dutyies of welding inspector

7/25/2019 Dutyies of Welding Inspector

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THE DUTIES OF THE WELDING INSPECTOR

VISUAL INSPECTION

At any point in the course of welding, i.e. tacking, root pass, filler pass or capping

pass, but particularly for the root and cap, a detailed inspection may be required.

British Standard 528! "#$ gi%es guidance on tools and responsibilities together with

sketches of typical defects.

&he inspector at this point must '

a( )bser%e identify and perhaps record *measure( the features of the weld.

b( +ecide whether the weld is acceptable in terms of the particular le%els that are

permitted defect le%els may be -in'house or national codes of practice.

/hen the defect si0e is in e1cess of the permitted le%el then either a concession must

be applied for *from a competent person(, or the weld reected.

AIDS OF VISUAL INSPECTION

3llumination! 4ood lighting is essential.

3nspection enses! &he magnification should not e1ceed 2 ' 2.5 diameters. 3f

higher magnification is required use a binocular microscope.

)ptical %iewing can progressi%ely de%elop from eyesight, to use of a hand torch and

mirror, to the addition of a magnifier and light source.

3n order to achie%e accessibility, remote probe units are a%ailable which must ha%e the

following properties.

a( arge field of %ision

b( 6reedom from distortion of imagec( Accurate preser%ation of colour %alues

d( Adequacy of illumination

CODE OF PRACTICE

A code of practice for an inspection department should take the form outlined below.

3t is appreciated that full implementation of the code would be e1tremely costly and

therefore it may be necessary to reduce the amount of inspection to less than is

theoretically required.

&he inspector should be familiar with the following!

a( All applicable documentsb( /orkmanship standards

c( All phases of good workshop practice

d( &ools and measuring de%ices

INSPECTION BEFORE WELDING

Before Assembly!

7heck All applicable documents.

9uality plan is authorised and endorsed with signature, date and company

stamp.

Application standard is up to date with the latest edition, re%ision oramendment.


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&he drawings are clear, the issue number is marked and the latest re%ision is

used.

/elding procedure sheets *specifications( are a%ailable, ha%e been appro%ed

and are

employed in production.

/elder qualifications with identification and range of appro%al are %erifiedand that only

appro%ed welders as required are employed in production.

7alibration certificates, material certificates *mill sheets( and consumer

certificates are

a%ailable and %alid.

:arent material identification is %erified against documentation and

markings.

;aterial composition, type and condition.

7orrect methods are applied for cutting and machining.

3dentification of welding consumables such as electrodes, filler wire, flu1es,

shielding and backing gases and any special requirements *e.g. drying( aremet.

:lant and equipment are in a safe condition and adequate for the ob.

Safety permits e.g. hot work permit, gas free permit, enclosed space

certificate are

a%ailable and %alid.

After Assembly

7heck +imensions, tolerances, preparation, fit'up and alignment are in accordance

with the

Appro%ed drawings and standards.

&ack welds, bridging pieces, clamping and type of backing ' if any used are

correct.

7leanliness of work area is maintained.

:reheat in accordance with procedure.


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+imensional accuracy to be ascertained.

7onformity with drawings and standards requirements.

:ost weld heat treatment, if any, monitored and recorded.

epair procedure and welding code should be authorised.

+efect area should be marked positi%ely and clearly.

7heck when partially remo%ed and fully remo%ed *%isual and e'welding should be monitored.

>e'inspect completed repair.

7ollect all documents and reports. :ass the document package on to a higher authorityfor final inspection, appro%al and storage.

THE WELDING INSPECTOR

RESPONSIBILITIES

=nsure compliance with standard or code.

=nsure workmanship.

=nsure welding criteria by -policing work and documentation.

ATTRIBUTES

@onesty and integrity.

iteracy.

6itness ' physical and eyesight.

DUTIES

)bser%e.

;easure.

3dentify.


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CODES AND STANDARDS

CLASS OF WORK

&here are many types of work which require engineering materials to be oined by

welding, for e1ample!

