Wa0001

CSWIP Welding Quality Control Co-ordinator
WIS20
Training & Examination Services

Granta Park, Great Abington
Cambridge CB21 6AL, UK
Copyright © TWI Ltd
Rev 0 August 2010
Contents
Copyright  TWI Ltd 2011
CSWIP Welding Quality Control Co-ordinator

Contents
Section Subject
1 Duties of the Quality Control Co-ordinator

1.1 General
1.2 Leadership skills
1.3 Technical skills
1.4 Knowledge of technology
1.5 Knowledge of normative documents
1.6 Knowledge of planning
1.7 Knowledge of organisation
1.8 General knowledge of auditing requirements
1.9 Summary
2 Inspection and Test Plans
2.1 Inspection and test plans (ITPs)
2.2 The purpose of ITPs
2.3 Essential content of an ITP
2.4 Using ITPs effectively
3 Planning
3.1 General
3.2 Gantt charts
3.3 Critical path analysis (CPA)
3.4 Programme evaluation and review technique (PERT)
3.5 Summary
4 Contract Design Review and Subcontractor Control
4.1 Manufacturing specifications and standards
4.2 Reading/interpreting shopfloor drawings
4.3 Drawing control
4.4 Works order (controlling the fabrication)
4.5 Material procurement and subcontracts
4.6 Material receiving
4.7 Equipment/facilities, handling and storage procedures
4.8 Welding and welding consumables
4.9 QC and QC inspectors
4.10 Completed member storage and final inspection
5 Materials and Consumables
5.1 Plain carbon steels – basic data
5.2 Alloy steels – basic data
5.3 Stainless steels – basic data
5.4 Material traceability
5.5 EN 10204 (2004) metallic products: Types of inspection documents
5.6 Material type
5.7 Alloying elements and their effects
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Contents

5.9 Material condition and dimensions
5.10 Welding consumables – storage and handling
6 Welding Documentation
6.1 General
6.2 Qualified welding procedure specifications
6.3 Welder standards for procedure qualification
6.4 Qualification process for welding procedures
6.5 Relationship between a WPQR and a WPS
6.6 Welder qualification
6.7 The qualification process for welders
6.8 Welder qualification and production welding allowed
6.9 Period of validity for a welder qualification certificate
6.10 Prolongation of welder qualification
7 Calibration of Welding and Inspection Equipment
7.1 Introduction
7.2 Terminology
7.3 Calibration frequency
7.4 Instruments for calibration
7.5 Calibration methods
8 Inspection and Testing Personnel
8.1 Responsibilities
8.2 Qualifications and registers
8.3 Reporting methods
9 Quality in Welding
9.1 Quality system standards
9.2 What areas of business need to be covered by ISO 9000
9.3 Company manuals
9.4 Auditing
9.5 Auditing of documentation
9.6 Typical quality record contents
10 Non-Destructive Testing
10.1 Radiographic methods
10.2 Ultrasonic methods
10.3 Magnetic particle testing
10.4 Dye penetrant testing
10.5 Surface crack detection (magnetic particle/dye penetrant): general
11 Repair Welding
11.1 Actions associated with welding repairs
11.2 Production repairs
12 Control of Preheat, Interpass Temperature and PWHT
12.1 Heat treatment of steel
12.2 Post weld heat treatment (PWHT/stress relief)
12.3 PWHT thermal cycle
12.4 Soak temperature
12.5 Cooling rate
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Contents
12.6 Local PWHT

12.7 Stress relieving weldments
13 Pressure Testing
13.1 Safety
13.2 QC co-ordinator role for pressure testing
14 Non-conformance Concessions and Engineering Queries
14.1 Preventative actions
14.2 Corrective actions
14.3 Concessions
14.4 Engineering query
15 Destructive Testing
15.1 Introduction
15.2 Test types, pieces and objectives
15.3 Macroscopic examination
15.4 European standards for destructive test methods
Appendix 1 Heat Treatment
Appendix 2 Homework/coursework
Appendix 3 Case Study Answer Sheets
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CSWIP QC Coordinator Welcome
• Safety procedures and fire alarms

• This course is designed to give an in-depth
knowledge of the roles and responsibilities of
Introduction a QC Coordinator in the workplace in
accordance with ISO 3834.
TWI Training & Examination • What modules does it contain?
TWI Training & Services
Examination Services • What class exercises will there be?
Introduction
Course Reference WIS 5
Copyright © TWI Ltd 2011 Copyright © TWI Ltd 2011
Course Content Class Exercises

Roles and duties of a QC Coordinator • Review of PWHT charts
Inspection test plans (ITPs) and planning
Contract review • Review of NDT procedures
Materials inspection • Review welding procedures
Weld procedures
Calibration
• General welding technology multi-choice
Inspection testing personnel
Quality in welding
Non-destructive testing
Heat treatments
Pressure testing
Non-conformances
Destructive testing
CSWIP QC Coordinator Examination Course Assessment
Exam after No continuous

50 general multiple choice questions 75min completion of course assessment
Assessment of three welds

Assessment of heat treatment reports 180min
Assessment of NDT reports
You will be required to review the documents for
errors, omissions and inconsistencies for the weld
numbers given.
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CSWIP QC Coordinator Examination Notification of Examination Results
70% pass
Any standard/code
required for the mark
examinations will be
provided on the For every section to be
examination day awarded the certificate
Closed book exam Two copies of certificates and an identity

card sent to delegate’s sponsor
QC Coordinator Examination Renewals CSWIP
Certification Scheme for Personnel

5 years 10 years
CV assessment renewal examination
Recognition worldwide
Any Questions
? Copyright © TWI Ltd 2011
2
Section 1
Duties of the
Quality Control Co-ordinator
Rev 0 August 2010
Duties of the Quality Control Co-ordinator
1 Duties of the Quality Control Co-ordinator

1.1 General
Quality Control (QC) Co-ordinators are employed to ensure that production
follows the QC activities necessary to ensure that the product will meet
specified requirements and be fit for application.
For employers to have confidence in their work, QC Co-ordinators need to

have the ability to understand/interpret the various QC procedures and also
have sound knowledge of fabrication and welding technology.
The relevant standards, rules and specifications that a QC Co-ordinator

should be familiar with at the start of a new contract are all the documents
he will need to refer to during the fabrication sequence in order to make
judgements about particular details.
The QC Co-ordinator has primarily a supervisory/managerial role, which

could encompass the management and control of an inspection contract.
The role would certainly include leading a team of inspectors (welding, non-
destructive testing, dimensional, painting/coating etc), who will look to the
QC Co-ordinator for guidance, especially on technical subjects. The QC Co-
ordinator will be expected to give advice, resolve problems, take decisions
and generally lead from the front, sometimes in difficult situations.
The attributes required by the QC Co-ordinator are varied and the emphasis
on certain attributes and skills may differ from project to project. Essentially
though the QC Co-ordinator will require leadership skills, technical skills and
experience.
1.2 Leadership skills

Some aspects on the theory of leadership may be taught in the classroom,
but leadership is an inherent part of the character and temperament of an
individual. Practical application and experience play a major part in the
development of leadership skills and the QC Co-ordinator should strive to
improve and fine tune these skills at every opportunity.
The skills required for the development of leadership include:
 Willingness and ability to accept instructions or orders from senior staff

and to act in the manner prescribed.
 Willingness and ability to give orders in a clear and concise manner,
whether verbal or written, which will leave the recipient in no doubt as to
what action or actions are required.
 Willingness to take responsibility, particularly when things go wrong,
perhaps due to the QC Co-ordinator’s direction, or lack of it.
 Capacity to listen (the basis for good communication skills) if and when
explanations are necessary and to provide constructive reasoning and
advice.
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 Willingness to delegate responsibility, to allow staff to get on with the job

and trust them to act in a professional manner. The QC Co-ordinator
should, wherever possible, stay in the background, managing their team.
 Willingness and ability to support members of the team on technical and
administrative issues.
1.3 Technical skills

A number of factors make up the technical skills required by the QC Co-
ordinator and these are:
 Knowledge of technology.
 Knowledge of normative documents.
 Knowledge of planning.
 Knowledge of organisation.
 General knowledge of auditing requirements.
1.4 Knowledge of technology

Welding technology knowledge required by the QC Co-ordinator is very
similar to that required by the Welding inspector, but with some additional
scope and depth.
Certain areas where additional knowledge is required are:
 Knowledge of QA and QC.

 A sound appreciation of the four commonly used non-destructive testing
(NDT) methods.
 A basic understanding of steel metallurgy for commonly welded
materials and the application of this understanding to the assessment of
fracture surfaces.
 Assessment of non-destructive test reports, particularly the interpretation
of radiographs.
 A basic understanding of the advanced NDT techniques ie phased array
TOFD, ACFM.
1.5 Knowledge of normative documents

It is not a requirement for inspectors at any level to memorise the content of
relevant normative documents, possibly with the exception of taking
examinations, where these may be a requirement.
Specified normative documents (specifications, standards, codes of

practice, etc) should be available at the workplace and the QC Co-ordinator
would be expected to read, understand and apply the requirements with the
necessary level of precision and direction required.
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The QC Co-ordinator should be aware of the more widely used standards as

applied in welding and fabrication.
For example:
 Application Standard (or Code).

 Quality plans or inspection check lists.
(For the type and extent of inspection.)
 Drawings.
(For assembly/fit-up details and dimensional requirements.)
 QC procedures.
(Company QC/QA procedures such as those for document control,
material handling, electrode storage and issue, welding procedure
specification, etc).
 BS EN ISO 15614/ASME IX.
Standards for welding procedure approval.
 BS 4872, BS EN 287/ASME IX.
Standards for welder approval.
 PED BS 5500/ASME VIII.
Standards for quality of fabrication.
 BS EN ISO 9000 – 2000.
Standards for quality management.
1.6 Knowledge of planning

Any project or contract will require some planning if inspection is to be
carried out effectively and within budget.
See section on planning for more detailed information.
1.7 Knowledge of organisation

The QC Co-ordinator must have good organisational skills to ensure that the
inspection requirements of any quality/inspection plan can be met, within the
allocated time, budget and using the most suitable personnel for the activity.
Assessment of suitable personnel may require consideration of their
technical, physical and mental abilities in order to ensure they are able to
perform the tasks required of them. Other considerations would include
availability of inspection personnel when required, levels of supervision and
the monitoring of the inspector’s activities from start to contract completion.
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1.8 General knowledge of auditing requirements

There are many situations in manufacturing or on a project where the QC
Co-ordinator may be required to assist in the audit process.
1.9 Summary
The QC Co-ordinator’s role can be varied and complex, a number of skills
need to be developed in order for the individual to be effective in the role.
Every QC Co-ordinator will have personal skills and attributes which can be
brought to his current working environment; some of the skills identified
above may already have been mastered or understood. The important thing
for the individual to recognise is not only do they have unique abilities which
they can bring to the role, but they also need to strive to be the best they
can by strengthening identifiable weak areas in their knowledge and
understanding.
Some ways in which these goals may be achieved are through:
 Embracing facts and realities.

 Being creative.
 Being interested in solving problems.
 Being pro-active not re-active.
 Having empathy with people.
 Having personal values.
 Being objective.
The role of the QC Co-ordinator can cover a myriad of disciplines, without

the need for the individual to be an expert in all of them.
The individual, who is to operate as a QC Co-ordinator, shall possess

certain attributes and knowledge coupled with relevant experience. This
introduction details the role of the QC Co-ordinator, insofar as the general
requirements are concerned, as the operation is the same for any industry
sector, it is only the level and specific technical knowledge required that
differs with the change in industry or the diversity of the disciplines.
The prerequisites for an individual aspiring to a QC Co-ordinator are

considered to be: previous QC experience, ie an inspector, particularly one
who has excelled within that field and who shows an aptitude to the overall
management of the QC function.
Depending on the industry sector chosen, the disciplines can be as varied

as, for example, control of welding and the control of supplied kitchen
equipment (manufacture of an offshore accommodation platform).
This shows that it is unlikely the individual will possess in depth knowledge
of all disciplines and is likely only to be technically competent and qualified
in one, with a general knowledge of associated others. The ideal QC Co-
ordinator candidate therefore is considered to be at the level of inspector or
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more likely senior inspector, to make the transition. This transition will
require the control of the application of inspection and testing derived from
QC principles, to all disciplines. It is clear that the more disciplines there are
to control the more general knowledge required.
This QC Co-ordinator course will provide the necessary knowledge and

application techniques, to allow the successful candidate to operate as a QC
Co-ordinator in the fabrication and welding industry.
QC and QA
The two terms are frequently misapplied, to clarify:
 Quality Control (QC) is concerned with the inspection function and

concentrates on the product quality. The QA management system
provides the detail as to how to apply the QC function.
 Quality Assurance (QA) is concerned with the management system that
provides the resources and procedures to produce the product.
The QC function is operated under a defined system to ensure product

quality is controlled as part of the assurance process.
Although they are two separate functions, they are related in their purpose
and complimentary in their implementation, the system cannot be
independent of the product (QA cannot do without QC) and the product
would not be produced without the system (QC cannot do without QA).
The role of the QC Co-ordinator with respect to QA and QC is to operate

under the QA system, to facilitate the management of the QC function,
within the management system. This requires the Co-ordinator to be aware
of the QC related QA activities (detailed later) and follow them to bring about
the QC activities.
QC activities for the QC Co-ordinator

Unless the QC Co-ordinator is employed in a dual role, which includes
carrying out inspection and testing, they are not required to carry out any
QC activities but rather take responsibility to ensure all required QC
activities are carried out and reported as agreed within a contract, ie in
accordance with the contract specification(s).
The QC Co-ordinators duties are given (Note: see first section duties of a
QC Co-ordinator) later within this section and when considered show that
QC activities are indeed excluded.
QA activities for the QC Co-ordinator

Review of the list of proposed QC Co-ordinator duties reveals that each one
of the 10 duties detailed can be considered QA activities under the QA
system of a company within the QC discipline, they are not part of the QA
discipline, ie activities that a QA Co-ordinator/auditor may carry out.
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All of the QC Co-ordinator duties refer to controlling the QC functions in

some way during implementation and in accordance with a management
system.
The duties described in terms of their QA activity:
1 Assurance that the requirements from the client for inspection and
testing and subsequently the required level of quality required, have
been reviewed and accepted as being within the company’s capability.
Knowledge and experience required in the interpretation of specification
requirements.
2 Once contract specifications have been issued the QC Co-ordinator

should confirm there are no deviations from the QC/product quality
requirements specified at the enquiry stage. Another QA management
system activity.
3 Generation of the ITP should be the responsibility of the QC Co-ordinator

which is a manifestation of the QA activity within the role ie the
production of a QA document to assist in the assurance of the function.
The ability to draw up and/or review and approve a relevant ITP is
required.
4 From the QC requirements the QC Co-ordinator should be able to

determine the necessary resource to cover inspection and testing
activities throughout the contract. Resource provision is part of the
management system and requires experience in the management of
Inspection and testing activities.
5 Arrange with document control to issue the required information eg ITP,

specifications or relevant parts of specifications or instructions containing
details that provide for the implementation of the specification
requirements to those who need to know. Knowledge of the
management system is required.
6 The QC Co-ordinator is a member of the project management team and

must be able to communicate at all levels.
7 Management of the inspection and testing resource is an important

function of the QC Co-ordinator but not the only function by far.
8 Management of the inspection function can extend to subcontracted

activities whereupon the QC Co-ordinator will be responsible for knowing
all QC/product quality requirements from the contract specification(s) are
applied and recorded.
9 Responsible for ensuring that the verification documentation is produced

(progressively) and compiled for future submittal. This is again a QA
action by the QC Co-ordinator within the project management system.
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10 All the previous functions require knowledge of the system and some
experience of QC activities as well as the main quality indicators within a
fabrication and welding company. This function takes this knowledge
requirement to a higher level to allow the QC Co-ordinator to actively
assist in the assurance that the product will be acceptable to the client at
handover/completion. This requires the application of knowledge (of
systems, product, interpretation of specifications and standards) and
experience of the problems that arise and assist in their solution to the
benefit of the client and the employer products, along with problem-
solving and communication skills.
Finally it is clear that the QC Co-ordinator does not carry out QC activities
but applies QA management system requirements to ensure that the QC
function operates as required for a contract/company.
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CSWIP QC Coordinator Duties of a QC Coordinator
• Generalisation would be to ensure that all
contractual obligations have been met in respect
of quality and that the finished product is fit for the
Role of a QC Coordinator service level to which it will exposed, fit for
purpose (FFP )
• For the manufacturer’s management teams to
TWI Training & Examination have confidence in their products the QC
Services Coordinator will need an extensive knowledge of
all the disciplines and procedures they will
coordinate to achieve this goal.
Duties of a QC Coordinator Attributes Required

• Before starting any project it is imperative • Strong personal skills at management and shop floor
you familiarise yourself with all the relevant level.
standards and specifications applicable. • Ability to listen and process the information received.
• Attend all kick-off and pre-production planning • Delegate and trust your staff.
meetings to ensure the correct sequence of • Make assertive and informed decisions and
operations are adhered to. judgements from the information you have and ensure
• Missing a hold point for example will result in a your staff have understood your direction.
lack of confidence from the owner/purchaser and • Take responsibility for your direction or lack of it?
cause concern as to what other procedures are • Support your staff as production and quality conflicts
not being adhered to with a possibility of rework are not uncommon and often require firm decisive
and impact on delivery dates. arbitration between managers involved.
Leadership Skills Technical Skills

Few are born leaders but many have the
inherent ability to deal with this challenging Which technical skills are required?
subject. Some personnel shy away from
responsibility, others thrive on a little power,
acting in a very aggressive manner (I am the • Knowledge of technology
BOSS and you will !!!). This attitude is very • Knowledge of normative documents
negative and does not promote discussion and • Knowledge of planning
team play, vital for the projects quality, allowing • Able to organise department effectively
it to run smoothly and on time. • General knowledge of auditing
Always remember there is no I in team.
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Knowledge of Technology Knowledge of Normative Documents
The knowledge of technology is similar to a • It is impossible to memorise normative
WI with some additional scope: documents for a project and each project
• QA and QC procedures. may have many.
• Limitations and advantages of the four most • All specifications, codes and workplace
commonly used NDT methods. instruction must be available at the workplace at
• Assessment of NDT reports for compliance to the current revision level. You must read and
procedure. understand all requirements to be able to direct
• Where applicable, advanced NDT (phased array your team.
or TOFD could be required).
• Basic understanding of metallurgy in welding
and fracture surfaces.
Knowledge of Normative Documents Planning

Typical examples of normative documents. • To fail to plan is to plan to fail.
• Later we will study effective tools to plan a project
• BS EN ISO 15614 Standard for welding from the contract review stage through to signing
procedure approval. the product off and shipping.
• BS EN ISO 17637 NDE of fusion welds • If the planning is not coordinated effectively
and visual inspection between all departments production and quality
• M-601 Norsok requirement for the welding and will suffer.
inspection of piping.
Knowledge of Organisation Organisation: An Example

