Welding . InspectionWELDING INSPECTION TECHNOLOGY American Welding SocietyDISCLAIMER ‘The American Welding Society, Ine. assumes no responsibility for the information contained in this publication. An independent, substantiating investigation should be made prior to reliance on or use of such information, {ntemasionat Standard Book Number 087171-467-1 Copyright © 1995 by American Welding Society, Miami, Peng. Fourth Edition 2000 All ighis reserved. No par ofthis book may oe reproduces in any form,or by and means, electron of ‘mechanical, incloding photocopying, recording. or by anc any inforrtionslorage or terval system, with ‘ut pecmssion in writing fram the publisher Printed inthe Unite States of meriewREVISION NOTES ‘The trsning materials format forthe Welting Inspection Technology seminar Werkbock as evolved over the past Several years, incorporating many upgrades and improvemeris. Originally, tere were 12 Modules io ‘lack and white pamphlet fon, followed nest by a format usrg a black and white, loose 3g binder fpproach which simplifies te task of revisions and printing format changes. The 1995 revision continued th loose lee and binder approach, bu icorported the literal ue ofcoloe graphics forthe fst ime. aswell at improvements in the layout and font types for improved legibility. Te curent revision simplifies Modules and 7 and comets the typographical errors that ‘rep’ into the 1985 version. It is hoped these recent changes ‘make the Iearing experience more enjoyable, and etl in greater retention ofthe lechnical material he technical content ofthe last two versions ofthe training materials has also been changed some- What t include several new technologies and topics, and to broaden the technical base for the Cerifed Welding Inspector. However, these latest versions are not entirely new texts, since it required reenion of rmuch of the orginal technical content to comply with the respenibilty of meeting the training coverage requirements ofthe existing CWI Cenification Test Question Bank, Future revisions will be necessary, and ‘ue andcipated as the welding technology evolves and the usige ofthe metre system becomes more common ‘vthin the welding community inthe United States. 4JLR. Roper, PAD., Roper Engineering, authored the new sections on EBW and LBW, Also, thanks to Richard . Campbell, Welding Solutions, ne for bis technical and editng input. Special thanks ae also given to Richard L: Holden, Senior Research Engineer, Bison Welding Institue, who authored the 1986 version of ‘he uaining material, whichis retained in lage part inthe current version, December 1998, Ted V, Weber Pancipal Consultant Weber & Associatesfelding In spec ion and Certification Contents “troduction ‘Who isthe Welding Inspector? Important Qualities of the Welding Inspector Ethical Requirements for the Welding Inspector ‘The Welding Inspector as « Communicator Personnel Certification Programs Key Terms and DefinitionsModule 1—Welding Inspection and Certification Introduction In today’s world there is increasing empbasis placed on the need for quality, and wld quality it tm importene part ofthe overall quality efor. This ‘concern for product quality is due to several actors, including economics, safety, goverment regula tions, global compasition, andthe use of les con servtive design. Wale nat singulely responsible for the attsinmeat of weld quality, the welding inspector plays & large role in any sucessful weld ing quality consol program, In realy, many people participate in the creation ofa quality welded pro. et. However, the welding inspector is one of the ron line” individuals who must check tose ofthe required manufacturing steps have be pleted property. To do tis job effectively, she welding inspector ‘must have a wide range of krowledge and sil, because it involves more than simpy looking at s. Consequently, this course is specifically esigned to provide both experienced and novi ing inspectors a basic background in the m0 citieal job aspects. This does not imply, however, that each welding inspector will use all ofthis nfor- nation while working for a particu company [Nor does it mean thatthe material presented ill inciude all of the information for every welding Inspector’ siteaton, Selection of these various tope ics is based on the general knowledge desirable for an individual o do general welding inspection The important thing to realize is that effective ding inspection involves mich more tan Just looking at finished welds. Section 4 of AWS GCI, Standard for AWS Certifeation of Welding Inspectors (see Figure 1.1) outlines the various functions of the welding inspectors, You should me familar with these vatious responsiiliies cause the welding inspectors job isan ongoing PNT ery a Petes Cr) re Figure 1.1—AWS QC, Standard for AWS entation of Welding Inspectors process. A successful quality contol program begins wel before the isl ar is struck. Therefore, the welling inspector must be familie with many facets ofthe fabrication process, Before welding, the inspector will check drivings and specications 1p detemine such information as the configuration of the component, its specific weld quality require ment, and what degree of inspection is require. ‘This review will ls show the need fr any special procesing during manufacturing, Once welding begins, the welding inspector may observe various processing seps to sesure that they are dane peopWELDING NSPECTION TECHNOLOGY ery. IF all these subsequent steps have been com: pleted satsfctoriy, then final inspection should simply confirm the sucoess ofthese opertions ‘Anothes benefit ofthis course is that it has been esigned to prove the welding inspector with the necessary information for the successful comple- tion of the American Welding Society's Ceriied Welding Inspector (CWI) examination. The ten modules listed below are sources for examination Information, The welding inspector must have at least some knowledge in each of these areas. ‘Typically, he information presented will simply be review, while sometimes it may represent an inwoduction to new topic. Module 1 ‘Welding Inspection ane Certication Module 2: Sate Practices for Welding Ingpectors: Module 3: Metal Joining and Cutting Processes Module 4: Weld Joint Geometry and Welding Symbols Module §: Documents Governing Welding Inspection and Qualification Module 6: Metal Properties and Destructive Testing Module 7: _ Metre Practice for Welding Inspection Module 6: . Wlding Metallurgy for the ‘Welding inspector Module sf" Weld ahd Base Metat og Discontinuties Module 10: Visual Inspection and Other INDE Methods and Symbols Additionally, selected technical references are included in the “Body of Knowledge” required ‘These include: + A Selected Code (AWS D1, API 1104, et) + Welding Inspection (WI-80) + AWS ALL, Metrie. Pracrce' Gilde for the Welding Tay MODULE WELDING INSPECTION Aho CERTIICATICN + AWS A24, Standard Symbols for Welding, Brazing, and Nondestructive Examination + AWSA3O, Standard Welding Terms and Definitions + AWSBI.IO, Guide Jor the Nondestructive Inspection of Welds + AWSBILI1, Guide forthe Visual Inspection of Welds + ANSI 249.1, Sofery im Welding, Cutting, and Allied Processes + AWSQCI, Standard for AWS Cerifeation of Weldng inspectors Who is the Welding Inspector? Before wing our discussion tothe technical subjects, let us tlk about the welding inspector as tn individual and the typical responsibilities tht accompany the poston. The welding inspector isa responsine person, involved in the deteninaion of ‘weld quiity aceording to applicable codes and/or specifications. In the performance of inspection ‘asks, welding inspectors operate in many diferent circumstances, depending primarily for whom they ae working. Thus, there isa special need for job ‘specifications due to the complexity of some com- Ponents and structures, “The nspection Workforce may include destruc. tive testng specialists, nondestrctve examination (NDE) peciaists, code inspectors, military er gov- eramentinspecors, owner representatives, in-house inspecters, and others. These individuals may, times, consider themselves “welding inspeccors Since thy inspect welds as part of their job respon sbi. The three general categories into which the welding inspctars’ work-functions can be grouped + Oveseer + Speciale, + Combination Overseer—Speciaist, ‘An ceerscer canbe one individual or many inl viduals whose sills vary such that any amount oF type of workmanchip may be inspected. Both ec2- omits and technical requirements will decide the ‘extent to which these types of inspectors will aoup(MODULE 1—WELDNG NSPECTION AND CemTFCATION themselves and fonction in various areas of expertise ‘The specialist, onthe other hand san individe tal who does some specific ask) inthe inspection process A specials may or may not at independ- cently of an overser. The nondestructive examine "on (NDE) specialist is an example of tis eategory (of inspector. This indvidval hat limited responsi- Dilities inthe welding inspection proces, is common tose inspetar serving as both ‘overseer and specialist. Such an individual may be responsible for general weld quality judgments in ech of the various fabrication steps, and be equired to perform any nondestucive tating that ' necessary. Fabricators may employ several over. seer type inspectors, each having their own area of tneral weld inspection responsibility, Because Inspection responsiilty is divided in these eases, inspeetors may have to ely on eters for specific pects of the total inspection program. For the purposes ofthis cours, we will eer to the welding inspector in general, without regard to how each individual will eased by an employer It is impractical to adress each individual's situation ‘in the scope of this discussion. To emphasize the ditferenees in job require. ‘ments, e's look at some industries using weiding Inspectors. We see welding inspection being done in the consinuction of buildings, bridges end other structural units. Energy related spplication include Power generation feilies, pressure vessels and 2iflines, and otber distribution equipment requi- ing pressure containment. The chemical industry Also uses welding extensively inthe fabrication of Pressire-containing processing felites and equip. ‘ment. The transportation industry requires assur. ‘nee of accurate weld quality in such ares as aero- space, automotive, shipbuilding ard apparatus and offroad equipment. Finally, the manufacturing of consumer goods often requires specific weld quality requirements, With the diversity shown by ‘his listing, various situations wil cleaiy require diferent ype and degres of inspection Important Qualities of the Welding Inspector ‘The individual who does welding inspection shoulé possess certain qualtes to assure that the ‘weLoms nsPeCnON TECHNOLOGY jb willbe done most effectively Figure 1.2 illus: ‘eae tase qu ‘Theft, and pechaps the most important quali- ‘3:18 a professional attitude, Professional atta is often the key fetor for welding inspector success. Inspect attude often determines the degree of respect nd cooperation received from others ding the performance of inspestion dates. Included in this category isthe ability of he welding inspector to make decisions base on fects to that inspections are fair imparial and consistent If decisions we Uunfeir cr show parialty ot inconsistency, they rely affect te inspector's xed. A welding inspector must be completely familiar withthe job requzeneats so that decisions are neither too ert a nor 10 Ix. It is @ mistake forthe inspector to hve preconceived ideas at to a component's sccepailty. Inspection decisions must be based on facts; the condition ofthe weld and the acceptance riteria specified in the appliceble specification must be the determining factors. Inspectors will fea nd themselves being “tested” by other petsonnsl on the job, especially when newly ‘signed to some tsk. Mainaining a profession tide eps overcome obstales to successful job perfomance. [Nett the welding inspector should bein’ good physical condition, Since the primary job invelves, visual inspection, obviously the welding inspector should lave good vision, whether natural of cor: rected. The AWS CWT program requires the inspec. ‘orto pas an eye examination, with or without eor- rectve lass, to prove near vision acuity on Jaeger 22a Zin, and complete a color perception test Another aspect of physical condition involves the size of some welded structures. Welds canbe loca. ed anywhere on very large stctures, and inspec: tors mus often go to those areas and make evalua: tions. Inipectors should bein good enough physical condi ogo 0 any locaton where the welder has been, Ths des not imply that inspectors must vo- late safety regulations just to do their duties, Inspecteacan often be hammered if not done imme Gately ster welding, because acess sis forthe welder wh as,tadders and scaffolding may. be removed. making inspection impossibie or danger fous. Wiin safely guidelines, welding inspectors should n> Tel their physical condition prevent them fiom doing the inspection propery,A WELDING INSPECTOR BRINGS CERTAIN AMOUNTS OF KASH TO THE JOB Knowledge of drawings and specifications Knowledge of welding terms Knowledge of welding processes Knowledge of testing methods Professional attitude ‘Training In engineering and metallurgy Inspection experience Welding experience Safe practices Abllity to maintain records Good physical condition Good vision Figure 1.2—The Inspector Possesses a Groat Amount of Knowiedge, Attudes, Skilis and Habits (KASH)MODULE !—WELDING INSPECTION AND CERTTOATION Another quality the welding inspector should develop isan ability to undesiand and apply the various documents deserbing weld requirement, ‘These can include drawings, codes, standards and specifications. Decuments provide most of the ‘formation regarding what, whea, whee and how the welding and subsequent inspections are t0 be done. Therefore, the rules or guidelines under Which the welding inspector does the job can be found in these documents. They slso state the scoeptable quality requiremests against which the ‘welding inspector will jdge the weld quality. I is important that these documents ae reviewed before the start of any work or production because the velding inspector must be aware of the job require- ‘ments. Often this pre-job review will reveal required “hold points” for inspections, procedure ‘and welder qualification requirements, special pro- cessing steps or design deficiencies such as Weld inaccessibility during fabrication: Although weld- Jing inspectors should be thorough in thee review, ‘his does not mean ihc the requiremenis should be ‘memorized, These are reference documen’s end shouldbe readily avaleble for detailed information ny time in the fabrication process. Generally, inspetors are the individuals most familias with all these documents so they may be called upon by oth- es for information and interpretation regarding the ‘welding ‘Most people associated with welding inspection will agree that having inspection experience is very ‘nportan. Text books and classroom Jaring ce ‘not teach an inspector all ofthe things fede to inspect effectively, Experience wil aid the welding inspector in becoming move ecient, Betor ways of thinking and working will develop with time, [Experience wil iso help the inspector develop the rope attitude and point of view regarding the jo, Experience gsined working with various codes and specifications improves an inspector's understand- lng of welding equiersents and generally improves jb ellectivenes. To emphasize the need for inspec tion experience, we often see 2 novice inspector Paired with an experienced one so the proper tech- igues can be passed along. Finally, We see that inspector certification programs require some min ‘mum feel of experienc fr qualification, Another desirable quality ofthe welding inspec tors basic knowledge of welding and the various ‘WeLoINa WSFECTION TEEHNGLOOY ‘welding processes. Because of this, former welders se sometimes selected to be converted into welding Ingpectrs. With a basic knowledge of welding, the inspector is beter prepared 1o understand cerain problems that @ welder encounters. This sids in fining spect and cooperation fromthe welders Further, this understanding helps the welding Inspect to predict what weld discontinities may be encountered ina specific situation, The welding inspector ean then monitor erial welding. vac ables to id in the prevention ofthese welding prob- lems. Inspectors experienced in several welding processes, who undefstand the advantages end lie italions of each process, ean probebly identity potential problems before they ooear. Kaovledge of various desictive and nonde- smote test methods are also very heipful tothe welding inspector. Although inspectors may not necessary perform these tess, they may from ime toime witness the testing or review the test results as they apply to the inspection. Justa wit welding processes, the welding inspector is sided by e basic understanding of testing processes, Tes important for the igpestor to be aware of alterate methods ‘hat could be applied to enhance visual inspection, Welding inspectors may not actually perform a vent but they may sil be called upon o decide ifthe reals comply with the job requirements, “The ebiity tobe trained isa necessity forthe fod of welding inspector Often, an individ is select for ths poston based primarily on this atbute, Inspects do their job most effectively when they receive taining in a variety of subjects. By gaining auditional knowledge, inspectors become more ‘valoableto thei employers. Anotier very important responsibilty of the welding inspector is safe work habits; good sfety habits pay a significant role in avoiding injury ‘Working safely requires a thorough knowledge-of| the safety hazards, an attitude tat all accidents ean be avoized, and leaming the necessary steps to avoid unsafe exposure. Safety traning should be 2 part of eich inspector's training program ‘A final atisbute, which i not tobe taken light |i the welding inspector's ability to complete and _nainain inspection records, The welding inspector ‘must accrately communicate all specs ofthe var- ious inspections, including the results. All econds developed should be understundable to anyoneWELDING NEPECTION TECHNOLOGY famitiar withthe work, Reports that can only be deciphered by the welding inspector are useless when he or She i absent. Therefore, neatness is