03 & 04 Duties of SWI and Quality

Duties & Responsibilities

Honesty

Integrity

Knowledgeable

Good communicator

Physically fit.

Personal AttributesPersonal Attributes

Supervise

Planning

Organisation

Auditing

Duties & ResponsibilitiesDuties & Responsibilities

DUTIES OF SENIOR WELDING INSPECTOR

What are the Duties of the Senior Welding What are the Duties of the Senior Welding Inspector?Inspector?

The senior welding inspector will be required to:-The senior welding inspector will be required to:-• manage and control.manage and control.• provide guidance and advice on subjects of a provide guidance and advice on subjects of a

technical nature.technical nature.• show leadership skills in addition to technical skills show leadership skills in addition to technical skills

and experience.and experience.

Technical skills required for the Senior Technical skills required for the Senior Welding Inspector?Welding Inspector?

1. Knowledge of technology.1. Knowledge of technology.2. Knowledge of normative documents.2. Knowledge of normative documents.3. Knowledge of planning.3. Knowledge of planning.4. Knowledge of organisation.4. Knowledge of organisation.5. Knowledge of auditing.5. Knowledge of auditing.


1. Knowledge of technology.1. Knowledge of technology.Similar to that required for a welding inspector. Similar to that required for a welding inspector.

Additional knowledge would include;Additional knowledge would include;• Commonly used NDT techniques.Commonly used NDT techniques.• Radiographic interpretation.Radiographic interpretation.• QA/QC knowledge.QA/QC knowledge.• Basic metallurgy of commonly welded materials.Basic metallurgy of commonly welded materials.• Assessment of fracture surfaces.Assessment of fracture surfaces.


2. Knowledge of normative documents.2. Knowledge of normative documents. Specified normative documents should be Specified normative documents should be

available at the work place. The SWI would be available at the work place. The SWI would be expected to read, understand and apply them expected to read, understand and apply them with the necessary level of precision and direction.with the necessary level of precision and direction.

The SWI should be aware of common standards The SWI should be aware of common standards applied in the welding industry.applied in the welding industry.


3. Knowledge of planning.3. Knowledge of planning.• Planning will be required for all phases of a project, Planning will be required for all phases of a project,

from start to completion.from start to completion.• Planning for inspection would usually relate to the Planning for inspection would usually relate to the

following areas as a minimum;following areas as a minimum;• Pre - contractPre - contract• In - contractIn - contract• Post - contract Post - contract


4. Knowledge of organisation.4. Knowledge of organisation. Organisational skills are necessary to ensure that the Organisational skills are necessary to ensure that the

inspection requirements of any plan can be met on inspection requirements of any plan can be met on time using the correct personnel for the job. time using the correct personnel for the job.

This may include assessment of;This may include assessment of;• Availability of inspectors.Availability of inspectors.• Competence of inspectors.Competence of inspectors.• Supervision / monitoring of inspectors.Supervision / monitoring of inspectors.


5. Knowledge of auditing.5. Knowledge of auditing.• Auditing may take place at any stageAuditing may take place at any stage in a project or contract.in a project or contract.• It is basically checking againstIt is basically checking against documented criteria.documented criteria. There are three areas of audit;There are three areas of audit;• Pre - productionPre - production• In - productionIn - production• Post - productionPost - production


Personality Professional Responsible Impartial Tolerant Factual Decisive Diplomatic Communicator

Technical Knowledgeable Qualification Experience Problem solver Advisory

SupervisionSupervision

What is a supervisor?• Supervisor – a person who supervises

another person(s),task, etc; manager, a superitendant,an on looker, a reviser, senior inspector,etc

To understand and what is a supervisor, put yourself those questions:

• What expected of me?• Where do I fit in?• What are my responsibilities?


What is expected of me?• Be knowledgeable of your job• Be a leader• Set a good example• Do your best and expect other to do the

same• Be a team player• Be fair but firm, earn respect

Duties & ResponsibilitiesDuties & Responsibilities

Where do I fit in?


