Section 1

Typical Duties of Welding Inspectors

1 Typical Duties of Welding Inspectors
1.1 General
Welding inspectors are employed to assist with the quality control (QC)
activities necessary to ensure that welded items meet specified requirements
and are fit for their application.

For employers to have confidence in their work, welding inspectors need to to

understand/interpret the various QC procedures and also have a sound
knowledge of welding technology.

Visual inspection is one of the non-destructive examination (NDE) disciplines

and for some applications may be the only form.

For more demanding service conditions, visual inspection is usually followed by

one or more of the other non-destructive testing (NDT) techniques - surface
crack detection and volumetric inspection of butt welds.

Application Standards/Codes usually specify (or refer to other standards) that

give the acceptance criteria for weld inspection and may be very specific about
the particular techniques to be used for surface crack detection and volumetric
inspection; they do not usually give any guidance about basic requirements for
visual inspection.

Guidance and basic requirements for visual inspection are given by:

ISO 17637 (Non-destructive examination of fusion welds - visual

Examination)

1.1.1 Basic requirements for visual inspection (to ISO 17637)

ISO 17637 provides the following:

 Requirements for welding inspection personnel.

 Recommendations about conditions suitable for visual examination.
 Advice on the use of gauges/inspection aids that may be needed/helpful for
inspection.
 Guidance about information that may need to be in the inspection records.
 Guidance about when inspection may be required during fabrication.

A summary of each of these topics is given in the following sections.

1.1.2 Welding inspection personnel

Before starting work on a particular contract, ISO 17637 states that welding
inspectors should:

 Be familiar with relevant standards, rules and specifications for the

fabrication work to be undertaken.
 Be informed about the welding procedure(s) to be used.
 Have good vision – in accordance with EN 473 and checked every 12
months.

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 ISO 17637 does not give or make any recommendation about a formal
qualification for visual inspection of welds. However, it has become industry
practice for inspectors to have practical experience of welding inspection
together with a recognised qualification in welding inspection – such as a CSWIP
qualification.

1.1.3 Conditions for visual inspection

Illumination
ISO 17637 states that the minimum illumination shall be 350 lux but
recommends a minimum of 500 lux (normal shop or office lighting).

Access
Access to the surface for direct inspection should enable the eye to be:

 Within 600mm of the surface being inspected.

 In a position to give a viewing angle of not less than 30°.

600mm (max.)

30° (min.)

Figure 1.1 Access for visual inspection.

1.1.4 Aids to visual inspection

Where access for direct visual inspection is restricted, a mirrored boroscope or a
fibre optic viewing system, may be used – usually by agreement between the
contracting parties.

It may also be necessary to provide auxiliary lighting to give suitable contrast

and relief effect between surface imperfections and the background.

Other items of equipment that may be appropriate to facilitate visual

examination are:

 Welding gauges (for checking bevel angles and weld profile, fillet sizing,
measuring undercut depth).
 Dedicated weld gap gauges and linear misalignment (hi-lo) gauges.
 Straight edges and measuring tapes.
 Magnifying lens (if a magnification lens is used it should be X2 to X5).

ISO 17637 shows a range of welding gauges together with details of what they
can be used for and the precision of the measurements.

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1.1.5 Stages when inspection may be required
ISO 17637 states that examination is normally performed on welds in the as-
welded condition. This means that visual inspection of the finished weld is a
minimum requirement.

However, ISO 17637 says that the extent of examination and the stages when
inspection activity is required should be specified by the Application Standard or
by agreement between client and fabricator.

For fabricated items that must have high integrity, such as pressure vessels and
piping or large structures inspection, activity will usually be required throughout
the fabrication process:

 Before welding.
 During welding.
 After welding.

Inspection activities at each of these stages of fabrication can be considered the

duties of the welding inspector and typical inspection checks that may be
required are described in the following section.

1.1.6 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 judgements
about particular details.

Typical documents that may need to be referred to are:

 The Application Standard (or Code): For visual acceptance criteria:

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.
 Quality plans or inspection check lists: For the type and extent of
inspection.
 Drawing: 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
Specifications, etc.

Examples of requirements 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 is.

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
finishing.