• Organise your inspection team to ensure that the Man 1 has an LPI ticket and is on night shift.
quality, inspection and test plans are adhered to. Man 2 has an MPI ticket and is on day shift.
Take considerable time as there can be many All pre-welding NDE is MPI, all post-welding NDE is
LPI (due to the welding consumables used being
permutations. non-ferro magnetic, Inconel overlay 625)
• To ensure you meet your budget and delivery There is a hold point on all finished component NDE by third
schedules, assessment of manning levels and the party inspectors who do not generally work night shift.
skills and qualification of each operative need to There would now be a requirement of a shift change with
financial implications to bring man 1 in at short notice to
be addressed before the start of a project. comply with the hold point.
Root causes: poor organisation and use of available
resources.
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Auditing Summary of a QC Coordinator
• It is not a requirement you are a lead auditor but it • Projects can highlight weakness in the coordinator’s
is an advantage to have in-depth knowledge of the technical ability or management style.
process you will often be involved in. • Strengthening these areas improves your personal
• It is often the case that we swap sides (contracting attributes and shows a willingness to embrace the
certainly) client to sub-contractor or vice versa for reality that we cannot know it all.
example. You may be part of the technical review • With a problem or question act professionally and
of a sub-contractor as easily as you could be the empathise with the person asking the question and be
sub-contractor being audited. interested in finding the solution. Delegation in this area
can cause problems if your technique is to tell your
subordinates to find the answer.
QC and QA QC and QA
Terms often misapplied, clarification is: • Although separate functions they are related in their
• Quality control (QC): Concerned with the inspection purpose and complimentary in their implementation.
function and concentrates on the product quality. The The system cannot be independent of the product (QA
QA management system provides the detail as to how cannot do without QC) and the product would not be
to apply the QC function. produced without the system (QC cannot do without
• Quality assurance (QA): Concerned with the QA).
management system that operates to provide the
resource and procedures to produce the product. The • The QC coordinator’s role with respect to QA and QC is
QC function is operated under a defined system to to operate under the QA system, to facilitate the
ensure product quality is controlled as part of the management of the QC function, within the
assurance process. management system. This requires strong awareness
of the QC related QA procedures and activities .
Summary of a QC Coordinator Summary of a QC Coordinator
• Be creative and strive to improve your knowledge. • A coordinator requires knowledge and experience
• Be pro-active to issues, not reactive and of welding and fabrication to the highest standards.
confrontational, try to resist apportioning blame. • In-depth knowledge of the systems and system
• Have strong personal and professional values that are requirements.
not for sale and ensure you cannot be compromised. • Application of this knowledge in different situations
Summary of a QC Coordinator
• Don’t be afraid to object to issues you are not entirely to give maximum confidence to the end user or
happy about. (ignorance is not an excuse your honour purchaser.
I know but I did not like to ask !) • It is not the coordinator’s role to carry out the QC
• Seek clarification on anything which you do not activities, only to apply the QMS requirements and
understand before proceeding. ensure that the QC department operates as required
within the company.
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Any Questions
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Section 2
Inspection and Test Plans

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2 Inspection and Test Plans

2.1 Inspection and test plans (ITPs)
ITPs are key working documents for the QC Co-ordinator and the inspection
team and normally have particularly high status in the QC hierarchy as they
are a direct instruction detailing the sequence of operations to be carried out
in accordance with the specification requirements. A large contract can have
several hundred ITPs, using different formats and containing varying
degrees of detail. They are one of the best mechanisms for controlling and
organising the various inspection activities.
2.2 The purpose of ITPs

They provide a mechanism for organising inspection activities and are a
forum for discussion and agreement of technical matters between
purchaser, contractor and manufacturer without the enforced rigidity of the
purchase contract. ITPs are an excellent documentary record of the
activities and commitments of the multiple parties involved and are an
excellent document for production and inspection personnel, as they define
all the inspection activities the level of involvement for each inspection
discipline and show them what to expect.
2.3 Essential content of an ITP

There are no hard and fast rules about what should be included in an ITP –
some standards include recommendations but any attempt at uniformity
gets very difficult when faced with the variety of equipment, processes and
practices in a large engineering plant contract. The tendency is for
contractors and manufacturers to use differing types of content and format
for their ITPs. Some contract specifications often include a specimen pro-
forma ITP to indicate the level of information required. See the table for a
typical example.
Checklist of ITP content:
 Clear list of manufacturing and test points for each manufactured

component.
 Cross references to important contract specification clauses.
 Detailed reference to which acceptance or technical standards are
applicable to each manufacturing and test step.
 Cross references to manufacturers’ more detailed working procedures
(so you can read and reference them for further clarification about a
particular activity).
 Indication of the records and certification requirements applicable to
each step which helps define the compilation list for the final
documentation package.
 System of activity codes, useful for understanding which tests are
required and when and what report is to be produced verifying the
particular activity has been carried out and is acceptable.
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2.4 Using ITPs effectively

Guidelines on the effective use of ITPs are:
First draft
The best party to produce the first draft of the ITP is the project
management team not the manufacturer or end-user because the project
management team is the party that will have best analysed and understood
the purchaser’s contract specifications. It is all too common for a project
management team to let their manufacturers produce the first ITP drafts,
which does not give the best results as they may not be fully aware of the
design/operational conditions requirements.
Marking-up
Aim for very early marking-up of the ITPs with the inspection witness points
for all the parties. The purchaser’s (end-user’s) inspectors mark-up his/her
inspection requirements last. (s)he can make his choices based on
knowledge of how much priority the other parties are giving to the various
works test activities. Prior to commencement of material purchase/
production, etc you must ensure that the ITP is approved by all parties. This
will define everyone’s level of commitment and inspection requirements for
each stage of the build.
Timescales
There should be plenty of pre-manufacturing contact between the contractor
and manufacturer to discuss the purchase order and formalise the ITPs
during these discussions.
Witness points Note

Witness or hold points are exactly what they say ie that particular point of
inspection needs to be witnessed by xxxxx or a hold point which means that
the activity is stopped until the required inspection/review has taken place or
has been approved. Note Where the client has defined a hold or witness
point they usually require a given time period eg 24 hours to 1 week prior
notification to mobilise their inspector to witness or review that activity.
You must have a mandatory document control procedure under BS EN ISO

9001 which will define the following, how you:
 Approve documents (eg procedures, flow charts, process maps, etc.)

prior to use eg signed-off paper versions or added to your computer
network via a password protected system.
 Update and re-approve amended documents computer-based systems
are much easier to maintain.
 Identify changes eg by date or issue number, identify changes with
different fonts or colours.
 Ensure that documents are available where they are needed.
 Control documents of external origin.
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 Prevent the inadvertent use obsolete documents obsolete but still in use
is the single most common non-compliance.
Document definition
An instruction of sorts eg any information where an unauthorised change
could cause a problem.
A mandatory records procedure is required to specify:

 Which records are kept?
 By whom.
 For how long.
 How they are disposed of.
.
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Revision No. 0
Op. Inspection / Test Code
2345/ITP/001 Reference 3rd Verifying
No. Operation details documents Responsibility Company party Client documents
A Design
1 Review contract and design requirements Client PO, PV code Project engineer R1 Contract order
2 Prepare manufacturing drawings Client spec.; PV code Project engineer R1. AP R1 Approved drawings
B Preliminary manufacturing operations
1 Place orders for materials and subcontracted operations QA poc. xx Purchasing A1 Purchase orders
2 Qualify Welding Procedures and welders QA poc xx Welding engineer A1, R1 WPQRs
3 Prepare WPSs and submit for approval QA poc. xx Welding engineer R1, AP R1 Approved WPSs
4 Prepare welder qualification register QA poc xx Welding engineer R1 Welder qual.records
5 Verify NDE operator qualifications QA poc. xx Quality manager R1 NDE operator certificates
6 Issue contract-specific documents to controlled distribution QA poc. xx Projects A1 Issue records
C Material control
QA Proc xx and delivery
1 Inspect materials for quantity, dimensions and damage Notes Material controller A1 Materials inward reports
2 Check material identification and test certificates QA Proc xx, purchase orders Inspector R1 Approved certificates
3 Check dimensions of heads H1 and H2 Drawing Inspector R1 Report
D Fabrication and NDE

1 Cut plate for shell, wrapper and saddles; maintain identities Drawings, head dimensions Material controller A1 Issue log
QA poc. xx Inspector S
2 Edge-prepare plates for welding WPSs, drawings Plater A1
3 Roll shell plates and wrapper plates Drawings Inspector S
4 Weld shell longitudinal seams (T1, T2, T3) WPS Welder/inspector S
5 Visually inspect welds; MPI and radiograph welds NDE proc. XXX and XXX Inspector A1 Report
6 Fit and weld N1 to H1, N2 to T1 and N3 to T3 WPS, drawing Welder/inspector A1/S
7 Visually inspect and MPI welds NDE proc. XXX Inspector A1 Report
8 Fit and weld circ. seams for tiers T1, T2 and T3
9 Visually inspect welds; MPI and radiograph welds NDE proc. XXX and XXX Inspector A1 Report
10 Fit and weld N1-H1 to T1-T2-T3 WPS Welder/inspector A1/S
11 Visually inspect welds,; MPI and radiograph welds NDE proc. XXX and XXX Inspector A1 Report
12 Fit and weld H2 to H1-T1-T2-T3 WPS Welder/inspector A1/S
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13 Visually inspect welds,; MPI and radiograph welds NDE proc. XXX and XXX Inspector A1 Report
14 Fit and weld wrapper plates W1 and W2 to shell WPS Welder/inspector A1/S
15 Visually inspect welds; MPI welds NDE proc. XXX Inspector A1 Report
Fit and weld saddles S1 and S2 to wrapper plates W1 and
16 W2 WPS Welder/inspector A1/S
17 Visually inspect welds; MPI welds NDE proc. XXX Inspector A1 Report
E Dimensional survey
QC proc XXX, drawings, PV
1 Dimensionally inspect finished vessel code Inspector A1 Report
F Post weld deat treatment
1 Prepare vessel and implement PWHT operation QC proc XXX Furnace controller A1 Chart records
G Pressure testing
1 Prepare vessel and implement pressure test QC proc XXX Inspector A1 Report
Dry and clean vessel; visually inspect and dimensionally
2 survey QC proc XXX Inspector A1 Report
H Coating (by subcontractor)
1 Prepare vessel and apply coating QC proc XXX Subcontractor A1
2 Inspect finished coating QC proc XXX Report
I Vessel name plate
1 Manufacture and attach vessel nameplate; make record Drawing, code Inspector A1 Photo; rubbing
J Despatch Vessel to Site
1 Prepare documentation for vessel transport and arrange QA proc XXX Inspector R1 N Client release note
for client release note
2 Despatch vessel QA proc XXX Despatcher A1 Release note
I Manufacturing records
1 Collate records for archive; transmit copies to client QA proc XXX Doc. controller H H Manufacturing records
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Links between the ITP and other contract documents

The ITPs used on projects do not exist in isolation, they take their place
among all the other documents; some contractual and some not, Figure 1
shows this.
The ITP highlights the contractual document requirements that are to be

referenced and used throughout all fabrication activities.
Figure 2.1 The ITPs and other contract documents.
How do the ITPs link with these other documents?

Figure 2.2 shows the linkages and this is basically the way that contracts
work.
Figure 2.2 The links which help to provide an effective inspection regime.
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Link 1: Responsibility
The responsibilities stated in the contract specification are used to pass the
requirements for compliance with standards down to subcontractors.
Link 2: Decisions
The document hierarchy has operational links to the ITPs which help ensure
that the acceptance criteria in the ITPs are closely controlled and compliant
with the actual contract requirements not the manufacturer’s opinion of what
they may be or those that he usually uses.
Link 3: Implementation
Link 3 is about the implementation of the ITP. The level of inspection
activities often depends on the contract requirements or any specific client/
end user requirements and any designated specific testing requirements
imposed due to service conditions.
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CSWIP QC Coordinator
Key working documents for the QC coordinator and

inspection team and normally have high status in the
QC hierarchy as are a direct instruction detailing the
sequence of operations to be carried out in
accordance with the specification requirements.
Inspection and Test Plans A large contract can have several hundred ITPs,
using different formats and containing varying
degrees of detail. One of the best mechanisms for
controlling and organising the various inspection
TWI Training & Examination
activities.
Services
They are a mechanism for organising inspection No hard and fast rules about what should be
activities, also forum for discussion and agreement of included in an ITP – some standards include
technical matters between purchaser, contractor and recommendations but any attempt at uniformity gets
manufacturer without enforced rigidity of the very difficult when faced with the variety of
purchase contract. Excellent documentary record of equipment, processes and practices in a large
the activities and commitments of the multiple parties engineering plant contract. The tendency is for
involved, ITPs are an excellent document for contractors and manufacturers to use differing types
production and inspection personnel as they define of content and format for their ITPs.
all the inspection activities and level of involvement Some contract specifications will often include
for each inspection discipline and show what to a specimen pro-forma ITP to indicate the level
expect. of information required
The Document Hierarchy

They clarify how you:
• Approve documents (procedures, flow charts, process maps,
etc) prior to use (signed-off paper versions or added to
computer network via password protected system). What is it?
• Update and re-approve amended documents often using
computer-based systems which are much easier to maintain. Does it vary between
• Identify changes (by date, issue number, different purchasers/supplier?
fonts or colours).
• Ensure documents available where needed.
• Control documents of external origin. What does it look like?
• Prevent inadvertent use of obsolete documents
– obsolete but still in use is the most common
non-compliance.
1
The Basic Document Hierarchy
• Links between the ITP and other contract

documents. The ITPs used do not exist in
isolation, they take their place among all the
other documents, some contractual and some
not.
• The ITP highlights the contractual document
requirements to be referenced and used
throughout all the fabrication activities.
What Else is in a Purchase Contract?
Contract spec: Relevant parts

How do the ITPs link with these other
documents?
All these
The following diagram shows the links
and how in essence the contract will operate.
things should
be included
(somewhere)
The ITPs are Link 1.The responsibilities stated in the contract

inked to other specification pass the requirements for
contract documents compliance with standards down to
sub-contractors
What are
these links?
2
Link 3 is about implementation of the ITP. The
Link 2.The document hierarchy has operational
level of inspection activities often depends on
links to the ITPs, helping to ensure the
the contract or any specific client/end user
acceptance criteria shown in the ITPs are
requirements and any designated specific
closely controlled and compliant with the actual
testing requirements imposed due to service
contract requirements, not the manufacturer’s
conditions.
opinion of what they may be, or those that he
usually uses.
Mark-up Codes on Plans A Simple ITP

H = Hold point
Manufacture will not proceed until all the parties shown on Inspection points
the ITP have witnessed the activity. Step

No. Operation
Reference
documents M C TPI
Certification
requirements
Record
No.
1 Weld procedures WPS/PQR R - - BS EN 288 XX/Y

W = Witness point
All parties will be informed about the inspection/test but if 2 Welder approvals BS EN 287 R - - BS EN 287 XX/Y
they do not attend, the work will continue.

3 10% RT BS 2600 R R - Record sheet XX/Y
S = Surveillance 4 100% MPI BS 6072 R R - Record sheet XX/Y

All parties can visit the works any time and carry out
surveillance of any work/tests, etc in progress. 5 Visual inspection BS 5289 R W W Record sheet XX/Y
R = Review 6 Document review - R R R - XX/Y
The parties will review relevant documentation at a W = Witness point R = Review M = Manufacturer
convenient time (either during a visit to the works or after C = Contractor TPI = Third party (or clients) inspection organisation
having received the document package by post).
ITPs: General Points to remember about ITPs
• All follow the same pattern (more or less).

• Most ITPs are job specific, there are no standard
designs • Some parts are more important than others.
• Look for the documentation requirements.
• Most manufacturers will want to limit the number of
• Technical standards should be referenced.
inspections as they are disruptive, time consuming and
costly! • Key acceptance criteria should be referenced.
• Too many hold points will delay the job and cause
disruption to the manufacturing process, which helps
no-one.
3
Specifications, Standards and ITPs
We will be looking at ITPs in class and will

review an ITP against the documents presented
Is the information that a QC Coordinator along with it:
references when planning and • Weld procedure.
coordinating inspections • Weld history log.
• Heat treatment procedure, report and chart.
• NDT procedures and reports.
• Pressure test procedure and reports.
4
Section 3
Planning
Rev 0 August 2010
Planning
3 Planning
3.1 General
The QC Co-ordinator is involved in planning for inspection and audit at one
or more of the following stages of a project:
Pre-contract
Identification of the contract requirements, recruiting and allocating suitably
trained and qualified staff, gathering together relevant normative
documents, technical data and drawings, producing work/inspection
schedules and ITPs as well as general administration.
In-contract
Application of inspection methodologies to the requirements of the contract
specification, production and collection of inspection and test
reports/documentation.
Post-contract
Compilation of inspection reports, certification and test data to produce the
final documentation and/or letter of conformity/final acceptance.
There are a number of methods of planning for inspection activities, the

method selected being dependent on a number of factors, primarily the
requirements of the client and specific project.
The various methods are as follows.
3.2 Gantt charts

Define stages of production and estimated work time for each stage, a
popular type of bar chart graph that illustrates a project schedule, ie list of
a project's terminal elements. Terminal elements comprise the work
breakdown structure (WBS) of the project and are the lowest activity or
deliverable with intended start and finish dates and elements are not
further subdivided.
Terminal elements are the items estimated in terms of resource

requirements, budget and duration linked by dependencies and schedules.
An example of a typical Gantt chart that could be used to plan inspection

activities for either manufacturing or construction is shown below.
The WBS/task elements are listed on the left-hand side and the start and
completion of each activity is represented by a bar to the right of the
activity.
The time period in this example is in months, both planned and actual.
Some charts show time in weeks, which can also be broken down into
days.
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Planning
Example of a Gantt chart.