important as well. The welding inspector should look at these epors as his rer ermanent records should «question arse ltt. When reports ae gon- crated, they should contain information regarding ‘how th inspection was done so, if necessary, it can be duplicated luer by someone else with similar resuls, Once records_have been develope, the Welding inspector should facilitate easy reference ler, ‘There are a few “ule of etiquette” relating to inspection repoms. First, they should be completed in ink, or typewriten. (In today's “age of comput- 8" typing of inspection repons into computer system is a very effective way of making legible ‘ports, easily retrieved when needed.) If enero ie ‘made in & handwrten report it canbe sngle-lined ut and corrected (he enor should not be totaly obliterated), This coretive action should then be ‘mitialed and dated A similar approach is used when lhe reports are computer generated. The zeport should also accurately and completely sate the job ‘ame and inspection location as well as specific test Snformation. The use of sketches and pictures may sso: help to convey information reyarding the inspection results. ‘Then the completed report shouldbe signed and dated by te inspector who did he work. Ethical Requirements for the Welding Inspector ‘We have described some ofthe qualities which ‘ace desired of a welding inspector. In addition to those listed abow, there are ethical requirements Which are dictated by the postion. Ethics simply eul what is considered to be common sense and honesty. Te position of welding ingpector can be very visible (0 the public if some critical dispute arses and is publicized. Therefore, welding inspec: tor should live by the mules and report to theit supervisors whenever some questionable sition ‘occurs, Simply sted, the welding inspector should ct with complete honesty and incegrity while doing the job since the inspection fetion is one of responsibilty and importance. If decisions are based because of essciations with dishonest peo MODULE 1—WELDING INSPECTION AND CERTIFICATION ple, or offers of fnanciat gain, then the inspector is ‘ot acting with integrity. A welding inspectors decisions shouldbe based latally on avilable facts without egard to who did the work in question, “The welding inspector's poston also caries with ite ceraintespoasitilty to the public. The ‘component andor structure being inspected may be used by others who could be injured should some failure oseur While inspects may be incapable of discovering every problem, itis their esponsibility 'o report any condition that could result in a safety hazard. When performing an inspection, inspectors should exly do those jobs for which they are prop- erly qualified. This reduces the possibility of erors in judgment. ‘There are siations that occur that may be reported the public. fhe inspector involved in ‘dispute regarding the inspection, be or she may’ be asked to publily express an opinion. IF sated, the opinion should be based totally on fats that the ingpecter believes 9 be vali. Probably the best ‘vay to deal with public statements, however, im- ply to avoid them whenever possible. The inspector should ot volunteer information jst to gain pub- lity, However, i stations where « public slate- ‘ments required, the welding inspector may wish to Solicit the advice of a legal representative before pecking "The chical requirements ofthe job cary with them a seat deal of responsibility. However, the ‘welding inspector who understands the difernce betweenethical and unethical behavior should have litle dificuly in pecfomning the job with every one's bes intorests in mind. Many inspectors are required to make decisions that may have great financial impact on vertsin partes. In such stu: tion, the inspector may be approached to overlook fome feature or reverse a decision for personal financial gun. The welding inspector must rsog- nize such dishonest acts and stand firm op all decision, The Welding Inspector as a Communicator ‘Ap important aspect of the welding inspector’ job is that of communication. The day-to-day Inspection effon requires effective communication with may people involved in the fabrcstion orconstriction of some item, What must be realized, however, is that communication isnot a ane way street. The inspector should be able to express ‘hough to others, and be ready co isten toa reply ‘To be effective, this communication sequence must be continuous loop 5 that both parties have an opportunity to express ther thoughts or interpret Sons (see Figure 1.3). Its wrong fr any individual Yo think that their ideas will always. preva Inspectors must be receptive to opinions to which further response can be made. Often, the best tori one whe listens well ‘AS mentioned, the welding inspector ‘has 1 -mmuniate with sever] egferent people involved the fabrication sequence (se Figure I). Infact ‘many situations occur where welding inspectors ae ‘he central figure of the communication network since they will constandy be dealing with most of the people involved. Some people thatthe inspector ‘may communicate with ae welders; welding engi cers, inspection supervisors, welding supervi welding foremen, design engineers, and producti supervisors. Each company will ita exactly how ts welding inspectors function, ‘The communication between the welder and inspector is important to the atsinment of quality ‘ior IF there is good communication, eke i Vidoal ean do a beter job, Welders can discuss problems they encounter or ask about spebifiequal iy requirements. For example, suppose the welders “ytsked to weld a joint having a root opening: «sch isso tight that a satisfactory weld cannot be: accomplished. They may conte! the inspector. ‘ast judgment and get the situation corrected rit then rather than after the weld is rejected for being ‘made improperly. When effective communication cocur, the welding inspector bas the oppertunity to supply answers andlor begin corective action (0 prevent the occurence of some problem The com ‘munication between the welder and an inspector's sully improved if the welding inspector has some weling experience. Ten the Welder has more coo fidence inte inspector's decisions. If there is poo communication between these two pares; quality can sue, Welding engineers rely heavily on welding inspectors to be their “eyes” ap the shop floor or consiraction site, Engineers count onthe inspector ‘© spot problems relating to the techniques. and SPEAKS WRITES ACTS DRAWS, WELDS, WRITTEN WORDS SENDER Oe picTURES NUMBERS, Gestures, “LISTENS READS — "Repaaek 4 OBSERVES TOSENDER INFERS. INSPECTS Figute 1.3—The Welding Inspoctor— ‘A Communicator ”ocesseé peciféd. The welding inspector can also confirm whether specified procedures are being fl- 4 olde. The welding inspector, in tum, can ask the ‘Welding engineer about certain aspects of those _plocedures 25 well Oten, if a welding procedure is ‘ah producing consistent, reliable results, the weld ing inspector may be the fist person to. spot the frubiem, At that point, dhe welding engineer is no fed so tha adjustments ean be made t alleviate the problem ‘The welding inspector wil probably work unde the direction of some supervisor. This individual is responsibl> for verifying. welding inspector's qualifications to perform the work. The supervisor shoud als answer the inspector's questions and aid in the intepretation of quality requirements, In some industry siuations, the welding insp ‘must being all questions to the supervisor In tit supervisor takes that question to someane in engineering, purchasing le. The welding inspector rust comey a question clearly so it can be deseibed openly by te inspection supervisor 19 the ober punyWeLome nSPECTON TECHNOLOGY Ws “Ad \ inte During the actual fabrication proces, the weld> Ing inspector will have opportunities to speak with ‘many other personnel In some situations, instead of communicating rectly with the welders the weld= ing inspecor will deal with the welding supervisor or foreman. This usually involves specific quality ‘equrements or explanations why some aspect of the welding isrejeciable The welding inspector may also have to gain information from design enginers about the setal veld requirements, During fabrication, oer prob- lems may arise which can ony be ansered by the person who actually designed the srt or com: Donent. Another way in which this aspect of com: Ionication takes place is rough drawings and Welding symbols. Alduough « powerful eommnice tion tool, welding and NDE symbols may require Clarfcaton by the symbol crestor, Finally, the welding ispector wil have some becasion to discuss job scheduling with produc ion personnel. This occurs especially. when rejections have been noted wich could alter the production schedule, I is important forthe weld ing ingector to Keep the production peceonnel rate of the status of the Welding inspection so that Schedules can be adjusted if necessary. As indicated, depending on the welding inspector's specific job description, be or she may not deal with all those noted above, or te inspector may communicate with others not discussed here. Its importint to realize that all will benefit if some effective communication tkes place so surprises do not secur