aws_it_201210

www.aws.org

October 2012 / Vol. 15 / No. 4

THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNELTHE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL

NDE Training Opportunities

Inspection per D1.1

CWI Ethics

OmniPCPC-Based OmniScan Data Analysis SoftwareThis new software is the most efficient and affordable option available for OmniScan data analysis. Now you can use a PC to perform the same powerful data analytical tools provided on board the OmniScan.

OmniScanThe Standard in Phased Array, RedefinedThis second generation OmniScan flaw detector increases testing efficiencies, ensuring superior manual and advanced AUT application performance with faster setups, test cycles, and reporting, in addition to universal compatibility with all phased array modules.

The OmniScan MX2 offers a high acquisition rate and new powerful software featuresin a portable, modular instrumentto efficiently perform manual and automated inspections.

Be truly in touch with phased arrayBright, large size screen

Fast, intuitive touch screen interface

Full screen mode

Advanced Weld Overlay

High-capacity data storage

Fast file transfer

Designed for IP66

Op

The OmniScan MX2 of

compatibility with all phased array modules.advanced AUT application performance with faster setups, test cycles, and rThis second generation OmniScan flaw detector incr

The StandarOmniScan

The OmniScan MX2 offers a high acquisition rate and new powerful softwar

compatibility with all phased array modules.advanced AUT application performance with faster setups, test cycles, and rThis second generation OmniScan flaw detector incr

The Standard in Phased ArrayOmniScan

fers a high acquisition rate and new powerful softwar

compatibility with all phased array modules.advanced AUT application performance with faster setups, test cycles, and r

reetector increases testing ef

yased Array, Rff

resoftwar ree featuresin a po

rees, and reporting, in additioficiencies, ensuring superio

, Redefined

esin a portable, modular

eporting, in addition to universal ficiencies, ensuring superior manual and

Full screen mode

Fast, intuitive touch scr

Bright, large size scr

Be truly in touch with phased array

instrumentto efThe OmniScan MX2 of

ff

een mode

Fast, intuitive touch screen interface

Bright, large size screen


efficiently perform manual aThe OmniScan MX2 offers a high acquisition rate and new powerful softwar


ficiently perform manual and automated inspections. fers a high acquisition rate and new powerful softwar

p

ficiently perform manual and automated inspections. resoftwar ree featuresin a po

p

esin a portable, modular

Designed for IP66

Fast file transfer


Advanced Weld Overlay

Full screen mode

Designed for IP66

Fast file transfer


eld Overlay

een mode

w.www.olym.olympus-ims.comFor Info go to www.aws.org/ad-index

IT

1/8 FOOT TRIM PAGE 1PAGE 4

1/8 HEAD TRIM

1/8

FAC

E TR

IM

1/8

FAC

E TR

IM

1/4"

HIG

H FO

LIO

LAP

SC

OR

E/F

OLD

BLIN

D P

ER

F

BLIN

D P

ER

F

Base Copy: 01Copy Changes: Code Color: 273218 _501F

PO#:

Flat Size: 16.75 X 11.25

Final Folded Size: 8.5x11.25

PANTONE 540 C

V. 01

Critical: If this box appears yellow turn the Overprint Preview setting on in Acrobat

Vol. 15 / No. 4

Features2417

Inspecting to the Requirements of AWS D1.1 by Gary S. Martin /Heres answers to often-asked questions related to Clause 6, Inspection, ofthe Structural Steel Welding Code / 13

College Works to Produce Grads Well-Versed in Core NDEInspection Methods by Rand Ernst / Central Piedmont CommunityColleges program was established to fill the need for trained NDEpersonnel in the Charlotte, N.C., area / 17

Ethics Alert: Ethical Conundrums by Joseph P. Kane / CWIs need to becareful because not every situation they will face is covered in the AWSCode of Ethics, Rules of Conduct, and Practice / 21

Moraine Valley Aims to Place Students on the Job Quickly by NancyGlickman and Salahuddin Razi / Students can learn the basics of NDE atthis Chicago-area community college / 24

Florida School Offers Go-to-Work Training by Linwood Noble / Jobplacement is an important element of the NDE program at thisJacksonville, Fla., area vocational school / 27

DepartmentsEditors Note................................6

News Bulletin ..............................8

Mail Bag.....................................10

Print and Product Showcase ......12

The Answer Is ............................30

Mark Your Calendar...................32

Certification Schedule................33

Just the Facts ..............................34

Technology Notes.......................38

Advertiser Index.........................40

INSPECTION TRENDS (ISSN 1523-7168) is

published quarterly by the American Welding Society.

Editorial and advertising offices are located at 8669

Doral Blvd., Miami, FL 33166; telephone (305) 443-

9353. Printed by R. R. Donnelley & Sons Co.,

Senatobia, Miss. Subscriptions $30.00 per year for

noncertified, nonmembers in the United States and its

possessions; $50.00 per year in foreign countries;

$20.00 per year for noncertified members and students;

$10.00 single issue for nonmembers and $7.00 single

issue for members. American Welding Society is located

at 8669 Doral Blvd., Miami, FL 33166; telephone (305)

443-9353, Periodicals postage paid in Miami, Fla., and

additional mailing offices.

POSTMASTER: Send address changes to

Inspection Trends c/o American Welding Society, 8669

Doral Blvd., Miami, FL 33166.

Readers of Inspection Trends may make copies of arti-cles for personal, archival, educational, or

research purposes, and which are not for sale or

resale. Permission is granted to quote from articles, pro-

vided customary acknowledgment of authors

and sources is made. Starred (*) items excluded from

copyright.

AWS MISSION STATEMENT

The mission of the American Welding Society is to advance the science, technology, and application of welding and allied processes, including joining, brazing, soldering, cutting, and thermal spray.

Inspection Trends / Fall 2012 5

These students are practicing their skills forweld inspection using ultrasonics. (Photocourtesy of Moraine Valley CommunityCollege, Palos Hills, Ill.)

Editors NoteBy Mary Ruth Johnsen

PublisherAndrew [email protected]

EditorMary Ruth [email protected]

Associate EditorHoward [email protected]

Associate EditorKristin [email protected]

Production ManagerZaida [email protected]

Senior Production CoordinatorBrenda [email protected]

National Sales DirectorRob [email protected]

Advertising Sales RepresentativeLea Garrigan [email protected]

Senior Advertising Production ManagerFrank [email protected]

Subscriptions RepresentativeEdalia [email protected]

American Welding Society8669 DoraL Blvd.Miami, FL 33166(800/305) 443-9353

Copyright

Copyright 2012 by American Welding Society in bothprinted and electronic formats. The Society is not responsible for any statement made or opinion expressedherein. Data and information developed by the authors ofspecific articles are for informational purposes only andare not intended for use without independent, substantiating investigation on the part of potential users.

Inspection Trends / October 20126

Dear Readers,

During this election season, Im sure

that, like me, youve been bombarded with

telephone calls asking you to vote for a

particular politician, donate to a

candidates campaign, or answer questions

for any number of polls. And, again, if

youre like me, youre ready for the

elections to be over, just so you dont have

to deal with the calls anymore. Calls that,

of course, always seem to come during the dinner hour.

Now all the calls I receive are either recorded messages or those

computer-generated robo calls, and I mostly ignore them. But if I

knew for certain that I could actually speak to a candidate, I might just

have something to say to that person. Because I have a pet peeve with

most politicians at all levels and both parties with regard to

education in this country.

How many times have you heard a politician and Im talking

about at the state as well as national level emote that Every child in

America needs to go to college! And while they dont specifically refer

to a university, we all know thats what they mean. That drives me crazy.

I believe every child should have the financial means to go to college,

but no, not every child in America needs to go to college. What every

child needs is training beyond high school. That training may mean a

four-year university, but it could also come from a community college,

vocational/technical school, or some other sort of specialized training.

In addition, I believe the politicians rhetoric gives our young

people unrealistic expectations. Now Im not saying that people cant

rise above their beginnings. I firmly believe in the American dream that

anyone can be whatever they want to be through education and hard

work. Im saying it makes kids feel there is something wrong with them

if they dont want to go to college; that it makes them ashamed to say, I

want to be a carpenter, electrician, cook, landscaper, welder, weld

inspector (you fill in the blank). And it makes parents not want to

encourage their children to become a part of any of those professions.

So what does this have to do with this issue of Inspection Trends?Well, education is the primary topic for this issue. Youll see profiles of

three educational institutions two community colleges and an

accredited vocational school that offer programs in nondestructive

examination. Theyre getting students who are transitioning right out of

high school, displaced workers retraining for new careers, and people

who want to upgrade their skills. The community colleges offer

associate degrees, of course, but all three programs are geared to getting

students into the work force.

I know that in the world of welding, were getting reports of

increased enrollment and new welding education programs opening up.

