production. production.

RecordRecordTo record, or log all production inspection points relevant to To record, or log all production inspection points relevant to quality, including a final report showing all identified imperfectionsquality, including a final report showing all identified imperfections

CompareCompareTo compare all recorded information with the acceptance criteria To compare all recorded information with the acceptance criteria and any other relevant clauses in the applied application standardand any other relevant clauses in the applied application standard

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

1 duties and responsibilities section 1

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