during fabrication. ‘When we ul of communication, we are not limiting our attention to speaking. There are sever al ways in which people effectively communicate ‘They include speaking, weting, drawing, gesting, and the ue of pitres or photographs, Each situs ion my be dealt with using one or more of these rethods. The method is not as raportan s the fet ‘hat cemmunication occurs; messages ste seat, received and understood by all concerned,MOOULE 1 —ELOMG INSPECTION AN CERTIFICATION Personnel Certification Programs ‘Thete ave sevecl progranis presently avilable to determine whether an individual possesses the ecessary experience and knowledge to perform Welding. inspection effectively. ‘The American Society for Nondestructive Testing. hat issued ‘suidelines for ceificason of NDE! personae! in ASNT SNE-TC-1A, This document describes the "ecommended procedures for crifying inspectors performing nondeswuctive testing. ASNT seco. ‘izes thes levels of eerfcaion, Levels I, I, and 1 AWS has also initiated an NDE Cénification Program, Presently, AWS can cerify one Level of Reclogrephie Interpreter (RI). The RI progeam cer= ties inspectors for interpreting weld radiographs, ‘Additional NDE methods’ cerifcation is avalsblé Utsough the joint effors of AWS and outside tain ing agencies, For visual inspection of welds AWS has devel- oped the Cerifed Welding Insectr programm. The font page ofthe Application foun for the Cerifed Welding Inspector is shown in Figure 1.5. AWS QCI, Standard for AWS Cerifcation of Welding Inspectors, Figure J, establishes the equizements for AWS certification of welding inspection personnel, Thre ae thee levels of ceri. Satin in AWS QC. The Senioe Certified Welding Inspector (SCWD isa person wit atleast 15 years ‘experience including 6 years experience while cet. fed as © Conttied Welding Inspector (CWD). The SCWI must pass separate examination frm the ‘CWI examination explained below, Information the SCW1 program and examination ave found in Separte course, Welding Quality Assurance and Inspection Manual~A Gulde for the Senior Certied Welding Inspecor. The next cetfication level isthe CWI and the thie level is the Cesied Associate Welding Inspector (CAWD, Both ofthese certifications are covered in this course, AWS QC! Ussribes how personnel are qualified iss the pein ples of conduct, and notes tie practice by which crtficaion may be maintined. Those major le. ‘ments wil be discussed here ‘The first step toward cerification is the ocumentation of relevane educational nd work ‘xperienee. To qualify for the Cerfed. Welding Inspector (CW examination, the individual must 140 WELDING NSPECTON TECHNOLOGY ocunent is oF her educational Background. tn ‘dition, the candidate's years of weldingrelated experince according to some code ot specification must ke documented, Win supporting documentation (eg, copes of ‘eanscipts, reference lester, credited hours of tain ing, quartet hours or semester hours), up to two YEW of work experience may be substinted by Post high school educational experience ‘Subst educational experience includes an Associne or higher degree in engineering, pbysies or phyiieal scence and welding technology. Trade ‘nd vocational courses can be applied o work expe rience sobsitution for completed courses related to ‘welding (upto one year maximum). Catdidates witha high school education, ether by diplma or state or military equivalence, must have least S years experience. Individuals with cighth grade schooling are required to have not ess ‘han 10 years job experience to quality for the ‘xaminution. Fr individuals with les than eighth ‘rade schooling, not less tha15 years is equized ‘A subordinate level of qualification is, the Cenifed Associate Welding Taspector (CAW, Which requires fewer years of experince foreach educational level. All of the experience noted for ‘both the CWT and CAWT must be work assoisted With some code or specification to be considered valid, Individuals whe qualify for the Certified Welding Inspecior Examination take a three-part examination: Port A~Fundamentals. The Fundamental exami ‘nation is closed book test consisting of 150 muli- ple choice question, The topics covered inthis por. tion of the exam include repens and records, desrotve tests, welding performance, duties and ‘esponsiilites, weld examination, definitions and lerminolbgy, sefety, welding and nondestructive ‘xaminsion symbols, nondestructive examination ‘methods welding processes, best control, metal 1; mathematical conversions and excitons, Part B—Practcal The Practical examinetioncon- Siss of 46 questions. It requires measurement of ‘weld Felicas with provided measuring tools, and eluaten in accordance with supplied "Book of Speciticsions" Nota questions require the use of‘American Welding Society AWS USE ONLY APPLICATION FOR AWS WELDING INSPECTOR | STESCEE _Plense PRINT or TYPE EXAMINATION ten 18, crcoe ms camaro es YOU DEERE tb, PERSONAL i Oo AWS CERTIFICATION STATUS. _ + ingens my 08 ci aan 8 ma igs NOT ‘16 CODES SOURCE CODE: act Testes Ta Spain "orb oes ead, ect ‘Seta § Seeclansenat acer” i ; Ki Figure 1.5—AWS Corlfad Welding Inspector Application Form Ma[MODULE 1—WELDING INSPECTION AND CERTBICATN the Book of Specifications; some require the indi- ideal 10 answer from practical knowledge. The Practical Test covers welding procedures, welder qualification, mechanical tests and properties, ‘Welding inspection and flaws, and nondestructive tess, Test candidates sbould be falar with fillet and groove weld gauges, micrometers, dal ealigers, and machinist's sales, Part C—Open Book Code. This portion consists ‘of 46 questions on the code the individual has selected for this pa ofthe examination. The fol- Towing codes are applicable to this potion of the + AWS DLA The AWS DLL, Simctural Welding Code—Siee! examination covers the following subject areas: general requirements, design of Welded connections, prequalication of WPSs, (qualification, fabrication, inspection, stud weld. ing and the annexes ‘APT104. The API 1104, Welding of Pipelines and Related Facilities examination covers the following subject arss: general, qualification of welding procedures, welder qualification, design and preparation of «joint for production Welding, inspection and testing of production ‘welds, sandaeds of acceptability NDT, reps of removal of defects, radiographic procedure, and automatic welding. AWS DLS. The AWS D1, Bridge Welding Code examination covers the fllsving subject ares: general provisions, design of welded can- fection, workmanship, technique, qualifis- tion, inspection, stud. welding, welded sts] bridges, fracture control plan for nonredundant members and the annexes, AWSDIS.1. The AWS DIS.1, Railroad Welding Specification—Cars and Locomotives examina tion covers welding of meta at lesst 18 in, ‘hick, specific requirements for welding ralroad cas, an the requirements forthe manufacturing and reconditioning of locomotives and paste erin vehicles. ‘To successfully complete the examination, in- viduals must puss all three parts of the test. The 112 \WeLoWG INSPECTION TECHNOLOGY passing score in each prt forthe CWLis 72 preent, the passing for CAWI is 50 percent, Beyond com- pletion of the examination, the test candidate mast, "ndego an eye examination to assure that the indi= vidual sosssses adequate vision, whether natural or corrected. After all tat resuls are succesfully compleed, the individual is considered qualifies to perform visual inspection of welds. When AWS Says that this individual is a Certlied Welding Inspec, this simply implies that the person's qualifications are documented with an approriate certificate, The CWI cerifiate does nt state what code ths inspector used on te examination, A CWI isquaed to use and interpret any welding code or standard, ‘Welling ispectors area ery important pat of any effective quality contol program. While there te various categories of welding inepectors, in gen- feral they are considered to be those individuals responsible for evaluation ofthe resling welding. ‘These individuals most possess physical, mental and etic quaites in oder to be effective. The remaining modules will desl those aspects of Welding considered imporant for the welding inspect In addition, these topics are also consid- fered relevant to the AWS Centfied Welding Tnspecioe Examination, Therefore, this text is an sppropite guide for individuals ta se in prepare tion for that seis of examinations {In pepartion fr tha ponion ofthe CWI exam: ination covering welding inspector certiation requizenents,, you are encouraged fo read and ‘becom Familiar wih AWS QCI, Standard for AWS Cerfcation of Welding. Inspectors. Pax of the ‘Welding inspectr's job is ihe review and interpreta tion of vasious documents relating to the welded fabriaion. Ths requires tha the individual have a full undersianding of the proper terms and defini tions tat are used. For this reason, included atthe end of each module the reader will ind, “Key ‘Terms and Definitions” applicable to. module's topic. AWS realizes the need for standardized erm and definitions for use by those involved in the fab- ‘ear of welded products. In answer to this need, AWS A30, Standard Welding Terma and Defnivons, Was published (se Fignre 6). [AWS A3.0 