Any project phase 1 inspection schedule
Work
breakdown 2010
structure
(WBS) January February March April May June
Recruit and
allocate
inspection
Review
fabrication
drawings
Review, WPSs,
WPQRs
and WATCs
Prepare
quality
Witness and
test WPSs,
WPQRs
Witness
welder qual
tests
Visual
inspection of
first production
welds
Legend
Planned duration Planned milestone
Actual duration Actual milestone
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Planning
3.3 Critical path analysis (CPA)

Critical path analysis is a powerful project management tool that helps with
scheduling and managing complex projects. Developed in the 1950s to
control large projects, it has been used routinely since. As with Gantt
charts, CPA helps in planning all tasks that must be completed as part of a
project. They act as the basis both for preparation of a schedule and of
resource planning. During management of a project they allow monitoring
of achievement of project goals.
CPA can also show where remedial action needs to be taken to get a
project back on course.
The benefit of using CPA over Gantt charts is that CPA formally identifies
tasks which must be completed on time in order for the whole project to be
completed on time and also identifies which tasks can be delayed for a
while if resources need to be reallocated to catch up on missed tasks.
A further benefit of CPA is that it helps to identify the minimum length of

time to complete a project. Where there is a need to run an accelerated
project, fast track, it helps to identify which project steps should be
accelerated to complete the project within the available time, helping to
minimise cost while still achieving objectives.
The disadvantage is that the relation of tasks to time is not as immediately

obvious as with Gantt charts which can make them more difficult to
understand for someone not familiar with the technique.
CPA are presented using circle and arrow diagrams, circles show events
within the project, such as the start and finish of tasks and are normally
numbered to allow identification of them.
An arrow running between two event circles shows the activity needed to
complete that task. A description of the task is written underneath the
arrow and the length of the task is shown above it and by convention, all
arrows run left to right.
0 4
4 wks
Start 1 2
A
Recruit and allocate inspection staff.
An example of a very simple circle and arrow diagram.
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Planning
This shows the start event (circle 1) and the completion of the recruit and
allocate inspection staff task (circle 2). The arrow shows the activity of
recruiting and allocating inspection staff’ and the time allocated for this
activity is 4 weeks.
In the example above, the numbers above the circles show the earliest
possible time that this stage of the project will be reached.
Where one activity cannot start until another has been completed and
when other activities need to be scheduled it is useful to tabulate the
terminal elements and allocate time against each activity.
The above tabulated terminal elements can now be shown as an algorithm.
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Planning
4
C E
2 2
0 4 wks 6 11 13 22
wks
A B D F 6 G
1 2 3 5 7 Finish
Start
4 wks 2 wks 3 wks 2 wks 9 wks
Critical path analysis for example inspection project.
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Planning
In the example, the activities of B and C cannot be started until A has been
completed.
This diagram also brings out a number of other important points:
 Within CPA reference to activities is made by the numbers in the circles

at each end. For example, task A would be called activity 1-2.
 Task B would be activity 2-3.
 Activities are not drawn to scale. In the diagram above, activities are 8,
4, 3 and 2 weeks long.
 In the example the numbers above the circles indicate the earliest
possible time that this stage will be reached.
CPA is an effective and powerful method of assessing:
 What tasks must be carried out.

 Where parallel activity can be performed.
 Shortest time in which you can complete a project.
 Resources needed to execute a project.
 Sequence of activities, scheduling and timings involved.
 Task priorities.
 Most efficient way of shortening time on urgent projects.
An effective CPA can make the difference between success and failure on
complex projects and be very useful for assessing the importance of
problems faced during the implementation of the plan.
3.4 Programme evaluation and review technique (PERT)

PERT is a variation on CPA but takes a slightly more sceptical view of time
estimates made for each project stage. To use it estimate the shortest
possible time each activity will take, the most likely length of time and the
longest time that might be taken if the activity takes longer than expected.
The formula below is used to calculate the time for each project stage:
Shortest time + 4 x likely time + longest time

6
This helps to bias time estimates away from the unrealistically short
timescales normally assumed.
A variation of both CPA and PERT is a technique known as reverse

scheduling where the completion date for the last terminal element for the
project is determined and then all other operations are worked back from
this date, each operation having its own target date.
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Planning
3.5 Summary
The QC Co-ordinator needs an in-depth knowledge of planning and is
responsible for the planning of inspection activities on the project or
contract, inspection tasks must link in with other terminal activities to ensure
that inspection tasks are carried out on a timely and cost effective basis, in
accordance with the planning system being used on a particular project or
contract.
When a contract starts you may only have 10 welders, however during the
peak of production you may have 100 welders and near the end of the
contract you may only have 20.
The QC Co-ordinator will need this information to ensure that he has

sufficient inspection personnel to cover the correct ratio of inspectors to
welder and the greater number of welders will produce a greater number of
welds this will lead to an increase in the number of NDT personnel.
At the beginning the paperwork will be small compared with the volume
produced during production activities so an increase in documentation staff
will also be required, all this is an important role of the QC Co-ordinator who
must ensure correct manning levels are maintained during manufacture.
The production of inspection documentation is carried out during the project

and cannot be produced retrospectively it can only be compiled if it has
been generated as part of the process.
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CSWIP QC Coordinator Why Do We Need Production Planning?
Dates agreed between client and

manufacturer must be maintained.
Reputation of the manufacturer
Planning in meeting those dates.
Fail to plan is to plan to Fail
Profit and loss controls.
TWI Training & Examination To plan future contracts.

Services
Planning Tools Planning Tools
A B D
Bar charts Start 1 2 3 5 End
1 week 2 weeks 4 weeks
1 week 1 week
C
Gantt charts
Critical path analysis (CPA)
Programme evaluation and review technique (PERT)
Planning Planning
End date rarely changes but production plan will.

Bar charts, Gantt charts, CPA show us when
to start activities and also planned end dates,
Factors affecting production plans:
- not enough to ensure success of a project, • Design office being late with designs and
supervision of activities within these technical drawings
timescales will be needed.
• Design changes
• Late delivery of materials and resources.
• Weather conditions.
• Resources available
1
Planning Planning
Material arrive
Cut Possible impacts of departments not meeting targets
and
on site
prep
3 wk
Procurement:
Assemble
2 wk
Steel delivery
1 wk
Weld late 1 week Cut and prep: Assembly:
NDE
4 wk Shot blast No work 1 week No work 1 week
and paint
3 days
Forced holidays Forced holidays
If a department is late in delivery then Load out
production becomes compressed within 2 wk
Lay offs Lay offs
1 day
the main production plan.
Low morale
Any slack in the production plan gets used Low morale
up putting each of the remaining departments Staff leaving
Staff leaving
under difficulty in trying to meet targets
Planning Planning
Possible impacts of departments not meeting targets Possible impacts of departments not meeting targets
Procurement:
Steel delivery arrives 1 week late When the production programme starts to slip
management/supervision needs to react.
Cut and prep:
Increased overtime Managers and supervisors look backwards on
High levels of supervision the production programme to view work still to
Holiday leave cancelled come and forward to look ahead and plan.
Low morale
Staff leaving
Planning Planning
Possible impacts of departments not meeting targets Possible impacts of departments not meeting targets
Supervision will use their own planning skills within the
Events that cannot be planned for:
main production plan and use different strategies.
• Staff sickness
• Holiday planning for staff
• Accidents
• Overtime and shift patterns
• Levels of supervision • Power failure
• The workforce (strengths and weaknesses) • Mistakes in assembly
• Manning levels
• Mistakes in welding
• Resources
• Production meetings • Weather conditions
• Major resource failure
2
Planning Planning
Gantt charts generally show more than one project or Quality plan
different parts of a particular project at production level,
adding complexity to the production at shop floor level. Document setting out the specific quality
practices, resources and sequence of
• Differing materials
activities relevant to a particular product,
• Differing client requirements project or contract.
• Differing skill levels
• Product knowledge
• Health and safety concerns
Planning
Any Questions
Quality Plan: 01
OP Operation details Reference Responsibility Inspection/ test code Verifying
?
No documents documents
Company Third Client
party
A Design
1 Review contract and Client and PV Project engineer R1 Contract order

design requirements code
2 Prepare manufacturing Client spec Project R1,PA R1 Approved drawings

drawings PV code engineer
B Preliminary manufacturing
1 Place orders for materials QA procedure Procurement A1 Purchase orders
2 Quality weld QA procedures Welding R1 wPQR

procedures engineer
3
Section 4
Contract Design Review and

Subcontractor Control
Rev 0 August 2010
Contract Design Review and Subcontractor Control
4 Contract Design Review and Subcontractor Control

The client will specify prior to contract award all the relevant codes and
standards that must be adhered to during fabrication. Before contract
placement it is essential that the following conditions have been met.
4.1 Manufacturing specifications and standards

 Does the contractor have a copy of the client’s code or specifications
and are the contractor’s personnel familiar with these specifications?
 Does the contractor have the latest copy of the code?
 Does the contractor have copies of all the current relevant material
specifications (eg BS EN ISO or ASTM etc)?
 Does the contractor have personnel who are knowledgeable and
experienced with the material standards, codes and specifications?
 Is there a written procedure in place to explain the specification
requirements and changes or special requirements to appropriate
personnel?
4.2 Reading/interpreting shopfloor drawings

 Does the contractor have personnel capable of supervising, evaluating
and coordinating shopfloor drawings for preparation and review?
 Do the shopfloor drawings for the current work clearly identify the NDT
requirements for the various welded connections?
 Do the materials and processes specified on the shopfloor drawings for
the current scope of work agree with the relevant contract documents
material requirements for work being issued to the shopfloor?
 Do the shopfloor drawings for the current work scope clearly identify the
materials to be used in fabrication?
4.3 Drawing control

 Does the contractor have a written procedure for tracking the fabrication
drawings and also how are modified drawings controlled and issued to
the shopfloor?
 Does the tracking procedure trace each phase from drawing preparation,
showing receipt, submittal for approval, approval, re-submittals and date
sent to the shopfloor for fabrication? This is controlled by the issue of a
drawing register
 Do the shopfloor plans for current work correspond to the latest revision?
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4.4 Works order (controlling the fabrication)

 Does the contractor have an established job control number and
identification system for all work in production or completed?
 Does the contractor have an established identification system in place
that clearly shows the material or fabricated components and has
provision for written acceptance by the in-house QC inspection team?
 Does the contractor have an established identification system in place
that clearly shows the fabricated components that are subjected to
repair, rework or corrections?
 Is all received correspondence marked with a distinguishable identifying
reference number?
 Are correspondence files maintained and segregated for each project?
 Are all received correspondence stamped, dated and signed by
personnel responsible for the evaluation and implementation of the
technical content?
4.5 Material procurement and subcontracts

 Are purchase orders or any other types of material procurement forms
filed for verification and documentation of the orders?
 Do the contractor procurement documents require that his suppliers
must provide material testing reports?
 Do the procurement documents state how the material should be
identified or marked?
 Are all materials items what are purchased to the required standards and
specifications specified in the corresponding contract documents?
 Are procedures in place to assure that subcontracted fabrication is
ordered to contract requirements?
4.6 Material receiving

 Is there an established written procedure for the reception of materials,
goods parts and sub-assemblies?
 Are reception inspections done to all incoming materials and sub-
assemblies arriving at this contractor’s facility?
 Are purchase orders or any other types of material procurement
documents available to the receiving Inspection team to ensure signing
off and confirmation or compliance?
 Are receiving inspections documented for?
 Acceptance and rejection of non-conforming materials and sub-
assemblies?
 Corrective actions taken to deal with non-correctable and correctable
non-conformities observed during the reception inspection?
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 Do the materials and sub-assemblies receiving inspection confirm and

document the following:
 Correct material markings and identification?
 Compliance with dimensional tolerances?
 Correct grade of material?
 Correct material dimensions?
 Heat numbers on material match heat numbers on corresponding
mill certificates?
 Are acceptance standards and tolerances available for reference at the

point of receipt or at the inspection station?
 Does the contractor segregate controlled materials by project?
 Does the contractor have a material identification system to ensure
control of materials of different grade and size (as applicable)?
 Does the contractor have approved mill test reports for all material
currently in fabrication?
 Are material test reports traceable to stored or stocked material?
 Is the material storage area or stockyard in good condition or protected
so as to prevent damage to the material or final fabricated pieces?
 Are the stored or stocked materials clearly marked or identified?
4.7 Equipment/facilities, handling and storage procedures

 Does the contractor have suitable and adequate equipment to fabricate
the proposed scope of work?
 Is the material handling equipment suitable for the type, size and load of
the work being performed?
 Does the contractor have adequate written procedures that describe or
illustrate the proper way to:
 Handle material in the stockyard?
 Handle materials on the shopfloor?
 Move in process materials and sub-assemblies?
 Provide correct bracing etc for materials and sub-assemblies?
 Prevent material and subassembly deterioration?
 Provide correct storage for fabricated products?
 Handle and ship the fabricated products?
4.8 Welding and welding consumables

 Does the contractor have welding procedure specifications and
procedure qualification records that comply with the scope of work and
the submitted welder qualification register?
 Is the contractor’s list of welders in the submitted Welder Qualification
Register up to date?
 Are approved welding procedures readily available or posted near all
welding machines?
 Do welders know and understand which WPS is to be used to produce
each specific production weld?
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 Are all welds on completed structures traceable to the welder(s) that

completed the job?
 Does the contractor have properly maintained appropriate equipment for
preheat and Interpass heating as agreed in the approved WPSs?
 When QC personnel monitor maximum interpass and minimum WPS
preheat temperatures are they using the correct type of measuring
equipment, is this equipment currently calibrated/validated and marked
with a sticker?
 Are flame cut edges visually inspected and checked using NDT
techniques (ie MPI or lamination checks using UT) by QC inspectors to
verify compliance with specification, standards or code requirements?
 Do the QC inspectors verify and document joint fit-up of each joint before
welding is permitted?
 Do the QC inspectors verify and document where the WPSs have been
used for production welding?
 Are meters and other devices used to record or display welding variables
checked for accuracy and have a current calibration/validation certificate
and sticker?
 Is the equipment used for verifying meters and other devices certified
annually by an approved national calibration centre?
 Are welding consumables stored in accordance with contract
procedures?
 Are welding consumables at the workstation protected from
contamination and damage and if applicable stored in calibrated heated
quivers?
 Does the contractor control the exposure time of low-hydrogen SMAW
electrodes or submerged arc welding fluxes following removal from
hermetically sealed containers, drying ovens, or storage ovens?
 Are consumable manufacturer certification reports on file and available
and have they been accepted and approved for use by the welding
engineer?
4.9 QC and QC inspectors

 Does the contractor have a written QC manual that describes the
company policy, support and commitment to quality?
 Does the contractor have a written job description and an organisational
chart that reflects its commitment to quality clearly defining the roles and
responsibilities of its staff?
 Does the QC manual include sections that deal with:
 Contract review?
 Document and drawing control?
 Materials purchasing?
 Product identification and traceability?
 Handling and storage?
 Process control?
 Internal audits?
 Inspection and testing?
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 Control of inspection, measuring and test equipment?

 Control of non-conforming products?
 Corrective and preventive actions?
 Packaging and delivery?
 Manual review and update?
 Does the contractor have a CSWIP approved welding inspector or
equivalent on his full time staff or on contract?
 Does the fabricator have certified NDT personnel on their full time staff
or on contract?
 Does the fabricator (main contractor) verify any subcontractor’s
qualifications?
 Does the contractor have current applicable certificates and eye
examinations (where required) for all inspection personnel?
 Does the contractor have a copy of the approved written practice for
certification of NDT personnel (staff and contractor) on file and readily
available?
 Does the written practice meet or exceed the recommendations of BS
EN 473 latest edition?
 Does the fabricator or manufacturer maintain documentation readily
available on file of the calibrations performed on NDT equipment used in
the facility by QC inspection personnel or contractors?
 Does the contractor maintain documentation for all QC testing?
 Do QC inspectors have sufficient equipment to adequately perform their
tasks, eg measuring tape, Vernier gauges, weld gauges, magnifying
glass, ampmeter, paint gauges, torches, preheat and interpass
temperature measuring and testing devices, mirrors, etc?.
 Does the contractor have written procedures for:
 Minor production repairs?
 Major production repairs?
 Site or shop repairs?
 Documentation for re-inspection of repairs?
 Do QC personnel mark or otherwise indicate clearly on the components
when the following checks are completed and the disposition of their
findings:
 Joint fit-up verified?
 Welding parameters verified?
 Final visual inspection completed?
 NDT completed (if required)?
 Confirmation of defect removal prior to repair welding (if required)?
 Dimensions of fabricated component verified?
 Fabricated structure or component verified for compliance with
contract documents?
 Does the contractor maintain a QC programme independent from
production?
 Are QC personnel aware and familiar with the QC requirements?
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 Do the QC inspectors have the responsibility of informing the line

foreman and superintendent when observing any non-conforming work
processes and performances?
 Are the contractor’s welding inspectors given sufficient authority to stop
work in order to prevent unacceptable work from proceeding or to issue
NCRs?
4.10 Completed member storage and final inspection

 Does the contractor understand why there may be a 48hr notification for
final inspection?
 Is the contractor aware that they must provide complete paperwork,
including a certificate of compliance and weights, for final inspection and
release from the shopfloor?
 Does the contractor have a designated location where material receives
final inspection?
 Are completed fabrications/sub-assemblies properly stored to prevent
damage?
 Are all components traceable to material test reports?
 Does the contractor understand that material release labels or
nameplates should be completed and attached only by the engineer or
his authorised representative?
In the construction process, the basic function of a fabricator is to provide all

necessary shopfloor drawings and construction documents to the contractor.
These drawings are prepared after thorough review of the design drawings,
specifications and bidding documents provided by the relevant engineer.
Fabrication drawings commonly include the following:
 Construction engineering drawings.