Manager

Welding supervisor

NDT

Welding supervisor Inspection

Welding supervisor production

Welding foremen Welding inspector NDT Technician

Welders Welders Welders

What are my responsibilities?• Quality control• Welding• Training• Inspection & training• Safety• Report


QUALITY CONTROL

• Know the requirements!• Check the materials• Schedule NDE,be first to know results• Calibrated equipment used where required• Maintain current records


WELDING• Know the requirements!• Know the WPS’S• Know joint fit up and tolerence,clean!• Know the electrode types, heat treatments & any

special storage requirements• Know welder qualification and skill levels• Ability to communicate WPS requirements to welders• Ability to carried out demonstration if needed• Overall check on welders performance and any repair

or defect trends


TRAINING It is the supervisors to aid in recruitment and

qualifying welders when required for the job. He must help welders to improve their skills and productivity. He does this by:

• Maintain his own proficiency in the various welding process

• Visually inspecting each welders work and progress• Encouraging welders to achieve higher standards of

quality and production• Participating actively in safety awareness and

training


INSPECTION & TESTING

• Ensure work meets standards and codes• Ensures all testing & NDT is correct and

properly done• All works is completed & signed off when

required• Outstanding repairs are completely in at

timely manner


SAFETY

• Set the example (always wear safety equipment/P.P.E)

• Participate actively in safety meeting• Highlight any unsafe practices to senior

management• RAP (reconised,avoid & prevent)• Daily safety contact (solve issues with

workforce)


REPORTS

• Record drawings (numbers,revisions,etc)• Check if NDT is completed and all report

sign and accepted• No safety issues are outstanding• Produce a weekly progress and overall

quality report for management meeting


Resources can be:All planning requires answers to the “five planning questions”• What?• Where?• When?• Who?• How?

Planning & organisationPlanning & organisation

It is your responsibility to organize and allocate resources to task

Those resources can be:1) PEOPLE• Knowledgeable• Experience• Training• Task and safety• Number


Resources can be:2) MATERIALS• Permanent /contract• Expendable• Drawings• Specifications• Procedures


Resources can be:3) EQUIPMENT• Major equipment:Crane,generator,welding

plant, air compressor ,etc• Tools: welding leads, air

hose,grinders,grinding ,etc• Supplies : welding consumables,gas,etc• PPE : Hardness, grinding shields, ear

plugs,glasses,etc


4) Documentation Specifications: revisions amendments etc. Manufacturing: job instructions, mill certs etc Modifications – concessions Quality manual Procedures: assembly, welding, repair welding, NDT etc Welder qualification: approval and history etc Inspectors: approvals and history etc Calibration certificates All reports


How much inspection is required? Total man hours required Number of personnel required Estimation of job times Analysis of job sequences Preparation requirements & time Travel and down time (mobilisation/demob) Leave time for personnel Ability of staff


The amount of planning required depends upon the company size

Why? To force people to think things through To optimise team/individual performance To provide documentation for traceability To convert solved problems into recorded knowledge To co-ordinate actions between departments To improve efficiency, Quality and cost effectiveness


1. Jobs are planned and issued in correct sequence, reducing unnecessary work

2. Men and equipment are supplied at the right time with the correct materials

3. The correct quality standards are achieved for the minimum cost

4. Completed goods are despatched as promised5. Adequate stock levels are maintained6. Greater job satisfaction/security

Advantages of planning


Auditing Auditing stagestage

Pre - productionPre - production

In - productionIn - production

Post - Post - productionproduction

Actions requiredActions required

Assess qualifications / ability of staff.Assess qualifications / ability of staff.Planned work scheduling.Planned work scheduling. Assess whether specifications are beingAssess whether specifications are beingworked to.worked to.

Assess overall standard of welding and Assess overall standard of welding and inspection.inspection.

AUDITING.AUDITING.

Definitions:systematic,independent and documented process for obtaining evidence it objectively to determine the extent to which criteria are fulfilled

AuditingAuditing

Audit

a system

a compliance

Is quite shallow; examines the system to confirm that if follows the quality manual and procedures are in place

It goes in- depth; examines the compliance with procedures and quality manual

Definitions Audit program: set of one or more audits planned Audit criteria: set of policies, procedures or requirements used as a reference Audit evidence: records, statements of fact which relate to audit criteria Audit findings: results of the evaluation of the collected audit evidence against audit criteria Audit conclusion: outcome of an audit provided by the audit team, after considerations of the audit findings

AuditingAuditing

Assessment of:

Staff

Equipment

Q.A / Q.C and Inspection

Documents

Safety

AuditingAuditing

Internal audits First Party Audits Conducted for the companies internal purposesExternal AuditsSecond Party Audits Conducted by parties having an interest in the company, such as customers or by other persons working on their behalfThird-Party Audits Conducted by external independent organizations, which provide certification of conformity

AuditingAuditing

Traceability

Definition: Ability to trace the history, application or location of that which is under consideration

Traceability Traceability can relate can relate

to:to:

The origin The origin of materials of materials

and partsand parts

The The processinprocessing historyg history

The The distribution distribution and location and location

of the product of the product after deliveryafter delivery

Traceability - HOW?hard stampingpainting/etchinglabelling

WHEN? Immediately after the operation!