was developed by the Commitee on Definitons and Symbols to ad in welding infor ‘mationcommunication, Standard terms and defini-Standard Welding Terms. and Definitions eg am tg, ‘See et es Satie nes Figure 1.6—AWS A3.0, Standard Welding Terms and Definitions ions published in A3.0‘are those that should be xed in the oral and written language of welding While thee are the standard, or prefered, tems, they are no he only terms used to describe vious situations. The purpose here i to edvcate, and ts often important to mention some ofthese common teoms, even though they are not prefered tem vology. When nonsiandird tems are mentcned, appear 'in parentheses afer the pre While mast ofthe terms used apply to the scr] welding operation, iis important forthe welding inspector to understand other definitions which appl to othe seated operations, Welding inspectors should understand how to describe weld joint con- figueaions and frp process elements requiring ‘comment, After welding te inspector may need to Aeseribe te location ofa weld ditcontiuit that has been discovered, I'a discontinuity requires funher stiention, tis impoctan that the inspector accutely Aeseribe the location of the problem so tat the welder will know where the cepa isto be made AVIS recommends that stnderd terminology NODULE WELDING INSPECTION AND CERTIFICATION used wherever possible, but the inspector must be familias with nonstandard terms a¢ wel Key Terms and Definitions API—Anerioan Petoleum society which provides te pevroleun industry API 1104—The API Standard, Welding of Pe lines and Related Facilites, This standard is often used in construction of cross-country pipelines ASME—Americen Society of | Mechanica Engineers. The technical society which provides technical guideuce for pressure contining vesels and equipnent. ASNT—American Society for Nondestructive ‘esting. che technical society which provides tect nical guidance for NDE. -American Welding Society. The technical Society which provides technical guidaee and leadership in all phases of welding AWS ARO—The AWS Standard Welding Terms and Defnitions. This standard defines welding related tems with stndard deiitions, AWS BS11—The AWS Specification for the ‘Quelifetion of Radiograph Inerpiters AWS DLI—The AWS Structural Welding Code— Stel, Used worlwide for construction of buildings fan structures, AWS DIS—The AWS Bridge Welding Code used inthe US. for constuction of bridges AWS DISU—The AWS Railroad Welding Specif- cation—Cars and Locomotives. Tis speiGeation covers welding of railroad cars and locometivs stitute. The technical eal guidance forthe CAWI—Certfed Associate Welding Inspect (CWICeritied Welding Inspector, KASH—An acroriym for Knowledge, Attn, Skills ard Habis, the basic tools of & welding NDE—Nondestrucive Examination, The act of etermining the suitebilty of some material or‘MODULE 1WELOIG INSPECTION AND CERTIRCATION component for its intended purpose using tech- Aigues that do not affect its servieabiity, NDE: is ‘he prefered tem per ANSUAWS, NDI—Nondestuctive Inspection, A noastandant ‘erm for nondestructive examination (see NDE). NDT—Nondesiuctive Testing. A nonstandard tem for nondestructive examination (see NDE), ‘ELON SPECTION TECHNOLOGY QCI—The AWS Standard for AWS Certication of Welding Inspectors. Defines the requirements and progr for the AWS to cerfy welding inspectors, SCWI-Senio: Certified Welding Inspector. SNT-TC-1A—This ASNT Recommended Practice, Persomel Qualfication and Certification in Nonderactve Testing, allines the cetifction program for NDT lechniciasSafe Practices fo Welding Inspectors Contents “troduction Eye and Face Protection Protective Clothing Note Machinery Guatds Fumes and Gases Exposure Factors Ventilation Handling of Compressed Gases tanto Gases etre Shock Key Terms and Definitions 29 29 210 2 213 2s a7 2.20WELDeG NEPECTION TECHNOLOGY Module 2—Safe Practices for Welding Inspectors Introduction ‘Welding inspectors often workin the same envi- ‘ronment as the welder, so they ean be exposed to ‘many potential safety hazards. These include elec: tric shock, filling, radiation, eye hazard such as ‘ltaviolet light and paricilate matter inthe sin, smoke and fumes, and falling object, Safety is not ‘o be taken light, although the welding inspector ray only be exposed to these conditions momen tanly. The welding inspector should strive to observe al fey preceutions such a us of safety lass, hard bats, protective clothing or anyother ‘ppropsate apparatus fora given situation. For a ‘more detiled look at recommended safety prea tions refer to ANSI 249.1, Safety in Welding Cutting, and Allied Procestes (see Figute 2.) Safety is an imporsot consideration inal weld ing, cutting, and related work. No activity is factorily completed if someon i injured. The hai- sd that may be encountered, andthe practioes that will reduce personal injry and property damage, ne discussed here. ‘The most important component of an effective safety and health program is leadership soppor and ‘Scecton. Management mus clearly state objectives and show its commitment to safety and health by consistent support of safe practices. Management ‘ust designate approved safe areas for conducting welding and cutting operations. When these oper: tions are done in other than designated aress, man~ Agerent must assure that proper procedures are ‘stublshed and followed to protect personnel and rope. Mangement must also be cermin that only spproved welding, cuting, and allied equipment are ‘used. Such equipment includes torches, regulators, Welding machines, electrode holders, and personal Protection devices (see Figure 2.2), Adequate 22. ety in Welding, Cutting, and Alied Processes supervision must be provided to assure that all ‘equipment is properly used and maintained. ‘Thorough and effective taining isa hey aspect of asalsty program. Adequate raining i mandated under provisions of the U.S. Occupational Safety dnd Health Act (OSHA), especially those of the Hazard Communication Standard (29° CFR 1910.1200), Welders and other equipment operators work most safely when they are properly tained in the sbjettng so shat thei heads are notin the gues or fume plume. A fime plume isa smoke-like cloud con lainng mire solid puticeswising ret fom the area of meling metal. The Funes are metalic ‘vapors thathave condensed ito paculates, Before work begins, users must lays rea and understand the manufactores nsirsctions on sle practices fer che material and equipment, and the “Material Salat Data Sheets (MSDS), Cetsin AWS specifications call for recsutionazy labels on con sumables yd equipment, These labels concern the sue use ofthe produes should he real nd fl lowed (see Figure 23 Manufacturers of welding consumables nus, ‘pon request, fish a Material Safery Data Sheet that idemiies materials present in their products at have hcardous properies, The MSDS provides OSHA permissible exposire limits, own athe ‘Threshold Limit Value FLV), and any other expo: sre limit wed or recommended by the manufator Figure 2.2—Persona Protective sf. TLY ie 1 registered trademark ofthe Amesicad Equipment (PPE) Conference of Governmental and lndustial ygleniss ;ACOUH Employss that use consumables must make all Proper taining includes instustion in the safe applicable HSDS data availabe to thei employees use of equipment and processes, and he safecy rules an also tan them o read and underiand the con hut must be followed. Personnel need to know and tents. The MSDS contain imporant information understand the rules and the consequences of dis- about the ingredients contained in welding ele jcying them. For example, welders must be odes, rods and fhies, These sheets also show the rained to position themselves while welding or eu mes genaated and other hszards LTARRING: PROTECT yourself and athers. Road and und FUMES AND GASES can be dangerous to your health [ARC RAYS can inure your eyes and burn your sn, ELECTRIC SHOCK can KILL. + Before use, read and understand the manufacturer's Instrctions, Material Safety Data Sheets (41808), and your empioyer's safety practices, + Keop your head out of fumes, Use enough ventilation, exhaust atthe are, or both, to kegp fumes and gases from your breath: {ng zone and the general eres + Wear correct aye, ear, and body protection + Do not touch ive electrics! parts. + See American National Standard 249.1, Safety in Welding, Cutting, and Allied Processes, pub- lished by the American Welding Society, 50 N.W, LaJoure Rl, itlami, Flride 28126, OSHA Safety and Health Standerds, vallable from U.S. Governmant Printing Otfice, Weshington, OC 20402, 00 NOT REMOVE LABEL Figure 2.3—Typieal Warning Label for Ace Wielding Processes and Equipthat may be caused during we. Tey also provide methods ta be followed to protect the welder and others who might be involved Under the OSHA Hazard Communication Standerd, 29 CFR 1910.1200, ermployers are responsible for employee hazardous materia rine inthe workplace. Many welding consumables ue included inte definition of hazardous materials according to this standard. Welding employers must comply with the communicuion and. taining requirements ofthis standre Proper use and maintenance ofthe equipment must alo be tnght Fr example, defective of wom lectical insulation in