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THE INDIAN INSTITUTE OF WELDING

BARODA BRANCH
202, Arckie View Complex, Tower-A,
Atmajyoti Ashram Road,
Opp. Water Tank,Vadodara 390 023

ROLE & RESPONSIBILITES


OF
WELDING INSPCTOR
INTRODUCTION: WELDING INSPECTOR

HOLDS A POSITION OF
RESPONSIBILITY
A PROFESSIONAL PERSON WITH GOOD
TECHNICAL KNOWLEDGE, ABILITY,
AND COMMON SENSE
STRICT OBSERVANCE OF ALL RULES
AND REGULATIONS
SHOULD STICK TO THE FACTS IN
MAKING DECISIONS
SHOULD NOT BE EASILY SWAYED BY
DIFFERING OPINIONS
MAJOR RESPONSIBILITES

HOLDS A POSITION OF RESPONSIBILITY


INTERPRET ALL WELDING DRAWINGS AND
SPECIFICATIONS
CHECK SPECIFICATIONS OF WELDING MATERIALS
AND CONSUMABLES
CHECK & IDENTIFY MATERIALS RECEIVED
AGAINST THE PURCHASE SPECIFICATIONS
CHECK THE CHEMICAL COMPOSITIONS AND
MECHANICAL PROPERTIES REQUIRED
INVESTIGATE BASE METAL IMPERFECTIONS AND
DEVIATIONS
CHECK STORAGE OF FILLER MATERIALS
CHECK EQUIPMENT TO BE USED
CHECK WELD JOINTS PREPARATIONS
CHECK JOINT FIT-UP
VERIFY THE APPLICATION OF THE APPROVED
WELDING PROCEDURE
VERIFY THE QUALIFICATIONS OF THE WELDERS
AND WELDING OPERATORS
SELECT PRODUCTION TEST SAMPLES
EVALUATE THE TEST RESULTS
MAINTAIN RECORDS
PREPARE REPORTS
KNOWLEDGE OF DRAWING &
SPECIFICATIONS

STUDY OF DRAWINGS AND DESIGNS IN


ADVANCE
NOTE OF MATERIALS TO BE USED IN
THE WELDED STRUCTURE & SPECIAL
TREATMENTS REQUIRED FOR
SATISFACTORY WELDING
ENHANCEMENT OF ABILITY TO MAKE
CLEAR AND CONCISE DECISIONS WITH
COMPLETION OF WORK UNDER
CONTRACT
DECISIONS REGARDING A DEVIATION
FROM THE DRAWING OR DETAILED
SPECIFICATION DURING THE
FABRICATION SHOULD BE PERMITTED
OR REJECTED
EXERCISE EXTREME CAUTIONS IN
ACCEPTING DEVIATIONS
RESPONSIBILITY FOR DETERMINING
THE MEANING AND INTENT OF THE
SPECIFICATION
PURCHASE SPECIFICATIONS CHECK

