Welding Inspector

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Duties and Responsibilities

Section 1

Main Responsibilities 1.1

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• Code compliance

• Workmanship control

• Documentation control

Personal Attributes 1.1

Important qualities that good Inspectors are expected to have are:

•Honesty

•Integrity

•Knowledge

•Good communicator

•Physical fitness

•Good eyesight

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Standard for Visual Inspection 1.1

Basic Requirements

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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)

Welding Inspection 1.2

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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°

30°

600mm

Welding Inspection 1.3

Aids to Visual Inspection (to BS EN 970)

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

Other aids:• welding gauges (for checking bevel angles, weld profile, fillet

sizing, undercut depth)• dedicated weld-gap gauges and linear misalignment (high-low)

gauges• straight edges and measuring tapes• magnifying lens (if magnification lens used it should have

magnification between X2 to X5)

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usually by

agreement}

Welding Inspectors Equipment 1.3

Measuring devices:

• flexible tape, steel rule

• Temperature indicating crayons

• Welding gauges

• Voltmeter

• Ammeter

• Magnifying glass

• Torch / flash light

• Gas flow-meter

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Welding Inspectors Gauges 1.3

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TWI Multi-purpose Welding Gauge Misalignment Gauges

Hi-Lo Gauge

Fillet Weld Gauges

G.A.L.

S.T.D.

10mm

16mm

L

G.A.L.

S.T.D.

10mm

16mm

01/4 1/2 3/4

IN

HI-

LO

S

ing

le P

urp

os

e W

eld

ing

Ga

ug

e

1

2

3

4

5

6

Welding Inspectors Equipment 1.3

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Tong Tester

AmmeterVoltmeter

Welding Inspection 1.3

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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

Typical Duties of a Welding Inspector 1.5

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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

Typical Duties of a Welding Inspector 1.5

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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 WPS‟s

• certificates are valid and ‘in-date’

Typical Duties of a Welding Inspector 1.5

Before Welding

Equipment:

• all inspection equipment is in good condition & calibrated asnecessary

• all safety requirements are understood & necessary equipmentavailable

Materials:

• can be identified & related to test certificates, traceability !

• are of correct dimensions

• are in suitable condition (no damage/contamination)

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Typical Duties of a Welding Inspector 1.5

Before Welding

Consumables:

• in accordance with WPS’s

• 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

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Typical Duties of a Welding Inspector 1.5

Before Welding

Fit-up

• complies with WPS

• Number / size of tack welds to Code / goodworkmanship

Pre-heat

• if specified

• minimum temperature complies with WPS

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Typical Duties of a Welding Inspector 1.5

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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

Typical Duties of a Welding Inspector 1.6

During Welding

Welding consumables

• in accordance with WPS

• in suitable condition

• controlled issue and handling

Welding Parameters

• current, voltage & travel speed – as WPS

Root runs

• if possible, visually inspect root before single-sided welds arefilled up

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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

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Typical Duties of a Welding Inspector 1.6

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After Welding

Weld Identification

• identified/numbered as required

• is marked with welder‟s 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

Typical Duties of a Welding Inspector 1.6

After Welding

Repairs

• monitor repairs to ensure compliance with Procedure, ensureNDT 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

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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.

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Summary of Duties

A Welding Inspector must:

• ObserveTo observe all relevant actions related to weld quality throughoutproduction.

• RecordTo record, or log all production inspection points relevant to quality,including a final report showing all identified imperfections

• CompareTo compare all recorded information with the acceptance criteriaand any other relevant clauses in the applied application standard

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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.