Us TWI Worp centre ror ve - Ve MATERIALS JOINING TECHNOLOGY WELDING INSPECTION (wis5) TWI Ltd, Training and Examination Servicesor eee ee vowed. Lo 22, le BR tippe Leth practice= Sheijprenn Q twisea. com WELDING INSPECTION Yaw: 160 36592378 CONTENTS. ~ Anvicerti feation Crew! co. Me Section Subject _ 1.0 TYPICAL DUTIES OF WELDING INSPECTORS 20 ‘TERMS AND DEFINITIONS 3.0 WELDING IMPERFECTIONS 40 DESTRUCTIVE TESTING 5.0 WPS ~ WELDER QUALIFICATIONS 6.0 MATERIALS INSPECTION 70 CODES AND STANDARDS 8.0 WELDING SYMBOLS 9.0 INTRO TO WELDING PROCESSES 10.0 MMA WELDING 11.0 TIG WELDING 12.0 MIGIMAG WELDING 13.0 SUBMERGED ARC WELDING 14.0 WELDING CONSUMABLES 18.0 NON DESTRUCTIVE TESTING 16.0 WELD REPAIRS 17.0 RESIDUAL STRESS AND DISTORTION 18.0 HEAT TREATMENT 19.0 CUTTING PROCESSES 20.0 ARC WELDING SAFETY 21.0 WELDABILITY OF STEELS 22.0 PRACTICAL VISUAL INSPECTION 23.0 APPLICATION AND CONTROL OF PRE-HEAT 24.0 CALIBRATION 25.0 MACROIMICRO EXAMINATION 26.0 APPENDIX ‘Welding Inspection Rev 0 Jun 08 ‘Copyright © 2006, TW Ltd TWI ialSection 01 Typical Duties of Welding Inspectors Weng inspection SSS omc Rev 0 Jun 06 Dy Ses Copyright © 2006, TWI Ltd1.0 VISUAL INSPECTION AND TYPICAL DUTIES OF WELDING INSPECTORS 4.1 GENERAL Welding Inspectors are employed to assist with the quality control (QC) activities that are necessary to ensure that welded items will meet specified requirements and be fit for their application, For employers to have confidence in their work, Welding Inspectors need to have the ability to understand/interpret the various QC procedures and also have sound knowledge of welding technology Visual inspection is one of the Non-Destructive Examination disciplines and for some applications may be the only form of NDE, For more demanding service conditions, visual inspection is usually followed by ‘one or more of the other NDT techniques - surface crack detection and volumetric inspection of butt welds. Application Standards/Codes usually specify (or refer to other standards) the acceptance criteria for weld inspection and may be very specific about the particular techniques to be used for surface crack detection and volumetric inspection, they do not usually give any guidance about basic requirements for visual inspection. Guidance and basic requirements for visual inspection are given by: jon of Fusion Welds - Visual Examination) BS EN 970 (Non-destructive Examin: 4.2. BASIC REQUIREMENTS FOR VISUAL INSPECTION (to BS EN 970) BS EN 970 provides the following 2 requirements for welding inspection personnel 2 recommendations about conditions suitable for visual examination othe use of gauges/inspection aids that may be neededihelpful for inspection @ guidance about when inspection may be required during the stages of fabrication 2 guidance about information that may need to be included in the inspection records ‘Welding inspection 14 — " Fe ee EAT ‘ciwousor Visual Inspection and Typical Duties of Welding Inspectors Copysight © 2008, TW LidA summary of each of these topics is given in the following sub-sections. 4.3. WELDING INSPECTION PERSONNEL Before starting work on a particular contract, BS 970 states that Welding Inspectors should a be familiar with relevant standards *, rules and specifications for the fabrication work that is to be undertaken (* standards may be National or Client) 2 be informed about the welding procedure(s) to be used a have good vision ~ in accordance with EN 473 & should be checked every 12 months BS EN 970 does not give make any recommendation about a formal qualification for visual inspection of welds. However, it has become industry practice for inspectors to have practical experience of welding inspection together with a recognised qualification in Welding Inspection ~ such as a CSWIP Qualification. 