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 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

Check Action

Material In accordance with drawing/WPS.

Identified and can be traced to a test certificate.
In suitable condition (free from damage and contamination).

WPSs Approved and 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

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 Free from defects, contamination and damage.

Preheat (if required) Minimum temperature is in accordance with WPS.

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 Duties during welding

Check Action

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.

Interpass 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 run 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

Check Action

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 Ensure test equipment is calibrated.

(if required)
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.

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1.1.7 Examination records
The requirement for examination records/inspection reports varies according to
the contract and type of fabrication and there is frequently no requirement for a
formal record.

When an inspection record is required it may be necessary to show that items

have been checked at the specified stages and have satisfied the acceptance
criteria.

The form of this record will vary, possibly a signature against an activity on an
inspection checklist or quality plan, or it may be an individual inspection report
for each item.

For individual inspection reports, ISO 17637 lists typical details for inclusion
such as:

 Name of manufacturer/fabricator.
 Identification of item examined.
 Material type and thickness.
 Type of joint.
 Welding process.
 Acceptance standard/criteria.
 Locations and types of all imperfections not acceptable (when specified, it
may be necessary to include an accurate sketch or photograph).
 Name of examiner/inspector and date of examination.

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 Duties of a WI Objectives

When this presentation has been completed you

will have a greater understanding of the
requirements of a Welding inspector before,
during, and after welding. Where he/she stands
in the hierarchy and the core competencies and
Typical Duties of Welding Inspectors skills required in his/her duties and obligations
to quality whilst trying to facilitate, and not hold
Section 1 up production.

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Main Responsibilities Personal Attributes

 Code compliance. Important qualities that good Inspectors

are expected to have are:
 Workmanship control.  Honesty.
 Integrity.
 Documentation control.
 Knowledge.
 Good communicator.

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Standard for Visual Inspection

Welding Inspection
Basic Requirements
BS EN ISO 17637 - Non-destructive examination Conditions for Visual Inspection (to BS EN ISO 17637)
of fusion welds - Visual examination.
Illumination:
 350 lux minimum required.
Welding Inspection Personnel should:  (recommends 500 lux - normal shop or office lighting).

 Be familiar with relevant standards, rules and Vision access:

specifications applicable to the fabrication work  Eye should be within 600mm of the surface.
to be undertaken.  Viewing angle (line from eye to surface) to be not less
 Be informed about the welding procedures to be than 30°.
used. 600mm
 Have good vision (which should be checked
every 12 months). 30°

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 Welding Inspection Welding Inspectors Equipment

Aids to Visual Inspection (to BS EN ISO 17637) Measuring devices:

 Flexible tape, steel rule.
 When access is restricted may use:
 Temperature indicating crayons.
 A mirrored borescope.
 A fibre optic viewing system. }
usually by agreement
 Welding gauges.
 Voltmeter.
Other aids:  Ammeter.
 Welding gauges (for checking bevel angles, weld profile,  Magnifying glass
fillet sizing, undercut depth).
 Torch/flash light.
 Dedicated weld-gap gauges and linear misalignment
(high-low) gauges.  Gas flowmeter.
 Straight edges and measuring tapes.
 Magnifying lens (if magnification lens used it should
have magnification between X2 to X5).

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Welding Inspectors Gauges Welding Inspectors Equipment

5
6

Multi-meter capable of
measuring amperage
HI-LO Single Purpose Welding Gauge

IN
0 1/4 1/2 3/4

and voltage.

TWI Multi-purpose Welding Gauge Misalignment Gauges

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Welding Inspection Duties of a Welding Inspector

Stages of Visual Inspection (to BS EN ISO 17637)  Before welding:

Extent of examination and when required should be  (before assembly).

defined in the application standard or by agreement  (after assembly).

between the contracting parties.
 During welding.
For high integrity fabrications inspection required  After welding.
throughout the fabrication process:
 Before welding.
 During welding.
 After welding.

