Duties of a Welding Inspector

General:
My duties are as a welding inspector to check that all welding and associated activities are being carried out at the job site in accordance with the requirement of the welding procedure specification, which is approved by the authority. More important, from where and how to find relevant information and how to interpret information and its understanding. My duties can be divided in to three categories.

Prior to welding
Check all applicable documents such as relevant inspection formats, quality inspection plan and project specification, code and standards with their latest edition. Check the availability of approved Welding Procedure pecification !WP " with supporting Procedure #ualification $ecord !P#$". %nsure the welders identification and their qualification range such as diameter range, position, deposit thickness range, filler metal etc. Check the material composition of base metal !pipe and plate" and filler metal !wires and electrode" by M&C' according to the project material specification. Check material condition and rating according to project material specification and project drawings. %nsure the correct consumable such as type, si(e, baking requirements, shielding gases etc. Check the condition of welding plant)equipment and ensure that is appropriate for job. Check the availability of the safety permit such as gas free and hot work permit. %nsure the correct method is being used to pre*heat and appropriate temperature is being maintained for tack welding and also prior to start the welding !if required". Check the surface preparation method. Check dimension and orientation according to drawings, and also ensure the correct fit up such as cleanliness, root gap, root face, bevel angle, misalignment and seam off set etc. Check the availability of the purging dump to adequate gas flow rate !if required". Check the weather condition and ensure the necessary requirement for protection.

During welding.
%nsure the correct welding process is being used according to welding procedure specification %nsure that the line*up clamp is being removed on the completion of root bead as specified in the welding procedure specification Check the laps time between the root pass and hot pass. Check the welding parameters such as voltage, amperage and polarity, welding technique, weld*direction and run sequence. Check the root pass internally where possible. Check back gouged welds, amount of gouge and cleanliness of gouge !if required" Check inter pass cleaning Checks inter pass temperature minimum and ma+imum range.

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.scertain the travel speed to control the heat in put with in the range. %nsure that the welding is being carried out in accordance with the approved WP and applicable code.

After welding
%nsure the welding is completed according to welding procedure specification %nsure the weld is post cleaned. Check dimensional accuracy. /isual inspection of the weld for defects such as undercut, overlap, surface porosity, incomplete filled groove, arc strike and etc. Check the weld contour and width. %nsure joint is cover with the heat resistance material to retard cooling rate where applicable. Post weld heat treatment if required. Check internal condition of the weld by $&)0& or in accordance with the requirement of the code)specification. %nsure that all relevant reports are available. 1elayed inspection after 23 hours for hydrogen cracking. 4ncase repair5 ,. Mark out area positively and clearly. 3. Check the availability of the repair procedure. 6. Monitor when removing of desired area and check visually and 71&. -. Check re*welding visually and 71&. %nsure that all relevant documents completed and signed off by the authority for keeping record and for final documentation.

Welding process defects

1 - Weld decay
Weld decay? Weld decay is corrosion between grains. Causes? &he reduction of the chromium from grains is main cause of the weld decay. When material is over heated 899: C;<99: C, chromium comes out from the grains, joins with carbon and becomes a chromium carbide on the grain boundaries. 4t happens in the heat*affected (one. Chromium is retard corrosion. Corrosion occurs between the grains as chromium is reduced. Avoidance? We can avoid weld decay =y using the low carbon content material such as 6,8> ? 69-> instead of 69- ? 6,8. =y using the stabili(ed stainless steel such as 63, ? 6-2. =y adding the titanium and niobium. &itanium and niobium join the carbon and become titanium and niobium carbide. &itanium and niobium give stabili(ation to chromium.

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=y the keeping of appropriate heat input. =y the keeping of appropriate inter pass temperature.

- !olidification crac"ing
!olidification crac"ing? olidification cracking is hot cracking, centerline cracking in the weld metal Causes? ulphur, stress and joint design are the main causes of the solidification cracking. ulphur comes from parent metal, joins with the iron and becomes iron sulphied. 4ron sulphied has low solidify temperature than steel. 4ron sulphied becomes a thin film in liquid form between the solidify grains on the center of the weld. 4ron sulphied possess a very little tensile strength. .ny stress make a solidification crack at this moment. Avoidance? We can avoid solidification cracking =y the using low sulphur content material =y changing of joint design. =y good cleaning of joint. =y the adding of manganese to join the ulphur to becomes manganese sulphied. Manganese sulphied has a same temperature to solidify with steel. Manganese reduces a ulphur content and discrete the iron sulphied. &herefore, less chance to crack.