 Structural drawings.
 Shopfloor fabrication drawings.
 Erection drawings.
The fabricator should review the shopfloor drawings and other submittals in
conformation with the contract documents. When required, the shopfloor
drawings should bear the signature and stamp of the responsible engineer.
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CSWIP QC Coordinator
Contract Review The client will specify prior to contract award all the
relevant codes and standards that must be adhered to
during fabrication. Before contract placement it is essential
that the following conditions have been met.
Services
Manufacturing Specifications and Standards Reading/Interpreting Shopfloor Drawings
• Does the contractor have a copy of the client’s code or

• Does the contractor have personnel capable of supervising,
specifications and are the contractor’s personnel familiar
evaluating and coordinating shopfloor drawings for
with these?
preparation and review?
• Does the contractor have the latest copy of the code?
• Do the shopfloor drawings for the current work clearly
• Does the contractor have copies of all current relevant identify the NDT requirements for the various welded
material specifications ? (eg BS EN ISO or ASTM) connections?
• Does the contractor have knowledgeable personnel • Do the materials and processes specified on the shopfloor
experienced with the material standards, codes and drawings for the current scope of work agree with the
specifications? relevant contract documents material requirements for work
• Is there a written procedure in place to explain the being issued to the shopfloor?
specification requirements and changes or special • Do the shopfloor drawings for the current work scope clearly
requirements to appropriate personnel? identify the materials to be used in the fabrication?
Drawing Control Works Order (Controlling the Fabrication)
• Does the contractor have a written procedure for tracking • Does the contractor have an established job control number and
the fabrication drawings and how are modified drawings identification system for all work in production or completed?
controlled and issued to the shopfloor? • Does the contractor have an established identification system that
clearly shows the material or fabricated components and has
• Does the tracking procedure trace each phase from provision for written acceptance by the in-house QC inspection
drawing preparation, showing receipt, submittal for team?
approval, approval, re-submittals and date sent to the • Does the contractor have an established identification system that
shopfloor for fabrication? This is controlled by the issue of shows the fabricated components subject to repair, rework or
a drawing register corrections?
• Are correspondence files maintained and segregated for each
• Do the shopfloor plans for current work correspond to the project?
latest revision? • Are all received correspondence stamped, dated and signed by
personnel responsible for the evaluation and implementation of
the technical content?
1
Material Procurement and Sub-contracts Material Receiving
• Are purchase orders or other types of material procurement • Is there an established written procedure for the
forms filed for verification and documentation of the orders? reception of materials, goods parts and sub-assemblies?
• Are all incoming materials and sub-assemblies arriving
• Do the contractor procurement documents require his at this contractor’s facility reception inspected?
suppliers provide material testing reports? • Are purchase orders or other types of material
• Do the procurement documents state how the material should procurement documents available to the receiving inspection
be identified or marked? team to ensure signing off and
confirmation or compliance?
• Are all purchased material items to the standards and • Are receiving inspections documented for:
specifications in the corresponding contract documents? - Acceptance and rejection of non-conforming
• Are procedures in place to ensure that sub-contracted materials and sub-assemblies?
fabrication is ordered to contract requirements? - Corrective actions to deal with non-correctable and
correctable non-conformities seen during reception
inspection?
Material Receiving Material Receiving
Do the materials and sub-assemblies being inspected • Are acceptance standards and tolerances available for
confirm and document the following: reference at the point of receipt or at the inspection station?
• Does the contractor segregate controlled materials by project?
• Correct material markings and identification?
• Does the contractor have a material identification system to ensure
• Compliance with dimensional tolerances? control of materials of different grade and size (as applicable)?
• Correct grade of material? • Does the contractor have approved mill test reports for all material
currently in fabrication?
• Correct material dimensions?
• Are material test reports traceable to stored or stocked material?
• Heat numbers on material match heat numbers • Is the material storage area or stockyard in good condition or
on corresponding mill certificates? protected to prevent damage to the material or final fabricated
pieces?
• Are stored or stocked materials clearly marked or identified?
Equipment/Facilities, Handling Equipment/Facilities, Handling

and Storage Procedures and Storage Procedures
Does the contractor have adequate written procedures that
• Does the contractor have suitable and adequate describe or illustrate the proper way to:
equipment to fabricate the proposed scope of work? • Handle materials on the shopfloor?
• Is the material handling equipment suitable for the • Move in-process materials and sub-assemblies?
type, size and load of the work being performed? • Provide correct bracing, etc, for materials and
sub-assemblies?
• Prevent material and sub-assembly deterioration?
• Provide correct storage for fabricated products?
• Handle and ship the fabricated products?
2
Welding and Welding Consumables QC and QC Inspectors
• Does the contractor have welding procedure
specifications and procedure qualification records that • Does the contractor have a written QC manual that
comply with the scope of work and the submitted welder describes the company policy, support and commitment to
qualification register?
quality?
• Is the contractor’s list of welders in the submitted welder
qualification register up to date? • Does the contractor have a written job description and an
organisational chart that reflects its commitment to quality
• Are approved welding procedures readily available or
posted near all welding machines? clearly defining the roles and responsibilities of its staff?
• Do welders know and understand which WPS is to be
used to produce each specific production weld?
QC and QC Inspectors
Does the QC manual include sections on: • Does the contractor have a CSWIP approved welding
• Contract review? inspector or equivalent on his full time staff or on
• Documents and drawings control? contract?
• Materials purchasing?
• Product identification and traceability? • Does the fabricator have certified NDT personnel on
• Handling and storage? their full time staff or on contract?
• Process control? • Does the fabricator (the main contractor) verify any
• Internal audits? sub-contractor’s qualifications?
• Inspection and testing? • Does the contractor have current applicable
• Control of inspection, measuring and test equipment? certificates and eye examinations (where required)
• Control of non-conforming products? for all inspection personnel?
• Corrective and preventive actions?
• Packaging and delivery?
• Manual review and update?
QC and QC Inspectors QC and QC Inspectors
• Does the contractor have a copy of the approved written • Do QC inspectors have sufficient equipment to
practice for certification of NDT personnel (staff and adequately perform their tasks, eg measuring tape,
contractor) on file and readily available? Vernier gauges, weld gauges, magnifying glass, amp
• Does the written practice meet or exceed the meter, paint gauges, torches, preheat and interpass
temperature measuring and testing devices, mirrors, etc?
recommendations of BS EN 473 latest edition?
• Does the contractor have written procedures for:
• Does the fabricator or manufacturer maintain
- Minor production repairs?
documentation readily available on file of the calibrations
performed on NDT equipment used in the facility by QC - Major production repairs?
inspection personnel or contractors? - Site or shop repairs?
• Does the contractor maintain documentation for all QC - Documentation re-inspection of repairs?
testing?
3
QC and QC Inspectors QC and QC Inspectors
• Do QC personnel mark or otherwise indicate clearly on • Does the contractor maintain a QC programme
the components or route card when the following checks
are completed and the disposition of their findings: independent from production?
- Joint fit-up verified? • Are QC personnel aware of and familiar with the QC
- Welding parameters verified? requirements?
- Final visual inspection completed? • Do the QC inspectors have the responsibility of
- NDT completed (if required)? informing line foremen and superintendents when
- Confirmation of defect removal prior to repair observing any non-conforming work processes and
welding (if required)? performances?
- Dimensions of fabricated component verified? • Do the contractors’ welding inspectors have the
- Fabricated structure or component verified for authority to stop work to prevent unacceptable work
compliance with contract documents?
from proceeding or to issue NCRs?
Completed Member Storage

and Final Inspection
• Does the contractor understand why there may be a 48hr • In the construction process the basic function of a fabricator
notification for final inspection? is to provide all necessary shopfloor drawings and
construction documents to the contractor. These drawings
• Is the contractor aware they must provide complete paperwork, are prepared after thorough review of the design drawings,
including a certificate of compliance and weights for final specifications and bidding documents provided by the
inspection and release from the shopfloor? relevant engineer.
• Does the contractor have a designated location where material
receives final inspection? Fabrication drawings commonly include:
• Are completed fabrications/sub-assemblies properly stored to - Construction engineering drawings
prevent damage? - Structural drawings
• Are all components traceable to material test reports? - Shop floor fabrication drawings
• Does the contractor understand that material release labels or - Erection drawings
nameplates should be completed and attached only by the
engineer or his authorised representative?
The fabricator should review the shopfloor drawings and

other submittals in conformation Any Questions
?
with the contract documents. When required, the
shopfloor drawings should bear the signature and
stamp of the responsible engineer.
4
Section 5
Materials and
Consumables
Rev 0 August 2010
Materials and Consumables
5 Materials and Consumables

Material properties are of great importance in all aspects of inspection. It is
essential to check the up-to-date version of the relevant British Standards,
Euronorm or equivalent when choosing or assessing a material. Depending
on the type of material, legislative requirements, contract clause stipulations,
design, and certification requirements, full QA traceability may be required
The most common steels used for mechanical plant are divided into the
generic categories of carbon, alloy and stainless steels, and non-ferrous
materials. Each has characteristic manufacturing flaws and various typical
fabrication defects are possible, the formation of millscale on rolled carbon
steel being an example. The knowledge of the types of material-specific
inherent discontinuities greatly enhance the inspector’s ability to conduct a
competent inspection or evaluation.
5.1 Plain carbon steels – basic data

Table 5.1 Typical properties of plain carbon steel
Yield, Re, MN/m2 UTS, Rm,

Type %C %Mn MN/m2
Low C steel 0.1 0.35 220 320
General structural steel 0.2 1.4 350 515
Steel castings 0.3 - 270 490
5.2 Alloy steels – basic data

Alloy steels have various amounts of Ni, Cr, Mn or Mo added to improve
properties. Typical properties are shown.
Table 5.2 Alloy steel properties.

Type %C Others % Re MN/m2 Rm MN/m2
Ni/Mn steel 0.4 0.85Mn 480 680
1.00Ni
Ni/Cr steel 0.3 0.5Mn 800 910
2.8Ni
1.0Cr
Ni/Cr/Mo steel 0.4 0.5Mn 950 1050
1.5Ni
1.1Cr
0.3Mo
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5.3 Stainless steels – basic data

Stainless steel is a generic term to describe a family of steel alloys
containing more than about 11% chromium and consists of four main
classes, subdivided into about 100 grades and variants. The main classes
are austenitic, duplex and ferritic and martensitic classes tend to have more
specialised application so are not so commonly found in general pressure
equipment use. The basic characteristics of each class are:
Austenitic
The most commonly used basic grades of stainless steel are austenitic
which have 17-25%Cr, combined with 8-20%Ni, Mn and other trace alloying
elements which encourage the formation of austenite. Low carbon content
makes them weldable and the most general corrosion resistant of the family
of stainless steels.
Ferritic
Ferritic stainless steels have high chromium content (>17%Cr) coupled with
medium carbon, which gives them good corrosion resistance properties
rather than high strength. They normally have some Mo and Si which
encourage the ferrite to form and are generally non-hardenable.
Martensitic
High carbon (up to 2%C), low chromium (12%Cr) variant but the high
carbon content can make it difficult to weld.
Duplex
Have a structure containing both austenitic and ferritic phases and can have
a tensile strength up to twice that of straight austenitic stainless steels and
are alloyed with various trace elements to aid corrosion resistance. In
general, they are as weldable as austenitic grades but have a maximum
temperature limit because of the characteristic of their microstructure.
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Table 5.3 Stainless steels – basic data.

Stainless steels are commonly referred to by their AISI equivalent classification (where applicable).
AISI Other Type *2 Yield Fty, Re, Ultimate R m, E(%), HRB %C %Cr % Properties
classifications ksi MPa Ftu, ksi MPa 50mm others *1
302 ASTM A296 Austenitic 40 275.8 90 620.6 55 85 0.15 17-19 8-10 Ni General purpose
(cast), Wk stainless steel
1.4300, 18/8,
SIS 2331
304 ASTM A296, Wk Austenitic 42 289.6 84 579.2 55 80 0.08 18-20 8-12 Ni Economy grade.
1.4301, 18/8/LC,
SIS 2333,
304S18
304L ASTM A351, Wk Austenitic 39 268.9 80 551.6 55 79 0.03 18-20 8-12 Ni Low C to avoid
1.4306 intercrystalline
18/8/ELC, SIS corrosion after
2352, 304S14 welding
316 ASTM A296, Wk Austenitic 42 289.6 84 579.2 50 79 0.08 16-18 10-14 Ni Addition of Mo
1.4436 18/8/Mo, increases corrosion
SIS 2243, resistance.
316S18
316L ASTM A351, Wk Austenitic 42 289.6 81 558.5 50 79 0.03 16-18 10-14 Ni Low C weldable
1.4435, variant of 316
18/8/Mo/ELC,
316S14, SIS
2353
321 ASTM A240, Wk Austenitic 35 241.3 90 620.6 45 80 0.08 17-19 9-12 Ni Variation of 304
1.4541, 18/8/Ti, with Ti added to
SIS 2337, improve
321S18 temperature
resistance.
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Table 3 Stainless steels – basic data

*1
Main constituents only shown.
*2
All austenitic grades are non-magnetic, ferritic and martensitic grades are magnetic.
*3
Avesta trademark
AISI Other Type *2 Yield Re, Ultimate R m, E(%), HRB %C %Cr % others Properties
*1
classifications Fty, ksi MPa Ftu,ksi MPa 50 mm
430 ASTM Non-hardening
A176/A240/A27 grade with
Ferritic 50 344.7 75 517.1 30 83 0.12 14-18 1 Mn
6, UNS 43000, good acid-
Wk 1.4016 resistance
403 UNS S40300, Turbine grade
11.5-
ASTM Martensitic 40 275.8 75 517.1 35 82 0.15 0.5 Si of stainless
13
A176/A276 steel
410 UNS S40300, Used for
ASTM 11.5- machine parts,
Martensitic 40 275.8 75 517.1 35 82 0.15 4.5-6.5 Ni
A176/A240, Wk 13.5 pump shafts,
1.4006 etc.
- Better
255 (Ferralium) resistance to
Duplex 94 648.1 115 793 25 280HV 0.04 24-27 4.5-6.5 Ni SCC than 316.
High strength.
Max
- Avesta SAF 575F (301C)
‘Super’
2507*3, UNS 7Ni, 4Mo, due to
duplex 99 682.6 116 799.8  25 300HV 0.02 25
S32750 0.3N embrittlement
40% ferrite
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Non-ferrous alloys – basic data

Non-ferrous alloy is used for those alloy materials which do not have iron as
their base element. The main ones used for mechanical engineering
applications, with their ultimate tensile strength ranges, are:
 Nickel alloys 400–1200MN/m2

 Zinc alloys 200–360MN/m2
 Copper alloys 200–1100MN/m2
 Aluminium alloys 100–500MN/m2
 Magnesium alloys 150–340MN/m2
 Titanium alloys 400–1500MN/m2
The main ones used are nickel alloys, in which nickel is frequently alloyed
with copper or chromium and iron to produce material with high temperature
and corrosion resistance. Typical types and properties are shown in Table 4
below:
Table 4 Nickel alloys: properties.

Alloy type Designation Constituent’s % UTS,
MN/m2
Ni-Cu UNS N04400 66Ni, 31Cu, 1Fe, 1Mn 415
(‘Monel’)
Ni-Fe Ni lo 36 36Ni, 64Fe 490
Ni-Cr Inconel 600 76Ni, 15Cr, 8Fe 600
Ni-Cr Inconel 625 61Ni, 21Cr, 2Fe, 9Mo, 3Nb 800
Ni-Cr Hastelloy C276 57Ni, 15Cr, 6Fe, 1Co, 16Mo, 750
4W
Ni-Cr Nimonic 76Ni 20Cr 800-1200
(age hardenable) 80A
Ni-Cr Inco Waspaloy 58Ni, 19Cr, 13Co, 4Mo, 3Ti, 800-1000
(age hardenable) 1Al

Material traceability is an important aspect of the inspection team’s role.
Most technical codes and standards make provision for QA activities
designed to ensure that materials of construction are traceable, however it is
often required to have full traceability usually certified by a third party, Type
3.2 certificate.
Figure 5.1 shows the typical chain of traceability which operates for
pressure equipment materials. Note: Although all the activities shown are
available for use (ie to be specified then implemented) this does not
represent a unique system of traceability suitable for all materials. In
practice there are several levels in use, depending on the type of material
and the nature of its final application. The most common document
referenced in the material sections of pressure equipment specifications is
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the European Standard EN 10204 (2004) Metallic products: types of

inspection documents.
It provides for two main levels of certification: Classes 3 and 2.
Figure 1The chain of material traceability.
Figure 5.1 The chain of material traceability.
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5.5 EN 10204 (2004) metallic products: Types of inspection

documents
a Non-specific inspection
Carried out by the manufacturer in accordance with his own procedures
to assess whether products defined by the same product specification
and made by the same manufacturing process, are in compliance with
the requirements of the order or not.
 Type 2.1 Documents in which the manufacturer declares that the
products supplied are in compliance with the requirements of the
order without inclusion of test results.
order and in which test results based on non-specific inspection are
supplied.
b Specific inspection
Carried out before delivery according to the product specification, on the
products to be supplied or on test units of which the products supplied
are part, to verify that these products are in compliance with the
requirements of the order.
order and in which test results are supplied.
 Type 3.2 Documents prepared by both the manufacturer’s
authorised inspection representative independent of the
manufacturing department and either the purchaser’s authorised
representative or the inspector designated by the official regulations,
and in which they declare that the products supplied are in
compliance with the requirements of the order and in which test
results are supplied.
Validation and transmission of inspection documents

The inspection document shall be validated by the responsible person(s)
(name and position). The retention and transmission of documents shall be
either in electronic data or paper form
Transmission of inspection documents by an intermediary

An intermediary shall only pass on either an original or a copy of the
inspection documents provided by the manufacture without alteration. This
document shall be accompanied by suitable means of identification of the
product, in order to ensure the traceability between the product and the
document
Copying of the original document is permitted, provided that:

 Traceability procedures are operated.
 The original document is available on request.
 When producing copies it is permissible to replace the information on the
original delivered quantity by the actual delivered partial quantity.
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BS EN 10204: Metallic materials
Types of inspection documents summary
a Non-specific inspection
Inspection document type 2.1

Inspection document type 2.2
Declaration of compliance with the
Test report
order
Statement of compliance with the
Statement of compliance with the
order, with indication of results of
order
non-specific inspection validated by
the manufacturer
a Non-specific inspection may be replaced by specific inspection if

specified in the material standard or the order.
b Specific inspection
Inspection certificate type Inspection certificate type 3.2

3.1 Statement of compliance with the
Statement of compliance with the order, with indication of results of
order, with indication of results of specific inspection.
specific inspection
Validated by the manufacturer’s Validated by the manufacturer’s
authorised inspection authorised inspection representative
representative independent of independent of the manufacturing
the manufacturing department. department and either the purchaser’s
authorised inspection representative or
the inspector designated by the official
regulations.
b Quality management system of the material manufacturer certified by a

competent body established within the community and having undergone
a specific assessment for materials
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One of the duties of the inspection team is to carry out materials inspection.
This will be required.
 At the plate or pipe mill.

 Of material during fabrication or construction.
 Of material after installation, usually during a planned maintenance
programme, outage or shutdown.
A wide range of materials is available that can be used in fabrication and

welding. These include, but are not limited to:
 Steels.
 Stainless steels.
 Aluminium and its alloys.
 Nickel and its alloys.
 Copper and its alloys.
 Titanium and its alloys.
 Cast iron.
These are all widely used in fabrication, welding and construction to meet
the requirements of a diverse range of applications and industry sectors.
There are three essential aspects to materials inspection that the Inspector
should consider:
 Material type and weldability.

 Material traceability.
 Material condition and dimensions.
5.6 Material type

Inspectors must be able to understand and interpret the material designation
to check compliance with relevant normative documents. For example
materials standards such as BS EN, API, ASTM, the welding procedure
specification (WPS), the purchase order, fabrication drawings, the quality
plan/the contract specification and client requirements.
5.7 Alloying elements and their effects

Iron Fe
Carbon C For strength.
Manganese Mn For toughness.
Silicon Si < 0.3% deoxidiser.
Aluminium Al Grain refiner, <0.008% deoxidiser + toughness.
Chromium Cr Corrosion resistance.
Molybdenum Mo 1% is for creep resistance.
Vanadium V Strength.
Nickel Ni Low temperature applications toughness.
Copper Cu Used for weathering steels (Corten).
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Sulphur S Residual element (can cause hot shortness)

Phosphorus P Residual element
Titanium Ti Grain refiner, used as a micro alloying element (strength
and toughness)
Niobium Nb Grain refiner, used as a micro alloying element (strength
and toughness)

The ability to trace the history, application or location of that which is under
consideration, in the case of a welded product, traceability may require the
Inspector to consider:
 Origin of the materials – both parent and filler material.