are welding or etingshoule ot be used. Aso defective or wern hoses used in 2s welding and cuting, brazing, or solder ing should not be used. Training in equipment oper athn is fundamental to safe operation Personnel must sleo be tuned to recognize safety hazards. Hf they ae 10 workin an unferiat Situton er environatent, they must be thoroughly briefed onthe potential hazards involved, Fer exam ple, consier a person Who mus work ip confined paces, Ite vention i poor and an ai-supplied helmet is required the need snd nstrsction Frits proper use must be thoroughly explained 10 the tamployee. The consequences of improperly using ‘he equipment must be covered. When employees believe thatthe safety precaution for a given task ae not adegoate, oF not undersioed, they should {question thir soperiser before proceeding Good housekeeping is also essential t0 avoid Injures. A welder’ visions afenrestcted by neo essary eye protecion, and personnel passing @ ‘welding salon must often shield their epee fom the Mame or arc radiation. This limited. vision makes both the welder and passersby vulnerable to tripping over objects on the floor Therefore, welders and supervisors mst always make sre tha the are is clear of upping hazards. shop produc fon area should be desiged so tha gas Doses, cables ssemblies, and other equip rent do not cross walkways or inlerfere with vou tin ash (see Figure 24), When work s aboveground of ou evel, safe ty malls or lines must be provided to prevent falls because of rented vision from eye protection devices, Safety ines and bamesses can be helpful est workers la sefe ares, and retain he in Figure 24—Designated Welding Area case of a fall. Unexpected evens, such us fume reas, fe and explosions, do occur in industri jendronients. AD escape roues should be ident fa and kept clear so that eden pid, and safe fevsenation of an area ean lke place. Employees ined in evacuation procedures. Storage ‘of goods end equipment in evacuation routes must be woided, IF an evacuation souve must be te rary blacked, employees who would norm us that route most be tuned 10 Equipmen, machines, ebles, hoses, and other apparatus should always be placed 0 tht they do 1a present a hazard to personnel in pasagennys, on ladders, or on suirways. Waring signs should be poste fo identify welding sre, and to specify tat eye protection mist be worn, Occasionally, & re Wateh” person must be asighed to mainsin salty during welding or cuing operations, Personnel in areas next to welding and cating snus aso be protected from radiant energy and hot sputer. This 6 aceemplished with Mame-essiant sevens or Shiels, or Sulable eye and fice prec i and protective clothing. Appropriate acai protective, semi-tunsparent materials ave permis Tete operations allow. work stutionsshoolé be separated by noncombusble screens oF shields see Figure 25). Boots and sereens shoul allow clieuiaion of a at Roor level and above the screen Where are welding or cating is regularly pr formed next to pained wall, the walls should be panied with a fnish having low reflectivity of Ulravole radiation. Pain fish formulated with certain pigments, such ay tanium dinide or zine bleFigure 2.5—Protective Screening Botween Workstations oxide, have low reflectivity o vtraviolet radiation “ior pigments may be added if they donot smetease reflectivity. Pigments based on powdered cor flaked metals are not recommended beets they reflect ultraviolet radiation, ‘In most welding, cutting, and allied processes, a high-imperature eat source is present” Open flames, eleetrc arcs, hot metl, sparks, and spater ae ray sources of ignition. Many fires ae Started by sparks, which can travel horizontally up 1035 feet from their source. Sparks can passthrough oF loge in cracks, oles, and ciher small openings in floors and walls ‘he rsk of fire's increased by combustibles in he work area, or by welding orcuting too close to combustibles that have not Deen shielded, Materials ‘most commonly igaited are combustible floor, roofs, partitions, and building contents including ss, wood, paper, tetls, plastics, chemical, and uammable Tiguids ard gases, Outdoors, the mort common combustibies are dry ‘sass and brush, ‘The best protection against fire is to do welding and cuting in specially designated areas or enclo- ‘sures of noncombusible construction kept fee of combustibles. Combustibles should always be Temoved from the work area or shielded from the pectin, Common combustibles found in welding mano- ‘turing include fuels for both equipment engines ‘nd welding or cutting operations. ‘These fuels should be stored and used with care. Equipment ‘manufacturers’ instructions: should be followed because fuels and thelr vapor ae combustible and MODULE 2A PRACTICES FoR WELOING NSPECTOAS can be explosive unéer some conditions, Acetylene, propane and other flammable gases used in cuting ‘nd welding areas require earful handling. Special stuenion should be given to fuel gas cylinders, ‘hoses, and apparatus to prevent gas leakage. ‘Combrstibes that cannot be removed fiom the area should be covered with tight fiting, flae- resistant nateial. These inelode combustible walls and ceiling. Floors around the work area should be free of combustible materials fora radius of 35 fee. Alldoorsays, windows, cracks, and other openings should becovered wit lame-reistant materia. It possible, the work area should be enclosed with porable Fame-resstat screens, ‘Combustibes onthe ater side of metal walls, ceilings ct partons must be moved to safe loca. tions when Welding or cuting is done on er next 19 the locaton, If this cannot be done, a fze watch shouldbe stationed near the combustibles, Welding heat can conduct through metal partons and ignite combustiles on the opposite side, A thorough examination for evidence of fie should be made ‘before leaving the work area Fie inspection should bbe continued for atleast 30 minutes after the opera- tionis completed ‘Welding or exting should not be done on mate sal having a combustible costing or internal truce ‘ure, asin walls or ceilings. Hot srap of slag must not be pliced in containers holding combustible ‘materials Suitable ire extinguishers shoold always be available nearby, and the fre watch tained in Abels ute, Wielding, brazing, or euting should not be done ‘on combustible lors or platforms that may readily be ignited by heat from the operation. Welders and Inspectors must be alert for traveling vapors from ‘ammable liquids. Vapors ae often heavier than ai. ‘Vapors fom flammable liquid storage areas can teavel several hundred feet along’ flaors and in Aepressions. Light vapors can travel along ceilings tw adjacent rooms, ‘When welding, cating or similar hot working operation: are tobe performs in are not normal Jy assign for such operations, a "hot work pemit™ system should be used (see Figure 2.6). The pur- pose ofthe hot work penn ystem i to ler area Supervisors to an extraordinary danger of fre that will exist ata parcular ime, The permit system should indude a check ist of safety precautions. AMODULE 2—SAFE PRACTICES FOR WELDNG NSPECTORS Figure 2.6—National Safety Counell ‘Hot Work Permit” checklist often includes fre extinguisher inspec- Won, establishes the fire watches if necessary, & ‘ammble material search, and area safety insrc= tions for personnel not involved in the hot work. ‘When a hot work permit is issued, the welding inspector must be aware of and adhere to all its requirements. Flammable gases, vapors, and dust sed with ‘erin proportions of se or oxygen present expla son and fire dangers. To prevent explosions, avoid all soures of ignition: Welding, brazing, soldering, ccuting, or operating equipment that ean produce ‘heat of sparks must not be done in atmospheres con ‘wining flammable gases, vapors, of dusts. Such flammabies must be kept in leak tight containers or be well removed frm the work ares. Heat or sparks may cause etberwie low-voaiity material 10 pro- duce Nammable vapors. 