The schools profiled here have experienced growth in their NDE

programs as well. I hope those are all signs that recognition is coming

that we need workers of all kinds and that theres all sorts of great

careers out there, not just ones that require a four-year degree.

If you have any comments, please contact me at

[email protected] or (800) 443-9353, ext. 238.

The all new S1 TITAN

[email protected]

Positive Material Identification Fast alloy ID and chemistry Completely non-destructive Prevents material mix-up Lightweight only 1.44kg / 3.17 lbs,

including battery

DeThe all new S1

DefinitionThe all new S1

on off PrecisThe all new S1 TIT

sionTATAN

www

elementXRF allo

UltrThe all new S1

[email protected]/s1titan

elemental chemistrXRF alloy analyzer whic

Ultra light and exThe all new S1

hhsales@Bruk r-er-Elemental.net

y of virtually any alloer which provides grade ID and

a light and exceptionally accurThe all new S1 TIT

-Elemental.net

y alloy.vides grade ID and

ceptionally accurate TATAN

Innovation with I

h Integrity

Handheld XRF

Handheld XRFFor Info go to www.aws.org/ad-index

News Bulletins


Liberty Second Stage Closer to Production

Astrium, the Europeanaerospace company, recentlycompleted a set of tests on tankstructures to prove that keydesign and manufacturingprocesses used for Arianelaunchers are ready forproduction of the Libertycommercial launch vehiclesecond stage with ATK.

Liberty is a completecommercial crew transportationservice, including thespacecraft, abort system,launch vehicle, and bothground and mission operations.The planned first test flight isset for 2014 and a Libertycrewed flight in 2015.

Astrium, as a majorsubcontractor, will provide thesecond stage of the Libertylaunch vehicle, based on the

liquid-fueled cryogenic core of the Ariane 5 vehicle poweredby the Safran-built Vulcan 2 engine. Work done to completethe stage testing includes the machining, forming,computerized automatic welding and inspection of cryogenictank elements to provide the increased thickness andstiffened profiles necessary for the Liberty second stage.Another tank panel of increased thickness was welded andtesting in a cryogenic environment at the Euro Cryospacefacilities, an Astrium and Air Liquide joint venture.

These tests take the Liberty second stage one stepcloser to production, said Alain Charmeau, CEO of AstriumSpace Transportation. They demonstrate conclusively thatour proven processes can manufacture thicker and stiffercryogenic tanks for the Liberty second stage. Welding,machining, and forming space hardware is a highlysophisticated industrial process.

LTI Adds Fracture Toughness Testing Services

Laboratory Testing, Inc. (LTI), Hatfield, Pa., recentlyadded fracture toughness testing to ASTM Standards E399and E1820 to the list of services it provides.

The computerized fracture toughness test equipment atLTI can generate 55,000 lb of tensile or compressive force.An environmental chamber controls the test temperature

An artistss rendering ofthe Liberty spacecraft.(Photo courtesy of ATK.


between 150 and 350F. The company has fixturing to test

specimens in a range of sizes, including single edge bend and

compact tension specimens. Fracture toughness tests require

precisely machined specimens prepared to specification.

LTIs machine shop prepares all required specimens,

including those with an EDM notch. Additional information

is available at www.labtesting.com.

SGS Completes Tank Inspections in Liberia

SGS SA Industrial Services recently completed the

out-of-service inspection of two idle tanks in Liberia in order

to determine whether they could be successfully and safely

returned to operation and to provide a relevant repair

program. The work was done for Second Harbor Engineering

Co., Ltd., a wholly owned subsidiary of China

Communications Construction Co., Ltd.

The tanks had been idle for years. SGSs inspectors

follow the requirements of API 653, Tank Inspection, Repair,Alteration, and Reconstruction. Due to the complexity of theLiberian project, SGS assigned two experienced inspectors to

examine the two tanks, which had volumes of 3100 and

26,000 m3, respectively. The inspectors performed vacuum

box testing, visual inspection, magnetic particle testing,

plumbness and settlement surveys, ultrasonic thickness

testing, and other methods. After completing the inspection

phase, the company designed a repair protocol based on the

current status of the tanks and in compliance with the API

653 requirements.

In other news, SGS recently entered into an alliance with

Atlas Material Testing Technology, a provider of accelerated

weathering instruments and weathering testing services. The

alliance allows for the expansion of the Atlas 25+

photovoltaic module durability test program.

Carestream Hires Regional Sales Manager

The Non-Destructive Testing Group

of Carestream, Inc., Rochester, N.Y.,

recently added Chris Woodard as sales

manager for digital products in the

southeastern region of the United States.

Woodard will focus on growth in

the companys digital and conventional

film markets in Houston, Tex. For the

past few years, Woodard has been

selling in the electromagnetic area of

the NDE industry.

Fischers Feritscope FMP30 is the ideal solution for fast, precise measurement of ferritecontent of constructional steels,welded claddings, austenitic stainless steels and duplex steels.

Non-destructive measurement in the range of 80% Fe or 0-120WRC number.

Battery or AC powered Large, backlit display Automatic probe recognition Statistical evaluation USB interface Multiple application memories Bluetooth wireless technology

1-800-243-8417 1-860-683-0781 Fax: 1-860-688-8496www.Fischer-Technology.com [email protected]

Measurementof the Ferrite Content in Austenitic

and Duplex Steel

FERITSCOPE FMP30

SGS inspectors performed a variety of tests on two aging tanksin Liberia to determine whether they can be restored to service.

Chris Woodard

For info go to www.aws.org/ad-index


Mail Bag


Safety Tip Offered

With regard to the article Performing Inspections inConfined Spaces in the July 2012 issue, as an independentinspector, I never know where or for whom I will beinspecting. Even though I have never had a work-relatedinjury, there have been injuries to others. When on the jobsite, they know nothing about me or my personal or medicalhistory. Through my sports background (cycling and inlineskate racing), I obtained a personalized ID bracelet fromwww.roadid.com. It can contain up to six lines ofinformation. Mine has name, address, emergency phonenumber, medical insurance provider, blood type, and NKA(no known allergies). I have no affiliation, monetary orotherwise, with Road ID.

Alan Johnson, CWISeal Beach, Calif.

Reader Comments on Safety Issues

I always enjoy reading the Welding Journal and InspectionTrends. As a former instructor at Oak Ridge High School andthe Tennessee Technology Center in Knoxville, Tenn., I wasalways using information from both magazines to share withmy students. One subject that was stressed first, and as mostimportant, was safety. Pictures were always a good learningtool, especially for the high school students. But there would betimes a picture would show a safety violation(s). The picture(s)would be representing a different subject and not necessarilysafety. It just surprises me that these unsafe practices were notcaught while the picture(s) was being taken and before beingpublished. Some examples are in the July 2012 issue ofInspection Trends.

On page 18, the welder in the picture is not wearing safetyglasses while using a slag hammer. On page 19, the welder inthe photo at left has his jacket unbuttoned, exposing his T-shirtto a possible burn or fire. The picture to the right has a welderusing a sledgehammer to test his weld with his welding helmetstill on. The extra weight not needed at that time couldpotentially cause a neck injury.

I dont want you to think I am picking on AWS, becauseIm not. Its just that I am proud to be a welder, a CWI, amember of AWS, and a contributor from time to time. I wantAWS to stay the example for others to follow. Safety first.

Gary L. BibbeeCWI, Olive Springs, Tenn.

Readers Weigh in Regarding QualifyingWelders on Fillet Welds

After reading the discussions by both Mr. Fluckiger(Understanding Welder Performance Qualification, page 11,July 2012) and Mr. Moore (Qualifying Welders on Fillet Welds,page 17 of the same issue) combined with my 21 years in theindustry, I agree with Mr. Fluckiger that the present way in

which welders who are qualified in groove welds are alsoqualified in fillet welds is correct. All the welders who werequalified in groove welds that I attended to made good filletwelds. We never had the problems Mr. Moore described. Hisidea would just complicate the industry even more for noreason that will merit this type of change. With all due respect, Igive Mr. Moores suggestion two thumbs down.

Joseph De PasqualeSCWI, Los Angeles, Calif.

I have been in the structural steel business for 34 years as awelder, supervisor, plant manager, and CWI/CWE, and I wouldlike to comment on Mr. Moores article about welderqualification.

AWS D1.1 has been written, revised, and rewrittennumerous times regarding finding and using the most commonprequalified joints most job shops would use. What he proposedunder the A Modified Test heading would not meet theprequalified status of AWS D1.1 in the as fit up tolerances asshown in Fig. 3.4, Prequalified Joints, and would be beyond thegiven tolerance in AWS D1.1.

The cases in which a welder may or may not need to betested should be in the contract documents and what code thatparticular job may be under should also be listed. If not, animmediate request for information (RFI) should be sent out. Onreturn of the RFI, if a code has been referenced, a PQR andWPS should be written along with job-specific welderqualification.