Conformity

RequiremeRequirementnt

ConformityConformity

fulfilmentfulfilment

NonconformiNonconformityty

non-non-fulfilmentfulfilment

Corrective Corrective actionaction

NonconformitNonconformity reporty report

RepairRepair ScrapScrap ConcessioConcessionn

ReleaseRelease

SDRSDR

Conformity evaluation

Test determination of one or characteristics according to a procedure can be non-destructive or destructive

ConformitConformity y

evaluatioevaluationn

Inspection evaluation by observation and judgement can be accompanied by measurement, testing or gauging

Inspection - terminologydetectable change in the

material

signal from a discontinuity typical to the testing method used

DiscontinuitDiscontinuityy

IndicationIndication

DetectioDetectionn

Acceptance Acceptance levellevel

EvaluationEvaluation

prescribed limit below which a component is accepted

RecordablRecordable e

indicationindication

DEFECTDEFECT

Quality Control & Quality Assurance

is a subjective thing……

..what is quality to you might not be quality to me……

‘Quality’

QualityQuality

Quality = degree to which a set of inherent characteristics fulfills explicit and implicit requirements

Quality - definitionsQuality - definitions

Quality

Management

Policy

system

Coordinated activities to direct control an organization

Overall intentions and directions of an organization related to quality as formally expressed by top management

A system to direct and control an organization with regard to quality

Quality management activitiesQuality management activities

Quality

Assurance

Control

Part of quality management focused on providing confidence that quality requirements will be fulfilled

Part of quality management focused on fulfilling quality requirements

Why we need QA?

• prevent defective work

• ensure programme commitment are achieved

• provide feedback to the management

Quality assurance documentsQuality assurance documents

Quality assurance documents

specification

Code of practice

Document stating requirements (related to activities or products)

Quality manual

Quality plan

procedure

Document specifying the quality management system of an organization

Document specifying which procedures and resources shall be applied by whom and when to a specific project

Specified way to carry out an activity

Set of rules for manufacturing a specific product or activity

- Is a check list specifies which procedures and associated resources shall be applied, by whom and when to a specific project,product,process or contract

- Is a list with the main operation following manufacturing sequences

- Stop/hold point with specific requirements (e.g. document check,NDT witnessed by customer representative, independent body supervision, procedure used, acceptance standards,etc)

- Type and number of document issued (NDT report,WPAR,welder qualification , dimensional check list,etc)

- Name and signature of welding coordinator in charge with each operation ( if required)

- Date of completion for each step

Quality planQuality plan

Quality planProcess Process

descriptiodescription activityn activity

ResponsiblResponsible persone person

Process Process reference reference documentdocument

ApprovaApproval l

/remark/remarkssHH

H - Hold point: work shall stop until H - Hold point: work shall stop until representative are present to representative are present to monitor/observe activitymonitor/observe activity

WW

W - Witness point: notifiable point; should W - Witness point: notifiable point; should representative fail to attend, work may representative fail to attend, work may proceedproceed

RR

R - Document reviewR - Document review

AA

A - Document approvalA - Document approval

MM

M - Monitor/periodic control of activityM - Monitor/periodic control of activity

Welding map

CC55

Information's to be Information's to be supplied:supplied:

LL11

LL22

LL33

LL44

LL55

CC11

CC22

CC33

CC44

CC66

NN11NN22 NN33

NN44

SS11SS22

•weld type and weld type and positionposition•WPS and PQR WPS and PQR numbernumber•type and extent of type and extent of NDENDE