26 Hollw contsiners mus be vented befor, and uring, sny applicaion of beat Heat must not be applied oa container that has held an unknown mate= al, a combustible substance ora substance thar may form flammable vapors. without considering the potential hazards. Such containers mus fst be thor- ‘oughly cleaned or filled with an ine gs, Adequate eye and body prostion must be-worn ifthe opera- tion involves explosion risks. Bums of the eye or body are serio hazards inthe welding industy Eye, fice, an body protection forthe operator and others in the work area are required to prevent buns from ‘lsavioet and infrared raisin, sack, and spater Eye and Face Protection Are Welding and Cutting ‘Welling. helmets or handshields containing appropiate filter plates and cover plates must beWe\OING NSPECTION TECHNOLO used by welders and welding operators and nerdy esonnel when viewing an are. Standaré for weld dng helmets, handeiede, face shields, gogales, 20d spectacles are given in’ ANSI Publication 227.1, Practice for Occupational and Educational Eye ‘nd Face Protection, atest eon, Safty spectacles, goggles, or ater suitable ye protection must aleo te wom daring oer welding Sod calling, operations (eee Figure 2.7. Such devices must have fll conforming side shill when thee is danger of exposure fo njerous rays oy ing parcls from ganding o cbipping operations. Spectacles and goggles may bave clear of colred lenses, Shading depends oo te intensity ofthe rd sion tat come from adacent welding or cuting ‘operations shen the welding helmet is raised or removed. Number fier plates are recomended Dr general purpose prosecion (ee Table 21). Cytuel Gas Welding nd Cutting, Submerged ‘rc Welding Safety gogses wih Str plates and fll con- forming side shies mist be worn while pefors- ing oxyfuel gas weldig and cuting (se Tobe 2). ising submerged are welding, the ac is covered by Max and i not readily visible; therefore, ea ae ‘welding helmet is not needed. However, because the ar occasionally farbes trough the fux bar- en the operator should wear ited saery less. ‘Torch Brazing and Soldering Safety spectacles wih side shields and appropri- ste filter plates are recommended for toch brazing tnd soldeing. As with oxyfel gas welding and cur Figure 2.7—Eye, Ear, and Face Protective Equlpment MODINE 2-SAFE PRACTICES FOR WELDING INSPECTORS ting, a bight yellow flame may be visible during (orch brazing. filer similar otha used with hase processes should be used for torch brazing (see ‘Table 2.). Other Brazing Processes and Resistance Welding ‘Opersors and helpers engage in these process~ es must wear safety spectacles, goggles, and face shield to proteet their eyes and face from spt Fier plates are not necessary but may be used for comfort refer to Table 2.1), Protective Clothing Sturdy shoes or boots, and heavy clothing should be worn protect the whole body from fy- ing sparks, spatter, and radiation bams. Woolen clothings preferable to coton because it isnot so ‘etily ignited, Cotton clohing, if used, should be chemicaly tested t0 rodice it combustiiy (Clothing tested with nondurable flame retardants must be weated again after each washing or clea ing, Cloing or shoes of synthetic or plastic mate- rials wich can melt and cause severe burs, should rot be worn, Outer clothing should be kept tree of cll and grease, especially in an oxygen-rich saumoepbee ‘Cuflss pats and covered pockets ae recoin- mended t0 avoid spatter or spark entrapment. ‘Pockets should be emptied of flammable or readily igoitable material before welding because they may be ignited by sparks or weld spatter and res in severe tums, Pants should be Wom outside sees. Protection ofthe hui with «cup is recommended, cspecaly if haipiece is wom. Flammable hair reparatons should not be used. ‘Darele glove of eather or othe suitable mste= Fal shold always be worn. Gloves not oly protect the han fom bors and abrasion, but also provide insulation from electrical shock. A vatery of spe- cial proletve clothing is also availble for welders. ‘Aprons legeings, sults, capes, sleeves, and caps, all of dural matsils, should be wom when wedi ‘overheat or when special circumstances warant |) tic etna te boy ‘Spaks0¢ ot spate in she ears can be panicu- larly painful and serious. Propecly fited, fame resistant ear plugs should be worn whenever opera= tons pose such risks. 2MODULE SAFE PRACTICES FORWELDNG MSPECTORS ‘Key Words—Eye piscton and hate Table 2.1—Lens Shade Selector WeLpina misPEcTION TECHNOLOGY AWS F22 ‘Shade numbers re given as a guide only and may heared to sult individual needs Operation Shleéod Meta Are Weng (ua Gas Metal Are Wolaing and Flux Cored Are Welding GMAW and FAW) Ges Tungsten Are Welding (cra Ar Carbon Ate Cutng (ght). (cacea) eam) Plasma Are Weng (PAW) Plasma Are Cutting (PAC) tae Madu Hea ‘Torch Brazing (78) - ‘10h Sotdering (75) Carbon Are Weng (AW) ‘as veang (a oe Mesum Hoary Oxygen cut a gon tng (OC) Ven ean ctrode Ske, mm (usa in) ss tan 25 9) 2s) ss468) ore ans 28 ae courent (ampere) ssa) coe, sta 30) estan) oo ser 2 es tn 0 1.2) seta so) "0-103 vestena) 210" ars >) sen tan 0) s-01 se timo Protective ‘Shade t a 0 7 0 0 0 a 4 8 » " 6 a ® " Susgastes ‘Shad No. (Conor ©. 2 2 “ ® 2 “ 2 “ one 0 ® 6Noise Excessive nose, patculary continous aise a high Teves, can severely cumoge bearing. Ie nay sais either temporary or permanent hearing loss US. Department of Lubor Occupational Safty and Health Ad ale noise exposure levels, Resuiteents of these regulations may be found ie. General Industry Standards, 20 CFR 1910.95, In welding, citing, and alli operations, mise may be generated by the proces athe equipment, or both Hearing protection devises ae reuied for ‘some operations (ee Figure 27). Additional info: mation is presented in Ave Welding and Cuting ‘Noise, American Welding. Society, 1979, Air Carbon Are and Plasma Are Cuting are processes that have very high noise lovels Engine-diven per alors sometimes emt a high noise level, #8 do some high-frequency, and induction welding power Machinery Guards ‘Wilders and other workers mst also be prec From injury by machinery and equipment they are aperuung orby ather machinery operating inthe work area Moving components and di rust be covered by ‘ao (see Figure 2.8 Because welding eliets and dak filter plates restrict the visibility of seers, these people may be even move suscepble than crdiary workers 10 injury from unguarded machinery. ard 0 prevent physical co Figure 2.6—techinery Guard Tettore, reauired ‘When repairing machinery by welding or baz ing, the power to the machinery must be discon inadvertent operation and Injury, Welders assigned co work on equipment with safety devices removed should fully understind the izards involved. and the eps w be taken to avoid injury When the work is eximpeted, the safety doviees must be replated Rotaing and autoratie welding machines, Extures and welding robots must be equipped with appre Prat guards or sensing devices to proven oe ‘ion when someone isis the dinger ares Finch points on welding and other mechanic fequisment can also result in. serious inj anples include resistance welding. machines robos, automatic are welding machines, jig. and fixtures, To avoid injury with such equipments the machine should be equipped so tat both of the operuor's hands mast be tse locations when the machine is actsted, Otherwise, the pinch points must be suitably guarded mechsnially. Mtl working equipment should not be located whore 3 welds could accidently fall into or against it while welding. During muntenance ofthe equi ment, pinch points should be Blocked to prevent fen rom closing in ease of equipment ire. 1a very hazardous sitions an observer should be Staoned to peevent someone from tuning the ower on until the repair completed special aention wo this hunard is locked out, ied, und tagged Wo preven Fumes and Gases Welders, welding operators, and other persons in the area must be protected from overexposure to fumes and gases produced during welding, brazing soldering, and cuuing, Overexposure i exposute thats haaardous to hel, or exceeds the permis ble limits specified hy 2 government agency. The U.S. Deparinen of Labor Oceypational Safety and Heath Administration (OSHA), Regulations 22 CER 1910.1000, covers this wopie. Also, the American Conference of Governinental Insta! Hiypenists (ACGIH) lists guidlines in dee publ cation, Threshold Limit Values for Ch Subs.onces and Physical Agents in the Workro Environment Persons with special health problem ‘may have ununish sensiiviy that requires er ‘more stringent protectionNG NSPECTORS Fumas and gases are usually 2 greater concern i re welding than sn oxyfuel gue welding exting cr brazing. A welding are may generate a larger! lume of fame ad gas, an s greater variety of mate Fils are usually involved, Protection from excess exposure is usully accomplished by ventilation, Where exposure would exceed permissible lime with avallable venation, suitable respiratory pro Teetion mu be wsed. Protetion must be provided fer welding. cuting, and ether personal in the Exposure Factors Position of the Head ‘The single mest imponant factor infue ‘exposire to fumes isthe positon of he head with respect ta che fumes plume, When the hea iin such phe face or helmet, exposure levels can be very high ‘Therefore, welders must be tained to Keep thet head tone side ofthe Fume plume. Sometimes, the work cin be positioned so the fume plume rises to fom hate fumes en “ypesofVentavon ‘Vewlaton Has significant infuene on fume nouns i the work afea, andthe welder expo- Sure b Gem. Venlaion may be lea, where the fumes re exis ear he post of welding (sce Figure 29) or gener were the shop sr Is or filtered. The eppropriate type will depend onthe welding process the material being welded aber shop conditions, Adequate ven inton is necessary to Keep the welde'sexposire 1 Figure 29—Movable Fume Extractor Positoned Near the Welding Are\ELONG NSPECONTECHNOLOGY Work Area “The size ofthe welding or ening enclosure is important. It affects the background fume lve Fume exposure inside a tank, pressure vessel, of ‘ther confined space will be higher than in a high ‘bay fabrication area, Background Fume Level ‘Background fume levels depend onthe number and type of welding stations and th duty cycle for each power source. Design of Welding Helmet The exteat a hele cures under the chin toward the chest affects the amount f fume exp sue, Close-ftingelmets ean be effective in retin exposure Base Metal and Surface Concition ‘The type of base mets being welded influences