# - $a%ellar tearing
$a%ellar tearing? >amellar tearing has characteristics step like crack. &ccurrence? 4t occurs in the thick section in the tee joints, close corner joint, wrought plate, in the @.A of steels, where fusion boundary of the weld and only in the rolled direction of parent material. Causes? Poor through thickness ductility, stress and high ulphur contents are main causes of lamellar tearing. .lthough, others non*metallic inclusions may also play a part. &he presence of the hydrogen increases steel's susceptibility to lamellar tearing quite significantly. Avoidance? >amellar tearing can be avoidedB =y reducing the si(e of the weld, try to use fillet weld instead of butt weld. =y changing the joint design, where stress moving in the roll direction. =y using the low ulphur content steel. =y buttering layer =y using ( quality plate that has been stra tested.

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Assessed? .ssess by short tensile test according to = C,6C.

' - (ydrogen crac"ing

(ydrogen crac"ing? @ydrogen cracking is known as cold cracking, hydrogen induced cracking !@4CC" and delayed crack. Cause? @ydrogen cracking can be occurred whenB @ydrogen is e+ceeds ,Cml),99gms of the weld metal. tress e+ceeds D yield stress &emperature is less than 6C9: C @ardness e+ceeds -99/P7 !/ickers pyramid hardness" Eil)greasy surface Moisturi(ed flu+ ome processes e.g. MM., .W ? FC.W give a potential to hydrogen. Avoidance? @ydrogen cracking can be avoid byB .ppropriate baking of flu+ covered electrode. .ppropriate pre*heating .dequate inter pass temperature .ppropriate heat in put. Post*heating to defuse hydrogen and reduce the residuals stresses.

Welding processes
G)AW *tig+ ,! #-1.
1rooping characteristics arc process !constant current". )ype of operation: 7ormally manual but can be mechani(ed. /ode of operation: .n arc is maintained between the end of tungsten electrode and parent metal. &he current is controlled by the of power source. Eperator must control arc length and feed the filler wire for correct welding. 7ormally argon gas is used for arc shielding to arc and weld pool to prevent from atmospheric gases. 7o flu+es are used with the process. &he arc is unstable at low current. pecial provision is made for starting. Power source: Generator, transformer and rectifier. Current: 7ormally operate at dcHve but can be used with ac for light alloys.

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Consu%a0les %etal: Wires are according to = 3I9, Pt ,*C. Gases according to = -,9C ? = -68C !1ielding gases: 4t provides a suitable, ioni(able atmospheric for electric arc. 4t protects a weld pool from atmospheric contamination. 7ormally argon gas is used for shielding but helium and nitrogen also can be used. .rgonB provides a smooth arc at low arc voltage with dc*ve also gives cleaning action with ac for light alloys. 4n addition of hydrogen, provides a high arc voltage and gives deeper penetration also increase speed on stainless steel. @eliumB less than argon therefore high flow rate !3;3.C times" required to achieve same effectiveness with argon. Gives high arc voltage and heat suitable for thick section. More cost e+pensive than argon. 7itrogenB inert gas in the room but becomes active with o+ygen therefore unsuitable for majority of material but gives good result on the copper. More cost effectiveness than argon or helium. )ungsten electrode: 0nactivated)PlainB .ctivated ,J thoriatedB .ctivated 3J thoriatedB .ctivated (irconiatedB 1irect current ,*6.3mm rarely used. uitable for lower quality welds. May cause of tungsten inclusion. used with dcHve for all materials e+cept light alloys. used where arc stability required with low amperage also used with dcHve for all materials e+cept light alloys. specifically used with ac on the light alloys. alternative current ,*8.-mm

23uip%ent: Power source !dropping H constant current" Welding torch Gas cylinder Welding cables Welding helmet Defect associated wit1 t1is process: &ungsten inclusion >ack of fusion >ack of penetration 0nder cut =urn through Porosity %+cess penetration E+ide inclusions.