If a code is not referenced, we as CWIs cannot dictate whatkind of test would need to be administered. Our job is to followthe given code that is being referenced to the best of our abilityand not make up our own rules. Only the Engineer of Recordhas the right to make changes to a particular code along withany special testing that may be needed including welderqualification.

I believe when welders fail the fillet weld break test or anyother test, it is solely due to not having enough training andexperience along with poor technique.

Most job shops want welders to start production as soon asthey are hired, assuming they can pass a WPQR. Trainingwelders should be a priority of every fabricator and AWS.

Fillet and groove welder qualification tests are a primaryfunction test of the welder and should not be changed. If awelder cannot pass a fillet or groove test, then that welderneeds more training.

Jim St.AmandQC Manager, CWI/CWE, United Steel, East Hartford, Conn.

I am an AWS CWI and CWE. I had 26 years of weldingbefore taking the leap (into inspection). So I am a veteranwelder and budding inspector, if you will. The welding fieldhas been and continues to be as rewarding as it ischallenging.

This is my take on the proposed welder performance testfor combination fillet and groove welds.

There is a test that one of my customers requires that I


qualify personnel by. It consists of a single-bevel groove weldfor GMAW joint designation B-U4a-GF, as shown in Fig. 3.4of AWS D1.1/D1.1M:2008. When used with a 38-in. rootopening on 38-in. material with backing, I feel it performs thesame function as the proposed test in the article with oneadded benefit. B-U4a-GF has an advantage over the other inthe aspect of backing strip removal. The one proposed in thearticle has a 1516-in. root opening and will make removal of thebacking strip more of a chore and hinder an accurate cut witha band saw. It will also take more time due to added materialto cut through. Removal of the backing strip will most likelyrequire use of a milling machine. For some, this will certainlylimit in-house coupon preparation for the guided bend test.

Mid-size to larger welding facilities that employ a dozenor more welders and an in-house CWI generally do in-houseperformance qualifications due to the cost of outsourcing.They send out for third-party testing for procedurequalification more for impartiality reasons.

While I can understand and agree with the frustration thatfillet weld break tests are more difficult to pass than groove

Tight!

1 800 552 1999

the best way to bolt!Which one would you rathershow to your inspector?

*USA's only manufacturer ofQuenched & Tempered DTIsper ASTM, RCSC and FQA.

SquirterDTIs*

Scan with smartphone to learn more. [email protected] www.appliedbolting.com

T R A I N I N G F I E L D S U P P O R T T E C H N I C A L E X P E R T I S E

Tight?



continued on page 35

Dear Readers:

The Inspection Trends encourages an exchange ofideas through letters to the editor. Please send your let-ters to the Welding Journal Dept., 8669 Doral Blvd.,Doral, FL 33166. You can also reach us by FAX at (305)443-7404 or by sending an e-mail to Mary Ruth Johnsenat [email protected].

Print and Product Showcase


Flashlight Rated Safe forHazardous Locations

The EXPRL-91 LED flashlightfeatures multiple operating modes,rechargeable operation, waterproofconstruction, and 360 lumens of totaloutput. It can operate for up to 16 h onone battery charge. It comes with a100240 VAC wall charger, chargingcradle, and 12-VDC vehicle chargingcord. It is U.L. approved asintrinsically safe for Class 1, 2, 3 - Div.1, 2 - Groups C, D locations and ATEXcompliant to Category 1, Zone 0,making it suitable for locationsregulated under both U.S. and EUstandards. It is useful for workers inpetrochemical processing facilities,water treatment plants, offshore oilplatforms, and anywhere flammablegases and vapors are present duringnormal work operations.

Larson Electronics

www.LXflashlights.com

(800) 369-6671

Track System OffersMaximum Lighting Coverage

The Spectroline ONT-365 On-Trak NDE inspection system utilizespowerful UV-A and white light LEDsattached to a mountable platform. It isuseful for NDE inspection booths, andfor preinspections and screening

applications requiring maximumuniformity of coverage over a largearea. It features four broadbeam lampheads that contain three ultrahigh-fluxUV-A (365-nm) LEDs for inspectionand one white light LED for generalillumination. The light sources producea nominal steady-state UV-A intensityof 9000 W/cm2 at 15 in. An optionalattenuating filter is available forreduced-intensity applications. Theyoffer instant-on operation and theLEDs have a rated life of 30,000 h.

Spectronics Corp.

www.spectroline.com

(800) 274-8888

Camera Elevator AllowsInspection of Nearly All Pipes

The companys remotely operatedcamera elevator accessory allows asingle crawler to inspect pipes indiameter from 6 to 72 in. The elevatorcan position the camera anywherethroughout its 7.1-in. vertical travelrange. The elevator plugs directly intothe crawlers camera port and securesquickly with two bolts. It is controlleddirectly from the pendant and workswith any ROVVER X system. It

accepts any ROVVER X auxiliarylamp and pan/tilt/zoom camera or theDigiSewer side-scanning camera. Thecamera elevator is constructed fromaluminum and stainless steel.

Envirosight, LLC

www.envirosight.com

(866) 936-8476

Force Tester Offers PC Control

The ESM301 test stand Version 2300-lbf-capacity universal force testercan be used for break testing; cycling;limit testing to a load, distance, or limitswitch; load holding; elongation testing;tensile and compression testing; andother applications. It features a modularmechanical design that allows the frameto be separated from the controller forcustom mounting applications. Thetester and the ESM301L, an extendedlength model, are compatible with thecompanys digital force gauges, grippingfixtures, and data collection software.

Mark-10 Corp.

www.mark-10.com

(888) 627-5836

FeatureBy


By Gary S. Martin

As the newly installed chairman ofthe inspection Clause (6), of AWSD1.1, Structural Welding Code Steel, I was honored with a request towrite an article for Inspection Trendsrelated to that clause in the code. Otherthan that, I was given a blank slate towrite about. Unfortunately, Im not ablank slate type of writer, so my friendJohn Gayler, a former D1 secretary (acritical job in keeping the committeeon track) gave me some ideas to writeabout. As a former D1 Committeesecretary, he saw all the inquiries thatcame in about all the D1 codes, and hewas able to offer plenty of ideas for meto write about. Following are answersto some often-asked questions. Keep inmind that any opinions expressed aremine alone.

Regarding Section 6.1.4.1 on whetherCWIs are required, how is option #3determined?

When determining therequirements for a fabrication projector product that falls under the scope ofAWS D1.1 Structural Welding Code Steel, you must review the contractdocuments. The requirements listed inthe code are only mandated wheninvoked by the contract. The Engineer,per Section 1.4 of the code, isresponsible for developing the contractdocuments. The code also allows widelatitude to the Engineer on makingmodifications or exemptions to thecode language. In the area of inspectorqualifications, there are three optionsoffered to the Engineer forconsideration in the contractdocuments. They are as follows:

1. Current or previous certificationas an AWS Certified Welding Inspector(CWI) in conformance with theprovisions of AWS QC1, Standard forAWS Certification of WeldingInspectors. Note that the inspector isnot required to have an active CWI

certification, only a prior one. It can bestipulated in the contract as to whetheror not a current certificate holder isrequired.

2. Current or previousqualification by the Canadian WeldingBureau (CWB) in conformance withthe requirements of the CanadianStandard Association (CSA) StandardW178.2, Certification of WeldingInspectors. This is offered as areciprocal agreement with CSA/CWBas their code and inspector certificationprocesses are very similar to those ofthe American Welding Society.

3. An individual who, by trainingor experience, or both, in metalsfabrication, inspection, and testing iscompetent to perform inspection of thework.

So Option 3 flies in the face of thetypical paradigm of requiring formallytrained and certified personnel toperform inspections, especially finalproduct release inspections, as is thecase. To get more insight on thisoption, the first thing I would do is goto the code commentary that coversthat portion of the code.

For those who have never lookedat the commentary of the code, it canbe a useful place to find furtherexplanation, examples, and guidanceon what the code language is trying toconvey. As formally stated in theforeword of the commentary, Thiscommentary on AWSD1.1/D1.1M:2010 has been prepared togenerate better understanding in theapplication of the code to welding insteel construction. The commentary islisted in the back of the code asinformation only, since this kind ofwording cannot be placed in the codelanguage itself. I like the fact that thereis this section in the code, and I wishother industry codes followed suit.

All that being said, there is,unfortunately, no commentarylanguage covering Section 6.1.4.1. It

actually skips from C-6.1.3 to C-6.1.5.Just my luck. That would havecertainly made this section easier towrite.

So I have to be careful here, else Imight be perceived as a one-mancommittee, writing code commentary.Even though it is not mandatory codelanguage, commentary language is stillproposed, discussed, and voted onbefore being added to the code.

