Typical Duties of a Welding Inspector

The relevant standards, rules and specifications that a Welding Inspector should be familiar with at the start of a new contract are all the documents he will need to refer to during the fabrication sequence in order to make judgments about particular details.

Typical documents that may need to be referred to are:

The Application Standard (or Code) (for visual acceptance criteria – see note below*)

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, WPSs etc)

Note: Although most of the requirements for the fabricated item should be specified by National Standards, Client Standards or various QC Procedures, some features are not easy to define precisely and the requirement may be given as to good workmanship standard.

Examples of requirements that are difficult to define precisely are some shape tolerances, distortion, surface damage or the amount of weld spatter.

Good workmanship is the standard that a competent worker should be able to achieve without difficulty when using the correct tools in a particular working environment.

In practice the application of the fabricated item will be the main factor that influences what is judged to be good workmanship or the relevant client specification will determine what the acceptable level of workmanship

Reference samples are sometimes needed to give guidance about the acceptance standard for details such as weld surface finish and toe blend, weld root profile and finish required for welds that need to be dressed – by grinding or linishing.

A Welding Inspector should also ensure that any inspection aids that will be needed are:

In good condition

Calibrated – as appropriate/as specified by QC procedures Safety ‘consciousness’ is a duty of all employees and a Welding Inspector should:

Be aware of all safety regulations for the workplace

Ensure that safety equipment that will be needed is available and in suitable condition

Duties before welding

Material:

In accordance with drawing/WPS, Identified and can be traced to a test certificate in suitable condition (free from damage and contamination

WPSs:

Have been approved and are available to welders (and inspectors)

Welding equipment:

In suitable condition and calibrated as appropriate

Weld preparations:

In accordance with WPS (and/or drawings)

Welder qualifications:

Identification of welders qualified for each WPS to be used. All welder qualification certificates are valid (in date)

Welding consumables:

Those to be used are as specified by the WPSs are being stored/controlled as specified by the QC Procedure

Joint fit-ups:

 In accordance with WPS/drawings tack welds are to good workmanship standard and to code/WPS

Weld faces:

 Are free from defects, contamination and damage

Preheat (if required):

Minimum temperature is in accordance with WPS

Duties during welding

Site/field welding:

Ensure weather conditions are suitable/comply with Code (conditions will not affect welding)

Welding process:

In accordance with WPS

Preheat (if required):

Minimum temperature is being maintained in accordance with WPS

Inter pass temperature:

Maximum temperature is in accordance with WPS

Welding consumables:

In accordance with WPS and being controlled as Procedure

Welding parameters:

Current, volts, travel speed are in accordance with WPS

Root runs:

Visually acceptable to Code (before filling the joint) (for single sided welds)

Gouging/grinding:

By an approved method and to good workmanship standard

Inter run cleaning:

To good workmanship standard

Welder:

On the approval register/qualified for the WPS being used

Duties after welding

Weld identification:

Each weld is marked with the welder's identification and is identified in accordance with drawing/weld map

Weld appearance:

Ensure welds are suitable for all NDT (profile, cleanness etc)

Visually inspect welds and sentence in accordance with Code

Dimensional survey:

Check dimensions are in accordance with drawing/Code

Drawings:

Ensure any modifications are included on as-built drawings

NDT:

Ensure all NDT is complete and reports are available for records Repairs Monitor in accordance with the Procedure

PWHT (if required):

Monitor for compliance with Procedure (check chart record)

Pressure/load test (if required):

Ensure test equipment is calibrated Monitor test to ensure compliance with Procedure/Code. Ensure reports/records are available

Documentation records:

Ensure all reports/records are completed and collated as required