:ressure %essels Bridges

)il rigs =arth mo%ing equipment

Aero'engines ?entilation systems

Storage tanks @ea%y %ehicle chassis7ar bodies 6ood processing plant

&he quality requirements of the oints in these fabrications depend on their fitness'for'

purpose and differ significantly from one application to the ne1t. :ressure %essels

require welds, which can withstand the stresses and high temperatures e1perienced in

operation. )ilrigs are designed to withstand the effect of wa%e formation and wind

loads. =arth mo%ing equipment has to accommodate differences in terrain and earth

conditions and is subect to fatigue loading. /elds in food processing plants must

withstand corrosion by hot acidic liquors.

Below are listed some typical codes of practice and standards which co%er

%arious types of constructions fabricated by welding.

Code Class of Wok

BS 55 nfired fusion welded pressure %essels

AS;= ?333 American boiler and pressure %essel code

BS 2$CC 7lass " arc welding of ferritic steel pipe work for carrying

fluids

BS D5"5 :rocess of welding steel pipelines on land and offshore

BS 55 Structural use of steelwork in building

A/S +"." Structural welding code *American(

BS 5D Steel, concrete and composite bridges

BS $2C5 7ode of practice for fi1ed offshore structureA:3 ""D Standard for welding pipelines and related structures


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&hese documents can also pro%ide a useful source of data for applications where

codes do not e1ist. 3t should be remembered, howe%er, that the principal criterion in

the codes listed is the quality of the oint in relation to the ser%ice conditions. &here

are other applications where success is udged by different criteria, such as

dimensional accuracy.Another important consideration is controlling the cost of welding. ?ariations in weld

times and quantities of consumables can readily result if the method of making a weld

is left to the welder to decide.

&he continuous and satisfactory performance of weldments made to %arious codes

requires that specific guidelines are laid down to co%er all %ariables. &hese guidelines

are usually grouped under the general heading of a /eld :rocedure.

CODE OF PRACTICE

A code of practice is a set of rules for manufacturing a specific product. 3t should

contain!+esign >equirements e.g. fit'up, preparation and type of oints

;aterials e.g. types, thickness ranges

;anufacturers /orking :ractice

3nspection 7riteria e.g. "E %isual, percentage other


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THE WELDING PROCEDURE

A welding procedure is a way of controlling the welding operation.

P!"ose of "oced!e!

"( &o pro%e a oint can meet design procedure ' consistency

2( 3nstruction for welder

C( =nsure repeatability

/eld procedures are appro%ed to ensure they are functional and fulfil the physical and

mechanical properties necessary to reach the required standard *to establish the

essential %ariables for contractual obligations(.

/elders are appro%ed to ensure a particular welder is capable of welding to a

procedure and obtaining a result that meets specification.

&he task of collecting the data and drafting the documentation is often referred to as

-writing a weld procedure. 3n many ways this is an unfortunate term as the writing of

documents is the last in a sequence of tasks.

Pod!c#$% a &eld "oced!e #$'ol'es

:lanning the tasks

7ollecting the data/riting a procedure for use or for trial


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;aking test welds

=%aluating the results of the tests

Appro%ing the procedure of the rele%ant code

:reparing the documentation

3n each code reference is made to how the procedures are to be de%ised and whetherappro%al of these procedures is required. 3n most codes appro%al is mandatory and

tests to confirm the skill of the welder are specified. +etails are also gi%en of

acceptance criteria for the finished oint.

&he approach used depends on the code, for e1ample!

BS 2$CC *7lass " arc welding of ferritic steel pipe work for carrying fluids( pro%ides

general comments on %arious aspects of a suitable weld procedure.

A/S +."." *Structural welding code ' steel( fa%ours more specific instructions for

different oints and processes that are, in effect, pre'qualified procedures.

)ther codes do not deal specifically with the details of the weld procedure but refer to

published documentation, e.g. BS 5"C5 -process of arc welding carbon and carbonmanganese steels.

CO(PONENTS OF A WELD PROCEDURE

3tems to be included in the procedure can be some of the following!

