Table of Contents The Role of the Welding Inspector . Overview . ae Inspection philosophy . Specific duties of a Welding Inspector Equipment used for welding inspection Weld Terminology Types of joint Types of weld . Types of joint preparation Weld zone terms Weld positions Welding Processes General . Oxy-gas welding . Manual metal arc (m.m.a) wel Metal inert gas and metal active gas welding Tungsten inert gas (t.i.g.) welding Plasma arc welding (p.a.w.) . ‘Submerged arc welding (s.a.w.) Electroslag welding Thermal Cutting . General .. Flame cutting processes Electric arc cutting processes Gouging processes ......... te oe Md Metallurgy « ‘The heat affected zone (h.a.2.) The effect of hydrogen in steel . The carbon equivalent of steel. Preheat ... Interpass temperature Weldability of Steels ..... Weldability .... ‘Steel types and their weldability Guidelines for the welding of steels Stress & Distortion . Stress ... Distortion Post-Heat Treatment . Stress relieving Annealing Normalising .Table of Contents Hamening/quenching, Tempering .. : Hydrogen release Welding Procedures and Welder Tests . Welding procedures Welder tests... Mechanical Testing of Welded Joints Tensile test . Bend test . Nick-break test Fillet weld fracture test. Impact test Hardness test Macroscopic (macro) examination Microscopic (micro) examination . Crack tip opening displacement test (¢. Weld Defects and Repairs . Terminology . Weld defects Classification and significance of defects Defect acceptance levels . Repair welding Cracking .. Weld process cracks Service induced failures . Weld decay in austenitic stainless steel Welding Consumables Filler rods and wires . M.ma. consumables (eet) ae Fusible inserts .. Welding Plant . Power sources Wire feeders . Welding heads, guns and torches. Control units. ‘ Mechanised, automatic and rol BS 499 : Part 2: Symbols fo for Welding : Elementary symbols ..... Supplementary symbols .... Position of symbols ........ Dimensions . Complimentary indications eee ee Soe ee eh eeeTable of Contents Are Welding Safety .. Protection against heat and light Protection against clectrical shock Protection against fumes and gases Welding Related Standards Quality Assurance ......... ‘Aim of quality assurance Benefits of adopting quality assuran What is quality assurance . Scope of quality assurance QA, QC and inspection compared . QA standards ... Normative Documents Non-destructive Testing Penetrant testing ............ ‘Magnetic particle inspection Radiographic testing Ultrasonic testing Eddy current testingPend (ONS Hin ODL C0) EO) BEAU ED GINS Gn TO) Overview It is not a requirement for a welding inspector to be able to weld, neither does a ‘welding inspector require an in depth knowledge of welding engineering, although some specific knowledge in these areas is essential. For certain contracts it is also necessary for a welding inspector io have a good working knowledge of other related subjects, ¢.g radiographic interpretation and post-heat treatment. ‘The presence of welding inspectors during welding will almost certainly reduce the number of weld defects and metallurgical problems which could otherwise occur, ‘which will in turn, reduce the overall number of failures in service. When an item has failed, it usually means that cracking or fracture has taken place, ‘There are many types of cracks associated with welds, some of which may initiate st the time of welding (process cracks) or years later (in-service cracks). In both these ceases, stresses, metallurgical problems and existing weld defects may have contributed to the cause of the cracking. Inspection philosophy ‘The duties of inspection personnel are essentially those inspection duties which the client or employer wants them to perform. A significant problem in industry is that different organisations use inspection personne! in different ways, or use inspectors for functions additional to inspection. For some, this has led to a misunderstanding as 10 the defined role of inspection. ‘The definition of inspection to EN 28402 : 1991 : Quality Vocabulary - “Activities such as measuring, examining, testing, gauging one or more characteristics of a Product or service and comparing these with specified requirements to deterraine conformity.” ‘The definition of inspection to EN 45020 : 1993 : Standardization and Related Activities - "Evaluation for conformity by measuring, observing, testing or gauging the relevant characteristics.” .. “Evaluation for conformity” is defined in the standard as: "Systematic examination of the extent to which a product, process or service fulfils ‘specified requirements. ” Inspection may be performed for fimess for purpose or quality control purposes, and may be carried out by the contractor, the client o a third party. Inspection is not supervision and inspection is nota substitute for supervision. 