Welding Inspector
4/23/2007 1 of 691
Duties and Responsibilities
Section 1
Main Responsibilities 1.1
4/23/2007 2 of 691
• Code compliance
• Workmanship control
• Documentation control
Personal Attributes 1.1
Important qualities that good Inspectors are expected to have are:
•Honesty
•Integrity
•Knowledge
•Good communicator
•Physical fitness
•Good eyesight
4/23/2007 3 of 691
Standard for Visual Inspection 1.1
Basic Requirements
4/23/2007 4 of 691
BS EN 970 - Non-destructive examination of fusion
welds - Visual examination
Welding Inspection Personnel should:
• be familiar with relevant standards, rules and specifications
applicable to the fabrication work to be undertaken
• be informed about the welding procedures to be used
• have good vision (which should be checked every 12
months)
Welding Inspection 1.2
4/23/2007 5 of 691
Conditions for Visual Inspection (to BS EN 970)
Illumination:
• 350 lux minimum required
• (recommends 500 lux - normal shop or office lighting)
Vision Access:
• eye should be within 600mm of the surface
• viewing angle (line from eye to surface) to be not less than
30°
30°
600mm
Welding Inspection 1.3
Aids to Visual Inspection (to BS EN 970)
When access is restricted may use: • a mirrored boroscope• a fibre optic viewing system
Other aids:• welding gauges (for checking bevel angles, weld profile, fillet
sizing, undercut depth)• dedicated weld-gap gauges and linear misalignment (high-low)
gauges• straight edges and measuring tapes• magnifying lens (if magnification lens used it should have
magnification between X2 to X5)
4/23/2007 6 of 691
usually by
agreement}
Welding Inspectors Equipment 1.3
Measuring devices:
• flexible tape, steel rule
• Temperature indicating crayons
• Welding gauges
• Voltmeter
• Ammeter
• Magnifying glass
• Torch / flash light
• Gas flow-meter
4/23/2007 7 of 691
Welding Inspectors Gauges 1.3
4/23/2007 8 of 691
TWI Multi-purpose Welding Gauge Misalignment Gauges
Hi-Lo Gauge
Fillet Weld Gauges
G.A.L.
S.T.D.
10mm
16mm
L
G.A.L.
S.T.D.
10mm
16mm
01/4 1/2 3/4
IN
HI-
LO
S
ing
le P
urp
os
e W
eld
ing
Ga
ug
e
1
2
3
4
5
6
Welding Inspectors Equipment 1.3
4/23/2007 9 of 691
Tong Tester
AmmeterVoltmeter
Welding Inspection 1.3
4/23/2007 10 of 691
Stages of Visual Inspection (to BS EN 970)
Extent of examination and when required should be defined in
the application standard or by agreement between the
contracting parties
For high integrity fabrications inspection required throughout
the fabrication process:
Before welding
(Before assemble & After assembly)
During welding
After welding
Typical Duties of a Welding Inspector 1.5
4/23/2007 11 of 691
Before Welding
Preparation:
Familiarisation with relevant „documents‟…
• Application Standard/Code - for visual acceptance
requirements
• Drawings - item details and positions/tolerances etc
• Quality Control Procedures - for activities such as material
handling, documentation control, storage & issue of
welding consumables
• Quality Plan/Inspection & Test Plan/Inspection Checklist -
details of inspection requirements, inspection procedures
& records required
Typical Duties of a Welding Inspector 1.5
4/23/2007 12 of 691
Before Welding
Welding Procedures:
• are applicable to joints to be welded & approved
• are available to welders & inspectors
Welder Qualifications:
• list of available qualified welders related to WPS‟s
• certificates are valid and ‘in-date’
Typical Duties of a Welding Inspector 1.5
Before Welding
Equipment:
• all inspection equipment is in good condition & calibrated asnecessary
• all safety requirements are understood & necessary equipmentavailable
Materials:
• can be identified & related to test certificates, traceability !
• are of correct dimensions
• are in suitable condition (no damage/contamination)
4/23/2007 13 of 691
Typical Duties of a Welding Inspector 1.5
Before Welding
Consumables:
• in accordance with WPS’s
• are being controlled in accordance with Procedure
Weld Preparations:
• comply with WPS/drawing
• free from defects & contamination
Welding Equipment:
• in good order & calibrated as required by Procedure
4/23/2007 14 of 691
Typical Duties of a Welding Inspector 1.5
Before Welding
Fit-up
• complies with WPS
• Number / size of tack welds to Code / goodworkmanship
Pre-heat
• if specified
• minimum temperature complies with WPS
4/23/2007 15 of 691
Typical Duties of a Welding Inspector 1.5
4/23/2007 16 of 691
During Welding
Weather conditions
• suitable if site / field welding
Welding Process(es)
• in accordance with WPS
Welder
• is approved to weld the joint
Pre-heat (if required)
• minimum temperature as specified by WPS
• maximum interpass temperature as WPS
Typical Duties of a Welding Inspector 1.6
During Welding
Welding consumables
• in accordance with WPS
• in suitable condition
• controlled issue and handling
Welding Parameters
• current, voltage & travel speed – as WPS
Root runs
• if possible, visually inspect root before single-sided welds arefilled up
4/23/2007 17 of 691
Typical Duties of a Welding Inspector 1.6
During Welding
Inter-run cleaning
in accordance with an approved method (& back gouging) to good workmanship standard
Distortion control
• welding is balanced & over-welding is avoided
4/23/2007 18 of 691
Typical Duties of a Welding Inspector 1.6
4/23/2007 19 of 691
After Welding
Weld Identification
• identified/numbered as required
• is marked with welder‟s identity
Visual Inspection
• ensure weld is suitable for all NDT
• visually inspect & „sentence‟ to Code requirements
Dimensional Survey
• ensure dimensions comply with Code/drawing
Other NDT
• ensure all NDT is completed & reports available
Typical Duties of a Welding Inspector 1.6
After Welding
Repairs
• monitor repairs to ensure compliance with Procedure, ensureNDT after repairs is completed
• PWHT
• monitor for compliance with Procedure
• check chart records confirm Procedure compliance
Pressure / Load Test
• ensure test equipment is suitably calibrated
• monitor to ensure compliance with Procedure
• ensure all records are available
4/23/2007 20 of 691
Typical Duties of a Welding Inspector 1.6
After Welding
Documentation
• ensure any modifications are on ‘as-built’ drawings
• ensure all required documents are available
• Collate / file documents for manufacturing records
• Sign all documentation and forward it to QC department.
4/23/2007 21 of 691
Summary of Duties
A Welding Inspector must:
• ObserveTo observe all relevant actions related to weld quality throughoutproduction.
• RecordTo record, or log all production inspection points relevant to quality,including a final report showing all identified imperfections
• CompareTo compare all recorded information with the acceptance criteriaand any other relevant clauses in the applied application standard
4/23/2007 22 of 691
It is the duty of a Welding Inspector to ensure all the welding and
associated actions are carried out in accordance with the
specification and any applicable procedures.