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Advantages: Good quality of the weld Good for thin material Wide range of weld material Clean weld, no slag, and no smoke. Can be achieved high mechanical and metallurgical properties. @igh root run quality. Disadvantage: @igh skill required for pipe welder /ery e+pensive as compare to other manual metal arc welding Good surface cleaning required $elatively slow process

G/AW *%.i.g. 4%.a.g.+

Flat characteristics !constant voltage" arc process. 4t may be considered together because same welding equipment and power source uses. hielding gases and filler wire may be differing to another. )ype of operation: Manual, mechani(ed or automatic /ode of operation: .n arc is maintained between the end of consumable electrode or wire, and work piece. Wire is continuously fed from a coil through a special designed gun. &he wire is fed at a constant speed selected to give required current. .n arc length is control by power source setting. .n arc length is not considerable for operator but depositing of the weld metal is considerable. .rc and weld pool shielded by the shielding gas. 7o flu+es are used with this process. Power source: Generator, transformer and rectifier. Current: 7ormally dc Kve !constant voltage" !1ielding gases: .rgon, hydrogen, nitrogen, helium .rgon K o+ygen !,*C" .rgon K Co3 !3*3C" for non*ferrous metal stainless steel carbon and low alloy steel

Consu%a0le: olid wire, cored wire, self shielded wire, rutile cored wire, basic cored wire, metal cored wire ! 9.< mm ; ,.8 mm". .ccording to = 3I9,. Gases according to = -68C ? = -,9C

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/ode of %etal transfer: pray or free flightB give high deposition rates and deep penetration welds. uited to thick materials e+cept light alloys. 1ip transferB used for thinner section and for all positional welding including v)down. Globular transferB intermediate range between spray and dip transfer mode, no manual application and success on mechani(ed and automatic. PulsedB arc is modified form of spray mode. Give high deposition rate and for all positional welding. 7o lack of root runs, regular penetration. 7o spatter, good profile, high quality welds. )ypical defect: >ack of fusion occurs is dip transfer mode. Centerline cracking in spray mode transfer Porosity, under cut, incomplete penetration, e+cess penetration and e+cessive spatters. Advantages: @igh quality of the weld /ery clean, no inter pass cleaning required. 7o slag with solid wire >ess skill required Minimal wastage of electrode @eavier weld bead produced Faster welding process Disadvantages: Costly equipment More maintenance required of equipment 7ot portable 4ncrease the risk of porosity due to shield gases @igh risk of lack fusion

!AW *!A+
Flat arc process !constant" voltage )ype of operation: Mechani(ed, automatic or semiautomatic. /ode of operation: &he arc is maintained between the end of electrode bare wire and the work piece. .s the electrode is melted, it is fed in to the arc a set of rolls, driven by a governed motor. Wire feed speed is automatically controlled to the equal the rate at which electrode is melted, thus arc length is constant. .rc is under the granular flu+. ome of flu+ is melt to provide a protective blanket !slag" over the weld pool. Flu+ is unaffected and can be recycled. Current: 1c Kve 1c Hve for best penetration. fast burn of rate.

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.c

for multy wire.

Consu%a0le: olid wire is used, ,.8 mm to 8 mm according to = -,8C, = C-8C, .W .C.,2 Fused and agglomerated according to = -,8C, = C-8C, .W .C.,2. 5used flu6 *granular+: Manufactured at high temperature, glassy appearance like crystal. Good chemical mi+ achieved. 1o not attract moisture. Good handling, storage, used and weldabilty %ach removal of impurities and fine particle during recycling Agglo%erated flu6: 1ry mi+ed and then bonded with either potassium or sodium silicate manufactured at high temperature. .bsorb moisture and limited recycling. Weld appearance not good. Defect: lag inclusion, under cut. Advantages: Good productivity Good quality of welding Good for thick material >ess skill required /ery clean 7o spatter is sticks smoke. 7o visible arc !no need eye protection" Disadvantages: /ery costly equipment >imited position of welding 7eed accurate fit*up Poor portability 7o good for thin material

