Ruadne & if Iesve # Now 95; Revo TP O'Neil Awest ee A-WI-S1 - Answer Sheet - Duties of a Welding Inspector sll lreeeeiee aa eeensteinene cen aenioeen Ses enna Question: In approximately 300 words, describe the duties of a welding inspector working in accordance with the specification R&O 123. Identify the specification sections which apply to each duty, Answer: ‘The duties of a welding inspector‘working in accordance with the specification R&O 123 are as follows Before production welding takes place ensure that the procedure welds are made in accordance with the agreed writtén procedures ‘atid ensure that the test coupons for.destructive testing’ are taken from ihe right areas after the results of NDT have been received. {Check that the test specimens have been prepared correctly and Witness destructive testing and ensure that the reporting of test results are ‘complete and correct, (Ref. 4.1).> BHD. 6, pe The inspector must ensure he has a copy of R&O 123 and all relevant procedurés and has’ access to celated normative documents listed in Section 2.2. , The weldet qualification tests must bé ‘witnessed to ensure compliance witl the approved procedures and R&O 123, (Ref. 6.2). It is also the duty of the inspector to ensure that the necessary approvals of welders are available and that only correctly approved welders are producing welds once production has started. 9 Play ‘The inspector must verify that all the parent materials and consurnabtes to be used to frm welders are of the correct type and condition (Ref. 4.1). All joint preparations must be checked for corectness, ic. bevel angles, root gap; root face must be int accordance with the procedure, (Ref. 7.2); pipe, misalignment must not exceed 1.5 tim, (Ref. 7.9); seam offset must be.at feast 250 mri (Ref. 8,3); the joint area must be cleaned at least-25 mm back from the bevel faces and must be free’ ‘fmm damage (Ref. 6:77, . Wy The preheat for each joint must be checked using temperature indicating crayons (the type that melt) or a thermocouple, to confitm it is within'the temperature range specific in the welding procedure, (Ref. 7.3). During welding the inspector must ensure that the correct welding procedure is being followed at all times, .g. amps, volts, polarity, interpass temperatures, time limits etc. must be checked, (Ref. 7.4.4). Each weld pass must be checked after completion to ensure that the joint is cleaned of slag befofe the deposition of the next pass, (Ref. 7.4.5) After each weld has been completed the inspector must carryout a visual check for defects in the weld and are strikes, (Ref. 3.2.5 and 7.4.8). The weld geometry must be checked for uniformity and correct size, (Ref. 7.4.9). A ceport must be submitted to the client giving details of all welds made and any non-compliances, (Ref. 10.1).RATPO-ms.NDT-ml Date: 11/0699 ise Merits and Limitations of NDT Test Methods Technique Visual Inspection Uses Surface inspection Merits Simple to use Limitations le Inspection of acces: _ of any materials Safe surface only gt TH *inexpensive «Surface breaking defects only ‘Rapid results Some surface defects may be ‘No post cleaning missed required No indication of depths Dye Pénetrant ‘Surface inspection | «Simple to use ‘Inspection of accessible of any non porous | «Inexpensive ‘surface only materials *Rapid results *Surface breaking defects only More sensitive than detacted visual inspection No indication of depth” Cave «Penetrant may contaminate component ‘*ls 0%. circumstances post } Gee required *Surt: ..: preparation critical po La Magn: tie Particle ‘Surface/slight sub- surface inspection of magnetic materials ‘Simple to use {inexpensive Rapid results)" Little surface preparation ‘More sensitive than | visual inspection i slnsp. sion of accessible Sun 3s *Suace or near surface ‘elects only detected «:fagnetic materials only *No indication of depths *Only suitable for linear defects Radiography Both surface and sub-surface defects | Little surface preparation | Permanent record | +Both surface and sub- | | surface defects | detected ‘No material thickness limitations +*Can be carried out on most materials ‘Bulky inspection equipment +Harmful radiation Defects require significant depth in relation to the radiation beam ‘*Results not normally mediately available *Costly Very little if no indication of defect depths | Not as refiant upon operator skill, when compared to UT ' Ultrasonics | Both surface and sub-surface defects ‘Both surface and sub- | surface defects detected *Safe *Probe may be driven remotely to inaccessible areas *Capable of measuring depth of defects Requires high operator skill *Good surface finish required ‘*Badly chosen couplant may contaminate component +*Costly equipment ‘In most circumstances no permanent recordRA TPO ane WIPPID issue I Date (1/1196 Acceptance Criteria for Plate Welds Specification No. PW 0123 Defect Type Acceptance Criteria External profile Excess weld metal (reinforcement) shall be uniform and not more than 3mm in height. It shall merge smoothly with the parent metal and not by more than 3mm on each side, In no area shall the weld face be lower than the adjacent plate surface. Internal profile ‘The root bead or any concavity shall merge smoothly with the adjacent surfaces but at no point shall the weld be thinner than the wall thickness of the thinnest plate. c. Root penetration Not to exceed 