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What is Inspection?

It is defined as inspection services including controlling and reporting whether the


purchased / ordered product and / or services are produced according to
international standards and order specifications.

Although it changes according to sector in manufacturing industry, The Inspection


subjects can be summarized as follows:

1. At the initial stage of work, examination and approval of Manufacturer /


Sub-Contractor Quality Control plan

2. Welding Procedures Specification (WPS) Control and Approval

3. Supervision in (Welding Procedure Qualification Records) and approval of


reports to be prepared and Encoding forms in compliance with WPS and
follow up,

4. Supervision in Welder Performance Tests and approval of welder test


certificates.

5. Control of any kind of material (metal sheet, profile, pipe, fittings) to be


used in manufacturing and consumables (electrode, welding wire, flux).
When necessary, having material mechanic tests conducted and approval of
reports

6. Supervision in all manufacturing process and tests to be carried out. (Non-


Destructive Tests, Vacuum Tests, Hydrostatic Tests) (Before the tests, test
procedures and test equipments are controlled and if appropriate then they
are approved.)

7. By controlling the reports to be prepared by subcontractor- manufacturing


company as a result of tests to be conducted, and if appropriate, they are
approved.

8. Supervision in manufacture size-dimension controls, approval of reports.

9. Controlling project-compliance of manufactures.

10.Determination of Non-Destructive Tests, if found necessary by manufactures


to be carried out, supervision in tests and approval of reports by assessing
the non-destructive test results.

11.Sanding-dying, if any, controls after manufacturing

12.Isolation controls (if any) under manufacturing

13.Preparation of Non-Compliance Reports for malfunctions in terms of Quality


during performance of work
NOTE: All necessary equipments and devices in compliance with standards for
tests are provided by subcontractor and/or employer.

AT THE END OF WORK, Below approved documents for work carried out are
submitted to CUSTOMER:

Material certificates

Welder documents

WPSs

PQRs

Gauge Control Report

Non-compliance reports

Reports for Measurements for removing non-compliance and preventing its


repeat

Non-destructive test reports

Hydrostatics test reports

Dye control reports

Revised images, pictures

Non-Destructive Testing Staff Qualification

Non-destructive test staff must be certified in compliance with relevant standard conditions
according to EN 473 or ASNT TC 1A.

Training and Qualification Exams (Certification) must have been carried out authorized
institutions complying relevant standard conditions.

Expertise levels

Person who is certified in compliance with relevant standard is classified under one or
several levels stated herein below, according to qualification he has.

Level I

A person who is certified as Level 1 is proved his expertise as he will carry out NDT
procedures according to written instructions and under supervision of staff certified with
level 2 or level 3. Under expertise scope stated in the certificate, a person, holder of level
1 certificate can carry out below jobs;
1. Installs Equipment,

2. Carries out Tests,

3. Records and classifies the results according to written criteria,

4. Reports the results.

Person certified with Level 1 is not responsible form selection of test method and
techniques or interpretation and evaluation of test results.

Level II

A person who is certified as Level 2 proved his expertise as he can carry out non-
destructive test according to known or established procedures. Under expertise scope
stated in the certificate, a person, holder of level 2 certificate can carry out below job:

1. Selects NDT technique for test method to be used,

2. Defines the limitations in implementation of test method,

3. Re-makes the NDT standard and specifications as NDT instruction,

4. Installs the Equipment and verifies the adjustments,

5. Conducts test and supervises,

6. Interprets and evaluates the results according to applicable standard, code or


specifications,

7. Prepares written NDT instructions,

8. Performs all jobs specified for Level 1 and supervises,

9. Guides the staff at Level 2 or under,

10. Arranges non-destructive test results and reports.

Level III

Person who is certified as Level 3 is proven his expertise as it will carry out and manage the
certified NDT operations. A person who has Level 3 certificate can carry out jobs stated
below:

1. Bears all responsibility of a testing facility or examination center and staff,

2. Prepares and validates the NDT instructions and procedures,

3. Interprets standard, specifications and codes,

4. Determines special testing method to be used, procedure and NDT instructions,


5. Performs all jobs specified for Level 1 and Level 2 and supervises,

Level 3 staff must prove that he has the below qualifications;

1. He must interpret and evaluate the results according the existing standard, code and
specifications,

2. He must have sufficient experience about material, manufacturing and product


technology in selection of NDT method, forming NDT technique and in helping the
formation of acceptance criteria in cases where other criteria are not available.

