Role and Responsibilities of Welding Inspector

• Welding coordination

• Specification and qualification of welding procedures (ASME Section IX, Latest Edition)

• Qualification test of welders and welding operators (ASME Section IX, Latest Edition)

• Non-destructive testing (ASME Section V, Section VIII Div. 1, Latest Edition)

• Meet requirements from clients

• Work according to a quality system specific to welding operations that is well-known and which
is used worldwide

• Prove the technical competence of the company

• Minimize costs and risks caused by absence of quality

• Secure a continuous development of production

Who is Welding Inspector?

Welding Inspector’s position is “RESPONSIBLE”.

Welding Inspector can be classified based on Role played.

• Shop floor Supervisor

• Shop floor Inspector

• Independent Internal Inspector of same organization

• External Third Party Inspector

• External Statutory Inspector

Why manufacturers are feared of Inspector?

• Inspector’s Authority

• Own negligence

• Out of respect
Important Characteristics of the Inspector:

• Accurate observation of Parameters and defects.

• Accurate reporting of the observations made

• Firm & Fearless without being arrogant.

• Positive attitude & open mind.

• Considerate to others’ point of view but Impartial

• Punctual

Please Note:

• Welding Inspector’s position is “RESPONSIBLE”.

• It is easy to reject but need sound technical knowledge & application to accept defects
consciously.

• Adherence to production schedule or targeted date is important.

• Inspector should be faithful to Job & not to appointing agency

Privileges of Inspector:

• Have privileges to examine all drawings, documents, certificates, materials, consumables,

manufacturing equipment, tools, tackles, jigs fixtures, etc.

• To have access to shop floor at any time but without hindering work & preferably with prior
arrangement.

• Re-inspection if felt necessary

Welding Inspector is Responsible to:

• Interpret all welding drawings and specifications.

• Check purchase orders to assure that welding materials and consumables have been properly
specified.

• Check and identify materials as they are received against the purchase specifications.

• Check the chemical compositions and mechanical properties shown on mill test reports against
specified requirements.

• Check storage of filler materials.

 • Check equipment to be used.

• Check welds joint preparations.

• Check joint fit-up

• Verify the application of the approved welding procedure.

• Verify the qualifications of the welders and welding operators.

• Select production test samples

• Evaluate the test results

• Maintain records

• Prepare reports

Knowledge of drawings & specifications:

• Advance study of Drawing & specifications, construction details, MOC, welding procedure, heat
treatment.

• Obtain necessary clarification/details from Design/Project Engineer.

This will help in;

• Precise interpretation & consider decision during inspection.

• Permitting or rejecting deviations observed.

• Decide feasibility of correcting error/deviation for large component.

• Determining specifications which are not defined.

Purchase specification chart & material verification.

• The specification for Raw material e.g. ASTM A-516 Gr 70 Grade?

• Consumable like electrode e.g. ER 70S-2(GTAW), Shielding Gas e.g. Argon 99.999% purity,
E 70 XX (SMAW), with batch certificates.

• Put identification mark at multiple locations.

• As far as possible preserve original markings, Transfer, if required.

• Sometimes necessary to preserve cases with original Batch No./Control No. e.g. Electrodes for
Nuclear application.

Storage of filler material & welding equipment check:

 • Check how stored e.g. Low Hydrogen Electrode.

• Check welding machine type, its capability, calibration of ammeter,volt meter.

Weld joint preparation

• Check edge preparation of joint for;

- Probable lamination

- bevel angle, root face

- Preferable to have gauges.

Cleanliness

Joint fit up:

Check Un-welded joint for:

• Alignment (offset)

• Root gap

• Allow for distortion

• Discuss with Engineer not with foreman/welder

• Back up bar/ring

e.g. No open joint in long back up bar. Distorted back of Bar.

Chemical Analysis & Mechanical Properties:

• Check of qualified supplier/manufacturer

• Random check of chemical & mechanical properties

• Representative sample no. & location

• It error are strongly suspected ask for check test.

Base Metal Defects:

 • Forging, plates, structural steel, etc. have discontinuity

• Small discontinuities may be acceptable.

• Some are repairable

• Defect identifies & evaluate defect for acceptance/repair/ rejection.

• Lamination not acceptable for some application but can be used at other places.

Qualification of Procedure & Welders

To establish written welding procedure specification

• Will be taken up in detail in other chapters

• Include welder as well as welding operator.

• Qualify through test

• Verify validity

• Interpret Qualification range.

• Avoid unnecessary qualifications.

Production Test Sample Solution:

• Often Sample Inspection is done on production line.

• Random selection or as per established pattern or order.

• Sometime left to inspector

• Select optimum & representative sample

• Typical test include RT, UT, Hydro, Chemical, Metallurgical & mechanical test.

• Witness wherever required/necessary.

Evaluation of Test Results:

• Sometime impractical to witness all the tests. Select enough.

• Ensure good equipment (calibrated & accurate).

• Consider overall results before deciding acceptance/ rejection.

Maintain Records & Reports:

 • Record keeping is most important.

• Detailed records of events.

• Preferable to cross errors & not erase.

• Final reports should include deviations, repairs carried out if any, difficulties faced, etc.

• Inspection Before Welding :

• Check :

• a) Application standard

• b) Welding procedure sheets

• c) Drawings

• d) Welder qualifications

• e) Material composition

• f) Condition of material.

• G) Joint preparation, Type of edge preparation, method & finish

• h) Consumables I.e. type of electrodes, filler wires, fluxes, shielding and backing gases

(Composition) and special drying requirements for electrodes.

• I) welding process-processes.

Inspection during Welding:

Check:

a) Welding Process

b) Preheat and inter pass temperature.

C) Inter-run cleaning

d) Filler metals

f) Control of distortion

g) Root and subsequent runs

h) Welding current and voltage.

I) Chipping, grinding, gouging

j) Fluxes and shielding gases.

K) Compliance with weld procedure sheet and application standard.

After Welding:

Check:

a) Dimensional accuracy, Weld reinforcement and/or fillet sizes using welding gauges.

b) Conformity of drawings and standard requirements.

C) Acceptability of welds. (Visual and other related NDT requirements), Destructive Testing

D) Post-heat treatment (if any).

(E) Repairs if any followed by applicable NDT.