So Im just going to offer myopinion as to why this third optionwas added. I dont have the completerevision history of the D1.1 Code, asit goes further back than anyone whois still alive today. I cant conveywhen and how this language was putinto the code as I have only been onthe committee for seven years, and theearliest revision of the code I have is2002. I can tell you that somewherebetween the 2002 edition and thecurrent one, the only change made toOption 3 was that it used to say anEngineer or technician whereas nowit only states an individual, furtheropening up the potential resourcepool. I can only hazard a guess thatthe reason for this third option is thatthere still arent enough CWIs in theworld to staff all the code-coveredprojects and there needed to be somerelief to this to allow projects to goon. It doesnt mean that just anyperson off the street will be approvedto conduct code inspections. If theEngineer approved this option in thecontract documents, he or she willalso likely have some stipulation onwho can be hired for this work. Mostlikely a rsum review, personalinterview, and some sort of practicaltest or examination will be conducted.In fact, Section 6.1.4.5 states thefollowing: Verification Authority. TheEngineer shall have authority to verifythe qualification of Inspectors.

I can also add that some of thesmartest people in welding and quality

Inspecting to the Requirements of AWS D1.1

Questions are answered regarding Clause 6, Inspection, of the AWS Structural Steel Welding Code


that I have known never bothered to

become certified. Even those who have

taken the test and failed can still be

excellent inspectors; it just may mean

they are not good test takers. Again, as

the Engineer carries great

responsibility in forming the contract

documents, it behooves him or her to

be careful in selecting the options for

inspector qualification for the project.

Who decides? Can an individuals

qualification be challenged? How

and by whom?

Well, we have already established

that there is no code commentary on

this code language, so no help there. I

guess as chairman of that clause task

group, I should propose some code

commentary: Ill put that on my to-do

list. Anyway, back to the subject at

hand, who can challenge an Option 3

inspector qualification? Well, for one,

the seller or contractor bidding on the

project can challenge anything in the

contract before it is accepted. Thus,

the seller may insist on using in-house

trained inspectors rather than having a

currently certified CWI or SCWI

manage all inspections. Of course, if

the buyer or customer insists on

current CWI certificate holders, the

seller may adjust its price and cycle

for this, and the customer can then

decide if it is worth the money and

time or not. There is always a balance

in any buyer-seller situation.

Typically, you dont get something for

nothing, and you usually get what you

pay for. There is also a term called

Authority Having Jurisdiction (AHJ).

Countries, states, provinces, counties,

cities, municipalities, and even home

owners associations can make some

or all of the code language mandatory

and can make modifications or

exemptions to the code language.

They can mandate certain options in

this regard or add controls on top of

Option 3. Another source to answer

this question is to look at the code

language covering CWIs in AWS

QC1. This is one of the free

publications that AWS offers, so

anyone can download it

(www.aws.org/certification) and seewhat it says about certification of

welding inspectors.

To answer this question, I looked

over QC1 again, something I hadnt

done since my last nine-year

recertification as a CWI, and I found

something interesting in Section 11

Code of Ethics, Rules of Conduct, and

Practice. Section 11.3.2 states as

follows: The SCWI, CWI, or CAWI

shall publicly express no opinion on

welding inspection subjects unless it

is founded upon knowledge of the

facts in issue, upon a background of

technical competence pertinent to the

subject, and upon honest conviction of

the accuracy and propriety of the

statement.

That being said, here I am

publicly expressing an opinion on

welding inspection subjects. Well, I

think I am safe here as Im sure I have

sufficient background, credentials,

training, and experience on the issue

to write about it.

So all that aside, what does QC1

say about challenging a CWIs

qualifications and how does that relate

to Option 3? Well, that sort of flies in

the face of a central certification

system such as the AWS CWI

program, as one of the key premises

of the program is that one need not

challenge a CWIs qualifications, as

that has already been vetted by the

AWS via a stringent examination and

certification process. Anyone who has

tried to obtain CWI certification

knows that you have to have a certain

amount of fabrication/inspection

experience, pass written exams, and

have good or correctable vision. You

must also maintain and document your

inspection experience and acceptable

vision every three years, and

document continuing education credits

every nine years to maintain your

certification. So, you really cant

challenge the qualification of a current

CWI certificate holder, you can only

challenge the conduct of the person

who may be in noncompliance with

the CWI Code of Ethics, Rules of

Conduct, and Practice. In other words,

we have to leave it that the buyer can

challenge the Option 3 inspector

qualification via contract

development, but not Options 1 or 2

inspector qualifications, except

perhaps that the CWI be a current

rather than past certificate holder.

Flaw, Discontinuity, Indication,

Defect, and Non-Conformance:

Are They the Same?

Recently, I was teaching a class

on NDE to some company personnel

using material someone else had

prepared that said nothing about these

terms. Its a pet peeve of mine that

many people, including NDE

professionals, bandy these terms about

incorrectly, which further increases

the misconceptions about them. There

are two places in AWS documentation

to find the meanings of these terms.

First is AWS A3.0, Standard WeldingTerms and Definitions. The second isthe definitions section of the specific

code, which may have additional or

specific definitions for terms used

exclusively in that code. The AWS

D1.1 Code and other D1 codes often

have definitions that differ from the

AWS A3.0 terms. In the 2010 D1.1

code, these are found in Annex K.

Lets see what these terms mean and

how the AWS codes define them.

Defect

D1.1: A discontinuity or

discontinuities that by nature or

accumulated effect (for example, total

crack length) render a part or product

unable to meet minimum applicable

acceptance standards or specifications.

This term designates rejectability.

A3.0: A discontinuity or

discontinuities that by nature or

accumulated effect render a part or

product unable to meet minimum

applicable acceptance standards or

specifications. The term designates

rejectability. See also discontinuity and

flaw.

The definitions are nearly the same,

except D1.1 gives an example of

accumulated defects and doesnt

reference discontinuity and flaw. I think

that reference can be confusing because

those are not the same as defect.

Discontinuity

D1.1: An interruption of the

typical structure of a material, such as a

lack of homogeneity in its mechanical

or metallurgical or physical

characteristics. A discontinuity is not

necessarily a defect.

A3.0: An interruption of the

typical structure of a material, such as

a lack of homogeneity in its

mechanical, metallurgical, or physical

characteristics. A discontinuity is not

necessarily a defect. See also defect

and flaw.

Again, nearly the same, except

D1.1 doesnt direct you to defect or

flaw, though Im happy for the


statement that a discontinuity is notnecessarily a defect.

Flaw

D1.1: Not defined.A3.0: An undesirable

discontinuity. See also defect.Okay, I have a bone to pick with

this definition. What constitutesundesirable, and what are we supposedto do about something undesirable? Isit rejectable? I dont think so. I alwaysthought flaw and discontinuity werethe same thing. Because I wanted tokeep an open mind about this, I lookedup both terms in an Oxford Dictionaryand, indeed, it describes a flaw assomething that is undesirable.However, I did find an interesting twistin one part of the definition: A fault orweakness in a persons character: Hehad his flaws, but he was still a greatteacher. To me, this says somethingcan have flaws, but still perform asintended. But, really, are anydiscontinuities desirable?

Indication

D1.1 defined for UT: The signaldisplayed on the oscilloscopesignifying the presence of a soundwave reflector in the part being tested. Generally, any response from a giveninspection method is an indication.

Non-Conformance

D1.1: Not defined.A3.0: Not defined.This term is used more in the ISO

code world, but carries the samemeaning as a defect. ISO chose thenon-conformance term to align withthe ISO 9000 series Quality Systemcodes, because it is a term used todefine a process that is noncompliant toan ISO requirement, and the termdefect didnt quite fit the vernacular ofthe ISO auditing world. However, itdoes nicely replace the term defect inall other code uses. We can say a defectis a nonconformance to the acceptancecriteria of the code.

To put it all in one sentence thatcan be remembered more easily: Anindication from an inspection processis a discontinuity or flaw that must beevaluated against acceptance criteriato determine if it is a defect ornoncompliance and subsequentlyrejectable to the code.

Explain the split between QA andQC regarding inspectionresponsibility. QC (inspector)required by code; QA (verification)not required, but a contract option.

Okay, lets look at the definitionsfor QA and QC in AWS A3.0oops,they arent defined there. Okay, letstry inspector; no, not there either.Verification? No, not there as well.Remember, A3.0 covers standardwelding terms and definitions. It reallyisnt supposed to cover NDT or otherinspection terms.

Lets see if D1.1 defines any ofthese terms. QC? QA? No. Inspector?No. Verification? No. John really gaveme a tough assignment here.Fortunately, Clause 6 in D1.1 doesdefine contractors inspection (QC) andverification inspection (QA).

Generally speaking, QC inspectionis performed by the producer orcontractor: 6.1.2.1 ContractorsInspection. This type of inspection andtest shall be performed as necessaryprior to assembly, during assembly,during welding, and after welding toensure that materials and workmanshipmeet the requirements of the contractdocuments. Fabrication/erectioninspection and testing shall be theresponsibilities of the Contractor unlessotherwise provided in the contractdocuments.