3. He must have general idea about other NDT methods,

4. He must have capability of guiding staff under Level 3.

5. When he is authorized by certification body, he must manage qualification exams on


behalf of level 3 staff and supervise.

Welding Procedure Qualification Record (WPQR)

Every welding to be carried out needs a report which specifies welding method,
material group and welding material is in compliance according to standards and
which its welding is performed in compliance with ASME or EN Codes according to
project standards and its mechanical tests are conducted and its results are in
compliance. Therefore, every Welding Procedure Specifications (WPS) must
require to have a supporting Welding Procedure Qualification Record (WPQR).

A WPQR can support several WPS under validity areas. WPQR preparation and
tests must be conducted and approved under supervision of Third Party Inspection
Bodies and WPQR must be in compliance with standard of the job carried out. For
jobs apart from ASME Code, related standard must be taken as a basis. For
example, for jobs under EN norm, WPQR that complies with EN standard will be
prepared. The welding terminology that will be used must be appropriate to
manufacturing standard.

Welding Procedure Specification (WPS)

Welding Procedure Specifications is a form that contains details of welding groove,


welding method to be employed, electrode and/or welding rod type and diameter,
current, voltage, welding position, welding run number and similar information
prepared in accordance with its codes relevant Project standard (ASME and/or EN
Standards).

WPS is prepared by Manufacturer / Sub-Contractor and approved by Authorized


Inspection Body before the start of job.
Welding Procedure Specifications must be in compliance with the job carried out.
For jobs apart from ASME Code, related standard must be taken as a basis. For
example, for jobs under EN norm, WPR that complies with EN standard will be
prepared. The welding terminology must be in compliance with manufacturing
standard, EN terminology must not definitely be used in US standards and US
welding terminology in EN manufacturing standards.

Welder Certificate

In the welded manufactures, welding must be performed by a welder who has


absolutely this qualification. For certification of this, welders will be tested
according to ACME SEC. IX or EN 287-1 standard in compliance with project
standard and will have a certificate and badge that covers the welding
specifications.

Tests of welders must be conducted under supervision of Independent Inspection


Bodies, then certificates must be given by these bodies. Welders who do not have
such a certificate or whose certificate is expired, then before the project, they
must be re-taken to test in supervision of authorized Inspection company. Badges
that is submitted by Independent Inspection Body and have also photograph on it
must be present on the welder during work and Customer controller will check
that welder is authorized to this welding or not by looking at this badge.

In certificate of every welder, there must a special cold seal mark. This seal must
be affixed next to welding job carried out by welder. Welder Certificate must be
in compliance with the job carried out. For jobs apart from ASME Code, related
standard must be taken as a basis. For example, for jobs under EN norm, Welder
Certificate that complies with EN 287-1 standard will be prepared. The welding
terminology that will be used must be appropriate to manufacture standard. EN
welding terminology definitely should not be used in US manufacturing standards,
and US terminology in EN standards.

Qualification Codes
BS EN 15614, EN 287, EN ISO 9606, BS 4872, ASME Section IX, CAA A8-10

Regulations/directives
Pressure Equipment Directive (PED)
Fabrication Standards/codes
PD5500, EN 13480, EN 13445, BS 4515, EN 1011, BS5400, DIN 6700
ASME B&PV Section VIII, Section III, Section XI, B31.1, B31.3, B31.4, B31.8
AWS D1.1
API 1104, API 510, API 620