 Processing history – for example before or after PWHT.
 Location of the product – this would usually refer to a specific part or
sub-assembly.
To trace the history of the material, reference must be made to the

inspection documents. BS EN 10204 Metallic products – Types of inspection
documents is one standard which provides guidance on these documents.
Under BS EN 10204 inspection documents fall into two types:
5.9 Material condition and dimensions

The condition of the material could have an adverse effect on the service life
of the component so is an important inspection point. The points for
inspection must include:
 General inspection.
 Visible imperfections.
 Dimensions.
 Surface condition.
General inspection
Takes account of storage conditions, methods of handling, the number of
plates or pipes and distortion tolerances.
Visible imperfections
Typical visible imperfections are usually attributable to the manufacturing
process and would include cold laps, which break the surface or laminations
if they appear at the edge of the plate. For laminations, which may be
present in the body of the material, ultrasonic testing using a compression
probe may be required.
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Dimensions
For plates this would include length, width and thickness.
For pipes, this would include length, wall thickness, but also inspection of
diameter and ovality. At this stage of the inspection the material cast or heat
number may also be recorded for validation against the material certificate.
Surface condition
Is important and must not show excessive millscale and rust, must not be
badly pitted or have unacceptable mechanical damage.
How much material inspection must the purchaser do? The manufacturer
should be an approved supplier and their systems assessed.
5.10 Welding consumables - storage and handling

Welding consumables are costly and some are very prone to deterioration in
storage. It is important stock levels are kept to a minimum but adequate
level to maintain productivity and that the storage and handling conditions
are correct.
Electrodes
Must be left in their packing in a warm dry environment as poor handling
and incorrect stacking will damage coatings rendering them unusable.
Treatment and use of electrodes are:
 Cellulosic
Use straight from the tins, must not be dried unless wet however it may
be prudent to scrap them.
 Rutile
Use straight from packets may be stored at up to 120oC, must not be
baked and if damp may be dried.
 Basic
For low hydrogen levels use either vacuum packing types (ensuring the
vacuum packing is still intact) or bake typically at 350oC for 1-2hr,
following baking, store in a holding oven at 150oC. Basic electrodes may
be rebaked once or possibly a number of times depending on the baking
temperature and manufacturer’s recommendations. The welders would
then use the electrodes from heated (75oC) quivers at the workstation.
Welders may take electrodes from the holding oven so there should be an
issue and return policy, as it is common to find loss of consumable control
due to human intervention.
Procedures for electrode treatment would form part of the Quality Manual.
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Wires
Must be kept clean and free from oil and dust, problems can arise through
losing their identity and allowing part used reels to become tangled.
Fluxes
Must be kept warm and dry and handling and stacking require care.
Fused fluxes are non-hygroscopic and in theory, are tolerant of poor control
procedures.
Agglomerated fluxes are very hygroscopic and prone to breakdown.

Rigorous handling procedures should be in place, eg storage in controlled
environment, control over amounts issued and number of times to be
recycled.
Gases
Used for cutting, heating, welding and as shielding and backing gases
during welding. For most applications gases are most convenient stored in
cylinders. Where large quantities of gas are required, large volume liquefied
gas storage systems become more economical and such systems may
incorporate gas mixers and ring main supply pipelines around the welding
shop.
 Compressed gases are subject to regulations concerning the quantities

and positioning of the storage areas.
 Cylinders are colour coded to minimise wrong use.
 Cylinders must not be reflected or decanted except by an approved
organisation.
 Cylinder outlets - seats and threads must not be damaged to avoid
leaks.
 Cylinders must not be handled by their valves or regulators.
 Cylinders must not be dropped, used as rollers or otherwise abused.
 Must be stored upright and securely chained in position or to a wall.
 Fuel gases and oxygen cylinders should be stored apart.
 Must be kept from heat sources, eg furnaces, boilers, etc.
 Storage area must be well ventilated, clear of flammable materials and
naked flames such as on portable heaters must be prohibited.
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CSWIP QC Coordinator Inspecting Materials
Materials and Inspection

Services
Materials Inspection – Plate Inspection Materials Inspection – Pipe Inspection

Condition: Corrosion, damage, wall thickness,
Condition: Corrosion, mechanical damage, ovality, laminations and seam
laps, bands and laminations
Specification LP5
Specification
5L Welded seam Size
Size
Other checks may need to be made such as: Other checks may need to be made such as: distortion
distortion tolerance, number of plates and storage tolerance, number of pipes and storage
Materials Inspection – Rolling Imperfections Laminations
Direction of rolling
Cold laps
Laminations
Segregation Plate lamination
1
Lapping Materials Inspection – Millscale and Rusting
Rust Grade A Rust Grade B

Steel surface largely covered with Steel surface which has begun to rust and
adherent millscale with little or no rust from which millscale has begun to flake
Materials Inspection - Rusting Materials Inspection
Critical control areas:

• FFP of materials
• Material guarantees
• Documented traceability
• Material testing
Rust Grade D Rust Grade C
Steel surface on which millscale has rusted
Steel surface on which millscale has rusted away.
away or from which it can be scrapped.
General pitting visible under normal vision.
Slight pitting visible under normal vision
Fitness for Purpose: Materials The Price of Failure
Determined by considering:
• Mechanical properties
(yield/UTS/hardness/tensile, etc)
• Temperature capability
(brittle failure, transition temperature or
use in the creep range?)
• Corrosion resistance
(sour or caustic service?)
• Positive material identification
(repairs and modifications)
2
The Price of Failure The Price of Failure
Catastrophic
failure of
Creep failure of a header steam turbine
rotor in
Germany.
Catastrophic failure of Original
steam line (Japan 2004) manufacturing
defect visible
Cooling water pipe leak
at valve weld (Korea 2006)
Manufacturing Processes Materials Inspection

Primary:
• Forgings What guarantees do you get when
• Castings you buy material?
• Extrusions
• Rolling Related to:
Secondary: • Specification
• Welding • Performance? (what type?)
• Heat treatment
• Machining • FFP?
• Plating • Lifetime?
All MUST have specific forms of documentation
Material Certificates Materials

Iron Fe
Carbon C For strength
Manganese Mn For toughness
It is the responsibility of you or your team Silicon Si < 0.3% deoxidiser
to check material certificates Aluminium Al Grain refiner, <0.008% deoxidiser and toughness
Chromium Cr Corrosion resistance
Molybdenum Mo 1% is for creep resistance
SO Vanadium
Nickel
V
Ni
Strength
Low temperature applications
Copper Cu Used for weathering steels (corten)
Sulphur S Residual element (can cause hot shortness)
Phosphorus P Residual element
You MUST have a Titanium Ti Grain refiner, used a a micro-alloying element,
good understanding of them strength and toughness
Niobium Nb Grain refiner, used a a micro-alloying element,
strength and toughness
3
Material Mechanical Properties
Mill Sheet and Test Certificate
- Abbreviations
Re
Rp 0.2% - proof stress. Refers to materials which do not have
Yield strength a defined yielding such as aluminium when it undergoes tensile
forces. It is a line drawn approximately parallel to the modulus
%A % elongation of elasticity (Hooke’s Law) at a 0.2% offset. The yield point is

the specific transition where the material turns from elastic
(able to transform back to its original shape) to
Rm Ultimate tensile strength partially/permanently deformed.

Re - yield point (YP) the stress at which deformation
Rp
changes from elastic to plastic behaviour, ie below the yield
Proof stress where material has no yield point unloading the specimen means it returns to its original
point (S/S, etc. A set % of deformation) length, above the yield point permanent plastic deformation
has occurred. In EN specifications this parameter is also
%RA % reduction of cross-sectional area identified as Re
Mill Sheet and Test Certificate Mill Sheet and Test Certificate
– Abbreviations - Abbreviations
Z% - steel with a tested level of ductility through the Z axis of
Rm - tensile strength, also known as the ultimate tensile
the plate. Specimens taken from the material are tested in a
strength (UTS), the load at failure divided by the original
tensile machine through the Z direction. The original cross-
cross-sectional area. In EN specifications this parameter
sectional area is measured before testing and the reduced
is also identified as Rm
cross-sectional area is measured after testing then deducted
from the original cross-section, giving a Z%.
% A– elongation, test to measure the ductility of steel. When
a material is tested for tensile strength it elongates a certain CEV = % C + Mn + %Cr + %Mo + %V + %Ni + %Cu
amount before fracture takes place. The two pieces are 6 5 15
placed together and the amount of extension is measured
against marks made before starting the test and is The CEV of a steel is calculated by inserting the material test
expressed as a percentage of the original gauge length. certificate values shown for chemical composition into the
formula. The higher the CEV the greater its susceptibility to
HAZ hardening so the greater the susceptibility to cracking.
Material Certification Inspection Certificates

The main material certification standard to Why? To assess whether the products are in compliance
ensure traceability is EN 10204 (2004) with the requirements of the order therefore see
BS EN 10204
3.2 gives the highest level of assurance and is verified
How? Specific inspection
by an independent body, so is considered the lowest
risk to the buyer. Non-specific inspection
• Carried out by • Carried out before delivery
3.1 is effectively self-certified by the manufacturer and
manufacturer in in accordance with
therefore has possible risk.
accordance with their product specification
2.2 is the most common level for low integrity use and procedures • Inspection performed on
is generally considered a certificate of conformity and • Products inspected are products to be supplied or
therefore has risks of non-compliance. NOT necessarily the on test units of which the
products supplied! products supplied are part
4
BS EN 10204 - Type of Documents BS EN 10204 - Type of Documents
Non-specific Specific
inspection inspection
documents documents
Type 3.1 Type 3.2
Type 2.1 Type 2.2
• Inspection certificate 3.1 • Inspection certificate 3.2
• Declaration of • Test report • Statement of compliance • Statement of compliance with
compliance with order • Statement of with order (includes specific order (includes
• Statement of compliance compliance with test results!) specific test results!)
• Validated by manufacturer
with order (doesn’t order (includes test • Validated by manufacturer
inspection, independent
include test results!) results!) inspection (independent of manufacturing department +
• Validated by • Validated by of manufacturing purchaser’s/
manufacturer manufacturer department!) official designated authorised
inspector
Traceability Material Testing
• Traceability of a material could be the most critical

part of the process you are involved in. ( 3.2 )
• Manufacturers of the less conscientious nature
have been known to be very malleable on the
exact figures obtained in testing and the
qualifications of the operators of the mechanical ( 3.1 )
testing and NDE operators.
• Most purchasers requiring materials for highly Material certificate
critical operations will require third party grades appear
witnessing or monitoring of these tests at the mills on ITPs
(low risk).
The Danger of Trusting Documentation!! Positive Material Identification
This fitting NITON hand-held

had a PMI unit
trustworthy Contact method
to determine
material cert! material type
5
Positive Material Identification Positive Material Identification
Calibration clip PDA palm-top Instant data recording

data processing unit of chemical content and
spectroscopic material
analysis
Welding Consumables
Each consumable is critical in respect of:

• Size
• Classification/supplier
Welding Consumables • Condition
• Treatments eg baking/drying
TWI Training & Examination • Handling and storage is critical for consumable
Services
control
• Handling and storage of gases is critical for safety
MMA Welding Consumables MMA Welding Consumables

Plastic foil sealed cardboard box
• Rutile electrodes
• General purpose basic electrodes
Three main electrode coverings used in
Courtesy of Lincoln Electric MMA welding
Courtesy of Lincoln Electric
• Cellulosic - deep penetration/fusion

Tin can
Cellulosic electrodes • Rutile - general purpose
• Basic - low hydrogen
Vacuum sealed pack
Extra low hydrogen electrodes
6
Welding Consumable Gases
• GMAW, FCAW, TIG, oxyfuel
• Supplied in cylinders or storage
tanks for large quantities.
Any Questions
?
• Colour-coded cylinders to minimise
wrong use.
• Subject to regulations concerned
handling, quantities and positioning
of storage areas.
• Moisture content is limited to avoid
cold cracking.
• Dew point (the temperature at which
the vapour begins to condense)
must be checked.
7
Section 6
Welding Documentation
Rev 0 August 2010
6 Welding Documentation
6.1 General
When structures and pressurised items are fabricated by welding it is
essential that all the welded joints are sound and have suitable properties
for their application.
Control of welding is by welding procedure specifications (WPS) that give

detailed written instructions about the welding conditions that must be used
to ensure that welded joints have the required properties.
Although WPSs are shopfloor documents to instruct welders, welding

inspectors also need to be familiar with them because they will need to refer
to WPSs when they are checking that welders are working in accordance
with the specified requirements.
Welders need to understand WPSs and have the necessary skill to make
welds that are not defective and demonstrate these abilities before being
allowed to make production welds.
6.2 Qualified welding procedure specifications

It is industry practice to use qualified WPS for most applications.
A welding procedure is usually qualified by making a test weld to

demonstrate the properties of the joint satisfy the requirements specified by
the application standard and the client/end user.
Demonstrating the mechanical properties of the joint is the principal purpose

of qualification tests but showing that a defect-free weld can be produced is
also very important.
Production welds made in accordance with welding conditions similar to

those used for a test weld should have similar properties and therefore be fit
for their intended purpose.
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Figure 6.1 shows a typical WPS written in accordance with the European Welding
Standard format (EN15609-1) giving details of all the welding conditions that need
to be specified.
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6.3 Welding standards for procedure qualification

European and American Standards have been developed to give
comprehensive details about:
 How a welded test piece must be made to demonstrate joint properties.

 How the test piece must be tested.
 What welding details need to be included in a WPS.
 The range of production welding allowed by a particular qualification test
weld.
The principal European Standards that specify these requirements are:
EN ISO 15614
Specification and qualification of welding procedures for metallic materials –
Welding procedure test.
Part 1: Arc and gas welding of steels and arc welding of nickel and nickel
alloys.
Part 2: Arc welding of aluminium and its alloys.
The principal American Standards for procedure qualification are:
ASME Section IX Pressurised systems (vessels and pipework).
AWS D1.1 Structural welding of steels.
AWS D1.2 Structural welding of aluminium.
6.4 Qualification process for welding procedures

Although qualified WPSs are usually based on test welds made to
demonstrate weld joint properties; welding standards allow qualified WPSs
to be written based on other data (for some applications).
Some alternative ways that for writing qualified WPSs for some applications
are:
 Qualification by adoption of a standard welding procedure

Test welds previously qualified and documented by other manufacturers.
 Qualification based on previous welding experience
Weld joints that have been repeatedly made and proved to have suitable
properties by their service record.
Procedure qualification to European Standards by means of a test weld (and

similar in ASME Section IX and AWS) requires a sequence of actions that is
typified by those shown Table 6.1.
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Table 6.1 Typical sequence for welding procedure qualification by means of

a test weld
The welding engineer writes a preliminary welding procedure specification

(pWPS) for each test coupon to be welded.
 Welder makes the test coupon in accordance with the pWPS.

 Welding inspector records all the welding conditions used to make the test
coupon (called the as-run conditions).
An independent examiner/examining body/third party inspector is requested to

monitor the procedure qualification.
The test coupon is subjected to NDT in accordance with the methods specified by
the standard – visual inspection, MT or PT and RT or UT.
 The test coupon is destructively tested (tensile, bend, macro tests).

 The code/application standard/client may require additional tests such as
hardness, impact or corrosion tests – depending on material and application.
 A welding procedure qualification record (WPQR) is prepared by the welding

engineer giving details of:
 The as-run welding conditions.
 Results of the NDT.
 Results of the destructive tests.
 The welding conditions allowed for production welding.
 Third party examiner/examining body is required to sign the WPQR as a true
record of the test
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Figure 6.2 A successful procedure qualification test is completed by the production

of a welding procedure qualification record (WPQR).
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6.5 Relationship between a WPQR and a WPS

Once a WPQR has been produced, the welding engineer is able to write
qualified WPSs for the various production weld joints that need to be made.
The welding conditions that are allowed to be written on a qualified WPS are
referred to as the qualification range and depend on the welding
conditions used for the test piece (the as-run details) and form part of the
WPQR.
Welding conditions are referred to as welding variables by European and

American Welding Standards and are classified as either essential or non-
essential variables.
These variables can be defined as:
 Essential variable
Variable that has an effect on the mechanical properties of the weldment
(and if changed beyond the limits specified by the standard will require
the WPS to be re-qualified).
 Non-essential variable
Variable that must be specified on a WPS but does not have a significant
effect on the mechanical properties of the weldment (and can be
changed without need for re-qualification but will require a new WPS
to be written).
Because essential variables can have a significant effect on mechanical

properties they are the controlling variables that govern the qualification
range and determine what can be written in a WPS.
If a welder makes a production weld using conditions outside the

qualification range given on a particular WPS, there is danger the welded
joint will not have the required properties and there are then two options:
 Make another test weld using similar welding conditions to those used
for the affected weld and subject this to the same tests used for the
relevant WPQR to demonstrate the properties still satisfy specified
requirements.
 Remove the affected weld and re-weld the joint strictly in accordance
with the designated WPS.
Most welding variables classed as essential are the same in the European
and American Welding Standards but their qualification ranges may differ.
Some application standards specify their own essential variables and it is

necessary to ensure that these are taken into consideration when
procedures are qualified and WPS’s are written.
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Examples of essential variables (according to European Welding Standards)

are given in Table 6.2.
Table 6.2 Typical examples of WPS essential variables according to European

Welding Standards.
Variable Range for procedure qualification
Welding process No range – process qualified must be used in production.
PWHT Joints tested after PWHT only qualify as PWHT production joints.
Joints tested as-welded only qualify ‘as-welded’ production joints.
Parent material Parent materials of similar composition and mechanical properties are
type allocated the same material group No. Qualification only allows
production welding of materials with the same group No.
Welding Consumables for production welding must have the same European
consumables designation (general rule).
Material A thickness range is allowed – below and above the test coupon
thickness thickness.
Type of AC only qualifies for AC; DC polarity (+ve or -ve) cannot be changed;
current pulsed current only qualifies for pulsed current production welding.
Preheat That used for the test is the minimum that must be applied.
temperature
Interpass The highest interpass temperature reached in the test is the maximum
temperature allowed.
Heat input (HI) When impact requirements apply maximum HI allowed is 25% above
test HI.
When hardness requirements apply minimum HI allowed is 25% below
test HI.
6.6 Welder qualification

The use of qualified WPSs is the accepted method for controlling production
welding but will only be successful if the welders understand and work in
accordance with them. Welders also need to have the skill to consistently
produce sound welds (free from defects).
Welding standards have been developed to give guidance on what

particular test welds are required to show that welders have the required
skills to make particular types of production welds in particular materials.
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6.6.1 Welding standards for welder qualification

The principal European Standards that specify requirements are:
EN 287-1 Qualification test of welders – Fusion welding.

Part 1: Steels.
EN ISO 9606-2 Qualification test of welders – Fusion welding.