:arent ;etal

a. &ype

b. &hickness *for pipe this includes outside diameter(

c. Surface condition

d. 3dentifying marks

Weld#$% Pocess

a. &ype of process *;;A, &34, SA/ etc.(

b. =quipment

c. ;ake, brand, type of welding consumables

d. /hen appropriate, the temperature and time adopted for drying and baking

of electrodes

and F or consumables

)o#$* Des#%$

a. /elding position

b. =dge preparationc. ;ethod of cleaning, degreasing etc.

d. 6it up of oint

e. Gigging or tacking procedure

f. &ype of backing

/elding :osition

a. /hether shop or site weld

b. Arrangement of runs and weld sequence

c. 6iller material, composition and si0e *diameter(

d. /elding %ariables ' %oltage, current, tra%el speed

e. /eld si0e

f. Back gougingg. Any specific features, e.g. heat input control, run'out length


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The+al Tea*+e$*

a. :reheat and interpass temperatures including method and control

b. :ost weld treatment including method and control

ESSENTIAL VARIABLES

An essential %ariable is a %ariable that will influence or change the mechanical or

metallurgical properties of the welded oint ' changes affecting the procedure

appro%al. Any change in an essential %ariable requires a new welding procedure

specification */:S(.

=ssential %ariables include! wall thickness, oint design, process, materials,

consumables, welding position, direction, heat input *%oltage, amperage, tra%el

speed(, heat treatment.

APPROVING THE PROCEDURE

/hen the data has been collected, the procedure must be %alidated by producing andtesting a trail weld.

3f the procedure is to be used on a fabrication, which has been designed to meet the

requirements of a code, the test weld is done under the super%ision of an independent

witness. &he detailed arrangements for the test are subect to agreement between the

contracting parties.

A number of British Standards make cross'reference to another standard which co%ers

appro%al testing. )ther codes of practice include their own weld procedure F welder

appro%al information. 3n general they include a standard format, which can be used to

report the results of an appro%al test.

>ange of appro%al. *e1tent of appro%al, scope of appro%al(

:ro%ides a working range o%er which certain %ariables may alter without requiring a

new welding procedure or welder appro%al.

?ariables include thickness *e.g. "F2 down to 21 abo%e(, diameter *e.g. "F2 down to

"F2 abo%e( materials *different materials can be co%ered(, position, process, parent

plate group, and consumables.

>e'appro%al of a welding procedure is necessary if there is a change of any of the

essential %ariables or considerable defect re'occurrence.

ABBREVIATIONS

/:S welding procedure specification ' an appro%ed and accepted welding

procedure,

An authorised document.

:9> procedure qualification records ' proof the procedure works ' record of

tests undertaken to qualify procedure.

/A7 welder appro%al certificate ' required to ensure a particular welder is

capable of welding to a procedure.

/A&7 welder appro%al test certificate.

/A> welder appro%al record.

/:A> welding procedure appro%al record./9& welder qualification test.


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p/:S preliminary /:S ' unauthorised *contains all essential %ariables and,

after welding the test piece and all gi%e final /:S *%arious /:S can deri%e from one p/:S(.

DOCU(ENTATION

&he obecti%es of a procedure or welder appro%al test are!

a. to pro%e the procedure meets the necessary requirements with reference to

feasibility, mechanical strength etc.

b. to pro%e the welders are competent to work on a particular ob.

3f a customer queries it, e%idence can and would be supplied to pro%e %alidity.

Appro%al &est Specifications call for a paper record, which can be known as!

:rocedure F welder appro%al certificate

:rocedure F welder appro%al record:rocedure F welder appro%al report

&he following records should also be kept!

ecords of %isual e1amination or mechanical testing

&est pieces from destructi%e testing

)ther records that are equally important are proofof regular employment on a ob for

scheduling re'tests to a%oid duplication on procedure appro%al.

WELDER APPROVAL

/elder appro%al tests are used to determine the ability of a welder to produce welds

of an acceptable quality with the processes, materials and welding positions that are to

be used in production. +ependant on the requirements and administration the

manufacturer or contractor may choose to qualify their own welders or they may

employ outside personnel who can meet the requirements. &hese requirements usually

specify %erification of the tests by an authorised inspector or independent body. &he

requirements for the qualification of welders are usually laid down in the go%erning

code or specification or the contract specification.

Appro%al tests impro%e the probability of obtaining satisfactory welds in production.