REVIEW THE PURCHASE ORDER OR


SUBCONTRACT FOR SPECIFIED
REQUIREMENTS

SPECIFICATIONS SHOULD IDENTIFY


ALL THE MATERIALS

ALL CONSUMABLE MATERIALS LIKE


WELDING ELECTRODES, WELDING OR
BRAZING FLUXES, SHIELDING GASES,
AND BACKING BARS AND RINGS.
JOB MATERIAL VARIFICATION

VERIFY THE MATERIALS FOR VISIBLE


IDENTIFICATION ON EACH PIECE

IDENTIFICATION OF WELDING
ELECTRODES SHOULD NOT BE LOST
DUE TO IMPROPER HANDLING

PREFERRED HOUSING FOR A WELDING


ELECTRODE IS ITS ORIGINAL
UNOPENED CONTAINER.
FILLER MATERIAL STORAGE CHECK

INVESTIGATION OF WELDING
ELECTRODES AND FILLER MATERIALS
STORAGE

FLUXES AND FLUX CORED


ELECTRODES NEED PROTECTION
FROM MOISTURE, WHETHER RAIN OR
HIGH HUMIDITY

LOW HYDROGEN ELECTRODES OUT OF


THEIR CONTAINERS MUST BE KEPT IN
HOLDING OVENS
WELDING EQUIPMENT CHECK

CHECK ALL WELDING EQUIPMENTS


FOR OPERATIONAL
CAPABILITY,CALIBRATION & SAFETY

FOR EXAMPLE,AMMETERS AND


VOLTMETERS MAY NOT BE ACCURATE
BECAUSE OF MISTREATMENT, DIRT &
GRIME & OVERLOADS

PERIODIC CALIBRATION MAY BE


NECESSARY
WELD JOINT PREPERATION CHECK

SPECIFIC TOLERANCES ARE LISTED IN


ALL CODES AND SPECIFICATIONS

RESPONSIBILITIES INCLUDE
EXAMINATION OF THE UNWELDED
JOINT FOR EDGE PREPARATION,
INCLUDING ROOT FACE DIMENSIONS
AND BEVEL ANGLE.
JOINT FIT-UP CHECK

OBSERVE THE FIT-UP OF THE PARTS


FROM UNWELDED JOINTS

RE-STRESSING OR CAMBERING IS
NEEDED FOR WELDS SUBJECTED TO
DISTORTION AS A RESULT OF
SHRINKAGE STRESS

OFFER THE SUGGESTIONS OF


PROCEDURE MODIFICATIONS TO THE
PROJECT ENGINEER, NOT TO THE
FOREMAN
CHEMICAL ANALYSIS & MECHANICAL
PROPERTIES TEST
CONFIRMATION OF TESTS FOR
INCOMING MATERIALS

THE PURCHASES FROM THE LOWEST


BIDDER ON A CONTRACT,MAY NOT MEET
THE FULL REQUIREMENTS FOR THIS JOB

THE NUMBER OF TESTS REQUIRED


DEPENDS ON THE INSPECTORS
JUDGEMENT AND PAST EXPERIENCE

THE INSPECTOR SHOULD REQUEST


TESTS ON REPRESENTATIVE SAMPLES
OF CRITICAL INCOMING MATERIALS

MATERIALS ONLY FROM RELIABLE


SUPPLIERS ,I.E. SUPPLIERS ACCREDITED
THROUGH A QUALITY ASSURANCE PLAN
OR SPECIFICATION
INVESTIGATE BASE METAL
IMPERFACTION & DAVIATIONS
THE QUALITY OF PRODUCTS SUPPLIED FOR
A JOB MUST EQUAL OR EXCEED THE
QUALITY SPECIFIED FOR THE FINAL
WELDMENT OR STRUCTURE

BASE METALS ALMOST ALWAYS CONTAIN


MANY SMALL DISCONTINUITIES, THEIR
EFFECT DEPENDS ON THE THICKNESS OF
THE METAL

FORGINGS OF ALL SIZES MAY DISPLAY


SPLITS, TEARS AND SURFACE
IRREGULARITIES

DUTY TO SEE THAT DISCONTINUITIES IN


THE BASE METAL ARE DETECTED,
IDENTIFIED, EVALUATED, AND REPAIRED
WHERE NECESSARY

COMMUNICATE WITH THE RESPONSIBLE


ENGINEER ABOUT MAJOR DEFECTS
QUALIFICATION OF A WELDING
PROCEDURE
THE FABRICATOR MUST PRESCRIBE
THE DETAILS OF THE WELDING
PROCEDURE FOLLOWED IN
PRODUCING WELDMENTS

WELDED JOINTS SHOULD BE WITH


ACCEPTABLE MECHANICAL
PROPERTIES BY THE PARTICULAR
SPECIFICATION OR CODE

QUALIFICATION LIMITED TO THE


ESSENTIAL VARIABLES OF THE
SPECIFIC PROCESS

PROVES THE QUALITY & PROPERTIES


OF WELD JOINT PREPARED BY A SET
OF WELDING VARIABLES
QUALIFICATION OF WELDER & WELDING
OPERATOR
CODES AND SPECIFICATIONS REQUIRE
QUALIFICATION OF ALL WELDERS AND
WELDING OPERATIONS