On the other hand, QA inspection(verification) is performed by theCustomer or Owner: 6.1.2.2:Verification Inspection. This type ofinspection and testing shall beperformed and their results reported tothe Owner and Contractor in a timelymanner to avoid delays in the work.Verification inspection and testing arethe prerogatives of the Owner who mayperform this function or, whenprovided in the contract, waiveindependent verification, or stipulatethat both inspection and verificationshall be performed by the Contractor.

Note the stipulation that the Ownercan waive this or reassign it to thecontractor.

Well, it seems that one wasnt sotough after all.

Which is correct, NDT, NDE, orNDI?

While which one of these terms touse is not really a pet peeve of mine, itdoes bring up the ire of many on the

code committee. I dont know if thishas been written about before inInspection Trends, but if it has, theanswer bears repeating in my opinion.NDT = Nondestructive testing.NDE = Nondestructive examination orevaluation.NDI = Nondestructive inspection.

Note that they all havenondestructive in common, but whichone is correct?

The wording in A3.0 is as follows:Nondestructive evaluation. A

nonstandard term when used fornondestructive examination.

Nondestructive examination(NDE). The act of determining thesuitability of a material or a componentfor its intended purpose usingtechniques not affecting itsserviceability.

Nondestructive inspection. Anonstandard term when used fornondestructive examination.

Nondestructive testing. Anonstandard term when used fornondestructive examination.

As you can see, AWS A3.0 statesnondestructive examination is the onlycorrect term and is the only one forwhich it lists the abbreviation, NDE.

Im not really sure why evaluationis not the standard. After all, isnt thatwhat a Level II does with the resultsfrom the nondestructive process?However, if you look at AWS D1.1Annex K, it states: *NDT.Nondestructive testing.

As stated previously, a code candefine nonstandard terms as long asthey are confined to that code. Thatswhat the asterisk means.

Here is the explanatory paragraphat the start of Annex K. The terms anddefinitions in this glossary are dividedinto three categories: (1) generalwelding terms compiled by the AWSCommittee on Definitions andSymbols; (2) terms, defined by theAWS Structural Welding Committee,which apply only to UT, designated by(UT) following the term; and (3) otherterms, preceded by asterisks, which aredefined as they relate to this code.

Now, that definition is pretty weakand there is a revision going throughcommittee to strengthen it, but until itmakes it into the code, I cant discussspecifics.

I have heard committee membersjokingly say that they will agree tochange NDT in AWS D1.1 to NDEwhen ASNT (American Society for


Nondestructive Testing) becomes ASNE.By the way, why is it NDT/E/I

instead of NT/E/I, when nondestructiveis one word? My guess is our technicalpreference for TLAs (three-letterabbreviations).

But, on a serious side, A3.0 mayhave a point. Testing can be inferred tomean obtaining quantifiable resultsfrom a material or object. How strong,tough, hard, etc., is that material orobject? That information is usuallyobtained by destructive testing such astensile, bend, fracture, or hardness(although more and more you can dothis nondestructively) and with thenondestructive methods used today,there is no testing, only examination.

As for Inspection (NDI), it can beunderstood that inspection is a processto determine if a material or componentmeets requirements, without having toput any energy into the part as is donewith traditional nondestructivemethods, such as sound, radiation,

magnetism, or capillary motion (dyepenetrant). Inspection traditionallymeans just looking at an object ormaterial to determine if it meetsrequirements.

That being said, the most popularabbreviations for the six most usednondestructive methods all end in T.VT, PT, MT, UT, RT, and ET. Somaybe ASNT should change its nameto ASNE and the two-letterabbreviations should become VI (sinceno energy is imparted to the object invisual), PE, ME, UE, RE, and EE.

I personally believe usage justreally depends on whatever vernacularyou grew up with in the industry. Mostof the old codgers like me willcontinue to use NDT and the newgeneration will likely use NDE, andwhen enough of them are on thecommittee, NDE might become theofficial term in AWS D1.1. For now,we just need to agree they all mean thesame thing.

GARY S. MARTIN ([email protected]) is supplier qualitymanager Wind Fabrications/Compos-ites, GE Wind Energy, Greenville, S.C. Heis a member of the AWS D1 Committee,

chair of the committees Task Group 4 onInspection, an AWS Certified Welding In-

spector, and an AWS Certified Radi-ographic Interpreter.

An ImportantEvent on Its

Way?Send information on upcomingevents to Inspection Trends, 8669Doral Blvd., Doral, FL 33166.Items can also be sent via FAX to(305) 443-7404 or by e-mail [email protected].

FeatureBy Rand Ernst

Central Piedmont CommunityCollege (CPCC) is an accredited, two-year community college located inCharlotte, N.C. Approximately 70,000students are enrolled in the collegessix campuses, and there is also anextensive online component.

The Harper Campus in southCharlotte is home to CPCCsNondestructive Evaluation TechnologyProgram (NDET). The program is thebrainchild of Dr. Anver Classens who, asa welding engineer and division directorat the college, saw the need for trainedNDE personnel in the area, but there wasa lack of training facilities. His visioncame to fruition in the fall of 2007 withestablishment of the NDET program atCPCC. From a humble beginning of fourstudents, the program has grown in fiveyears to the current enrollment ofapproximately 90 students. The schoolhas recently completed a new 7000-sq-ftlab facility in which it has investedalmost $2 million dollars inequipment and supplies to build afirst-class educational environment.

The new facility includes anX-ray vault to house a new 320-kVportable X-ray machine anddarkroom (Fig. 1A, B), as well asclassroom and lab areas.

What the NDET ProgramOffers and EntranceRequirements

Central Piedmont CommunityColleges NDET program is one of thefew in the country to offer an Associatein Applied Sciences degree (AAS) innondestructive examination. The two-year degree is comprised of the coreinspection methods, welding, andblueprint reading classes, as well asgeneral education requirements in

English, mathematics, and socialsciences.

The NDE programs length andcontent follow the guidelines of theAmerican Society for NondestructiveTesting (ASNT), a professional societythat establishes recommendedguidelines for training and certificationof personnel in NDE in the UnitedStates. In order to be certified by anemployer, the guidelines require a

minimum number of formal traininghours as well as on-the-job experiencehours for each test method. Through acombination of lecture and hands-onlab work, CPCCs program providesthese required hours of training. Sincethese guidelines are the basis of theprogram, the colleges graduates satisfythe training requirements across thecountry and in most all industries.

The requirements for admission to


College Works to Produce GradsWell-Versed in Core NDE Inspection MethodsCentral Piedmont Community College has built a new state-of-the-artlaboratory/classroom facility to house its growing NDE Technology program

Student Justin Pearson inspects a pipe weld using ultrasonics.

the program are Completion of a high school diploma

or equivalent A CPCC placement test in English

and mathematics. Developmentalclasses are available for students tobuild basic skills and knowledge.

A counseling/orientation appointmentfollows placement testing.

In addition to the degree, thecollege offers a certificate program.Students earn certificates for specificNDE methods as they complete them,and it has been documented that thestudent has satisfactorily completed therequired training in that test method.Students can choose to go for thecertificate(s) alone or work toward adegree to get the certificates as they gothrough the program. The certificateallows the student to obtainemployment in a test method if anopportunity arises while continuing hisor her education or, if the need arises,to work before completing the fulldegree.

Another option available tostudents is a diploma in Nuclear PlantInspection. This is a course thatspecializes in advanced ultrasonicinspection of piping in nuclear powerplants, which is a highly technical andsought-after job skill.

Test Methods Covered

The test methods taught at CPCCare those considered the mainnondestructive examination methodsused in industry. While there are othermethods used in the various industries,CPCC teaches the most commonlyused and the core of the NDE business.The program includes classes in thefollowing methods:


Fig. 1 A The X-ray vault that houses theschools new 320-kV X-ray tube is on the leftwith an X-ray cabinet that houses a 160-kV tubeshown on the right; B students are shownperforming radiography on weld samples usingthe 160-kV X-ray tube.

Fig. 2 Students Jeff Fite and Ron Williams (bothseated) calibrate prior to performing an eddycurrent inspection.

1B

1A

2


Visual Testing (VT) Liquid Penetrant Testing (PT) Magnetic Particle Testing (MT) Eddy Current Testing (ET) Fig. 2 Radiographic Testing (RT) Ultrasonic Testing (UT) see lead

photo and Fig. 3.

Where Do CPCC StudentsCome From?

Contrary to the general conventionfor a community college, the vastmajority of students in NDET arentstraight out of high school. There is aneclectic mix of young people, not-as-young people with a lot of lifeexperiences, and people who have beenin the workplace for a few years andwant to train to do something else.Because of the economic downturn, thecollege has experienced an influx ofdisplaced workers, some of whom haveworked for years in a particularindustry, but have come back to collegefor retraining.