4.4 CONDITIONS FOR VISUAL INSPECTION lumination BS EN 970 states that the minimum illumination shall be 350 lux but recommends a minimum of 500 ux’. * normal shop or office lighting Access Access to the surface, for direct inspection, should enable the eye:~ 2 to be within 600mm of the surface being inspected a to be in a position to give a viewing angle of not less than 30° 600mm nina) 7 30° (min.) ‘barging ‘val Inepecion and Typical Duties of . Welding inspectors ecvena® Aer tie: el 2 . Cnowledgeatte «+ Cork Commuaicectoy « Dhagecally A1.5 AIDS TO VISUAL INSPECTION Where access is restricted for direct visual inspection, the use of a mirrored boroscope, or a fibre optic viewing system, are options that may be used - usually by agreement between the contracting parties. It may also be necessary to provide auxiliary lighting to give suitable contrast and relief effect between surface imperfections and the background. Other items of equipment that may be appropriate, to facilitate visual examination, are: 2 welding gauges (for checking bevel angles and weld profil, filet sizing, measuring undercut depth) a dedicated weld-gap gauges and linear misalignment (high-low) gauges a straight edges and measuring tapes a magnifying lens (if magnification fens used to aid visual examination it should be X2 to X8) BS 970 has schematics of a range of welding gauges together with details of what they can be used for and the precision of the measurements that can be made. 4.8 STAGES WHEN INSPECTION MAY BE REQUIRED BS EN 970 states that examination is normally performed on welds in the as- welded condition. This means that visual inspection of the finished weld is a minimum requirement. However, BS EN 970 goes on to say that the extent of examination, and the stages when some inspection activity is required, should be specified by the Application Standard or by agreement between Client and fabricator. For fabricated items that must have high ‘integrity’, such as pressure vessels and piping or large structures inspection activity will usually be required throughout the fabrication process, namely: o before welding a during welding a after welding Inspection ‘activities’ at each of these stages of fabrication can be considered to be the ‘duties of the welding inspector’ and typical inspection checks that may be required are described in the following section. Wielding inspection 3 TW sonscomsro: Clove nspedt GMT stwonso Visual Inspection end Typical Duties of Welding Inspectors Copyright © 2008, TWI Ltd1.7 TYPICAL DUTIES OF A WELDING INSPECTOR ‘The relevant standards, rules and specifications that a Welding Inspector should be familiar with at the start of a new contract are all the documents he will need fo refer to during the fabrication sequence in order to make judgements about particular details, Typical documents that may need to be referred to are: a the Application Standard (or Code) (for visual acceptance oniteria — see note below’) quality plans or inspection check lists (for the type & extent of inspection) 2 drawings (for assemblyfi-up details and dimensional requirements) 2 QC procedures (Compeny QC/QA Procedures such as those for document control, material handling, electrode storage and issue, WPSs etc) Note’ Although most of the requirements for the fabricated item should be specified by National Standards, Client Standards or various QC Procedures, some features are not easy to define precisely and the requirement may be given as ‘to. qood workmanship standard’. Examples of requirements that are difficult to define precisely are some shape tolerances, distortion, surface damage or the amount of weld spatter. ‘Good workmanship’ is the standard that a competent worker should be able to achieve vaithout diffcully when using the correct tools in a particular working environment. In practice the application of the fabricated item will be the main factor that influences what is Judged to be good workmanship as well as the standard that @ particular fabricator has ‘become used (0 satisfy particular Clients. ‘Reference’ samples are sometimes needed to give guidance about the acceptance standard for details such as weld surface finish & toe biend, weld root profile and finish required for welds that need to be dressed - by grinding or linishing. ‘Welding Inspector should also ensure that any inspection aids that will be needed are: a in good condition 2 calibrated - as appropriate/as specified by QC Procedures ‘Welding Inspection 14 wont ceva rox \Visual Inspection and Typical Duties of Welding Inspectors Copyright @ 2008, TWI LtdSafety ‘consciousness’ is a duty of all employees and a Welding Inspector should. a be aware of all safety regulations for the workplace | ensure that safety equipment that will be needed is available and in suitable condition Duties Before Welding Check Action Material is in accordance with drawing VPS is identified & can be traced to a test