VERIFICATION OF EVERY WELDER AND


WELDING OPERATOR FOR PROPER
QUALIFICATION IN ACCORDANCE WITH
THE SPECIFICATIONS

LIMIT TO WORK WITHIN THEIR


QUALIFICATIONS

ASSURE THAT PROCEDURES & WELDERS


OR WELDING OPERATORS ARE
ADEQUATE FOR THE INTENDED PURPOSE

ASCERTAIN THE SKILL OF A WELDER OR


A WELDING OPERATOR TO PRODUCE
DEFECT FREE/SOUND WELD
SELECTION OF PRODUCTION TEST
SAMPLES
INSPECTION OF THE PRODUCT ON
SAMPLES TAKEN FROM THE
PRODUCTION LINE

TYPICAL TESTS ARE RADIOGRAPHY &


OTHER NON-DESTRUCTIVE TESTS,
HYDROSTATIC TESTS, CHEMICAL
ANALYSIS, METALLURGICAL
EXAMINATION & MECHANICAL
TESTING TO DESTRUCTION

SAMPLES SELECTED BY CHANCE OR


ACCORDING TO AN ESTABLISHED
ORDER

WITNESS OF THEIR SELECTION AND


TESTING
EVALUATION OF TEST RESULTS

IMPRACTICAL TO WITNESS ALL TESTS

WITNESS ENOUGH TO ENSURE THAT


THE TESTS ARE BEING PERFORMED IN
THE PROPER MANNER & THAT THE
RESULTS, ARE ACCURATE

MAKE SURE THAT THE TESTING


EQUIPMENT HAS BEEN CALIBRATED &
IS ACCURATE

EVALUATE THE RESULTS & MAKE


DECISIONS
MAINTAINING RECORDS AND REPORTS

CODE WORK ALWAYS REQUIRES RECORD


KEEPING

KEEP COMPLETE RECORDS, MAY BE IN FORM


OF DETAILED NOTES

CHECK OFFICIAL RECORDS FOR


COMPLETENESS & ACCURACY AND MAKE
CERTAIN THAT THEY ARE AVAILABLE

ERRORS ARE TO BE CROSSED OUT AND NOT


ERASED

FINAL REPORT SHOULD COMMENT ON THE


GENERAL CHARACTER OF THE WORK, HOW
WELL IT STAYED WITHIN PRESCRIBED
TOLERANCES, DIFFICULTIES THAT OCCURRED
AND ANY DEFECTS. REPAIRS SHOULD BE
EXPLAINED

DISTRIBUTE THE NECESSARY COPIES, AND


KEEP A COPY IN OWN FILE
THE RESPONSIBILITES OF WELDING
INSPECTOR (THREE STAGES)
A. INSPECTION BEFORE WELDING

CODE WORK ALWAYS REQUIRES


RECORD KEEPING
APPLICATION STANDARD
WELDING PROCEDURE SHEETS
DRAWINGS
WELDER QUALIFICATIONS
MATERIAL COMPOSITION
CONDITION OF MATERIAL
TYPE OF EDGE PREPARATION,
METHOD AND FINISH
CONSUMABLES, I.E., TYPE OF
ELECTRODES, FILLER WIRES, FLUXES,
SHIELDING AND BACKING GASES
(COMPOSITION) AND SPECIAL DRYING
REQUIREMENTS FOR ELECTRODES
WELDING PROCESS-PROCESSES
CONT.

B. INSPECTION DURING WELDING

CODE WORK ALWAYS REQUIRES


RECORD KEEPING
WELDING PROCESS
PREHEAT AND INTERPASS
TEMPERATURE
INTER-RUN CLEANING
JOINT PREPARATION
FILLER METALS
CONTROL OF DISTORTION
ROOT AND SUBSEQUENT RUNS
WELDING CURRENT AND VOLTAGE
CHIPPING, GRINDING, GOUGING
FLUXES AND SHIELDING GASES
COMPLIANCE WITH WELD
PROCEDURE SHEET AND
APPLICATION STANDARD
CONT.

C. INSPECTION AFTER WELDING

DIMENSIONAL ACCURACY
CONFORMITY OF DRAWINGS AND
STANDARD REQUIREMENTS
ACCEPTABILITY OF WELDS
REGARDING APPEARANCE
POST-HEAT TREATMENT (IF ANY)
THANK
YOU