1 is not the duty of an inspector to deviate from specified requirements; generally speaking, if the specification is inadequate the work will be inadequate. Inspector qualification schemes do not require, or test for, a sufficient depth of engincering, technology or design knowledge which would enable an inspector (o pass judgement on the correctness of an application specification. It could be argued that experienced senior inspectors may be in a position to take certain engineering decisions, but it is ‘dangerous to generalise on this point. ‘An inspector (working solely as an inspector) is not there to provide solutions to problems. Inspectors are taught never to deviate from the agreed specifications unless given ‘written permission to do so from the client or supervisor. Accurate reporting needs highlighting as an important duty for any inspector, but what ‘constitutes a correct report can differ between organisations and projects. Who the pector actually reports to is also an important consideration,FRB N TNT aN It should be made clear to all workers, including inspector, as to what is expected from them for the activities they ‘are to pesform - this is a basic quality assurance} requirement. I ‘This is not to say an inspector should not perform duties outside the scope of inspection, this may be acceptable providing the person is competent to perform the ‘work and providing it has been made clear what is required from the outset. 1 —_—_————_—_—_—— Specific duties of a Welding Inspector I The main duty of a welding inspector is to check that all the welding and associated ‘actions are carried out in accordance with the requirements of the agreed welding specification(s) relevant to the contract or work being carried out. {It is important for a welding inspector to know where to find relevant information, interpret the information and understand it. i Duties prior to welding: 1, Obtain all relevant documentation or ensure access to it: a. relevant specification( b. relevant procedures; © copies of welders test cenificates (where applicable); 4. copies of drawings (where applicable). Ensure welder qualification ‘Correct material-type, condition, size (pipe/plate ete.) Correct consumables-type, condition, size filler material, gas, inserts etc.) Comect equipment-cenified where necessary. Correct preheat (where applicable) ‘Assess/measurefit-up: root face, bevel angle, root gap, alignment, seam offset (where applicable), joint cleanliness, Correct environment. Ensure no undue stress is applied tothe joint. Duties during welding: ‘Check amperage, voltage, polarity, Ensure correct welding technique-weld direction, run sequence. ‘Check welding time-time lapses and/or run out lengths (1.01's) Ensure adequate cleaning between passes. (Correct interpass temperatures-minimum and/or maximum. ‘Check root internally (pipes) where access permits Check back gouged welds - amount gouged, shape of gouge, cleantiness of gouge (where applicable), Sanna = = &ee ea Duties after welding: Ensure weld is post cleaned. Visual inspection of weld for defects, e.g. undercut, overlap, surface porosity, incompletely filled groave ec. ‘Visual check for are strikes. (Check weld contour and weld width. Basure joint is covered with heat resistant material to retard cooling rate (where applicable). Inspecttmonitor pos-beat treatment (where applicable). 1. Report en weld. 8. Check NDT reports-tic up with NDT (where applicable). SS Equipment used for welding inspection ‘The equipment a welding inspector will nced to carry out inspection will depend partly fon the work which is to be performed. For example, a welding inspector will not require a fillet weld gauge if only butt welds are being made. The client or specification will also determine the equipment to be used, ¢.g. portable arc ‘monitoring unit (PAM unit) may be used to measure and record amperage and voltage instead of a band held volumeter and ammeter. The equipment which may be used by a ‘welding inspector is listed below: Steel rule. Flexible tape measure, ‘Temperature indicating crayons or thermocouple (pyrometer). Bevel angle gauges. Root gap gauges. Fillet weld gauges for leg length and throat thickness. Misalignment gauge. Voltmeter. Armineter. Polarity indicator. Heightepth gauge. Contour gauge. Torch or other light source. Modetting clay or resin. Magnifying glass - 5x magnification. Marking crayon or paint stick. pPesgr rere ms ange