Welding Inspection Technology PDF

# Chapter 1: Welding Inspection and Certification ## Objectives 1. Identify the responsibilities of a welding inspector. 2. Identify the desirable qualities that facilitate and enhance performance of welding inspection. 3. Discuss the various elements of the AWS welding inspector certification pro...

# Chapter 1: Welding Inspection and Certification ## Objectives 1. Identify the responsibilities of a welding inspector. 2. Identify the desirable qualities that facilitate and enhance performance of welding inspection. 3. Discuss the various elements of the AWS welding inspector certification program. 4. Identify the minimum education and experience requirements for the three levels of AWS welding inspector certification. ## Key Terms | Term | Definition | |---|---| | American Petroleum Institute (API) | | | API 1104 - Welding of Pipelines and Related Facilities | | | American Society of Mechanical Engineers (ASME) | | | American Society for Nondestructive Testing (ASNT) | | | American Welding Society (AWS) | | | AWS A3.0 - Standard Welding Terms and Definitions | | | AWS B5.1 - Specification for the Qualification of Welding Inspectors | | | AWS D1.1 - Structural Welding Code - Steel | | | AWS D1.5 - Bridge Welding Code | | | AWS D15.1 - Railroad Welding Specification for Cars and Locomotives | | | AWS QC1 - Specification for AWS Certification of Welding Inspectors | | | Certified Associate Welding Inspector (CAWI) | | | Certified Welding Inspector (CWI) | | | Destructive testing (DT) | | | Nondestructive examination (NDE) | | | Nondestructive testing (NDT) | | | Senior Certified Welding Inspector (SCWI) | | | SNT-TC-1A - Personnel Qualification and Certification in Nondestructive Testing | | ## Introduction There has been an increasing emphasis placed on the need for quality in construction and manufacturing in the modern world. This concern for product quality is due to several factors, including economics, safety, government regulations, global competition, and the use of less conservative designs. While not singularly responsible for the attainment of weld quality, the welding inspector plays a large role in any successful welding quality control program. In reality, many people participate in the creation of a quality welded product. However, the welding inspector is one of the "front line" individuals responsible for monitoring production throughout the construction or manufacturing process. ## Overview To do this job effectively, the welding inspector must have a wide range of knowledge and skills. This book is specifically designed to provide both experienced and novice welding inspectors a basic background in the more critical job aspects. This does not imply, however, that each welding inspector will use all the information contained in this book while working for a particular company. Nor does it mean that the material presented will cover every situation a welding inspector will face. The topics included in this book are based on the general knowledge necessary for an individual to perform welding inspection effectively. It's important to realize that effective welding inspection involves much more than just looking at finished welds. Section 4 of *AWS QC1, Specification for AWS Certification of Welding Inspectors*, outlines the various functions of the welding inspector. You need to become familiar with these various responsibilities because the welding inspector's job is an ongoing process. A successful quality control program begins well before the first arc is struck. Therefore, the welding inspector must be familiar with many facets of the fabrication process. Before welding, the inspector will check drawings and specifications to determine information such as the configuration of the component, its specific weld quality requirements, and what degree of inspection is required. This review will also show the need for any special processing during manufacturing. Once welding begins, the inspector may observe various processing steps to ensure that they are done properly. If all these subsequent steps have been completed satisfactorily, then final inspection should simply confirm the success of those operations. Another benefit of this book is that it has been designed to provide the welding inspector with the necessary information for the successful completion of the *American Welding Society's Certified Welding Inspector (CWI)* examination. The welding inspector must have a working knowledge of the subjects covered in each chapter. A large part of the information presented will be a review for most individuals. However, almost everyone will learn some new concepts as well. The eleven chapters of this book are as follows: - Chapter 1: Welding Inspection and Certification - Chapter 2: Safe Practices for Welding Inspectors - Chapter 3: Metal Joining Processes - Chapter 4: Cutting Processes - Chapter 5: Weld Joint Geometry and Welding Symbols - Chapter 6: Documents Governing Welding Inspection and Qualification - Chapter 7: Metal Properties and Destructive Testing - Chapter 8: Metric Practice for Welding Inspection - Chapter 9: Welding Metallurgy for the Welding Inspector - Chapter 10: Weld and Base Metal Discontinuities - Chapter 11: Visual Inspection and Other NDE Methods and Symbols Additionally, the following publications are valuable resources for prospective welding inspectors and are recommended for reference and self-study purposes: - A selected code (*AWS D1.1*, *API 1104*, etc.) - *AWS A2.4*, Standard Symbols for Welding, Brazing, and Nondestructive Examination - *AWS A3.0*, Standard Welding Terms and Definitions - *AWS B1.10*, Guide for the Nondestructive Examination of Welds - *AWS B1.11*, Guide for the Visual Inspection of Welds - *AWS B2.1*, Specification for Welding Procedure and Performance Qualification - *AWS B4.0*, Standard Methods for Mechanical Testing of Welds - *AWS B5.1*, Specification for the Qualification of Welding Inspectors - *AWS QC1*, Standard for AWS Certification of Welding Inspectors - *AWS WHB*, Welding Handbook Series - *AWS WI* - *ANSI Z49.1*, Safety in Welding, Cutting, and Allied Processes ## Who is the Welding Inspector? Before focusing on the technical subjects, let's discuss the typical responsibilities that accompany the position of welding inspector. The welding inspector is involved in the determination of weld quality according to applicable codes and/or specifications. In the performance of inspection tasks, welding inspectors operate under many different circumstances, depending primarily on where they are working. Thus, there can be a need for job specifications due to the complexity of some inspection environments. The inspection workforce may include destructive testing (DT) specialists, nondestructive examination (NDE) specialists, code inspectors, military or government inspectors, owner representatives, in-house inspectors, and others. These individuals may, at times, consider themselves "welding inspectors," since they inspect welds as part of their job responsibility. The welding inspectors' work functions can be grouped into three general categories: - Overseer - Specialist - Combination Overseer-Specialist The overseer, as the title implies, is usually one who oversees the duties of several inspectors. The specialist, on the other hand, is an individual responsible for one or more specific tasks in the inspection process. For example, an inspector could specialize in nondestructive examination. A specialist may or may not act independently of an overseer. It is common to see inspectors serving as both overseer and specialist. Such an individual may be responsible for general weld quality judgments in each of the various fabrication steps and be required to perform any nondestructive testing that is necessary. Fabricators may employ several overseer-type inspectors, each having their own area of general weld inspection responsibility. Because inspection responsibility is divided in these cases, inspectors may have to rely on others for specific aspects of the overall inspection program. To emphasize the differences in job requirements, let's look at some industries using welding inspectors. We see welding inspection being done in the construction of buildings, bridges and other structural units. Welding inspection is also a big part of energy-related applications like power generation facilities. The chemical industry uses welding extensively in the fabrication of pressure-containing processing facilities and equipment. The transportation industry requires assurance of weld quality in such areas as aerospace, automotive, shipbuilding, railroad equipment, and off-road equipment. Finally, the manufacturing of consumer goods often calls for specific weld quality requirements. This level of diversity clearly requires different types and degrees of inspection. ## Important Qualities of the Welding Inspector Generally speaking, welding inspectors need to exhibit various attributes and skills that go beyond welding in order to be successful. These are covered in greater detail in the following section. ## Professionalism Professionalism is possibly the most important quality for a welding inspector to possess. A professional attitude is often a key factor for success. Inspector attitude often determines the degree of respect and cooperation received from others during the performance of inspection duties. The ability of the welding inspector to make decisions that are fair, impartial, and consistent is also important. Inspectors will often find themselves being "tested” by other personnel on the job, especially when newly assigned to some task. Maintaining a professional manner throughout the inspection process helps overcome obstacles to successful job performance.