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 Typical Duties of a Welding Inspector Typical Duties of a Welding Inspector

Before welding Before welding

Preparation:
Welding procedures:
Familiarisation with relevant documents…
 Are applicable to joints to be welded and
 Application standard/code - for visual acceptance approved.
requirements.  Are available to welders and inspectors.
 Drawings - item details and positions/tolerances etc.
 Quality Control Procedures - for activities such as Welder qualifications:
material handling, documentation control, storage  List of available qualified welders related to WPS’s.
and issue of welding consumables.  Certificates are valid and in-date.
 Quality Plan/Inspection and Test Plan/Inspection
Checklist - details of inspection requirements,
inspection procedures and records required.

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Typical Duties of a Welding Inspector Typical Duties of a Welding Inspector

Before welding Before welding

Equipment: Consumables:
 All inspection equipment is in good condition and  In accordance with WPS’s.
calibrated as necessary.  Are being controlled in accordance with procedure.
 All safety requirements are understood and
necessary equipment available. Weld preparations:
 Comply with WPS/drawing.
Materials:  Free from defects and contamination.
 Can be identified and related to test certificates.
 Are of correct dimensions. Welding equipment:
 Are in suitable condition (no damage/contamination).  In good order and calibrated as required by
procedure.

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Typical Duties of a Welding Inspector Typical Duties of a Welding Inspector

Before welding During welding

Fit-up Weather conditions

 Complies with WPS.  Suitable if site/field welding.
 Number/size of tack welds to code/good
workmanship. Welding process(es)
 In accordance with WPS.
Pre-heat
 If specified. Welder
 Minimum temperature complies with WPS.  Is approved to weld the joint.
 Pre-heat (if required).
 Minimum temperature as specified by WPS.
 Maximum interpass temperature as WPS.

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 Typical Duties of a Welding Inspector Typical Duties of a Welding Inspector

During welding During welding

Welding consumables Inter-run dressing

 In accordance with WPS.  In accordance with an approved method (and back
 In suitable condition. gouging) to good workmanship standard.
 Controlled issue and handling.  Distortion control.
 Welding is balanced and over-welding is avoided.
Welding parameters
 Current, voltage and travel speed – as WPS.
 Root runs.
 If possible, visually inspect root before single-sided
welds are filled up.

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Typical Duties of a Welding Inspector Typical Duties of a Welding Inspector

After welding After welding

Weld identification Repairs

 Identified/numbered as required.  Monitor repairs to ensure compliance with
 Is marked with welder’s identity. procedure PWHT.
 Monitor for compliance with procedure.
Visual inspection
 Check chart records confirm procedure compliance.
 Ensure weld is suitable for all NDT.
 Visually inspect and sentence to code
Pressure/load test
requirements.
 Ensure test equipment is suitably calibrated.
Dimensional survey  Monitor to ensure compliance with procedure.
 Ensure dimensions comply with code/drawing.  Ensure all records are available.
Other NDT
 Ensure all NDT is completed and reports available.
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Typical Duties of a Welding Inspector WI Duties Before Welding

After welding Resume:

 Check all documentation.
Documentation  Check all consumables.
 Ensure any modifications are on as-built drawings.  Check materials, dimensions and condition.
 Ensure all required documents are available.  Preheating, method and temperature.
 Collate/file documents for manufacturing records.  Check fit and set-up.
 Sign all documentation and forward it to QC  Ensure no undue stress is applied to the joint.
department.  Check welding equipment.

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 WI Duties During Welding WI Duties After Welding

Resume: Resume:
 Check amperage, voltage, polarity.  Post cleaning.
 Ensure the correct technique, run sequence.  Visual inspection of completed welded joint.
 Check run out lengths, time lapses.  Check weld contour and width.
 Cleaning between passes.  PWHT.
 Interpass temperatures.  Dimensional accuracy.
 Consumable control.  Weld reports.
 Maintenance of records and reports.  Tie up with NDT.
 Monitor any repairs.

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Summary of Duties Summary of Duties

It is the duty of a Welding Inspector to ensure A Welding Inspector must:

all the welding and associated actions are carried
Observe
out in accordance with the specification and any
 To observe all relevant actions related to weld
applicable procedures. quality throughout production.
Record
 To record, or log all production inspection points
relevant to quality, including a final report showing
all identified imperfections.
Compare
 To compare all recorded information with the
acceptance criteria and any other relevant clauses
in the applied application standard.

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Any Questions

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