Central Piedmont CommunityCollege has an excellent weldingprogram that is also an AWSAuthorized Test Facility. The NDETprogram has gained some studentswho have graduated from thewelding program or who havechanged programs after having beenidentified as good NDE candidatesby their welding advisors.

The students have chartered theNorth Carolina Student Section ofASNT, and the group is very active Fig. 4. It is a means for students tonetwork with professionals in thebusiness who are the areas owners,managers, supervisors, and technicians.By working closely with the CharlotteASNT Section, students get to visitactual worksites and see the day-to-daywork environment. In addition, eachyear the students put on a benefit golftournament using the proceeds to sendstudents to the national ASNT FallConference where they network withNDE professionals from around thecountry, see the latest technology, andcan view various aspects of the industrythey dont get to see locally.

The Programs FutureChallenges and Possibilities

Plans are being discussed forworking with the CPCC weldingdepartment on welder qualifications.Students and instructors both could

The Students Perspective

Justin Sadek is in his third semester and has already been working in NDE fora year and a half.

Since youve already been working in the field, has it beenworthwhile for you to come back to college?

The training that Ive received while attending Central Piedmont hashelped a tremendous amount. Being able to apply the theory with the hands-onapplications has made a world of difference. Being able to understand whatIm doing and why has helped me understand why Im getting the results Iam. Anyone can calibrate a machine or follow a procedure, but to understandwhat can and will change, plus understanding the theory behind it all helpswhen someone asks what Im doing and how it works.

Would you recommend the program to anyone else?I would recommend the NDE program because there is always an effort

to expand the program and provide as much knowledge as possible.

Giovanni Gbemudu is in his second semester in the NDET program. Hisbackground is in the fields of architecture/construction.

How has the experience been for you in the NDET program?The experience has been a confidence booster. Coming from a different

background, making the choice of NDT without full comprehension of theindustry left me anxious about the training requirements. Surprisingly, I amamazed at the similarities between NDT and architecture/construction and itsdirect influences on everyday life safety.

What are your career objectives and/or priorities?As I better understand the NDT world, the opportunities within are

becoming clearer. My ultimate goal would be to gain enough experience at alllevels and hopefully contribute to the NDT industries of the third world. I believethe third world in the near future will come to rely more on NDT as we have inthe United States today.

Would you recommend the program?Yes, I would. I feel I am already an ambassador of the program, and it

only benefits me to have a strong alumni group.

Nate White is a former student now working for Structural IntegrityAssociates, Inc. He has been working in the field for a little over a year and isbased in Charlotte.

What was your background prior to coming to CPCC?Prior to coming to CPCC, my background was in the handyman/

construction industry.How has the experience been and what has been your favorite part?The experience has been wonderful. I have enjoyed all of my classes,

and the instructors are always willing to help. My favorite part has beenlearning from instructors who have been in the field.

What kind of industries and what type of projects have you worked on?I have worked in chemical plants, new construction sites, and in fossil

plants.With what youve seen in the field so far, do you feel that there is a

current need for trained technicians and will there be a need in the future?Yes. There is a huge need in the NDT industry for well-trained

technicians. The industry is getting more and more advanced, and as theindustry continues to advance, we need well-trained people who can keep theNDT industry thriving!

test weld coupons for internal defectsusing UT and RT.

With the college becoming betterknown in the industry, the hope is tobuild partnerships with companiesthroughout industry. Following are someof the ways this could be achieved: Having students work through the co-

op program. This is a win-winsituation for both the employer and thestudent because the student getsvaluable on-the-job training hours,sees how the work is actually done inthe field, and earns some money. Theemployer gets a trainee with a solidtheoretical background, who isanxious to learn the industry, andwhom the company can test out as a

potential future employee. Industry professionals could come and

speak at club meetings or directly toclasses. This would help studentsdispel their anxiety about not reallyunderstanding the day-to-day life of aninspector by hearing personal accountsof how the NDE business reallyworks. People who have specialexperience or equipment could sharetheir knowledge with the students.

Companies or manufacturers couldpartner with the school by loaning ordonating equipment. Industry wantspeople trained on the equipment thatthey use in the field and could beaccomplished through a loan ordonation program.

Further Information

For more information on CPCCsNDET program, visitwww.cpcc.edu/ndet.


Fig. 4 Student Emilie Peloquin from Quebec, Canada,has a degree in welding and worked as a welder beforeentering the NDET program. She is also chair of theschools student section of ASNT. Here she thanks formerstudent Nate White after he spoke at a section meeting.

Fig. 3 CPCC Instructional Lab Facilitator and formerstudent John Burke calibrates an ultrasonic testingmachine for an inspection.

RAND ERNST([email protected]) is

Nondestructive Examinationinstructor, Applied Technologies Div.,

Central Piedmont CommunityCollege, Harper Campus, Charlotte,

N.C. He is also an AWS member, AWSCertified Welding Inspector, and

ASNT Level III in RT, MT, and PT.

January(Winter)

The CWIs Roles and Responsibilities Common Weld Flaws and Their Causes Nov. 19, 2012 Dec. 7, 2012

April(Spring)

Tips for Working Overseas Inspection of Pipes, Vessels, and Tanks Feb. 19 March 13

July(Summer)

The Benefits of the AWS Senior CertifiedWelding Inspector Program

Aids to Visual InspectionMay 15 June 14

October(Fall)

Profiles of Top CWIs Update on Radiography and Radiographic

Interpretation. Aug. 19 Sept. 13

Editorial Deadline Advertising Deadline2013 Editorial Calendar

FeatureBy Joseph P. Kane

This is the final article in a four-partseries related to the Code of Ethicsfound in AWS QC-1: 2007, Standardfor AWS Certification of Welding

Inspectors.

Surely, most CWIs think they caneasily see a blatant ethical problemwhen they are confronted with one. Itis easy to see and avoid an outrightcash bribe. (Well, maybe the mind willget hazy, and the eyes will get foggy ifthe proposed bribe amount starts atnine figures to the left of the decimalpoint!) We know that we do not submitfalse welding inspection reports. Weknow we do not forge inspectionreports. We know that we do not signfor inspections that we do not perform,or for which we did not have directknowledge. We know that we do notpostdate reports or backdate reports ifthat action is meant to imply somequality that does not exist, or toconfuse the reader, lead the reader toinfer some quality that is incorrect, orsupport some dishonest venture.

However, I think the personalcomputer age brings new problems thatwould seem to be outside currentinterpretations of some of theindividual articles of the AWS Code ofEthics, Rules of Conduct, and Practice.I think it probable that the AmericanWelding Society will not be able towrite a comprehensive policy that willcover even a small part of the ethicalsituations that will be posed because ofthe use of computers and new reportingsystems. It is likely the requirements ofour customers to use computer systemswill require actions and reports that aregoing to pose some very differentethical challenges, and will createconundrums and ambiguities that donot fit the traditional idea and conceptof ethical conduct and practice.

Computer Reporting Systemsand Electronic Signatures

It is likely that most of us wouldnot sign for something on a report thatwe did not agree with, or sign forsomething we did not inspect orwitness. This seems to be a simpleconcept, but the computer age bringsout scenarios that can start any numberof what if situations. What is meantby personal knowledge throughdirect supervision (Article 11.2.5)? Iam concerned that computer reportingprograms, which are designed tostandardize project management,inspection recording, record keepingand reporting, may not leave enoughoptions to the inspector to fully complywith all the articles of the AWS Codeof Ethics, Rules of Conduct, andPractice as they exist today.

For example, right now I aminvolved as a third-party QA Inspectorfor a department of transportation(DOT) in a state that uses a computerprogram for all reporting activities. It isbasically a paperless system. However,in this filing system, some of theseparate reporting items are listed withme as the witness or as the inspector ofrecord. The reporting system includessign-off blocks for the dates of variousfabrication steps. I can only guess atsome of these dates, yet I have to fill inthe fields on the electronic form. Thesedates are really not critical to thequality or serviceability of the item, butit worries me when I have to enter adate that is simply my best guess.There is no remarks field where I canwrite in a disclaimer.

In some cases, I am required to fileother inspectors reports, and there isno way for me to refuse to accept thosereports. For instance, in the case of QCmagnetic particle testing (MT) report

submissions, I am automatically listedas witness. In many instances I may nothave witnessed all, or even any part, ofthat particular activity. Now, I havetaken advantage of an optional field inthis particular electronic report to posta short comment. I usually write I didnot witness any of this activity, Ionly observed part of this activity, or,I only witnessed MT on pieces 86F1and 86F2. There is also a field in thatsame report that has a drop-down menuthat asks, Report Accepted? 1. Yes, 2.No. The report doesnt give me anyother choices. So, I accept the report,because QC was required to submit anNDE report for me to enter, and I amrequired by contract language to enterit.

