Welding inspectors follow this procedure when performing work.



Inspection Procedure Before Welding



Weld joint designs and dimensions are specified in drawings. Welding symbols and weld sizes are specified in drawings. Weld maps identify the welding procedure specification (WPS) to be used for the weld joints. Dimensions detailed and potential for distortion addressed. Mechanical properties and required testing identified. Pressure testing requirements, if any, clearly specified Knowledge of the codes, standards, and specifications required for this project. Roles of technicians, engineers, welding organization, and welding inspectors are defined. Procedure qualification records (PQR) are properly performed and support the WPS(s). NDE procedures are current and accurate. Calibration of NDE equipment is current and accurate. Welding machine calibration is current and accurate. Instruments such as ammeters, voltmeters, contact pyrometers, have current and accurate calibrations. Storage ovens for welding consumables operate with automatic heat control and visible temperature indication. Heat treatment procedure is available and appropriate Pressure testing procedures are available and detail test requirements.

17. Electrode marking, bare wire flag tags, and identification on spools of wire.

18. Filler material markings are traceable to a filler material certification.

19. Base metal markings are traceable to a material certification.

20. Recording of filler and base metal traceability information is performed.

21. Base metal stampings are low stress and not detrimental to the component.

22. Paint striping color code is correct for the material of construction.

23. PMI records supplement the material traceability and confirm the material of construction.

24. Weld preparation surfaces are free of contaminants and base metal defects.

25. Preheat, if required, applied for thermal cutting.

26. Weld joint is free from oxide and sulfide scales, hydrocarbon residue, and any excessive build-up of weld-through primers.

27. Weld joint type, bevel angle, root face and root opening are correct.

28. Alignment and mismatch are correct and acceptable.

29. Dimensions of base materials, filler metal, and weld joint are correct.

30. Piping socket welds have proper gap.

31. Preheat equipment and technique are acceptable.

32. Preheat coverage and temperature are correct.

33. Reheat, if required, applied to thermal cutting operations.

34. Preheat, if required, applied to remove moisture

35. Filler metal type and size are correct per procedure.

36. Welder performance qualifications (WPQ) meet requirements for the WPS.

37. NDE examiners are properly certified for the NDE technique.

38. Weather protection and wind break requirements defined.

39. Preheat requirements and acceptable preheat methods defined.

40. Post-weld heat treatment (PWHT) requirements and acceptable PWHT method defined.

41. Inspection hold-points and NDE requirements defined.

42. PWHT equipment calibration is current and accurate.

43. Pressure testing equipment and gauges calibrated and meet appropriate test requirements.

44. Material test certifications are available and items properly marked

45. Filler metal type and size are correct per procedure.

46. Filler metals are clean and free of contaminants.

47. Coating on coated electrodes is not damaged or wet.

48. Flux is appropriate for the welding process and being properly handled.

49. Inert gases are appropriate for shielding and purging.

50. Gas composition is correct and meets any purity requirements.



Inspection Procedure During Welding



Welder meets qualification requirements Welder is responsible for quality craftsmanship of welds Welder understands welding procedure and requirements for the work. Special training and mock-up welds performed if required. Welder understands the inspection hold-points. Essential variables are being met during welding. Preheat temperatures. Travel speed (key element in heat input). Heat input (where appropriate). Filler material, fluxes, and inert gas composition/flow rate. Purge technique, flow rate, O2 analysis, etc. Rod warmers energized or where rod warmers are not employed, the welder complies with maximum exposure times out of the electrode oven. Preheating during tack welding and tack welds removed (if required). Welding technique, weld progression, bead overlap, etc. Equipment settings such as amps, volts, and wire feed. Mock-up weld, if required, meets requirements with welder and welding engineer. Welder displays confidence and adheres to good welding practices. Tack welds to be incorporated in the weld are of acceptable quality. Weld root has adequate penetration and quality. Cleaning between weld passes and of any back-gouged surfaces is acceptable. Additional NDT performed between weld passes and on back-gouged surfaces shows acceptable results. Final weld reinforcement and fillet weld size meets work specifications and drawings. In-process rework and defect removal are accomplished. In-process ferrite measurement, if required, is performed and recorded.

Inspection Procedure After Welding



No welds added without approval. Size, length and location of all welds conform to the drawings, specifications, and codes. Dimensional and visual checks of the weld don’t identify welding discontinuities, excessive distortion and poor workmanship. Temporary attachments and attachment welds removed and blended with base metal. Discontinuities reviewed against acceptance criteria for defect classification. PMI of the weld, if required and examiner’s findings indicate they comply with the specification. Welder stamping and marking of welds confirmed. Perform field hardness check. Verify NDE is performed at selected locations and review examiner’s findings. Specified locations examined. Specified frequency of examination. NDE performed after final PWHT. RT film quality, IQI placement, IQI visibility, etc. complies with standards. Inspector agrees with examiners interpretations and findings. Documentation for all NDE correctly executed Work of each welder included in random examination techniques. Verify post-weld heat treatment is performed to the procedure and produces acceptable results. Paint marking and other detrimental contamination removed. Temporary attachments removed. Machined surfaces protected from oxidation. Temperature monitoring system calibrated. Local heating bandwidth is adequate. Equipment internals, such as valve internals, removed to prevent damage. Equipment supported to prevent distortion. Thermocouples fastened properly. Thermocouples adequately monitor the different temperature zones and thickest/thinnest parts in the fabrication. Insulation applied to the component where required for local heating. Temperature and hold time is correct. Heating rate and cooling rate is correct. Distortion is acceptable after completion of the thermal cycle. Hardness indicates an acceptable heat treatment. Verify pressure test is performed to the procedure. Pressure meets test specification. Test duration is as specified. Metal temperature of component meets minimum and maximum requirements. Pressure drop or decay is acceptable per procedure. Visual examination does not reveal defects. Perform a final audit of the inspection dossier to identify inaccuracies and incomplete information. All verifications in the quality plan were properly executed. Inspection reports are complete, accepted and signed by responsible parties. Inspection reports, NDE examiners interpretations and findings are accurate.

Citations

Welding Inspection Procedure / Checklist. (n.d.). Retrieved December 30, 2019, from https://www.inspection-for-industry.com/welding-inspection.html.