fume components and the amount generated Surface contaminants or coatings may contibute Spnificany to the hazard potential of the fume Pins containing lead, a platings conning cad injum, generate dangerous fumes during welding and cutting, Galvanized material creates zine fumes ‘which are harmful Ventilation ‘The bulk of fumes generated during welding and ‘cuing consists of small panicles that remain sus pended in the stmasphere for a consdersle time. ‘Asa resil, fume concentration in closed are ean build up overtime, as ean the concentration of any ‘uses evolved or used inthe proces. Patclesevea- ‘wally sete on the walls and los; but the setling tate is low compared to the generation rate ofthe ‘welding or cuting processes. Therefore, fume con- ceatration must be contoled by ventilation. Adequate ventilation is the Key to contol of fomes and gases in the welding. environment, ‘Natural, mechanical, or respirator vention must be provided forall welding, cutng, brazing, and related opézations The verilation must ensure that ‘concentrations of hazardous sgbome contaminants are maintained below recommended level. ‘Many ventilation methods are svulble. They ange from natural defi olaalied devices uch late welding helms. Exanplesofven- at OOLLE 2-58 PRACTICES FOR WELDING NSPECTORS ual Gere arse mechanical vation Oratead exaust hoods Pobi oeal exhaust devices Dov bios ssa ites xsi bite he wade espment iortated ints Welding in Confined Spaces Special consideration must be given 1 the sa {y and feath of welders and other workers in can- fined syuces. See ANSI Publication 2117.1, Saery Requirenents for Working in Tanks and. Other Confined Spaces, atest edition, for futher preeat- tions. Cas, cylinders must be located ouside the confined space to avoid possible contamination of the space with leaking gases of volatiles. Welding power rourees should also be located ouside redace danger of engine exhaust and electric shock. Lighting inside the work area should be low volt age, 12, orif 110Vis required, the circuit must be protectal by an approved Ground-Fault Cieuit- Inexrgter (GECD, ‘A means for removing persons quickly in case of emenency has tobe provided. Safety beis and lifelines, when used, should be atached 10 the ‘workers body in away that avoids the possibilty of ‘he person becoming jammed in the exit A waned helper, "standby." shouldbe stationed outside the confined space with 2 preplaned rescue procedure in cas of an emergency (including not entering the ‘confined space to aid the fst worker without prop- er breathing apparatus). ‘Besies keeping arbor contaminant in breath- ing amaspheres at or below recommended limits, ‘entation in-confined spaces must alo (1) assure AMequats oxygen fr life suppor (atleast 19.5% by volume! @2) prevent accumulation of an oxygens cenviched atmosphere, (Le, not over 73.5% by vol- time) sad @) prevent accumulation of flammable mixtures (see Figure 2.10). Aspyxiaion can quick ly resultin unconsciousness and death without war ing if oxygen isnot present in suficient concentra- tion to suppor life. Air contains approximately 21% ‘oxygen by volume. Confined spaces must not be entered unless well vented, or th Inspector isFigure 2.10—Welding in Confined Spaces ‘wearing an approved sir supplied beating appre ts and has proper uning i workin such spaces. A sinilnly equipped second pers be presen Belore entering confined spuces, the space shouldbe tested for toxie or ammable gases and rs, und adequate of excess oxygen. The tess hou be rade wit insruments appro US. Burew of Mines Heaviershansir gis sceylene- pron ie, my atis, and near fs such as argon, meth snd carbon dhox weak bottoms, lw ns helium and hydrogen, may accumu in ark tops high areas, and ear celings, The precations re spaces also apply to thote aves. IP ‘continuous monitoring. system wit arn should be used for work in can ‘Onyeen-enriched etmaspheres pose great dan fave up violemly ia an phere. Clothing may Soaked doting or may catch fie spontaneous per may fae nt lame, Nery severe ad fal su can Fs tion in confined spaces mast be provided welders and other personnel inthe enclsure. Only ir most be wsed for ventaten. ean, pir Postive pressure self-contained breathing appa ratus must be used when welding or euting rested proceses are done in confined ads wh entiation eat be provided und there isin fe danger to life an heath, 1 mus have ax en ‘gency ir supply ofa east five minus duration in the eve hat the main source fils Welding of Containers ‘Welling or euting ouside or inside conuines and vessels tit have held dangerous substances presen special hazards. Flammable of txie vepor Thay be presen, or maybe generated by the applied heat. The immediate area eutside and inside the conttirer shoul be cleared of ll obstacles and haz ‘stdous materials, If repairing a enniiner in place feniy of hazardous substances into the from the ouside mst be = snl nd fre prtecsion equipment ust thle, serviceable, and in poston for immediate we When welding or ting inside vessels 2 spaces must sso be observed dng welding should be dschar mentally sceeptable mane according must be made co prevent pressure buildup inside enaivers, Tesi ors method of providing safe i ill hem with an uch 8 wey, ine gas, sand, When asing Wales the le pt 0 within a fe i the point where the welding is ove te water should be vented wo al fd arto escape, With inert gus, the percentage oce and maintain 2 safe atmosphere daring wel fing must also be known, Highly Toxic Materials Certain material, which re sometimes present, in consumables, tase metals, costings, oF atmos pheres for welding or cuting operations, have pe fsible exposure mis of 1.0 min? or Jes. ‘Among these matesals ae the metals noted in ‘ble 22. Manulacturer’s Material Safety Data Sheets should be consulted to find out if any ofthese mate al represent in welding filler metals and faxes being use. Material Safety Data Sheets shouldbe requested from supplies. However, welding Ger rutals and uns ate nol he ony source of these materials. They may lobe preset in base metals Soatings, of other sources in the work ac Radioactive materials under Nuclear Repoitry CConunission jurisdiction require special considera tions and may also require compliance with sate tnd lea regulations. Thee mates algo include ray machines and adlogrphi isropes. ‘When totic mates are ecountred as desig- tated constinent in welding being o eating operations, special venlaion pecauens mst be taken. The peceuions assure Gat the levels of these comaminans in the atmosphere we at or below the Limits alowed foe human exposure. ll persons inthe immediate viii of welding out fing opeaions iavlving these matedals must be smiley protected Handling of Compressed Gases Gases used. in welding and curing operations se packaged in containers called cylinders. Only colinders designed and maintaed in accordance ‘Table 22—Toxle Metals: () Aeon © ind 2 keene (1) esas 8 bie (i) ec Sey (Naa 8) Gan {3 Seen {8 Gronvn fs) Sho {Gren {3} emu 8 Cape \WOOULE SAFE PRACTICES FOR WELDING NSPECTORS ‘with US, Deparment of Transportation (DOT) specfieaions may be usd inthe United States. The use of eter cylinders may be exremely dangerous and is illegal. Cylinders requiring periodic retest under DOT regultions may not be led unless the retest i caent CCylicders may be filled only with the per rision of the owner, and shouldbe filled only by recognized gas suppliers or those with the prope: training and feces to do so. Fling one eylinder from arother is dangerous and should not be attempted by anyone not qualified to da so, Com- bustible or incompatible combinations of gases ‘ust never be mixed in eylinders. ‘Welding most net be performed on: gas cylin ers. Cinders mst not be allowed to become part ‘of an eetrical ciruit because arcing may result Cplindes contening shicling gases used in com. jnetion with are welding must not be grounded. ‘Hlecurode holders, welding torches, cables, hoses, and took should not be stored on gs cylinders to avoid ascing or inteference wih valve operton ‘Aré-danaged gas eylinders may rupture and result in injury or death, Cylinders must not be used as work rests ot rollers, They should -be protected from bumps, falling eect, weather, and should not be dropped. CCyindas should not be kept in passageways where they might be stuck by vehicles. They should be ‘opt in seas where temperatares do nct fll below “BOE or excord 10°F. Any of these exposures, misuses or abuses could demage them to te extent that they might fil with serious consequences. Cylinders must not be hoisted using ordinary stings orchain. A proper cradle ar cradle sling that securely" reins the eylinder should be. used Hlectronagnetsshould_not be used to handle olindes, ‘Cylinders mist always Be secured by the user sgsinst falling during either ust or storage (se= Figure 211). Acetylene and liquefied gas cylinders {Gewats) should always be stored and used in the ‘pright postion. Other cylinders axe. preferably stored and used inthe upright poston, but this is ‘not essential inal circumstances, ‘Before using gas fom a cinder, the contents shouldbe ideotifed by the label thereon. Contents should got be identified by any other means suchas «ylinder color, banding, or shape. These may vary