Sometimes I do not agree with theway the QC Tech does MT, so inaddition to the witnessing disclaimer,I also enter my technicaldisagreement remarks in the commentblock. To be safe and redundant, Iusually also make additional notes inmy separate Daily Narrative Reportdisclaiming 100% surveillance and/orexplaining my objections about thefabricators NDE activity.

Are all these disclaimersnecessary? I think so because I am stillthe person signing off on this activity.And, yes, it is often quite timeconsuming. Even if I do not actuallyphysically sign anything, I am stilldeemed to be the responsible inspectorfor the project. I am not a lawyer, so Ireally dont know how much can beused against me in a court of law, but Ijust wouldnt want to bet my career onit. Even if it is not a court of law, howdo you defend your activity or lack ofactivity to a DOT supervisor, or to anAWS Hearing Panel?

I have spoken about the

impossibility of adequately and

completely covering the whole project to


Ethics Alert: Ethical ConundrumsAs a CWI, you may be confronted with situations that arent exactly covered in the Code ofEthics and that will force you to make some tough choices

one of the state DOT engineers to whom

I report. He said the state recognizes it is

only paying for part-time or partial

coverage. The state emphasizes that you

are only a QA inspector, not a QC

inspector. Your primary job is to make

sure that the fabricators QC does all the

checks and tests for which they are

contractually obligated. In his words,

You only perform spot check

inspection. You are not expected to catch

everything, their QC is.The state policy is that it only

gives contracts to fabricators who havea nationally recognized fabricatorcertification such as from the AmericanInstitute of Steel Construction.Fabricators are required to have currentCWIs on the floor whenever there iswelding being performed, and theCWIs are to perform the inspectionfunctions. American Society forNondestructive Testing SNT-TC-1A-qualified technicians are required toperform NDE operations other thanvisual testing. A real, documented, andfully operational quality program hasto be in place, and it has to be actuallyused in daily operations. The statebelieves these prerequisites will weedout the hacks and fly-by-nights.Finally, the fabricator is required todemonstrate several years ofexperience, and pass a cursory audit bythe state or its designated inspectionagency. After all this, it is deemed thatonly QA spot checking of the operationwill ensure product quality. (Ha! If allthis inspires your confidence, maybe Ishould stop here and try to sell you abridge in Brooklyn, N.Y., for realcheap! But, that would be a fraudulent or dishonest venture anda clear violation of the AWS Code ofEthics, Rules of Conduct, and Practice,Article 11.2.6.)

I assume the Engineers I report toare honorable men. I truly believe themwhen they tell me what they expect ofme. I accept that they recognize that Iwill miss many things when I am doingonly partial inspection activity. Butwhat happens after they retire or arepromoted? What would happen, ifsometime in the future, there was afailure and another Engineer/Investigator researches the causes ofthe failure? Suppose he findssomething I missed, or something Iroutinely did not do, or my signature orjust my electronic name associatedwith some pertinent approval

document? This failure may havehappened shortly after the bridge is inoperation or several years from now. Inthat case, I dont know if I would evenremember anything about the failedpart. Without that disclaimer, andwithout the support of the Engineer, Icould be thrown under the bus. If Icannot remember any particulars aboutthe failed part, how can I expect theEngineer to be able to rememberanything and support me? He may havea dozen projects and fabricators underhis purview at any one time. It isunreasonable to think that he would beable to remember every detail of all theprojects he supervises. I, at least, livedwith the project. The Engineer reliedon me and my expertise, but cannot beexpected to remember any small detailshe did not directly work with.

What if It Isnt a Weld YoureInspecting?

As part of my duties, I am alsoexpected to inspect the coatingoperations. Most third-party inspectorsworking for DOTs are required toinspect coating operations, includinggalvanizing. (I cannot remember acontract where the third-party QA CWIdid not have to also inspect the shopcoatings operation.) Some states alsorequire the inspector to have a NationalAssociation of Corrosion Engineers(NACE) Level 1, 2, or 3 CoatingsInspector certification. However, mostonly require the supervisor to have aNACE Level 3 CIP certification. I donot have any NACE certifications, butI do have documentable experienceperforming basic coatings inspection.The client deems me qualified toperform coating inspections, includingthe blast cleaning, at least to the levelthey desire, as part of my inspectionduties.

Now there is nothing in the AWSCode of Ethics, Rules of Conduct, andPractice that addresses coatingsinspection. However, we do havegeneric requirements for honesty inArticles 11.1, 11.2.4, and 11.2.6.

Recently, I heard about a CWI QCinspector at a large bridge fabricationfacility who forged a paint report andhanded it to the QA inspector. The QCinspector had reportedly altered thedates and the piece number on thereport, but left the dry film thicknessvalues and paint batch numbers of theoriginal girder on the year-old report.

Unfortunately for that QC inspector,the QA inspector somehow recognizedthe old report, dug it out of the files,and compared it to the other one byholding both copies up to a light. (Howis that for a winning the bad lucklottery?) The QC inspector reportedlywas then asked if this was his report,and he asserted that it was. Reportedlyhe was asked again, and affirmedagain. Then he was confronted with theoriginal.

I have heard that the CWIsubsequently resigned his position. Insome jurisdictions submitting a falsedocument for filing is a seriousmisdemeanor or even a felony. Thereare federal funds involved in thisbridge contract, so there could also befederal criminal charges. What willhappen to this individual has yet to beseen. As for the AWS Code of Ethics,Rules of Conduct, and Practice,Section 11.2.4 applies even though itwas paint inspection instead ofinspecting welds. In this case, coatingsinspection was part of the CWIscontractual duties on the project.Therefore, there may yet be AWS Codeof Ethics violation charges in this case.

Other Situations

The ethical dilemma doesntalways start with computer-generatedforms. Some ethical questions may justbe a problem of perception. A simpleWelding Procedure QualificationRecord (WPQR) is rife with possibleethical traps. As a QA CWI, Iwitnessed all the welding, performedthe postweld visual inspection, andperformed the macro-etch testing, but Idid not witness the removal of themechanical test specimens from thewelded coupon assembly, themachining of the backing bar or of thespecimens, nor the bend and tensiletesting. I did not see the Charpy V-notch specimens machined or tested.All the machining and mechanicaltesting was performed by a third andfourth party. Yet I was the one requiredto sign off on the WPQR and send it tothe customer. In that case, I trusted thelab involved, but the staff there mademany data entry mistakes when theytransferred my handwritten notes ontotheir beautiful computer-generatedform and sent it out for my signature. Ihad to send it back for correctionbefore I would sign it. Therecommended PQR forms in Annex L


of D1.5, Bridge Welding Code, seem toallow inspectors to be very specificabout what they have witnessed.However, not so with the WelderQualification Form (L-5). The CWIsignature anywhere on the form couldlead someone to infer that the CWI hadsigned the welder off.

In another instance, I was thethird-party witness at a testing lab thatdid not have a tensile machine strongenough to pull the reduced sectiontensile specimen required for a majorhigh-rise project, and they had to cutthe reduced section tension specimenin half lengthwise and pull fourcoupons instead of two. (This was donewith the approval of the customersengineer.) As you can imagine, thiscreated a lot of extra work. I asked thetesting lab owner how he does this typeof testing normally. Well, if youwerent here to witness it, we wouldhave just penciled it in. What anastounding answer! To drive home whyI believe he was being truthful and not

just giving me a smug answer, theejecta area near their Charpy testingmachine had a whole pile of rustedspecimens laying in the corner on thefloor. Now, if you do not pick up thespecimens each time, examine andmeasure them, how do you report onthe percentage of shear and thepercentage of lateral expansion?

Because most times you do nothave to report anything but the impactvalue at temperature, this might havejust been a housekeeping issue.However, this lab does work for abranch of the government that usuallyrequires the additional data. So thisobservation, combined with theoutrageous response to the question,made me suspicious.

I was able to find my specimens,because they were the only shinyspecimens there. Think about it, if youdo not trust the testing lab, shouldntyou worry about signing your name tothe rest of the report?

Summary

The point of all this is that intodays age not every ethics issue is ascut and dried as those in the past. Iadvise that you think things throughbefore signing your name to electronicand/or paper documents. As a CWI,you need to not only adhere to theAWS Code of Ethics, Rules ofConduct, and Practice, but also payclose attention to your own moralcompass.

Inspection Trends / Winter 2011 23

JOSEPH P. KANE([email protected]) is with

A&A Consultants, Pittsburgh, Pa. He is amember of the AWS Certification Subcom-mittee on the Code of Ethics, and chair ofthe Structural Inspection Subcommittee.

He is also an AWS Senior Certified Welding Inspector.

Publications

ASNT Helps You Achieve

With publications needed for nondestructive

testing information, the catalog shows ASNTs

full-range of method handbooks, personnel

qualification, training materials, study guides,

journals and standard documents.

In the field, in the lab, in the shop, on the floor

or in the classroom, ASNTs publications help

you achieve positve outcomes.

