WELDING INSPECTION

Duties and Responsibilities

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Main Responsibilities

• 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
Standards for Visual Inspection-Basic Requirements
ISO 17637: 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

Conditions for Visual Inspection

( ISO 17637 )
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°
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
}
usually by
agreement

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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Welding Inspectors Equipment
1.3
Measuring devices:
• flexible tape, steel rule
• Temperature indicating crayons
• Welding gauges
• Hi-Lo Gauge
• Voltmeter
• Ammeter
• Magnifying glass
• Inspection Mirror
• Torch / flash light
• Gas flow-meter

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Welding Inspectors Gauges 1.3

10mm 10mm 1

G.A.L. G.A.L. 3

S.T.D. L S.T.D.
16mm 5
16mm
6

Fillet Weld Gauges

HI-LO Single Purpose Welding Gauge

IN
0 1/4 1/2 3/4

TWI Multi-purpose Welding Gauge Misalignment Gauges

Hi-Lo Gauge

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Welding Inspectors Equipment 1.3

Voltmeter Ammeter

Tong Tester
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 Welding Inspection 1.3
Stages of Visual Inspection
( ISO 17637 )
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 IS required throughout the

fabrication process:
Before welding
(Before assemble & After assembly)
During welding
After welding

Inspection activities at each of these stages can be

considered as the duties and responsibilities of Welding
Inspector.
 BEFORE WELDING:
 Check the applicable Code, Drawing , Welding Procedure
Specification(WPS).
 Check the welder qualification certificates, whether welder is qualified
to perform welding as mentioned in the WPS.
 Check the Welding Machine is of good condition and the Calibration
details.
 Check the materials are as per the test certificate, condition,
dimension etc.
 Ensure the welding consumables are in accordance with the WPS.
 Check the weld preparations comply with the drawing/ WPS.
 Check the Fit-up Inspection complies with WPS.( Root gap, number
and size of tack welds etc.)
 Ensure preheat temperature before starting welding if specified in
WPS.
 Check the climatic conditions before starting the welding.
 DURING WELDING:
• Check the Weather conditions are suitable for site / field welding
• Ensure the Welding Process in accordance with WPS
• Ensure minimum Pre-heat (if required) as specified by WPS
• Ensure maximum inter pass temperature as specified in WPS.
• Monitor the Voltage ,Current and Travel speed are as stated WPS.
• If possible, visually inspect root before single-sided welds are filled
up.
• Inter-run cleaning are in accordance with an approved method.
• Balanced Welding to be done & Over-welding is avoided for
Distortion control.
AFTER WELDING:
Weld Identification: Weld to be identified or numbered as required and to
be marked with welder ID
Post Weld Heat Treatment (PWHT) : PWHT to be done to remove induced
hydrogen from Weld metal. Normally done for materials containing high
% of Carbon.
Visual Inspection to ensure the weld is free from visual defects & suitable
for NDT.
Dimensional Survey : To ensure the dimensions complies with drawing.
NDT: ensure all NDT is completed & reports available
Repair: If any defects are found, repair to be done with approved procedure
& perform NDT after repair.
Perform PWHT again, after repair.
Perform Pressure tests, Hardness Test etc. If specified in procedure.
Final documentation of all test reports.
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
Welding Procedures:
• are applicable to joints to be welded & approved
• are available to welders & inspectors
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Typical Duties of a Welding Inspector 1.5

Before Welding
Welder Qualifications:
• list of available qualified welders related to WPS’s
• certificates are valid and ‘in-date’

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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)

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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

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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 / good
workmanship
Pre-heat
 if specified
 minimum temperature complies with WPS

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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 – Post weld heat Treatment
 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
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

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 Materials arriving at the site need to be inspected for
the following:

1) Size
2) Condition
3) Specification*

Heat Number: a number assigned to each heat of steel by the

manufacturer.
MTC: Material (or Mill) Test Certificate.
MTR: Material (or Mill) Test Report.
 Rolling Imperfections
Direction of rolling

Cold Laps*

Laminations
Segregation
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 Plate Inspection
Check Condition for
(Corrosion, Mechanical damage, Laps, Bands and Laminations)

Specification
5L
Size

Other checks may need to be made such as:

distortion tolerance, number of plates and storage*
 Pipe Inspection
Condition
(Corrosion, Damage, Wall thickness Ovality, Laminations & Seam)

Specification / LP 5
Heat number
Size
Welded seam

Other checks such as:

distortion, tolerance, number and storage*
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 Laminations

Plate Lamination

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Lapping

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Documents required for material inspection
 Copy of Purchase Order (P.O)
 Copy of Delivery note
 Material test Certificate
 Drawing / Specification
 Purchase requisition form ( for more clarity)

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