THE DUTIIES OF A WELDING INSPECTOR: My duties as a welding inspector are involved before, during and after welding. Before welding: + Allapplicable documents are checked, « = Application standard is up to date with the latest edition, revision or amendment; = The drawings is clear and issue number is marked; Welding procedure sheets (specifications) is available and has been approved as required by authority and is employed in production; Welder qualification with identification and range of approval are verified and that only approved welders as required are used in production; Safety permits such as gas free (entering enclosed space) certificate, hot work permit are available and valid; Calibration certificates, material certificates (mill sheets) and consumer certification are available, Quality plan ‘is authorized and endorsed with signature, date and company stamp; Parent material identification is verified against documentation and markings; Material composition, type and condition are checked; Identification of welding consumables such as electrodes, special drying requirements for electrodes, filler wires, fluxes, shielding and backing gases are verified correct; Plant and equipment are in a safe condition and adequate for job; Correct methods are applied in cutting and machining; Dimensions, tolerances, preparation, fit-up and alignment are in accordance with approved drawings; * — Cleanliness is maintained, + Preheating for any tack welding is in accordance with specified procedure; During welding: + Welding processes such as root pass and tack welds must be monitored and inspected; + Welding should be completed without undue interruption and within specified period; + Hot pass must be timed; + Essential variables such as current, voltage, travel speed and number of runs must be monitored; Inter-pass cleaning, temperature and run sequence should be inspected (roving inspection), Welding is in compliance with welding procedure sheet and application standard. After welding: Dimensional accuracy must be checked; Visual inspection is carried out to ascertain acceptability of appearance of welds; Post weld heat treatment if any should be monitored and recorded. NDT report is assessed; Delayed inspection is carried out 72 hours later to check hydrogen'(Hz) cracking; Factors influencing the formation of weld defects and their acceptability in relation to the written specification are appreciated. If repairs are required then Procedures and welder codes should be authorized. Defect area should be marked out positively and clearly. Partial and fully removal should be monitored with visual inspections and NOT. Re-welding should be monitored and re-inspected (visual and NDT) Benoe Collate all documents and reports, pass on for final inspection, approval and sioraye.THE WELDING INSPECTOR RESPONSIBILITIES ENSURE ENSURE ENSURE COMPLIANCE WORKMANSHIP WELDING TO STANDARD OR CODE CRITERIA BY | “POLICING” WORK & (DOCUMENTATION) | > ATTRIBUTES HONESTY ureracy FITNESS INTEGRITY | PHYSICAL EYESIGHT l Se oyries OBSERVE MEASURE IDENTIFY BEFORE DURING AFTER WELDING LDING MATERIAL VOLTAGE CONSUMABLES AMPERAGE WELDING PROCESSES TRAVEL SPEED ASSESSMENT JOINT FIT UP INTERPASS TEMPERATURE NDT PREHEAT INTERPASS CLEANING ASSESSMENT TACK WELDING/CLAMPING ALLIGNMENT CALIBRATION SAFETY ee _ y ACCEPT REJECT , Rena COLLECT & COLLATE ALL, DOCUMENTS: 1.D. AREA MARK OUT v WHICH MAY INCLUDE: REMOVE CONCESSION CODE OR STANDARD RE-WELD MATERIAL CERTIFICATES RE-INSPECT CONSUMABLE CERTIFICATES CALIBRATION CERTIFICATES DRAWING(S) WELDING PROCEDURES APPROVAL CERTIFICATES INSPECTION RECORDS ACCEPTANCE OF THE PRODUCT P.W.H.T. RECORDS: + OTHER TEST RECORDS CONCESSIONS INSPECTOR PASSES THE COMPLIANCE CERTIFICATES DOCUMENT PACKAGE TO A HIGHER AUTHORITY FOR FINAL APPROVAL5.7 Welding positions Fos tne purpose of his standard the welding positions identified in figures 1 and 2 shall apply