Role and Responsibilities of Welding

Inspector

RR Chari
 Role and Responsibilities of Welding
Inspector

Who is Welding Inspector?

Welding Inspector Can be classified based on Role played.

• Shop floor Supervisor

• Shop floor Inspector
• Independent Internal Inspector of same organization
• External Third Party Inspector
• External Statutory Inspector
 Role and Responsibilities of Welding
Inspector
Why manufacturers are feared of Inspector?

• Inspector’s Authority
• Own negligence
• Out of respect

Important Characteristics of the Inspector :

• Accurate observation of Parameters and defects.

• Accurate reporting of the observations made
• Firm & Fearless without being arrogant.
• Positive attitude & open mind.
• Considerate to others’ point of view but Impartial
• Punctual
 Role and Responsibilities of Welding
Inspector

Please Note :

• Welding Inspector’s position is “RESPONSIBLE”.

• It is easy to reject but need sound technical knowledge &

application to accept defects consciously.

• Adherence to production schedule or targeted date is

important.
• Inspector should be faithful to Job & not to appointing
agency
 Role and Responsibilities of Welding
Inspector
Privileges of Inspector :

• Has privileges to examine all drawings, documents,

certificates, materials, consumables, manufacturing
equipment, tools, tackles, jigs fixtures, etc.
• To have access to shop floor at any time but without
hindering work & preferably with prior arrangement.
• Re-inspection if felt necessary

• Do not have special privilege in :

• Personal conduct
• Maintaining Punctuality
• Safety
• Security
 Role and Responsibilities of Welding
Inspector
Welding Inspector is Responsible to :

• Interpret all welding drawings and specifications.

• Check purchase orders to assure that welding materials
and consumables have been properly specified.
• Check and identify materials as they are received against
the purchase specifications.
• Check the chemical compositions and mechanical
properties shown on mill test reports against specified
requirements.
• Check storage of filler materials.
• Check equipment to be used.
• Check weld joint preparations.
 Role and Responsibilities of Welding
Inspector
• Check joint fit-up

• Verify the application of the approved welding

procedure.

• Verify the qualifications of the welders and welding

operators.

• Select production test samples

• Evaluate the test results

• Maintain records

• Prepare reports
 Role and Responsibilities of Welding
Inspector

Knowledge of drawings & specifications :

• Advance study of Drawing & specifications, construction

details, MOC, welding procedure, heat treatment.
• Obtain necessary clarification/details from Design/Project
Engineer.

This will help in;

• Precise interpretation & conside decision during inspection.

• Permitting or rejecting deviations observed.
• Decide feasibility of correcting error/deviation for large
component.
• Determining specifications which are not defined.
 Role and Responsibilities of Welding
Inspector

Purchase specification chart & material verification.

• The specification for Raw material e.g. ASTM A-106

Grade?
• Consumable like electrode e.g. E 70 XX
• Shielding gas, backing barrel.
• Put identification mark at multiple locations.
• As far as possible preserve original markings
• Transfer, if required.
• Sometimes necessary to preserve cases with original
Batch No./Control No. e.g. Electrodes for Nuclear
application.
 Role and Responsibilities of Welding
Inspector
Storage of filler material & welding equipment check:

• Check how stored e.g. Low Hydrogen Electrode.

• Check welding machine type, its capability, calibration of
ammeter,volt meter.

Weld joint preparation

• Check edge preparation of joint for;

- Probable lamination
- bevel angle, root face
- preferable to have gauges.

• Cleanliness
 Role and Responsibilities of Welding
Inspector
Joint fit up :
Check UN-welded joint for:
• Alignment (offset)
• Root gap
• Allow for distortion
• Discuss with Engineer not with foreman/welder
• Back up bar/ring
e.g. No open joint in long back up bar. Distorted back of Bar.

Chemical Analysis & Mechanical Properties :

• Check of qualified supplier/manufacturer
• Random check of chemical & mechanical properties
• Representative sample no. & location
• It error are strongly suspected ask for check test.
 Role and Responsibilities of Welding
Inspector
Base Metal Defects :

• Forging, plates, structural steel, etc. have discontinuity

• Small discontinuities may be acceptable.

• Some are repairable

• Defect identify & evaluate defect for acceptance/repair/

rejection.

• Lamination not acceptable for some application but can

be used at other places.
 Role and Responsibilities of Welding
Inspector
Qualification Of Procedure & Welders

To establish written welding procedure specification

• Will be taken up in detail in other chapters

• Include welder as well as welding operator.

• Qualify through test

• Verify validity

• Interpret Qualification range.

• Avoid unnecessary qualifications.

 Role and Responsibilities of Welding
Inspector
Production Test Sample Solution :

• Often Sample Inspection is done on production line.

• Random selection or as per established pattern or order.

• Sometime left to inspector

• Select optimum & representative sample

• Typical test include RT, UT, Hydro, Chemical,

Metallurgical & mechanical test.

• Witness wherever required/necessary.

 Role and Responsibilities of Welding
Inspector
Evaluation of Test Results :

• Sometime impractical to witness all the tests.Select enough.

• Ensure good equipment (calibrated & accurate).
• Good agency & procedures.
• Consider overall results before deciding acceptance/
rejection.

Maintain Records & Reports :

• Record keeping is most important.

• Detailed records of events.
• Preferable to cross errors & not erase.
• Final reports should include deviations, repairs carried out if
any, difficulties faced, etc.
 Role and Responsibilities of Welding
Inspector
Inspection Before Welding :

Check :

a) Application standard
b) Welding procedure sheets
c) Drawings
d) Welder qualifications
e) Material composition
f) Condition of material.
G) Type of edge preparation, method & finish
h) Consumables I.e. type of electrodes, filler wires, fluxes,
shielding and backing gases (composition) and special
drying requirements for electrodes.
I) Welding process-processes.
 Role and Responsibilities of Welding
Inspector
Inspection during Welding :

Check :
a) Welding Process
b) Preheat and interpass temperature.
C) Inter-run cleaning
d) Joint preparation
e) Filler metals
f) Control of distortion
g) Root and subsequent runs
h) Welding current and voltage.
I) Chipping, grinding, gouging
j) Fluxes and shielding gases.
K) Compliance with weld procedure sheet and application
standard.
 Role and Responsibilities of Welding
Inspector

After Welding :

Check :

a) Dimensional accuracy

b) Conformity of drawings and standard requirements.

C) Acceptability of welds regarding appearance.

D) Post-heat treatment (if any).

THANK YOU