Part 2: Aluminium and aluminium alloys.
EN 1418 Welding personnel – Approval testing of welding

operators for fusion welding and resistance weld
setters for fully mechanised and automatic welding of
metallic materials.
The principal American Standards that specify requirements for welder

qualification are:
ASME Section IX Pressurised systems (vessels and pipework).
AWS D1.1 Structural welding of steels.
AWS D1.2 Structural welding of aluminium.
6.7 The qualification process for welders

Qualification testing of welders to European Standards requires test welds
to be made and subjected to specified tests to demonstrate the welder
understands the WPS and can produce a sound weld.
For manual and semi-automatic welding the emphasis of the tests is to

demonstrate the ability to manipulate the electrode or welding torch.
For mechanised and automatic welding the emphasis is on demonstrating

that welding operators have ability to control particular types of welding
equipment.
American Standards allow welders to demonstrate that they can produce

sound welds by subjecting their first production weld to NDT.
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Table 6.3 The steps required for qualifying welders in accordance with European
Standards.
The welding engineer writes a WPS for welder qualification test piece.
 The welder makes the test weld in accordance with the WPS.
 A welding inspector monitors the welding to ensure that the welder is working
in accordance with the WPS.
An independent examiner/examining body/ third party inspector is requested to

monitor the test.
 The test coupon is subjected to NDT in accordance with the methods specified
by the standard (visual inspection, MT or PT and RT or UT).
 For certain materials and welding processes, some destructive testing may be
required (bends or macros).
 A welder’s qualification certificate is prepared showing the welding conditions

used for the test piece and the range of qualification allowed by the standard
for production welding.
 The qualification certificate would be endorsed as a true record of the test by
the examiner/examining body.
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Figure 6.3 Typical welder qualification certificate in accordance with European

Standards.
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6.8 Welder qualification and production welding allowed

The welder is allowed to make production welds within the range of
qualification recorded on his welder qualification certificate.
The range of qualification is based on the limits specified by the welding

standard for welder qualification essential variables - defined as: a
variable that if changed beyond the limits specified by the welding
standard may require greater skill than has been demonstrated by the
test weld.
Some welding variables classed as essential for welder qualification are the
same types as those classified as essential for welding procedure
qualification, but the range of qualification may be significantly wider.
Some essential variables are specific to welder qualification.
Examples of welder qualification essential variables are given in Table 6.4.
Table 6.4 Typical welder qualification essential variables according to European

Welding Standards.
Variable Range for welder qualification
Welding process No range – process qualified is what a welder can use in production.
Type of weld Butt welds cover any type of joint except branch welds.
Fillet welds only qualify fillets.
Parent material Parent materials of similar composition and mechanical properties are
type allocated the same material group No.; qualification only allows production
welding of materials with the same group No. but the groups allow much
wider composition ranges than the procedure groups.
Filler material Electrodes and filler wires for production welding must be of the same form
as the test (solid wire, flux cored, etc); for MMA coating type is essential.
Material Thickness range is allowed; for test pieces above 12mm allow
thickness  5mm.
Pipe diameter Essential and very restricted for small diameters. Test pieces above 25mm
allow  0.5 x diameter used (min. 25mm)
Welding position Position of welding very important; H-L045 allows all positions (except PG).
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6.9 Period of validity for a welder qualification certificate

A welder’s qualification begins from the date of welding the test piece.
The European Standard allows a qualification certificate to remain valid for

two years provided that:
 The welding co-ordinator, or other responsible person, can confirm that

the welder has been working within the initial range of qualification.
 Working within the initial qualification range is confirmed every six
months.
6.10 Prolongation of welder qualification

A welder’s qualification certificate can be prolonged every two years by an
examiner/examining body but certain conditions need to be satisfied:
 Records/evidence available that can be traced to the welder and the

WPS that have been used for production welding.
 The supporting evidence must relate to volumetric examination of the
welder’s production welds (RT or UT) on two welds made during the 6
months prior to the prolongation date.
 The supporting evidence welds must satisfy the acceptance levels for
imperfections specified by the European welding standard and have
been made under the same conditions as the original test weld.
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Review of welding procedure qualification:
Company:
Project:
Specification:
Design code:
Welding code:
Design temp:
Material:
WPS No:
WPQR No:
WPQR checklist WPQR data Comments
Test thickness
Thickness range
Test diameter
Diameter range
Material group No
Cvn Charpy impact
Transweld tensile
All weld tensile
Macro/micro
Hardness
Bends
Welding process(es)
Current type/polarity
Consumable 1
Consumable 2
Gas(es)
Min preheat temp
Application method
Max interpass temp
Amps
Volts
Weld speed
Wire feed speed
Welding position
Backing
Heat input
Third party approval
PWHT
Visual
Radiography
Ut
MPI/DPI
Ferrite determination
Ferric chloride g48a
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CSWIP QC Coordinator Welding Procedure Qualification
Question:
What is the main reason for carrying out a Welding
Procedure Qualification Test? What is the test trying to
show?
Welding Procedures Answer:
That the welded joint has the properties that satisfy the
design requirements (fit for purpose)
TWI Training & Examination Mechanical properties are the main interest –
Services ALWAYS STRENGTH but toughness and hardness
may be important for some applications. Test also
demonstrates that the weld can be made without defects
Welding Procedure Qualification Welding Procedure Qualification
According to EN ISO 15614

Preliminary Welding Procedure Specification
Preliminary Welding Procedure Specification pWPS)
pWPS
Welding Engineer writes a pWPS for each
Welding Procedure Qualification Record test weld to be made.
WPQR
Welding Procedure Specification

WPS

Welding Procedure Qualification Record (WPQR) Welding Procedure Qualification Record (WPQR)
Test weld is subjected to destructive testing (tensile, bend,
• Welder makes a test weld in accordance with pWPS macro).
• Welding inspector records welding conditions used
The application standard or client may require additional tests
for the test weld (referred to as the as-run conditions) such as impact, hardness (and for some materials corrosion
tests).
Independent examiner/examining body/third party
inspector MAY BE requested to monitor the Welding Procedure Qualification Record (WPQR) details:
qualification process. • Welding conditions used for the test weld
• NDT results
Finished test weld is subjected to NDT in accordance • Destructive test results
• Welding conditions the test weld allows for production
with methods specified by EN ISO Standard – welding
visual, MT or PT and RT or UT. The third party may be asked to sign the WPQR as a true record.
1
According to EN Standards:
Welding Procedure Specification (WPS) Welding conditions are called welding variables.
Welding variables are classified as:
Welding engineer writes qualified WPS for • Essential variables
production welding.
• Non-essential variables
• Additional variables
Production welding conditions must remain
Note: Additional variables = ASME supplementary
within the range of qualification allowed by essential.
the WPQR. The qualification range for production welding is based
on the limits EN ISO Standard specifies for essential
variables (and when applicable - the additional variables).
According to EN Standards: According to EN Standards)

Welding Additional Variables
Welding essential variables
Question:
Question:
Why are some welding variables classified as additional?
What is an essential welding variable?
Answer:
Answer: A variable that if changed beyond certain limits (specified
A variable that if changed beyond certain limits by the welding standard) may have a significant effect on
(specified by the welding standard) may have a the toughness and/or hardness of the joint.
significant effect on the properties (particularly Note: ASME calls variables that affect toughness
joint strength and ductility) of the joint. supplementary essential variables (but does not refer to
hardness).
Welding Procedure Qualification Welding Procedures
According to EN Standards Producing a welding procedure involves:

Some typical essential variables: • Planning the tasks
• Welding process
• Collecting data
• Post-weld heat treatment (PWHT)
• Material type • Writing a procedure for trial
• Electrode type, filler wire type (classification) • Making a test weld
• Material thickness
• Polarity (AC, DC+ve/DC-ve) • Evaluating results
• Preheat temperature • Approving the procedure
Some typical additional variables: • Preparing the documentation
• Heat input
• Welding position
2
Welding Procedures Components of a Welding Procedure
In most codes reference is made to how the procedure are Parent material:
devised and whether approval is required. • Type (grouping)
• Thickness
The approach for procedure approval depends on the code:
• Diameter (pipes)
Example codes: • Surface condition
• AWS D.1.1: Structural steel welding code
Welding process:
• BS 2633: Class 1 welding of steel pipe work • Type of process (MMA, MAG, TIG, SAW, etc)
• API 1104: Welding of pipelines • Equipment parameters
• BS 4515: Welding of pipelines over 7bar • Amps, volts, travel speed
Other codes may not specifically deal with the requirement Welding consumables:
of a procedure but may contain information that may be • Type/diameter of consumable
used in writing a weld procedure • Brand/classification
• EN 1011 Process of arc welding steels • Heat treatment/storage
Components of a Welding Procedure Objective of a Welding Procedure Test

Joint design:
Give maximum confidence that the welds
• Edge preparation
• Root gap, root face mechanical and metallurgical properties
• Jigging and tacking meet the requirements of the applicable
• Type of backing code/specification.
Welding position: Each welding procedure will show a range
• Location, shop or site
• Welding position eg 1G, 2G, 3G, etc
to which the procedure is approved (extent
• Any weather precaution of approval).
Thermal heat treatments: If a customer queries the approval evidence
• Preheat temperatures can be supplied to prove its validity.
• Postweld heat treatments eg stress-relieving
Welding Procedures Purpose of a WPS
• Achieve specific properties

(mechanical strength, corrosion resistance,
composition)
Example of • Ensure freedom from defects
Welding Procedure • Enforce QC procedures
Specification (WPS) • Standardise methods and costs
• Control production schedules
• Form a record
• Application standard or contract requirement
3
Range of Qualification Range of Qualification
Examples include:
• The extent of qualification for an essential • Material thickness and pipe diameter
welding variable.
(depending on the type of joint!)
• Also known as extent of approval, range of • Welding process
approval or scope of approval.
• Welding position, amperage range, current type
• Provides working range for each welding or number of runs
procedure approval or welder approval
• Parent material groups
• Filler material type and size
Outside the range of qualification
re-qualification is MANDATORY! • Preheat/interpass temperature
• PWHT type and parameters
• Heat input range, kJ/mm
Grouping System for Steels BS EN ISO 15614-1 Provisions

Group 1 – C-Mn steels
Group 2 – Fine grain/TMCP steels Range of qualification for welding positions:
Group 3 – QT or PH steels (except stainless) • Welding in any position qualifies for all positions
Group 4 – Low vanadium Cr-Mo steels except PG and J-L045 which requires a separate
Group 5 – Vanadium free Cr-Mo steels test.
Group 6 – High vanadium Cr-Mo steels • In cases of impact/hardness requirements, impact
Group 7 – Ferritic, martensitic and PH stainless steels tests shall be taken from highest heat input
Group 8 – Austenitic stainless steels position (ie PF) and hardness tests from the
Group 9 – Ni alloy steels lowest heat input position (ie PC or PE) in order
to qualify all positions
Group 10 – Duplex stainless steels
Group 11 – HSLA steels
Welding Position Designation

Welding Positions – Fillet Welds on Plate
PA 1G/1F Flat/downhand
PB 2F Horizontal-vertical
PC 2G Horizontal
PD 4F Horizontal-vertical (overhead)
Flat - PA Horizontal - PB Overhead - PD
PE 4G Overhead
PF 3G/5G Vertical up
PG 3G/5G Vertical down
H-L045 6G Inclined pipe (upwards)
J-L045 6G Inclined pipe (downwards) Vertical up - PF Vertical down - PG
4
Welding Position Designation
Welding Positions
– Fillet Welds on Pipe
ISO
Flat - PA Horizontal - PB Overhead - PD

axis: inclined at 45° axis: vertical axis: vertical
pipe: rotated pipe: fixed pipe: fixed
Horizontal - PB Vertical up - PF Vertical down - PG

axis: horizontal axis: horizontal axis: horizontal
pipe: rotated pipe: fixed pipe: fixed
Welding Procedures Welding Procedures

Monitoring Heat Input EN 288 Part 2 15614-1-2-3 specifies contents of WPS
As required by BS EN ISO 15614-1:2004, ‘shall give details of how a welding operation is to
in accordance with EN 1011-1:1998 be performed and contain all relevant information.’
• When impact requirements apply, the upper limit of heat • Definitions
input qualified is 25% greater than used in welding the test
piece. • Processes to be designated in accordance with
• When hardness requirements apply, the lower limit of heat ISO 4063
input qualified is 25% lower than used in welding the test
piece. • Welding positions in accordance with ISO 6947
• Heat input is calculated in accordance with EN 1011-1.
• Typical WPS form
• If welding procedure tests have been preformed at both
high and low heat input level, all intermediate heat inputs
are also qualified.
Welding Procedures Monitoring Heat Input
Monitoring Heat Input Arc Energy and Heat Input
5
Monitoring Heat Input Monitoring Heat Input
Arc energy: Heat Input:

Amount of heat generated in the welding arc per Energy supplied by the welding arc to the
unit length of weld. workpiece.
Expressed in kiloJoules per millimetre (kJ/mm) of Expressed in terms of
weld. arc energy x thermal efficiency factor
Arc energy (kJ/mm) = Volts x Amps Thermal efficiency factor is the ratio of
welding speed(mm/s) x 1000 heat energy introduced into the weld to
the electrical energy consumed by the arc.
Monitoring Heat Input Monitoring Heat Input

Thermal efficiency factor k of welding processes
Example
Process No Process Factor k
121 Submerged arc welding with wire 1.0 A MAG weld is made and the following
111 Metal-arc welding with covered electrodes 0.8
conditions were recorded:
131 MIG welding 0.8
135 MAG welding 0.8

Arc volts = 24
114 Flux-cored wire metal-arc welding without gas shield 0.8 Welding amperage = 240
136 Flux-cored wire metal-arc welding with active gas shield 0.8
Travel speed = 300mm/min
137 Flux-cored wire metal-arc welding with inert gas shield 0.8
138 Metal-cored wire metal-arc welding with active gas shield 0.8
139 Metal-cored wire metal-arc welding with inert gas shield 0.8 What are the arc energy and heat input?
141 TIG welding 0.6
15 Plasma arc welding 0.6
Monitoring Heat Input
AE (kJ/mm) = Volts x amps

Travel speed(mm/ sec) x 1000
= 24 x 240
(300/60) x 1000
Welder Approval
Example BS EN 287
= 5760
5000
AE = 1.152 or 1.2kJ/mm
HI = 1.2 x 0.8 = 0.96kJ/mm
Services
6
Welder Qualification Welder Qualification According to EN 287
According to EN Standards
An approved WPS should be available covering the
Question: range of qualification required for the welder approval.
What is the main reason for qualifying a welder? • The welder qualifies in accordance with an
approved WPS.
Answer:
To show he has the skill to make production • A welding inspector monitors the welding to ensure
welds that are free from defects. the welder uses the conditions specified by the WPS.
Note: When welding in accordance with a EN welding standard states that an independent
examiner, examining body or third party inspector may
qualified WPS
be required to monitor the qualification process.
Welder Qualification According to EN 287 Welder Qualification According to EN 287

The welder is allowed to make production welds within
The finished test weld is subjected to NDT by methods
the range of qualification shown on the Certificate. The
specified by EN standard - visual, MT or PT and RT or UT
range of qualification allowed for production welding is
The test weld may need to be destructively tested - for based on the limits that the EN Standard specifies for
certain materials and/or welding processes specified by the welder qualification essential variables.
the EN Standard or the Client Specification
A welder’s qualification certificate automatically expires
• A welder’s qualification certificate is prepared if the welder has not used the welding process for
showing conditions used for the test weld and the 6 months or longer.
range of qualification allowed by the EN Standard for
production welding. A certificate may be withdrawn by the employer if there is
reason to doubt the ability of the welder, for example:
• The qualification certificate is usually endorsed by a • High repair rate
third party inspector as a true record of the test. • Not working in accordance with a qualified WPS
Welder Qualification According to EN 287 Welder Qualification According to EN 287
Essential Variables: Typical Welder Essential Variables:

Question: • Welding process
What is a welder qualification essential variable? • Material type
What makes the variable essential?
• Electrode type
Answer: • Material thickness
A variable that if changed beyond the limits • Pipe diameter
specified by the EN standard may require more
skill than has been demonstrated by the test • Welding position
weld. • Weld backing (an unbacked weld requires
more skill).
7
Welder Qualification Welder Qualification
Information that should be on a welders test certificate:
Numerous codes and standards deal with welder
• Welder’s name and identification number
qualification, eg BS EN 287. • Date of test and expiry date of certificate
• Standard/code eg BS EN 287
Once the procedure is approved the next stage is to
• Test piece details
approve the welders to the approved procedure using a • Welding process
test known as a welders qualification test (WQT). • Welding parameters, amps, volts
• Consumables, flux type and filler classification details
Objectives of a welding qualification test: • Sketch of run sequence
• Give confidence that the welder meets the quality • Welding positions
• Joint configuration details
requirements of the approved procedure (WPS).
• Material type qualified, pipe diameter, etc
• The test weld should be carried out using the same • Test results, remarks
• Test location and witnessed by
material and conditions as for the production welds.
• Extent (range) of approval
Example of Welder Approval

Inspection of a Welder’s Qualification Test
Qualification Certificate
• It is normal for a qualified inspector, usually from an
independent body to witness the welding.
• Under normal circumstances only one test weld per
welder is permitted
• If the welder fails the test weld and the failure is not
the fault of the welder eg faulty welding equipment
then a re-test would be permitted.
• The test weld is tested in accordance with the
applicable code.
• It is not normal to carry out tests to ascertain the
mechanical properties of welds eg tensile, Charpy and
hardness tests.
Any Questions
8
Section 7
Calibration of Welding
and Inspection Equipment
Rev 0 August 2010
Calibration of Welding and Inspection Equipment
7 Calibration of Welding and Inspection Equipment

7.1 Introduction
BS 7570 - Code of practice for validation of arc welding equipment – a
standard that gives guidance to:
 Manufacturers about the accuracy required from output meters fitted to

welding equipment to show welding current, voltage, etc.
 End users who need to ensure that the output meters provide accurate
readings.
The standard refers to two grades of equipment - standard and precision

grades.
 Standard grade equipment is suitable for manual and semi-automatic

welding processes.
 Precision grade equipment is intended for mechanised or automatic

welding because there is usually a need for greater precision for all
welding variables as well as the prospect of the equipment being used
for higher duty cycle welding.
7.2 Terminology
BS 7570 defines the terms it uses, such as:
Calibration
Operations for the purpose of determining the magnitude of errors of a
measuring instrument, etc.
Validation
Operations for the purpose of demonstrating that an item of welding
equipment or a welding system conforms to the operating specification for
that equipment or system.
Accuracy
Closeness of an observed quantity to the defined, or true, value.
Thus, when considering welding equipment, those with output meters for
welding parameters (current, voltage, travel speed, etc.) can be calibrated
by checking the meter reading with a more accurate measuring device and
adjusting the readings appropriately.
Equipment without output meters (some power sources for MMA,

MIG/MAG) cannot be calibrated but can be validated, that is make checks to
see that the controls are functioning properly.
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7.3 Calibration frequency

BS 7570 recommends re-calibration/validation: (parameter monitoring on a
monthly basis would be preferred to ensure no great amount of welding
could be carried out using out of calibration or invalidated equipment leading
to no confidence in the welds made).
 Yearly intervals (following an initial consistency test at 3 monthly

intervals) for standard grade equipment.
 Six monthly intervals for precision grade equipment.
However, the standard also recommends that re-calibration/validation may

be necessary more frequently. Factors that need to be considered are:
 Equipment manufacturer’s recommendations.