Shop online at ShopASNT at www.asnt.org/shopasntPhone (614) 274-6003, (800) 222-2768 forUS and Canada, FAX (614) 274-6899


FeatureBy


By Nancy Glickman and Salahuddin Razi

Moraine Valley Community

College, Palos Hills, Ill., is the only

community college in the state with a

nondestructive examination (NDE)

training facility. Offering both classes

on campus and customized training for

businesses, this nationally recognized

program provides training to meet the

American Society for Nondestructive

Testing (ASNT) certification procedure

SNT-TC-1A and can be modified to

meet the requirements of CP189 and

NAS410.

Through this program, the college

is helping the unemployed and

underemployed, veterans, and career

changers return to work. Incumbent

workers looking to progress in their

careers also can receive advanced

training. Lewis Universitys aircraft

mechanics degree program also uses

the programs high-quality training

with hands-on experience.

The NDE Program

The courses taught at Moraine

Valley provide the required training for

Level I and Level II students in SNT-

TC-1A. The program includes

theoretical and practical training

needed for different levels of

certification. Faculty members are

required to be certified to meet the

NDT Level III requirements of SNT-

TC-1A and hold either the Level III

certificates issued by ASNT or

equivalent certificates issued by other

certifying organizations. Additionally,

they are expected to stay current with

technological changes in NDE by

attending conferences, seminars, and

other technical training.

The colleges laboratory has a vast

collection of test samples, including

welding samples, for instructional

purposes. Sometimes students can

work with test specimens similar to

Moraine Valley Aims to Place Students on the Job Quickly

The schools four-course core program prepares students for entry-level technician positions

A Moraine Valley CommunityCollege student practices hisultrasonic testing skills.


those they anticipate will be used in

their careers. However, all students are

expected to test a variety of different

specimens and are graded at levels

appropriate to their certification.

Students are required to get enough

practice to perform the NDE tests since

NDE is essentially an applied

discipline.

Why Is Training Essential?

While NDE is used in numerous

fields, including aircraft inspection,

building construction, power plants,

power generation, shipbuilding, and

drilling rigs, all manufacturers or

construction fields could benefit from

nondestructive techniques to ensure a

high-quality product is being produced

and is suitable for continued use.

As nondestructive examination is a

general-purpose method used to inspect

various parts, it is essential

professionals have a solid

understanding of the technology and

techniques that will be used, as well as

knowledge of the materials on which

these methods are employed.

Students in Moraine Valleys NDT

program study theory, but they also get

plenty of hands-on practice.

Nondestructive examination is built on

strong foundations of physics,

chemistry, and math. Understanding

these basic principles is critical to

becoming a competent NDE

professional. Without this knowledge,

students will find they are severely

handicapped in the NDE profession.

Using a computer to write reports and

acquire data also is becoming essential

for all NDE professionals. The college

encourages students to access

information online to get comfortable

with using a computer and offers many

credit and noncredit programs to

increase skills in this area.

Existing Training and Plans

Moraine Valley Community College

enables students to complete basic

training to enter the job market or

improve skills needed for a promotion.

After completing training and passing a

qualifying examination, the college

certifies that the students have

completed the required hours of formal

training for Level I or Level II

certification in the methodology studied.

Students then are prepared to take

the next step in their professional

careers. Nondestructive examination

certification programs also require

students to complete a significant

number of on-the-job training hours

before taking their certification tests.

Certification is given through the

employing company.

Moraine Valley offers several

courses in NDT. Radiography courses

usually are preceded by a Radiation

Safety class. Regulatory bodies at state

Fig. 1 A group of students is shownsetting up the X-ray equipment for aninspection of a weld inspection.

About Moraine Valley Community College

Located in the southwest suburbs of Chicago, Moraine Valley Community College is the second-

largest community college in Illinois, serving 36,000 credit and noncredit students annually. Founded in

1967, the college offers 115 degree and certificate programs, ranging from healthcare, cyber security, fire

science, mechanical design, culinary arts, and university-transfer curriculum, as well as noncredit programs

and customized training. Moraine Valley ranks in the top 3% of the more than 2800 two- and four-year U.S.

institutions granting associate degrees. The college is a member of the League for Innovation in the

Community College and is one of 12 national Vanguard Colleges.

For information on Moraine Valleys NDE program, and how to enroll, visit its Web site at

www.morainevalley.edu.


and federal levels require all personnel

performing radiography to be trained in

the fundamentals of radiation

protection so they can adequately

protect themselves and the general

public from hazards associated with

radiation.

Radiography can be performed

either with an X-ray source or a

radioactive source (usually Ir-192 or

Cobalt 60). Both methods have

advantages and disadvantages, but both

can find defects and are widely used

for inspection of welds. Radiography

has the advantage of providing a visual

record of the quality of the weld being

inspected, but the increasing use of

computers to scan images and analyze

defects is impacting this method

Fig. 1. Digital radiography is becoming

more popular and is expected to

replace the conventional film

techniques.

In the field of ultrasonic testing,

students learn on the equipment

commonly used for performing the

inspections, which allows them to

succeed in the job market Fig.2.

Moraine Valley plans to introduce

phased array inspection, but these

courses are in development.

Ultrasonic testing has long been

used for weld inspections and, until

recently, had the disadvantage that it

did not produce a permanent record of

the inspection. However, with the

increased use of scanners, phased array,

and computerized equipment, making

visual records is easy additional

support for the future of inspection

technologies becoming more heavily

influenced by the improvement of

computer technologies.

Magnetic particle and dye

penetrant testing historically have been

used as surface inspection techniques

primarily in the inspection of fillet

welds and as supplementary

examination of surface defects in

complete-joint-penetration welds.

These techniques historically have

been very successful in detecting

surface discontinuities and, therefore,

have been widely used. The operator

does not need as much training, and the

equipment/materials are less

sophisticated.

Eddy current testing and visual

testing techniques are taught based on

need and demand for the course.

Students studying these techniques also

use the large collection of the colleges

samples so they can learn about the

different materials they are likely to

encounter in their work.

Collaboration betweenCollege and Industry

Moraine Valley maintains an

Advisory Board composed of

administrators, faculty, and members of

business and industry who have been

instrumental in helping design a four-

course core program that prepares

students for entry-level technician

positions. This group, along with local

businesses, makes up the 28 partner

companies that review rsums of

course completers and employ program

graduates. The board also assists

Moraine Valley with staying current in

the industry by assessing needs and

adjusting the curriculum to address

those needs.

Local and national job

opportunities are plentiful in NDE.

After graduation, most students have

found employment at companies that

perform in-house NDE, including

foundries, aircraft repair, and

manufacturing. A significant number of

students are employed at independent

laboratories and facilities where they

can get a wide range of experience.

Those who like to travel or are looking

to relocate should easily find work in

other areas of the country. The average

annual salary for NDE technicians in

Chicago is $52,000 (www.indeed.com,9/4/12). As in other skilled trades, the

NDE industry is experiencing many

retirements by Baby Boomers. That,

coupled with the opening of additional

pipelines and federal- and state-funded

infrastructure projects, means that jobs

are being created for younger workers.

In this day and age, NDT

absolutely is a solid career choice. Like

anything else, it can be what you make

of it, said Rich Flores, a Moraine

Valley NDT program graduate. You

can be the best assistant in your

company or a fully certified technician

across the board. Your personal drive

will be the deciding factor. Like most

crafts, there are inherent risks. You can

expect to get dirty in the field as well

as spend time preparing reports back in

the trailer. You will remain reasonably

physically fit and will be trained to be

observant, sharp, and professional. At

the end of the day, when you discover

that indication that could have been a

serious failure, it is very rewarding. All

of this is the result of your decision to

begin your career in NDT, and the

program at Moraine Valley is the best

place to start. .

NANCY GLICKMAN ([email protected]) is program co-

ordinator, Corporate, Community andContinuing Education, and SALAHUD-

DIN RAZI is an instructor, Moraine ValleyCommunity College, Palos Hills, Ill.

Fig. 2 At the schools ultrasonic lab, astudent uses a transducer to conduct aweld inspection.

FeatureBy Linwood Noble

CDA Technical Institute (CDA) is

located in Jacksonville, Fla., on the banks

of the St. Johns River only a few miles

from the Atlantic Ocean. It is a federally

accredited vocational school that was

established as Commercial Diving

Academy in 1995, in Orange Beach, Ala.,

to provide training and employable skills in

the commercial diving profession. Captain

Ray Black founded the school to answer the

need for trained commercial divers because

schools of this type were rare at that time.

CDA is the realization of his dream of

sharing his 15 years of experience and

training with others. In 2001, CD

aws_it_201210

Documents

phased array modules

manual athe omniscan

phased arrayomniscanfers

phased arraybright

high acquisition rate

new powerful softwarbe

faster setups

test cycles