2.5mm. 4d. Root concavity Length not to exceed 25% of the total length of the weld, Depth not, to exceed 2.0mm. €. Root undercut/Shrinkage groove | Length not to exceed 30mm in any continuous weld length of 300mm or not to exceed 1/10" of the total length of the weld when this is less than 300mm. Depth not to exceed 1.5mm. Incomplete root penetration Lack of root fusion Length not to exceed 30mm in any continuous weld length of 300mm or not to exceed 1/10" of the total length of the weld when this is less than 300mm. Cracks Not permitted Cap undereut The toes of the weld shall blend smoothly and gradually into the parent material, Length not to exceed 60mm in any continuous weld length of 300mm or not to exceed 20% of the weld when this, is less than 300mm, Depth not to exceed 1.5mm. Elongated linear porosity Lack of inter-run fusion Lack of side wall fusion Elongated inclusions Length not to exceed 60mm in any continuous weld length of 300mm or not to exceed 20% of the total length of the weld when this is less than 300mm. . Porosity (other than elongated porosity in the root) An isolated pore greater than 25% of the wall thickness or 3mm whichever is the smaller in any direction, shall be considered unacceptable. Inclusions (other than elongated) Size of an inclusion not to exceed 3 mm in any direction. Total length of inclusions not to exceed 15mm in any continuous weld length of 300mm and not more than five inclusions of maximum width in this 300mm length. Adjacent inclusions shall be separated um distance of 20mm. Weldoee Iosepsecetieee Poeetienl (PRAUIIY meee 1ah>-RATPO-mer-WIPPI2 issue | Dat: 1/1196 1. Burn through Not to exceed Smm in any direction and only one in any continuous weld length of 300mm. m, Wormhole Not to exceed 6mm in length or 1.5mm in diameter. o, Stray ares Stray ares on the surface of the parent material should be avoided; any that do occur shall be subject fo an acceptable repair procedure. n, Root alignment Misalignment at the root shall not exceed 10% of the metal thickness or 2.5mm, whichever is the smaller. p. Weld proximity ‘The toes of the adjacent welds including branches and fittings should be separated by a minimum of twice the wall thickness, or 25mm, whichever is the least. Welding Inspection Practical (CSWIP) page 2of 2Page 11 EN 287-L: 1992 Table 3: Ranga of approval for tests on butt joints (Details of weld typed Range of approval Bun wai tae Sun was nooe Detats of weld type Welded vomrone nde | velard Vom bait sides] welded lam one side oe FA [wih bacengy no backng_fusih gouge] no souene foun oacnne] no bain ~ * es 7 me = weueation | wihoeckng [ob : * - i aux | “nese rd a movactng [|v Pi « : : " 7 sine | veidea rom | win govsing [9 : ; e 5 . Corn ses fs negovana | ra : : * ri ; un ant] aida rom | warn neking | mo : 5 x 5 : ‘aiiae') “ona sce = nopsears | nb ‘i zi z 7 5 ~ See 6 abrana 8 90) Ker 2 naicaes te wt ar hich the welder i aporoved nthe aporoval est ‘elds for which the welders 3180 approved 6.4 Material groups Axccording to the material group of the test piece, the range of materials for which a welder is approved is shown in tables 4 and 5 (see 5.4), For any steel not cavered by any of the steel groups the welder shall carry out an approval test. which only approves for that stee! Table 4: Range of approval for parent metal Material group of Range of approval approval test oiece La Twos Twos Tee TT wor he z : wor fle | eeta | Pia wos «fs. [- | wot «| -[- at Pe Pe ee eee " when using Yiter meta rom group W 11 { + Indicates tose mae groups for which the walaar also intents ase material groups for wich the welder is 901 NOTE: Ths able applies only when parent metatincicated by + and ier metal are in tne sare group,“Buiyoyeios pue uoiseiqe ‘uolejuapul }SISOJ 0} JeWe}ew e jo Ayjige ey, :ssoupsey “‘Buryoeso }SISOJ O} JeLayew e jo AyiIqe eu, :ssauyBnoy ‘OZIS [eUuIBLO s} 0} yoeq WNJoJ O} jeLe}eW e jo Ayjiqe aul :AWONSe|y “OUIM OjU! UMBIP Eq O} JeLE}eW e Jo Ayjiqe ey, :ApWONG “aJn|ley aiojoq J2LeyewW Sy} JO UOHeWJOJSp o}Se/d jnoyIM BuIyeeig Aq Ajueppns |e} 0} Jelseyeui e yo Aouspus} ay :ayyug sonsodoig [eoTURYsIIAIPage 13 BN 287-1: 1992 Table 7: Range of approval according to walding position z ange of approval co oy Wielding postion of aanmtas ie aes So wade — | Fara approval test piece Pipe-ans and angie es o> pofass|" [o> poor Pa ]Pc Po] [Pe | [8 [Pc] Pr [ro [ma [ra or [rc ha] P0 [PO] por ut we A ee eee ants a PF x [t-te yey fe] [eT ey eT aa ange so ec Jefe t-t-T-]elel--t-Pe fet pe 2 pes afro [Pe [-[e fete t |e tet Pade ee Shot welds “ ia apa tata ee ah *4-}- | Peas | ieg [0° [eo [-|-|-1-]-1-]-fel-|-1-1-1-1-|-|-|-t-1- anavans 7 et nna nae a ea emf =n 1 8 for pes maybe welded in two versions 21 This ran goproved sostion and covered by the other slit tes ey a. 7 Examination and testing 7.1 Supervision The welding and testing of test pieces shall be witnessed by an examiner or test body acceptable to the contracting parties: hey may be members of a manufacturing company or of the purchaser or of a thitd party. ‘The test pieces shall be marked with the identification of the examiner and the welder before welding starts The examines or tes! body may stop the test ifthe welding conditions arenot correct orf it appears that the welder does net have the technicai competence fo achieve the required standard. eg, where there are excessive andior systematic repairs