faccording to ISO 6947). Angles af slope and rotation for straight weids in the welding positions shall be in accordance with {SO 6247, » Yartical cownwards / M taeneenas used in the approval test shall be based on the same tolerances as used in production, | PC Horizontal vertical PE Ovemead PF Vertical upwards ) Burt walds SS > x P83 Horizontal vercal J PO Monzontal over I Filter wales Figura 1: Walding positions tor platesWELDING POSTTIOKS (8S 499:1991/7S0 8347) / Overhead Po cal overheadSEN 287 IBSEN ISO 5817 HSEN 22553 BSEN STANDARDS "| WELDING PROCEDURE _| aluminium) DESCRIPTION VISUAL INSPECTION OF FUSION JOINTS. QUILIFICATION TEST (for steel & WELDER QUALIFICATION TEST (aluminium) — WELDER QUALIFICATION (steel) . APPECPTANCE CRITRIA (Lor sti WELDING SYMBOLSAWS System American Welding Soclety Specification: ANSI/AWS AS.1-81 Glsuincaion | Teraiesirength | Vild peng Wem! cae Niroeat tare “20 Pr eon 0 So econ “so x0 con} o 30 tore = xo ton & ae 0 $0 + Electrical charecterfatics Cavsiicaton. | AC Positive | Negative Eeor0 wor fy | f feo | corn | Gi £6070 F602? wore e705 E016 018 7 e077 7028British Standards System BS specification: BS 639: 1986 inst Grour coveniua emnenucy Minimum vad : Indiaiee Sevan feans, Nl? a ediogen Pry t iter convoled 7 § | cxtsing (<15m009) £6 | aosse x0 R_ | athe (medium coatedt &1_| si06s0 30 fn fon [Tomes] [1 tear] Brean [Rimata eel eee | Renate | ae ee ee eS te nrc | Micro ei : ° Not wpecified § | Rat vertical down and, for fillet welds, Lata a mn horizontal vertical ‘Polarity a8 Not suitable for 2 & 9 | any position or combination of positions not recommanded | use on AC 2 2 classified sbove by manutece a a @ | new hale __| | poset 7) sca) eapsee ryt z calcu aS y Tales 7 cul picorons 4 z ¢ Per aie z eae | | a 4 = = ‘aes tty ae alee i| 3They att | ents seopensetton aN dts oa. 0} 0.9 - ua = > t-29]— saan raetieemtetat ha 2-06 fos. es Arg other sgreed compoaltion te a ms fis C= eullete covering > rae reine AR ~ eve tNck covering RC » evtlecedilede coeing RA = eutdens covering RB = rude bade crering eres cae - 816.3 IN B 54 Hi a i potions: 2) at potions, exeen vee dow: 2) Mat but weld, a et wel, wert fle welds (1 buts wee, fat tee wel 5 weal down tnd positions scnting to mbel 3 tos wssis fee ae W210 Jae ede nse daePrime cracking modes fm Steel Key words 06-02-01 AB Whitaker Hydrogen induced HAZ or weld metal cracks, Key words: Cause: Prevention: Hydrogen. Moisture. Consumable type. Absorbtion. Paint. Oil, Solublity. High hardenability. HAZ hardness. Martensite. Diffusion. Transformation, Hardness. Stress concentrations. Weld toes. Delayed inspection 48 hours after welding. The four critical factors and levels, >15ml H?, VPN > 350, Temperature < 300. Stress > 0.5 YS Hydrogen Weld metal cracking (High strength low alloy steels) [Rereased carbon content to match of parent metal strength. Higher hardenabilty in the weld metal. Transverea, cracks Preheat. Hydrogen control, Consumable checks. Low H? Process, Restraint. Remove plate coatings. Control of stable, arc length. Are energy. Joint design. Carbon equivalent 1 content. Austenitic stainless steel weld metal, Solidification cracking in C/Mn steels, Keywords; Cause: Prevention: Sulphur. Fe/Sulphides. Weld centreline. Contraction. Low m. p. flms. Contractional forces. Lose of cohesion, faut Strength hot shortness of solidifying weld meter High Mn/S:Carbon ratio Manganese. Low dilution processes, Lower carbon ratio, Restraint. Avoid aluminium deoxidised wires. Low sulphur Plate. Minimise contractional Strain. Lamellar tearing in C/Mn steels, Key words: Cause: Prevention: Poor through thickness ductility. Below HAZ. Plastic strain. Sulphur laminations and bands. Contraction T joints. Comer joints. Stepped like crack. uttering layers. Contraction gap. Fillet welds, Re-design Dornier plates, Reduce restraint. Control heat input. Maximise ductility in weld metal and minimise Strain.