 User’s requirements.
 If the equipment has been repaired re-calibration should always be
carried out.
 If there is reason to believe the performance of the equipment has
deteriorated.
7.4 Instruments for calibration

Instruments used for calibration should:
 Be calibrated by a recognised calibrator using standards traceable to a

national standard.
 Be at least twice and preferably five times more accurate than the
accuracy required for the grade of equipment.
 For precision grade equipment instruments with much greater precision
must be used for checking output meters.
7.5 Calibration methods

The standard gives details about the characteristics of power source types,
how many readings should be taken for each parameter and guidance on
precautions that may be necessary.
For the main welding parameters, recommendations from the standard are:
Current
Details are given about instrumentation requirements and how to measure
pulsed current. There are no requirements specified or recommendations
made about where in the circuit current measurements should be made.
The implication is that current can be measured at any position in the circuit
– the value should be the same.
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Voltage
The standard emphasises that for processes where voltage is pre-set (on
constant voltage power sources) the connection points used for the
voltmeter incorporated into the power source may differ from the arc
voltage, which is the important parameter.
To obtain an accurate measure of arc voltage the voltmeter should be

positioned as near as practical to the arc.
The figure shows the power source voltage meter connected across points 1
and 7.
Power
Source
7 1 2 3
Wire Feeder
4
arc voltage {
5
6
Figure 7.1 Example of a welding circuit (for MIG/MAG).
However, because there will be some voltage drops in sections 1-2, 3-4 and
6-7 due to connection points introducing extra resistance into the circuit, the
voltage meter reading on the power source will tend to give a higher reading
than the true arc voltage.
Even if the power source voltmeter is connected across points 3 and 7

(which it may be) the meter reading would not take account of any
significant voltage drops in the return cable - section 6-7.
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The magnitude of any voltage drops in the welding circuit will depend on
cable diameter, length and temperature and the standard emphasises the
following:
 It is desirable to measure the true arc voltage between points 4-5 but for
some welding processes it is not practical to measure arc voltage so
close to the arc.
 For MMA it is possible to take a voltage reading relatively close to the
arc by connecting one terminal of the voltmeter through the cable sheath
as close as ~2m from the arc and connect the other terminal to the
workpiece (or to earth).
 For MIG/MAG the nearest practical connection points have to be 3-5 but
a change from an air- to a water-cooled torch or vice versa may have a
significant effect on the measured voltage.
 Voltage drops between points 5-6 will be insignificant if there is a good
connection of the return cable at point 6.
The standard gives guidance about minimising any drop in line voltage by
ensuring that the:
 Current return cable is as short as practical and is heavy, low resistance,

cable.
 Current return connector is suitably rated and is firmly attached so does
not overheat due to high resistance.
The standard gives data for line voltage drops (DC voltage) according to
current, cable cross-section and cable length (for both copper and
aluminium cables).
Wire feed speed

For constant voltage (self-adjusting arc) processes such as MIG/MAG the
standard recognises that calibration of the wire feeder is generally not
needed because it is linked to current.
If calibration is required, it is recommended that the time be measured (in

seconds) for ~1m of wire to be delivered (using a stopwatch or an electronic
timer).
The length of wire should then be measured (with a steel rule) to an

accuracy of 1mm and the feed speed calculated.
Travel speed
Welding manipulators, such as rotators and robotic manipulators, as well as
the more conventional linear travel carriages, influence heat input and other
properties of a weld and should be checked at intervals.
Most of the standard devices can be checked using a stopwatch and

measuring rule but more sophisticated equipment, such as a tacho-
generator, may be appropriate.
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What is instrument calibration?

It is one of the main processes to maintain instrument/equipment accuracy.
This process configures an instrument to provide an accurate result for
within an acceptable range, highlighting any factors that may cause
inaccurate measurements.
Procedures may vary from product to product; the calibration process

involves the use of instrument with test samples with known values called
calibrators. The results are used to establish a range of accuracy between
the measurement technique used by the instrument and the known values.
Calibrations are performed using a range of calibrators to establish the

accuracy at specific points within the instrument’s operating range. While it
may be an advantage to use a large number of calibrators to establish the
calibration relationship or curve, the cost associated with preparing and
testing a large number of calibrators may be prohibitive and time
consuming.
How often should an instrument be calibrated?

When it needs it.
Calibration interval
Base the calibration interval on the instrument’s stability, purpose, usage,
environment, past history of equivalent instruments and manufacturer’s
recommendations. Use the table below as a guideline:
Table 7.1 Suggested calibration frequencies

How often used Calibration interval, months
Daily 3
Every second day 6
Once per week 12
Once per month 24
One per year 36
Calibration may be required when any of the following occur:
 Observations appear questionable.

 Specified time has elapsed.
 Specified time or usage (based on operating hours) has elapsed.
 A new instrument is introduced.
 Results seem inconsistent.
 An instrument has been damaged or used beyond its working range
which potentially may have put it out of calibration.
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Procedure
All measuring and test equipment is calibrated, the production related
equipment is maintained and there must be calibration and maintenance
records. It is recommended each record should include:
 Equipment number, marked on the equipment.

 Equipment description, type, manufacturer and model.
 Location - calibration requirements.
 Calibration interval with justification for the interval.
 Calibration procedure.
 Calibration history.
 Calibration due.
A database should be set up to identify all due and overdue calibration

requirements. Each piece of equipment is due for calibration based on the
requirements set out for that instrument. These records are maintained by
the quality department and any equipment past the calibration due date
must be pulled from production and kept in a secure area and labelled as
quarantined until it has passed calibration.
Calibration labels
Minimum calibration label requirements:
 Date of calibration.
 Calibration record number.
 Calibration due date.
 Calibration employee signature.
Typical labels used:
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CSWIP QC Coordinator Calibration/Validation
BS 7570: 2000 Covers the calibration and validation

of welding equipment.
Grade 1 (general purpose equipment)
Calibration all parameters should be 10%.
Grade 2 (Automatic or automated equipment)
parameters should be 2.5% for current and
TWI Training & Examination 5% for all other parameters.
Services
Calibration/Validation Measuring in Welding

Purposes of
Calibration can only be done on equipment with measuring
meters or gauges as these can be adjusted.
Validation can be done on equipment with and Demonstration of Welding
without meters or gauges. conformance to process
specified requirements control
Oil fill transformers, etc.
Parameters to be measured:
All equipment can be validated but not all • Welding current • Preheat/interpass
equipment can be calibrated. • Arc voltage temperature
• Travel speed • Force/pressure
• Shielding gas flow rate • Humidity
Welding Current Measurement The Tong Tester
Definition: the current delivered by a welding • Used for AC current

power source during welding • No need to insert the meter
• Measured with an ammeter into the circuit
• Measured in A
• The ammeter may be connected at any
point in the circuit
• Due to its sensitivity, a shunt is needed
• Indirect measurement: tachogenerator and
tong tester
1
Arc Voltage Measurement Travel |Speed Measurement
Definition: Potential difference across the welding arc Definition: Rate of weld progression
• Varies with the arc length • Measured for mechanised and automatic
• Measured with a voltmeter welding processes
• Measured in V • For MMA determined using ROL and arc time
• Voltmeter may be connected only across the circuit
(to the workpiece and as close as possible to the
electrode!)
• if the voltmeter is connected at the welding power
source, a higher voltage will be recorded (due to
potential drops across cables)
• Usually not required for MMA and TIG
Gas Flow Rate Measurement Welding Temperatures - Definitions
Definition: Rate at which gas is caused to flow Preheat • Temperature of the workpiece in the weld
temperature zone immediately before any welding
Set with a gas Can be checked operation (including tack welding).
regulator with a flowmeter • Normally expressed as a minimum
Interpass • Temperature in a multi-run weld and

temperature adjacent parent metal immediately prior to
the application of the next run
• Normally expressed as a maximum
Minimum interpass temperature = preheat temperature
Preheat • Minimum temperature in the weld zone which
maintenance shall be maintained if welding is interrupted
temperature • Monitored during interruption
Welding Temperatures - Where? Welding Temperatures - Where?

Point of measurement
Point of measurement
- see BS EN ISO 13916
- see BS EN ISO 13916
• If t > 50mm therefore
• If t  50mm A = minimum 75mm
therefore A = 4 x t • Where practical the temperature
shall be measured on the face
but maximum 50mm opposite that being heated
• Temperature shall • Allow 2min per 25mm of parent
metal thickness for temperature
be measured on equalisation
the surface of the • Interpass temperature shall be
workpiece facing measured on the weld metal or
the welder immediately adjacent parent
metal
2
Welding Temperatures - How? Temperature Test Equipment
Test equipment Temperature sensitive

materials:
Thermocouple • Crayons, paints and pills
(TE)
• Cheap
Temperature
sensitive Thermistor • Convenient, easy to use
materials (CT)
• Doesn’t measure the actual
(TS)
Optical/electrical temperature!
devices for
Contact contactless
thermometer measurement
(CT) (TB)
Temperature Test Equipment Temperature Test Equipment
Contact thermometer
• Uses bimetallic strips – Thermocouple
steel + INVAR • Based on measuring the thermoelectric
(36%Ni - 64%Fe alloy) potential difference between a hot junction
• Accurate (on weld) and a cold junction.
• Easy to use • Accurate method.
• Gives the actual temperature • Measures over a wide range of temperatures.
• Need calibration • Gives actual temperature.
• Suitable for moderate • Needs calibration.
temperatures
Temperature Test Equipment Temperature Test Equipment
Thermistors Devices for contactless measurement

• Temperature-sensitive • IR radiation and optical
resistors whose resistance pyrometer
varies inversely with • Measure the radiant energy
temperature. emitted by the hot body
• Used when high sensitivity • Contactless method
required. therefore can be used for
remote measurements
• Gives the actual temperature
• Very complex
• Needs calibration
• For measuring high
• Can be used up to 320°C
temperatures
3
PAMS (Portable Arc Monitor System) PAMS (Portable Arc Monitor System)
PAMS Unit What does a PAMS unit measure?

Purposes Welding Gas flow
of PAMS current (Hall rate (heating
effect element
For measuring For calibrating device) sensor)
and recording and validating
welding welding
parameters equipment
Arc voltage Wire feed

(connection speed
Temperature (tachometer)
leads)
(thermocouple)
Use of PAMS
Use of PAMS – Wire Feed Speed Monitoring
– Shielding Gas Flow Rate Monitoring
Incorporated pair
of rolls connected
to a tachogenerator Heating
element
sensor
Calibration, Validation and Monitoring Calibration and Validation

- Definitions – When is it Required?
• Measurement = set of operations for determining the value
• Once a year unless otherwise specified
of a quantity
• Repeatability = closeness between successive measuring • When there are indications that the
results of the same instrument carried out under the same instrument does not register properly
conditions
• Accuracy class = class of measuring instruments intended • When the equipment has been damaged,
to keep the errors within specified limits misused or subject to severe stress
• Calibration = checking the errors using a meter or
measuring device
• When the equipment has been rebuilt or
• Validation = checking control knobs and switches provide repaired
same level of accuracy when returned to a pre-determined
point
• Monitoring = checking welding parameters (and other items) See BS EN ISO 17662 for details!
are in accordance with the procedure or specification
4
Welding Parameter Calibration/Validation Example 1 - MMA Elementary Monitoring
Which parameters need calibration/validation? In theory any MMA operation could require monitoring of:
• Depends on the welding process • Welding current
• See BS EN ISO 17662 and BS 7570 for details • Arc voltage
How accurate? • ROL
• Depends on the application
• Preheat/interpass temperature
• Welding current ±2.5%
• Electrode treatment and storage
• Arc voltage ±5%
• Wire feed speed ±2.5%
• Gas flow rate ±20% In practice (depending on the application) only the
(±25% for backing gas flow rate) welding current could require monitoring with a
• Temperature (thermocouple) ±5% tongue test ammeter.
Example 2 - High Integrity MMA Operation Example 3 - MIG/MAG Welding with a Robot
In theory this might require monitoring of all the In theory the following would require monitoring:
activities previously mentioned. • Wire feed speed
Equipment required: • Amperage
• Ammeter • Voltage
• Voltmeter • Travel speed
• Stop watch or • a PAMS • Gas flow rate
• Tape measure • Repeatability of the controls
• Thermometer In practice a data logger would be preferred to
• Calculator monitor all the parameters; also a PAMS would be
All the above plus any meters fitted to the power required to check the repeatability of the control
source or electrode ovens would require calibration. knobs.
Summary What to Look For
• Welding power sources can only be calibrated if

meters are fitted.
Always check the
• The inspector should check for calibration stickers, certification matches
dates, etc. the sticker and that
• A welding power source without meters can only serial numbers are
be validated that the control knobs provide correct for the
repeatability. equipment attached.
• The main role is to carry out in process monitoring
to ensure that the welding requirements are met
during production
5
Any Questions
6
Section 8
Inspection and Testing Personnel

Rev 0 August 2010
8 Inspection and Testing Personnel

8.1 Responsibilities
Inspection and testing personnel should be approved for the level of
responsibility they have been authorised to work to: Specifications, contracts
and standards will define the minimum level of the required qualification.
It is sometimes permissible for a level one person to work under the

supervision of a level two, (only if the level two is the required level, some
contracts would require a level three), however the level two must accept all
responsibility for the level one’s work and sign it off to say that as the
responsible level two (or level three dependent on contract requirements) he
is completely satisfied with the techniques used and the interpretation of the
results and will demonstrate this by signing off the report.
8.2 Qualifications and registers

An up to date register with all the operators names and qualifications should
be maintained and approved and may include the main contractor and any
subcontractors
The initial approval should be carried out by reviewing the register and the
original copies (or verified copies*) of the applicable operator’s certificates,
verified copies are usually used and become part of the final documentation/
certification.
*Verified copies are established by the client or third party inspectorate

reviewing the original and stamping the photocopy as a true and verified
copy of the original.
8.3 Reporting methods

An established system for reporting shall be agreed prior to any production
activities.
There are several systems available as standalone packages which can be

bought off the shelf.
Electronic databases are becoming more popular, such systems when input
with all the required data, ie:
 Welder’s register site and subcontractor.

 Inspector’s qualification register site and subcontractor.
 Welding procedure register site and subcontractor.
 NDT operators-register site and subcontractor.
 Drawings.
 Materials/associated test certificates.
 PWHT.
 Whatever is required as per the project traceability requirements?
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The use of databases is very useful in highlighting problem areas, eg if

welder A was recorded as welding pipe spool weld number 1 using WPS
number abc1 and this did not match the system data welder A may not have
been qualified to that procedure or WPS abc1 was not suitable for that
material etc. Systems are only as good as the data input operator and
associated information rubbish in rubbish out.
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CSWIP QC Coordinator Responsibility
• Inspection and testing personnel should be approved

for the level of responsibility they have been authorised to
work to. Specifications, contracts and standards will define
the minimum level of the required qualification.
Inspection and Test Personnel • It is sometimes permissible for a level one person to work
under the supervision of a level two, (only if the level two is
the required level, some contracts would require a level
three), but the level two must accept all responsibility for the
TWI Training & Examination level one’s work and sign it off to say that as the responsible
level two (or three dependent on contract requirements) he is
Services completely satisfied with the techniques used and the
interpretation of the results, he will demonstrate this by
signing off the report.
Qualifications and Registers Reporting Methods
• An up to date register with all operators names and • Established system for reporting shall be
qualifications should be maintained and approved, agreed prior to any production activities
this may include the main contractor and any sub-
taking place.
contractors he uses.
• Initial approval should be carried out by reviewing the • Are several systems available as standalone
register and the original copies (or verified copies) of the packages which can be bought off the shelf.
applicable operators certificates, verified copies are usually • Use of electronic databases is becoming
used and become part of the final more popular.
documentation/certification.
*Verified copies are established by the client or third
party inspectorate reviewing the original and stamping
the photocopy as a true and verified copy of the original.
Any Questions
Electronic databases are very useful in highlighting
problem areas eg if welder A was recorded as
?
welding pipe spool weld number 1 using WPS
number abc1 and this did not match the system data
as for example welder A may not have been
qualified to that procedure or WPS abc1 was not
suitable for that material, etc.
However it is worth noting that the systems are only
as good as the data input operator and associated
information. Rubbish in, rubbish out.
1
Section 9
Quality in Welding
Rev 0 August 2010
Quality in Welding
9 Quality in Welding
QC in a fabrication and welding situation is achieved by working to company
procedures and codes of construction or standards. The latter may be
international, national, company’s own or specific to the particular client or
contract.
Company procedures are usually covered in quality manuals the scope of

which may vary widely depending on the size of company, range of work,
working practices and many other factors.
9.1 Quality system standards

Quality system standards specify the minimum requirements of quality
systems for application to specific products or services.
Standards are normally used for the following purposes:
 Guidance to an organisation introducing QA.

 The basis for evaluating an organisation's quality system (an
assessment).
 To specify the QA requirements when invoked in a contract.
The standard common in the UK is ISO 9000.
9.2 What areas of a business need to be covered by ISO 9000?