@owe%er it is true to say that appro%al test welds are made with special attention and

effort and so cannot show whether or not the welder can do so under e%ery production

condition. 6or these reasons complete reliance should not be placed on thesequalifications ' production welds should be inspected regularly to ensure that the

standard is being kept up.

T,"es Of A""o'al Tes*s.

&ests that are prescribed by most codes and standards are in the main similar.

7ommon tests are!

a. :late and structural members.

b. :ipe welding.

c. :ositions of welding.

d. &esting of appro%al testpieces.

e. >e'tests.a. :late and structural members.


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&he requirements for welders of plate and structural parts *including pressure %essels(

usually require the welder to make one or more test welds on plate or pipe assemblies

with the qualified welding procedure. =ach weld is tested in a specific manner, often

both destructi%ely and non'destructi%ely. &he requirements normally state the

applicability of material thickness and welding positions that will qualify for

production work. )ther details will co%er oint type and direction of welding whendepositing %ertical welds *%ertically up or %ertically down(.

-. P#"e &eld#$%.

&he requirements for the appro%al of welders for pipe welding differs from those for

welding plate and structural members chiefly in the type of test assemblies and test

positions. As a rule the welds must be made on pipe and not plate. 3n some cases the

space within which the test piece must be welded may be restricted if the production

work in%ol%es welding in cramped conditions. As a general rule welders who qualify

for certain oints on pipe need not qualify for plate work, but qualifications on plate

do not apply to pipework.

c. Pos#*#o$ of &eld#$%.

Appro%al tests are normally e1pected to be made in the most difficult positions that

will be encountered in production welding. 6or e1ample qualification in the %ertical,

hori0ontal and o%erhead positions usually qualifies for welding in the flat position.

d. Tes*#$% of &elde a""o'al *es*"#eces.

All codes and specifications will ha%e definite rules for the testing of appro%al welds

to determine compliance. ;ost frequently this in%ol%es the remo%al of specimens for

mechanical tests, such as bend tests, and specimens for macro e1amination from

specific locations in the test pieces.


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". &he test being carried out is the correct one required.

2. /elders are in possession of all rele%ant information concerning the test.

C. &est materials confirm in all respects to requirements.

D. Goint configuration and tolerances are correct.

5. /elding plant and consumables.

$. &he welderHs identification is clearly marked on the testpiece.#. /here it is specified for a root run to be stopped and restarted in a certain

position, that this

position is clearly marked.

8. 3n the case of oints welded in fi1ed positions the test piece is so fi1ed that it

cannot be mo%ed.

. All ancillary tools such as chipping hammers, wire brushes, grinders, etc. are

a%ailable.

&he tests should be carried out without interruption but with sufficient super%ision to

ensure that the requirements are being complied with. /here welder appro%al is

carried out in accordance with AS;= section 3I it states that the person super%ising

the test may, if in his opinion he considers that the welder will not meet the requiredstandard, terminate the test at any time. 3f it is necessary to apply this ruling, it is

suggested that full reasons for termination be recorded. 3t is further recommended that

the testpiece should also be kept for a short period as a means of backing up written

statement.

3f the test is to be super%ised by a representati%e of an independent authority he

should be gi%en all the rele%ant details of the testing required.

/here British standards are in%ol%ed, they generally state that if the welder is of the

opinion that his first attempt may not pass any subsequent testing, he may withhold it

and weld a second. 3n this case it is the second testpiece that is submitted for

e1amination and the first one must be scrapped.

TEST CERTIFICATE

Should state clearly that it is a welder appro%al and not a procedure appro%al, and,

depending on the particular standard, should contain the following!

a. welders name and identity number

b. date of test

c. standard of code in full, e.g. British Standard D8#2 :& "! "82

d. test piece details including material specification

e. equipment and consumable details

f. e1tent of appro%al

g. sketch of run sequence, preparation and dimensions

h. other factors, operating parameters etc.i. the test results *%isual,


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DESTRUCTIVE TESTING

+estructi%e tests on welded oints are usually made as part of the appro%al of a

welding procedure or a welder.

7ommonly used destructi%e tests are!

Bend

&ensile

7harpy

6racture tests

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