certificate is in suitable condition (free from damage & contamination) WPs's have been approved and are available to welders (& inspectors) ‘Welding Equipment is in suitable condition and calibrated as appropriate Weld Preparations are in accordance with WPS (and/or drawings) Welder Qualifications _identification of welders qualified for each WPS to be used all welder qualification certificates are valid ('in-date’) Welding Consumables those to be used are as specified by the WPSs are being stored/controlled as specified by the QC Procedure Joint Fit-ups are in accordance with WPS / Drawings tack welds are to good workmanship standard & to CodeiwPs: Weld Faces are free from defects, contamination and damage Preheat (if required) min. temperature is in accordance with WPS Duties During Welding Check Action Site/field Welding ‘ensure weather conditions are suitable/comply with Code (conditions will not affect welding) Welding Process. is in accordance with WPS Preheat (if required) min. temp. is being maintained in accordance with WPS Inter-pass Temp. max. temp. is in accordance with WPS. Weidiginspecien TWI wonnwnce Trainee CEM Wee Yisual Inspection and Typical Duties of Welding Inspectors Copyright @ 2008, TWI Lid‘Welding Consumables are in accordance with WPS & being controlled as Procedure Welding Parameters current, volts, travel speed, are in accordance with WPS Root Run is visually acceptable to Code (before filing the joint) (for single sided welds) Gouging /Grinding is by an approved method & to good workmanship standard Inter-run Cleaning is to good workmanship standard Welder is on the approval register/qualified for the WPS being used Duties After Welding Check Action Weld Identification each weld is marked with the welder’s identification each weld is identified in accordance with drawing/weld map Weld Appearance ensure welds are suitable for all NDT (profile, cleanness etc) visually inspect welds and sentence in accordance with Code Dimensional Survey check dimensions are in accordance with Drawing/Code Drawings ensure any modifications are included on ‘as-built’ drawings NOT ensure all NDT is complete & reports are available for records Repairs monitor in accordance with the Procedure PWHT (if required) monitor for compliance with Procedure (check chart record) Pressure/Load Test ensure test equipment is calibrated (if required) monitor test to ensure compliance with Procedure/Code ensure reportsirecords are available Documentation Records ensure all reports/records are completed & collated as required tient A Reyes Wetding | 16 ~ wont cewaero Visual Inspection and Typical Duties of recnsouooy Welding inspacters Copyright © 2008, TW! Led1.8 EXAMINATION RECORDS The requirement for examination records/inspection reports will vary according to contract and type of fabrication and there is frequently no requirement for a formal record. ‘When an inspection record is required it may be necessary to show that items have been checked at the specified stages and that they have satisfied the acceptance criteria The form of this record will vary - possibly a signature against an activity on an Inspection Checklist or on a Quality Plan, or it may be an individual inspection report for each item, For individual inspection reports, BS EN 970 lists typical details for inclusion such as: name of manufacturerffabricator a Q identification of item examined a material type & thickness 2 Ypeorjom 3 welding process @Scteptance standaraacoeptanceertera a locations and types of all imperfections not acceptable (when specified, it may be necessary (0 include an accurate sketch or photo.) u name of examiner/inspector and date of examination Tila rapecen iF TWI eons Bea a ae Visual inspection and Typical Duties of Welding Inspectors Copyright © 2006, TW LidTWI worn centre ror MATERIALS JOINING ‘TECHNOLOGY Questions qui uz. U3. aus. ies and duties of a welding inspector Responsibi List 4 areas that would generally be covered by a non-destructive examination (NDE) inspection standard for welds? List desirable characteristics that all welding inspectors should possess? List 5 areas of knowledge with which a proficient welding inspector should be familiar with? Give six main duties of a welding inspector before welding, during welding and after welding. Welding inspection Ree Jun D6 Copyright © 2006, TWH. qui