The standard requires the following elements to have set procedures:
 Management responsibility
Who is responsible for what?
 Quality system
How does the system operate?
 Contract review
Allows personnel to see what the requirement is and who has been
asked to do what.
 Design review and control
Ensure smooth passage from drawing board to end product.
 Documentation controls
Make sure the correct documents are available.
 Purchasing
Make sure we have the right products and services.
 Purchaser supplied product
Make sure those items are OK.
 Product identification and traceability
What and where is it?
 Process control
Lets everyone know clearly how to make the product.
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 Inspection and test

Lets everyone know how to inspect and test it.
 Inspection, measuring and test equipment
Makes sure the equipment used is correct.
 Inspection and test status
Where is the product in the inspection cycle?
 Control of non-conforming product
Ensures incorrect product is not used.
 Corrective action
Find the root cause of the problem and solve it.
 Handling, storage, packing and delivery
Don't damage it now it's made.
 Quality records
Documented evidence that the company meets specific requirements.
 Internal quality audits
Are quality activities performing as planned?
 Training
It cannot be manufactured effectively if people are not adequately trained
and qualified.
 Servicing
If carried out by the company, effective procedures are required.
 Statistical techniques
Use them to build-in product quality.
9.3 Company manuals

9.3.1 QA manual
QA is defined in IS0 9000 as; part of quality management focused on
providing confidence that quality requirements will be fulfilled.
Essentially what the QA manual sets out is how the company is organised,
lays down the responsibilities and authority of the various departments, how
these departments interlink and usually covers all aspects of the company
quality structure, not just those aspects of manufacture.
QC manual
QC is defined in ISO 9000 as; part of quality management focused on
fulfilling quality requirements.
The QC manual will be the manual most often referred to by the senior
welding inspector (SWI) as it details how different departments and
operations are organised and controlled.
Typical examples would be: Production and control of drawings, how

materials and consumables are purchased, how welding procedures are
produced, etc.
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Essentially all operations to be carried out within the organisation will have
control procedures laid down.
In particular it will lay down how inspection functions, whether visual,

dimensional or NDT will be performed.
Inspection being defined as the activity of measuring, examining and testing

characteristics of a product or service and comparing these to a specified
requirement, such requirements are laid down in codes of practice and
standards.
QA refers to a programme for the systematic monitoring and evaluation of

the various aspects of a project, service or facility to ensure that standards
of quality are being met.
It is important to realise that quality is determined by the programme

sponsor. QA cannot absolutely guarantee the production of quality products,
unfortunately, but makes this more likely.
Two key principles characterise QA: fit for purpose (the product should be
suitable for the intended purpose) and right first time (mistakes should be
eliminated). QA includes regulation of the quality of raw materials,
assemblies, products and components; services related to production and
management, production and inspection processes.
It is important to realise that quality is determined by the intended users,

clients or customers, even goods with low prices can be considered quality
items if they meet a market need. QA is more than just testing the quality of
aspects of a product, service or facility, it analyses the quality to make sure
it conforms to specific requirements and complies with established plans.
QA versus QC
QC emphasises testing products to uncover defects and reporting to
management who make the decision to allow or deny the release, whereas
QA attempts to improve and stabilise production and associated processes,
to avoid or at least minimise issues that led to the defects in the first place.
QA does not eliminate the need for QC, some product parameters are so
critical that testing is still essential. QC activities are treated as one of the
overall QA processes.
QC reviews quality factors involved in production and this approach places

emphasis the following aspects:
 Elements such as controls, job management, defined and well managed

processes, performance and integrity criteria and identification of
records.
 Competence, such as knowledge, skills, experience, and qualifications.
 Soft elements, such as personnel integrity, confidence, organisational
culture, motivation, team spirit and quality relationships.
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Quality in Welding
QC co-ordinator
References the company’s quality manual, quality system and relevant
internationally recognised standards thereby ensuring that the company’s
QC procedures/inspection and test plans reflect these requirements during
subsequent inspection and testing of fabricated components.
The QC co-ordinator is responsible for the issue and control of all QC

procedures (QCPs) and inspection test plans (ITPs) and their
implementation during fabrication. He controls via the QCP and ITP the
timely inspection activities of all QC inspectors who report directly to him on
all quality matters.
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Quality in Welding
Quality programme documentation.
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Codes and standards

It is not necessary for the inspector to carry a wide range of codes and
standards in the performance of his/her duties. Normally the specification or
more precisely the contract specification is the only document required but
this may reference supporting codes and standards and the inspector
should know where to access these normative documents.
The following is a list of definitions relating to codes and standards which

the inspector may come across whilst carrying out inspection duties.
9.3.2 Definitions
Normative document
Document that provides rules and guidelines or characteristics for activities
or their results.
The term normative document is a generic term covering documents such

as standards, technical specifications, codes of practice and regulations.*
Standard
Document established by consensus and approved by a recognised body.
A standard provides for common and repeated use guidelines, rules and
characteristics for activities or their results, aimed at the achievement of the
optimum degree of order in a given context.*
Harmonised standards
Standards on the same subject approved by different standardising bodies,
that establish interchangeability of products, processes and services or
mutual understanding of test results or information provided according to
these standards.*
Code of practice
Document that recommends practices or procedures for the design,
manufacture, installation, maintenance, utilisation of equipment, structures
or products.
A code of practice may be a standard, part of a standard or independent of

a standard*
Regulation
Document providing binding legislative rules that is adopted by an
authority.*
Authority
Body responsible for standards and regulations, legal or administrative
entity that has specific tasks and composition) that has legal powers and
rights.*
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Regulatory authority
Authority responsible for preparing or adopting regulations.*
Enforcement authority
Authority responsible for enforcing regulations.*
Specification
Document stating requirements. Meaning full data and its supporting
medium stating needs or expectations that is stated, generally implied or
obligatory.**
Procedure
Document that describes how an activity is to be performed and by whom.
Usually a written description of all essential parameters and precautions to
be observed when applying a technique to a specific application following an
established standard, code or specification:
 BS 4778: Part 1: ISO 8402: Quality vocabulary international terms.

 BS 4778: Part 2: Glossary of terms used in QA.
Note: A procedure is not a detailed work instruction such as a welding

procedure but a statement of who does what and how; it describes the
corporate plan for achieving quality. There may be times an organisation
needs to operate in a different way from the corporate system, for example,
for a unique project or to satisfy a specific customer's requirements.
In these circumstances an appropriate quality system can be documented in

the form of a project or contract specific quality plan.
Project procedures may well include:
 Existing procedures appropriate to the contract.

 Existing procedures amended for the contract.
 New procedures to meet specific requirements or the contract.
Some contracts may call for a combination of all three.
Instruction
Written description of the precise steps to be followed based on an
established procedure, standard, code or specification.
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ITP
Document specifying which procedures and associated resources shall be
applied by whom and when to a specific project, product, process or
contract.*
*ISO IEC Guide 2 – Standardisation and related activities – general

vocabulary.
**EN ISO 9000 – 2000 – Quality management systems – fundamentals and
vocabulary.
The quality plan is the corporate quality system suitably modified to reflect
specific requirements. It may comprise a project quality manual
incorporating appropriate sections from the corporate quality manual as they
apply and is generally a detailed document.
Project procedures may include:
 Existing procedures appropriate to the contract.

 Existing procedures amended for the contract.
 New procedures to meet specific requirements for the contract.
Some contracts may well call for a combination of all three.
Quality records
Any document that indicates the inspection performed, quantities inspected,
results obtained, positive identification of the material inspected to drawing
or part number, the signature or stamp of the person carrying out the
inspection and date of inspection. Quality records might also indicate the
qualification of personnel, calibration of equipment or other records not
directly related to the product.
Summary
Application of the requirements of the quality manuals, standards and codes
of practice ensure that a structure or component will have an acceptable
level of quality and be fit for the intended purpose.
Applying the requirements of a standard, code of practice or specification

can be a problem for the inexperienced inspector. Confidence in applying
the requirements of one or all of these documents to a specific application
only comes with use.
If in doubt the inspector must always refer to a higher authority to avoid

confusion and potential problems.
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QA is therefore the documented plans and systems by which confidence in

a product is provided and comprises all the paperwork systems used to
plan, control and record activities - the documentation.
QC is those activities which monitor the quality of the product, the

operational techniques of checking materials and dimensions, inspection
before, during and after welding, NDT, hydraulic or leak testing. Activities
which take place after the event and which check that a specified activity
has been carried out correctly.
QA was introduced to ensure that the activity is right first time since
prevention is better than cure, achieved by planning and anticipating
problems.
To satisfy this requirement a documented quality system is needed which

sets out in a formal framework the basis of control for the critical activities.
This framework in general comprises four tiers of documentation: The
highest being the company quality manual, cascading down through quality
systems, quality plans and detailed manufacturing and inspection
instructions.
Quality requirement for welding

Within the international community welding has been confirmed as a special
process and requires control by specialist management and uses specialist
personnel.
The welding co-ordination standard (ISO 14731) and the welding quality
systems (ISO 3834) have been prepared in support of this ruling.
It is perceived that these standards will be referenced in other application

standards and used as set criteria for the qualification of fabricators.
The role of a welding QC co-ordinator

BS EN ISO 14731 defines tasks and responsibilities for the responsible
welding QC co-ordinator:
1 Must be involved at all stages of BS EN ISO 3834 requirements.

2 Needs to be a named individual, although tasks can be delegated in the
quality plan.
3 Suggested ways of demonstrating knowledge requirements (clause 6.2):
 Comprehensive: International Welding Engineer (IWE).
 Specific: (IWT).
 Basic: (IWS).
The welding co-ordinator is required to demonstrate a level of knowledge

appropriate for the work being carried out.
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Working to the requirements of BS EN ISO 3834

(Quality requirements for fusion welding of metallic materials)
BS EN ISO 3834, covers 3 levels of quality requirements.

 Part 2 Comprehensive.
 Part 3 Standard.
 Part 4 Elementary.
The standard is compatible with ISO 9001 (QA standard) but concentrates
on welding as a special process.
Level 2, 3 or 4 dependent on:

4 Safety criticality.
5 Complexity of manufacture.
6 Range of products and materials used.
7 Likelihood of metallurgical problems.
8 Extent of likely manufacturing problems.
BS EN 3834 Part 2 Comprehensive needs a procedure for review of

requirements and technical review.
1 Technical requirements.
2 Parent materials, specifications and welded joint properties.
3 Quality and acceptance requirements for welds.
4 Location, accessibility and sequence of welds, including accessibility for
inspection and NDT.
5 Specification of welding procedures.
6 NDT procedures.
7 Qualification of welding procedures.
8 Qualification of personnel.
9 Selection, identification and/or traceability eg materials and welds.
10 Inspection and testing.
11 PWHT.
12 Other welding requirements eg batch testing of consumables, ferrite
content of weld metal, ageing.
13 Hydrogen content, permanent backing, use of peening, surface finish
and weld profile.
14 Dimensions and details of joint preparation and competed weld.
15 Handling of consumables.
16 Sub-contracting: requires all sub-contracting activities relating to welding
to be controlled.
17 Welding personnel - welders, inspectors and welding co-ordinator must
all be appropriately qualified.
18 Responsible welding co-ordinator must be named and the
responsibilities shown in a written procedure.
19 Equipment must be listed, suitable for the work, well maintained and
calibrated.
20 Production planning: Specification of sequence of assembly, order and
timing of processes and Inspection and testing.
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21 Qualification: Procedures, welders inspection. (Are written and specific

WPS available? Do welders have a written work instruction?)
22 Handling of materials and consumables: Bonded stores, written
procedure for handling.
23 PWHT: Inspection and testing, before welding are welding certificates
signed off? Is fit up specified? During welding are parameters checked?
After welding, final inspection, PWHT.
Procedures also required for:

 Non-conformance and corrective actions.
 Identification and traceability.
 Quality records.
9.4 Auditing
Ensuring success by audit
How do you ensure that the system is working? The well adopted and
recommended method is auditing.
Auditing originates from accountancy practice and involves an independent

accountant checking the accounts of a company to see if the accounts are
fair and accurate. A similar checking process is widely practised in
manufacturing and construction industries and inspection personnel will be
involved in carrying out this operation.
Quality manuals, procedures, work instructions, etc provide the objective

evidence that the systems of control have been adequately planned.
The records and documentation generated by carrying out work in

accordance with these systems provide evidence that the systems are being
followed but all systems of control, no matter how effective, tend to
deteriorate because of human error or changes in the nature of the
business.
To ensure the systems are being followed, are effective and if changes are
needed it is necessary to monitor the systems, achieved by auditing the
system and reviewing the results and implementing any changes.
9.4.1 What is an audit?

Quality audits examine a quality system for adequacy and correct
implementation and are defined in BS 4778. Pt 1 as:
Systematic and independent examinations to determine whether quality

activities and related results comply with planned arrangements and
whether these arrangements are implemented effectively and are suitable to
achieve objectives.
Auditing provides objective evidence that the system is working in

accordance with the procedures. When an audit is complete, the results are
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analysed by management who must ensure that the quality policy is

satisfied and modify the quality system if necessary.
There are two depths of audit:
 Systems audit: Simply examines the system to confirm that it follows

the quality manual and that procedures are in place.
 Full audit of a company usually carried out by a third party such as a
certifying authority, checking the company for the award of a QA
accreditation system such as ISO 9000 or ASME stamp.
 Compliance audit: In-depth examining compliance with procedures.
 Major audit by a potential customer prior to placement of a large
contract usually carried out to demonstrate the company has all the
necessary facilities, plant, machinery, personnel and quality systems
in place to enable them to successfully complete the contract.
There is also an ongoing audit:
 Part audits carried out as an on-going demonstration that the quality

system is working properly.
An example of the latter would be a senior inspector responsible for signing-

off the data book or release certificate for a product. After checking that all
the necessary documents are in the package and have been correctly
completed and approved where necessary, the SWI would look at a part of
the job – a beam, a piece of pipework, etc and cross-check against the
drawings, mill certificates, inspection reports, etc that all comply with the job
requirements.
9.5 Auditing of documentation

Regarded as being a compliance audit, it is where documentation is
examined in depth.
Items to check include:

 Is all the documentation available?
 Is the documentation schedule in accordance with contract or
specification requirements?
 Does the documentation comply with contract or specification
requirements, eg are weld procedure and welders correctly qualified? Is
it the correct material composition?
 Is the documentation legible?
 Have all interested parties, eg inspection department, independent third
party inspectors, client inspectors, signed off where required?
 Has provision been made for storage, including the ability to retrieve
documents and the storage conditions to prevent deterioration?
Documentation audits should be carried out by the manufacturer/supplier as

a matter of course.
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Customers frequently require access to carry out their own audits,

remember no job is finished until the paperwork is complete.
Failure of a documentation audit carried out by a client often results in a

delay in payment even though the component may have been delivered to
the client and often carries a consequential financial penalty.
Questions that need to be addressed include:

 Which quality records are to be maintained; eg receiving inspection
reports, NDT results, test certificates, final inspection reports, non-
conformance reports (including any feedback or corrective action
generated)?
 Where are the records filed and by whom?
 How long are the quality records retained?
 Are the quality records available to the customer for analysis and
review?
 Are records easily retrievable?
 Is a suitable environment available to minimise deterioration or damage
to stored records?
9.6 Typical quality record contents

The quality record package for a welded product will be defined specifically
for a contract and may include:
 Records of stage inspections in the form of check sheets or quality

plans.
 Non-conformity reports and concession records.
 Where appropriate as-built drawings.
 Welding procedures.
 Welder approvals.
 Welding consumable records.
 Weld history records.
 NDT reports.
 NDT operator qualifications.
 Heat treatment records.
 Hydraulic and/or other testing records.
 Where appropriate material test certificates.
 Final acceptance certificates.
9.6.1 Class exercise

You are required to visit a site where your inspection team has been
working. The fabrication is completed in accordance with a nominated
specification and is awaiting your final inspection/approval and sign off.
Your role is to select a random number of welded joints and investigate the
complete start to finish of these welds including material certification, welder
ID, etc through to final NDT.
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Prior to signing the certificate of conformance:
1 What questions do you ask?

2 What measurements would you take?
3 What documents would you review?
Prior to the site visit it is vital to spend time planning the visit so that a logical
approach be made and important details are not overlooked. Knowledge of
the standard used and an idea of the service conditions would be useful in
assessing the fitness-for-purpose of the product.
A list of all personnel in the inspection team(s) and contact details of team
leader(s) will ensure that relevant personnel are available to answer
questions as required. Questions may include any difficulties encountered
with the job, particular attention being given to those concerning the
contractor.
Further information regarding repair rates, safety standards on-site and the
general morale and standard of work amongst the inspection team(s)
throughout production. Any unusual incidents may need investigating.
The availability of quality plans will help greatly in planning the sign off. The
review/audit of all relevant documentation is a major requirement prior to
signing any Certificate of Conformance or compliance. In some major
standards/codes the list of documents to be included within the fabrication
file are listed. In the absence of such the following is a basic guide to the
documents for review/audit:
 Review of the quality plan and inspection check list to ensure all stages
are completed and signed off.
 Material certificates, mill test reports, and material traceability records
are documented and accepted. This may include welding consumables.
 Process control procedures should be reviewed for adequacy, accuracy
and approval. These should include approved procedures for cutting,
welding, repair, NDT, heat treatment, coating, etc.
 Review of qualifications should include welder approvals, NDT operator
or technician approvals. All inspection approvals should be in date at
time of fabrication and as identified and described within the contract
documents.
 Inspection reports should be reviewed and include visual inspection,
NDT, dimensional control, painting/coating, etc.
 If the product is pressure containment ie pressure vessel or high
pressure pipeline, etc. then hydrostatic testing procedures and a test
report/acceptance reports should be reviewed along with test gauge
calibration certificates and any associated documentation.
 As-built drawings showing materials and weld maps/history should be
reviewed for completeness.
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CSWIP Welding Quality Control Co-ordinator

Training & Examination Services

CSWIP Welding Quality Control Co-ordinator

1 Duties of the Quality Control Co-ordinator

5.8 Material traceability

12.6 Local PWHT

• Safety procedures and fire alarms

Course Content Class Exercises

CSWIP QC Coordinator Examination Course Assessment

Exam after No continuous

Assessment of three welds

Copyright © TWI Ltd 2011 Copyright © TWI Ltd 2011

Closed book exam Two copies of certificates and an identity

QC Coordinator Examination Renewals CSWIP

Certification Scheme for Personnel

? Copyright © TWI Ltd 2011

1 Duties of the Quality Control Co-ordinator

For employers to have confidence in their work, QC Co-ordinators need to

The relevant standards, rules and specifications that a QC Co-ordinator

The QC Co-ordinator has primarily a supervisory/managerial role, which

1.2 Leadership skills

The skills required for the development of leadership include:

 Willingness and ability to accept instructions or orders from senior staff

 Willingness to delegate responsibility, to allow staff to get on with the job

1.3 Technical skills

1.4 Knowledge of technology

Certain areas where additional knowledge is required are:

 Knowledge of QA and QC.

1.5 Knowledge of normative documents

Specified normative documents (specifications, standards, codes of

The QC Co-ordinator should be aware of the more widely used standards as

 Application Standard (or Code).

1.6 Knowledge of planning

See section on planning for more detailed information.

1.7 Knowledge of organisation

1.8 General knowledge of auditing requirements

Some ways in which these goals may be achieved are through:

 Embracing facts and realities.

The role of the QC Co-ordinator can cover a myriad of disciplines, without

The individual, who is to operate as a QC Co-ordinator, shall possess

The prerequisites for an individual aspiring to a QC Co-ordinator are

Depending on the industry sector chosen, the disciplines can be as varied

This QC Co-ordinator course will provide the necessary knowledge and

 Quality Control (QC) is concerned with the inspection function and

The QC function is operated under a defined system to ensure product

The role of the QC Co-ordinator with respect to QA and QC is to operate

QC activities for the QC Co-ordinator

QA activities for the QC Co-ordinator

All of the QC Co-ordinator duties refer to controlling the QC functions in

The duties described in terms of their QA activity:

2 Once contract specifications have been issued the QC Co-ordinator

3 Generation of the ITP should be the responsibility of the QC Co-ordinator

4 From the QC requirements the QC Co-ordinator should be able to

5 Arrange with document control to issue the required information eg ITP,

6 The QC Co-ordinator is a member of the project management team and

7 Management of the inspection and testing resource is an important

8 Management of the inspection function can extend to subcontracted

9 Responsible for ensuring that the verification documentation is produced

Copyright © TWI Ltd 2011 Copyright © TWI Ltd 2011

Duties of a QC Coordinator Attributes Required

Copyright © TWI Ltd 2011 Copyright © TWI Ltd 2011

Leadership Skills Technical Skills

Copyright © TWI Ltd 2011 Copyright © TWI Ltd 2011