•welder’s stamp welder’s stamp numbernumber•type of PWHTtype of PWHT

Quality pack

a.k.a. doc pack, history a.k.a. doc pack, history docketdocket

Quality pack Quality pack contentcontent

Documents supplied Documents supplied before before

commencement of commencement of manufacturemanufacture

Documents Documents supplied on supplied on

completion of completion of constructionconstruction

Quality pack content

•certificate of conformance with different codes/standards•design calculations (optional)•manufacturing drawings•WPS with supporting WPQR (copies)•welder qualifications•qualification of NDT personnelNDT procedures•PWHT oven calibration record (optional)

•material test certificates (list!)•welding production tests (if required)•PWHT record (if required)•NDT test reports: dimensional, pressure test and coating thickness are included•quality plan and weld map•as-built drawings•non-conformity reports (SDR)•operating/mounting instructions

Documents supplied Documents supplied before manufacturebefore manufacture

Documents supplied Documents supplied after manufactureafter manufacture

QA applies to all areas which have

an affect on quality

QC deals with the actual measurement

of quality performance

“has the work been performed correctly?”

“is the work/action been performed correctly?”

QA – Vs - QCQA – Vs - QC

QA is mainly about documentation

And must see the whole picture

Inspection is mainly about physical reality,

monitoring and measuring, a QC tool

“quality assurance is not inspection”

“comparing the results against documented criteria”

QA – Vs - InspectionQA – Vs - Inspection

Quality Assurance: All those planned and systematic actions necessary to provide adequate confidence that a product or service will satisfy given requirements for quality or that quality requirements will be fulfilled

Quality Control: The operational techniques and activities that are used to fulfil the requirements for quality

Inspection: Activities such as measuring, examining, testing, gauging one or more characteristics of a product or service and comparing these with specified requirements to determine conformity. Inspection is a tool used for quality control

Testing: Determination of one or more characteristics according to a procedure

Definitions Relating to QualityDefinitions Relating to Quality

top management

quality management

quality planning quality assurance quality control

Inspection

Concepts Relating to Quality ManagementConcepts Relating to Quality Management

Grade

QualityDegree to which a set of inherent characteristics

fulfils requirements

Customer satisfactionCustomers requirements

have been fulfilled

Requirements

Concepts Relating to Quality ManagementConcepts Relating to Quality Management

You are required to visit a site on which your welding inspectors have been involved

The work concerns the inspection of a welded fabrication to a specific application standard and is now ready for final approval

What question do you ask?

What documents do you review and what inspections do you require before submitting an inspection report to the authorities concerned?

CSWIP 3.2 Mandatory Question CSWIP 3.2 Mandatory Question


Prior to your visit on site it is important to spend time planning and organizing the visit, in order that all the vital details are not overlooked.Knowledge of the product with regards to the specification and codes and standards from which it has been fabricated and the service life and service conditions of the product are beneficial in assessing the fitness of the product for service.A list of the inspection team will ensure that those involved with the fabrication and inspection of the product are at hand to answer any question.

The following documents should be reviewed as a minimum prior to the final approval of the product.


1. Review the quality plan and inspection check lists ensuring all stages have been completed and signed.

2. Review the client specification as to ensure weld and materials suitability.

3. Check material/mill certs, ensuring all heat numbers have been transferred where applicable.

4. Review procedure and qualification test certs for bending, rolling and all other cold forming operations.

5. Review all welding procedure specifications, repair welding procedure.

6. Review all NDT procedures7. Review all NDT personal, checking qualifications against clients

requirements.8. Review PWHT records, check calibration certs of equipment

used where applicable.


9. Check the technical data sheets of all welding consumables used, storage conditions and heat treatments where applicable.10. Check welder approval certs, check all welding operations carried out by qualified welders only.11. Check that all production tests on parent material and welds have been carried out, where applicable.12. Check and review all NDT reports.13. Review all technical drawings, showing materials and weld maps tractability.14. Dimension checks.15. Check all painting/coating procedures.16. Check all painting/coating reports.17. If applicable, check the final as-build drawings, locating all material used in the fabrication, cross-referencing the weld identification numbers to the NDT reports.

Weld Procedures& Welder

Quals

Missing Documents

Material Traceability &

Mill Certs

Pressure

testing

Coatings

Inspection Reports,

Distortion &

Dimensions

Inspection personnel,

Any QuestionsAny Questions

??

03 & 04 Duties of SWI and Quality

Documents

senior inspector

knowledge of planning

knowledge of auditing

knowledge of technology

knowledge of organisation

welding industry

additional knowledge

qaqc knowledge