/anual /etal Arc Welding

1rooping characteristics !constant current" )ype of operation: Manual /ode of operation: .rc is created between the tip of electrode and work piece. .rc melts parent metal and electrode to form a weld pool, which is protected by flu+ cover. Welder controls arc length

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and electrodes feed rate by the hand movement. &he slag must be removing after each deposited layer. 7ormally a small degree of penetration, plat edge preparation required. Power source: Generator, transformer and rectifier. Current: 7ormally dc Kve but also use dc Hve or ac. 1c Kve best penetration 1c Hve deposit is high Defect: Porosity, slag inclusion, under cut, e+cessive penetration and spatters. 23uip%ent: Power source Welding cables %lectrode holders %arth return Welding shielding helmet Consu%a0le: = %7 -II, .W .C.,, 4 E 3C89, = 3I38, = 3-I6 =asicB %29,<, %29,C, %29,8 $utileB %89,6, %6< 3$ CellulasicB %29,9, %<9,9 Advantages: >ow cost equipment %asy to operate at site %asy shift to site %asy and more deposit thickness Wide range of material Welding all position Disadvantages: >ow production due cleaning required after every layer 1irty and smoke production 7ot sufficient to weld all material successfully.

Advantages and disadvantages

7adiograp1y )esting
Advantages: Permanent record. Good for thin material.

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Wide range of material. 7o skill required for gamma rays. 7o surface cleaning required. 7o power required for gamma rays.

Disadvantages: 1angerous for health. >amination and lack of sidewall fusion cannot detect. %+pensive film. .ffected all other activities. Power source required for L*rays. 7ot good for thick material. @igh skill required for L*rays.

8ltrasonic )esting
Advantages: Give accurate location and depth of defect. 7o health ha(ard. 7o need power supply. 7ot affected other activities. Good for thick material. >amination and lack of sidewall fusion can detect. Portable. Disadvantages: 7o permanent record. @igh skill required. urface defect cannot detect. mooth surface required. 7ot good for thin material. >arge grain si(e material defect cannot detect.

Dye Penetrant )esting

Advantages: Can check all materials. 7o need power source. >ow cost. 1irect indicate to defect location. 7o high skill required. Disadvantages: For surface defect. More dwell time as compare to M&.

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/agnetic Particle Inspection

Advantages: urface and sub*surface defect can check. >ow cost. >ess time and more output. 1irect indicate to defect location. Disadvantages: Cannot use for non*ferrous. May be danger for operator. Power required.

Consu%a0les
Welding consumables are the electrodes, wires, flu+es and gases. %ach consumable is critical in respect to specification)supplier, condition and treatment !if any". Many codes are covered the various consumables. Covered electrodes: = %7 -II, .W .C.,, 4 E 3C89, = 3-I6, = 3I38. Gas s1ield wires: = 3I9, Part ,*C Gases: = -68C, = -,9C 5lu6es 9 wires *!AW+ = -,8C !C ", = C-8C !.) ", .W .C.,2 !C "

5unction of s1ielding gases *)IG4/IG4/AG+: 4t provides a suitable, ioni(e able atmosphere for the electric arc. 4t protects the weld pool from the atmospheric contamination. 5unction of flu6es: Provides a gas shield to protect the weld pool and arc from atmospheric o+ygen and nitrogen. Provides a slag, which gives additional shielding to the weld pool and assists in manipulation during the welding. 4mproves the physical properties of the arc !arc initiation and stability" 4ntroduces weld metal alloys such as iron powder, de*o+idant etc. 4mproves metallurgical properties to lowering o+ygen and nitrogen levels. 4ncreasing deposition factors and over all efficiency )ypes of flu6es *//A+:

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$utile, cellulose and basic flu+es are the common types of covering s for MM. electrodes5 others include acid and o+idi(ing coverings. 7utile: Medium weight of titanium dio+ide plus fluorspar. Constituents5 titanium dio+ide, clay and sodium silicate. 0sed for general purpose such as ms fabrication, low pressure pipe work, supports, structure and bracket etc. Gives fluid fast free(ing slag, suitable to easy use in all positions but not for vertical down. hould be kept dry but never baked. Cellulose: @igh cellulose content produces a large volume of gas around the arc. hield gas consist on @3, Co, CE3 ? @3o Most important gas is hydrogen, which increases the arc voltage and corresponding in power, which cause for deep penetration. $apid, rate of burn. Produces fast free(ing weld pool and thin slag, suitable for vertical down and overhead work. Main use on stovepipe welding of high strength large diameter pipelines and storage tanks. Good quality of penetration bead. $ough appearance and uneven ripples of completed weld. patter content higher than other electrode. @ydroscopic flu+ designed to hold between -*2J moisture. Must be kept dry but never baked. Constituent's cellulose !wood pulp", titanium dio+ide, sodium silicate. ,asic: @igh limestone and fluorspar content to produce weld metal with low hydrogen content. >imestone has good stabili(ing and produces carbon dio+ide gas shield. May be bake up to C99C appro+imately or depending on the manufacturer. .bility to weld low alloy, high ? medium tensile strength with high sulphur content without any cracking, also reduce the possibility of the hydrogen induced cracking in the weld metal and heat*affected (one, but dependant upon the properly dried. = 86I certifies for MM. as hydrogen controlled. Must be less than ,Cml),99gms of the weld metal but can be reduced less than C ml),99gms of the weld metal with proper control. 7eed higher degree of skill and must be used vertical up technique. Productive and e+pensive. Constituents5 limestone !calcium carbonate" gas former, Co3 secondary ioni(er, fluorspar slag former, sodium)potassium silicate main ioni(er. 5iller wire 9 5lu6es *!AW+B olid wire is used, ,.8 mm to 8 mm according to = -,8C.

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Fused and agglomerated according to = -,8C. 5used flu6 *granular+: Manufactured at high temperature, glassy appearance like crystal. Good chemical mi+ achieved. 1o not attract moisture. Good handling, storage, used and weldability %ach removal of impurities and fine particle during recycling Agglo%erated flu6: 1ry mi+ed and then bonded with either potassium or sodium silicate manufactured at high temperature. .bsorb moisture and limited recycling. Weld appearance not good.

Difference 0etween %icroscopic and %acroscopic.

/icroscopic
For grain structure analysis Cross*section view at high magnification e.g. ,99+ or ,999+ ome defects could also be detected and assessed. &he degree of preparation is much higher than macroscopic e+amination, e.g. for ferrite steel5 P,399 grade finished followed by ,um polish using a diamond paste then an etch using ,*CJ nital &his test is primarily used by the metallurgists

/acroscopic
For welder)procedure qualification &o view the cross*section view magnification is required C+ &o detect the weld defect and also to measure the actual defects already detects. Carried out on full thickness specimen included reinforcement Width of cross*section should include the heat*affected (one plus some parent material. ame test piece is sometimes used for hardness testing after macro e+amination pecimen transversely cut from the weld %ach test specimen is then ground, polished and etched to the degree required by the specification, e.g. for ferrite steels P-99 grade finish with an acid etch using ,9*,CJ nital !nitric acid K alcohol" &est specimen e+amined visually &he intent is to disclose any cracks, lack of fusion, porosity, slag etc.

!teel 2le%ents
,. .luminum5 3. Carbon5 de*o+idi(er, grain refiner

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6. Chromium5 -. Cobalt5

,. @ardening agent 3. trength hardening element, increase the strength of steel ,. Mnow as red hardness 3. 0sed where high strength, high hardness at high temperatures are desired increase toughness and hardening ability increase hardness also increase corrosion resistance qualities ,. 4ncrease strength and toughness at low temperatures 3. 4ncrease tensile strength about 8999psi for each additional ,J of nickel

C. Manganese5 8. Molybdenum5 2. 7ickel5

<. Phosphors5 ,. 0sually found in all steels 3. 4mproves machine ability of high*carbon steel 6. 4mprove strength and corrosion resistance of low carbon steel I. ilicon5 ,. Promotes fluidity of molten steel 3. 4mproves o+idation resistance and increase the harden ability 6. .lso contributes to the strength of >. steel ,9. /anadium5 ,,. ulphur5 ,. Promotes control of grain si(e, grain refine 3. 4ncrease harden ability less than 9.9-J

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