Welding Inspector

Duties and Responsibilities Section 1

Year-2007 (Egypt)

Main Responsibilities

1.1

Code compliance

Workmanship control Documentation control

Year-2007 (Egypt)

Personal Attributes

1.1

Important qualities that good Inspectors are expected to have are:

Honesty Integrity

Knowledge

Good communicator

Physical fitness

Good eyesight
Year-2007 (Egypt)

Standard for Visual Inspection 1.1

Basic Requirements
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)

Year-2007 (Egypt)

Welding Inspection

1.2

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
600mm

30

Year-2007 (Egypt)

Welding Inspection
When access is restricted may use: a mirrored boroscope a fibre optic viewing system

1.3

Aids to Visual Inspection (to BS EN 970)

usually by agreement

Other aids: welding gauges (for checking bevel angles, weld profile, fillet sizing, undercut depth) dedicated weld-gap gauges and linear misalignment (highlow) gauges straight edges and measuring tapes magnifying lens (if magnification lens used it should have magnification between X2 to X5)
Year-2007 (Egypt)

Welding Inspectors Equipment

Measuring devices:

1.3

flexible tape, steel rule

Temperature indicating crayons

Welding gauges Voltmeter

Ammeter
Magnifying glass Torch / flash light

Gas flow-meter

Year-2007 (Egypt)

Welding Inspectors Gauges

10mm 10mm
1 2

1.3

G.A.L.
S.T.D. 16mm

G.A.L.

3 4

S.T.D. 16mm

5 6

Fillet Weld Gauges

0 IN 1/4 1/2 3/4

TWI Multi-purpose Welding Gauge

Year-2007 (Egypt)

Misalignment Gauges Hi-Lo Gauge

HI-LO Single Purpose Welding Gauge

Welding Inspectors Equipment

1.3

Voltmeter

Ammeter

Tong Tester Year-2007 (Egypt)

Welding Inspection 1.3

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

Year-2007 (Egypt)

Typical Duties of a Welding Inspector

1.5

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
Year-2007 (Egypt)

Typical Duties of a Welding Inspector

1.5

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 WPSs certificates are valid and in-date

Year-2007 (Egypt)

Typical Duties of a Welding Inspector 1.5

Before Welding
Equipment:

all inspection equipment is in good condition & calibrated as necessary all safety requirements are understood & necessary equipment available

Materials:

can be identified & related to test certificates, traceability ! are of correct dimensions are in suitable condition (no damage/contamination)

Year-2007 (Egypt)

Typical Duties of a Welding Inspector 1.5

Before Welding
Consumables:

in accordance with WPSs 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

Year-2007 (Egypt)

Typical Duties of a Welding Inspector 1.5

Before Welding
Fit-up

complies with WPS

Number / size of tack welds to Code / good workmanship

Pre-heat

if specified minimum temperature complies with WPS

Year-2007 (Egypt)

Typical Duties of a Welding Inspector

1.5

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
Year-2007 (Egypt)

Typical Duties of a Welding Inspector

1.6

During Welding
Welding consumables

in accordance with WPS in suitable condition controlled issue and handling current, voltage & travel speed as WPS

Welding Parameters

Root runs

if possible, visually inspect root before single-sided welds are filled up

Year-2007 (Egypt)

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

Year-2007 (Egypt)

Typical Duties of a Welding Inspector

1.6

After Welding
Weld Identification identified/numbered as required is marked with welders 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

Year-2007 (Egypt)

Typical Duties of a Welding Inspector

1.6

After Welding
Repairs

monitor repairs to ensure compliance with Procedure, ensure NDT 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
Year-2007 (Egypt)

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.

Year-2007 (Egypt)

Summary of Duties
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.

A Welding Inspector must:

Observe To observe all relevant actions related to weld quality throughout production. Record To record, or log all production inspection points relevant to quality, including a final report showing all identified imperfections Compare To compare all recorded information with the acceptance criteria and any other relevant clauses in the applied application standard
Year-2007 (Egypt)