LIMITS OF AUTHORITY

The welding inspector derives his or her authority ro! a contract or e!ploy!ent" Inspections per or!ed on #ehal o the a#ricator or contractor during a#rication or erection$ or #oth$ are so!eti!es ter!ed %in&house% inspections" In&house is also used to re er to actory operations as opposed&to those per or!ed in the ield" Here$ the inspector !ay or !ay not #e authori'ed to hold up production$ depending on the policy o the a#ricator or contractor or contract re(uire!ents" A a#ricator who recogni'es the high cost o repairing de ects in co!pleted welds will esta#lish routines or rapid response to every deviation discovered #y the inspector" Usually$ the inspector reports the deviation directly to a (uality control depart!ent" Fa#rication)erection inspections are !ade as necessary prior to asse!#ly$ during asse!#ly$ during welding$ and a ter welding$ to ensure that !aterials and wor*!anship !eet the re(uire!ents o the contract docu!ents" Options provided in contract speci ications or in codes !ust #e care ully studied to identi y the inspector+s authority" ,onsider the case o an unaccepta#le weld discovered in a structure #eing a#ricated to !eet A-S ./"/$ Structural -elding ,ode & Steel" 0enerally spea*ing$ a de ective weld !ay #e corrected #y !a*ing repairs locally$ or the entire weld !ay #e ta*en out and replaced" Is the inspector authori'ed to say which repair !ethod shall #e used1 2o$ the option is given to the contractor 3see paragraph 4"5"6 o the ./"/ code7" The decision is a !anage!ent choice$ #ased on cost and ti!e considerations"On the other hand$ suppose the inspector inds that a welder certi ied or the shielded !etal arc process$ who has #een hired or a contract covered #y the sa!e ./"/ code$ has in act not used that process at all during the past si8 !onths" ,an the inspector re(uire that this welder #e (uali ied$ or is the inspector+s authority li!ited to reco!!ending such action1 Here the code is speci ic9 The inspector shall re(uire the welder+s re(uali ication" The authority is given to hi!"

Inspections are also !ade or veri ication and acceptance on #ehal o the owner or his engineer" These are the prerogative o the owner and should #e descri#ed in the contract" Authori'ed veri ication inspections and tests that are !ade during a#rication should #e conducted in a ti!ely !anner to avoid delays in the wor*"

TH: -:L.I20 I2S;:,TOR+S R:S;O2SI<ILITI:S

The welding inspector holds a position o responsi#ility" This responsi#ility de!ands a pro essional person with good character$ a#ility$ and co!!on sense" As a welding inspector$ you !ay wor* at various a#rication plants and at various =o# sites" In all cases$ you should o#serve the wor*ing hours o the a#ricating organi'ation" Strict o#servance o all rules and regulations$ especially those pertaining to personal conduct$ sa ety$ and security$ is !andatory" At no ti!e should you consider yoursel entitled to special privileges" In dealing with the a#ricator organi'ation$ you should #e i!partial$ !a*e your decisions pro!ptly$ and #e tolerant o the opinion o others" Re!e!#er$ however$ to stic* to the acts in !a*ing your decisions" .o not #e easily swayed #y di ering opinions" Rely on your trained =udg!ent o the (uality level speci ied in the contract" An inspector+s pri!ary unction is to inspect the a#ricator+s wor* to ensure it !eets the re(uire!ents o the contract" This will re(uire *eeping in touch with the activities o the a#ricator+s organi'ation" The duties o an inspector or !ost types o a#rication will ollow the general order o the a#rication procedure" As welding inspector$ you will have the responsi#ility to9 3/7 Read and understand all welding drawings and speci ications" 367 >eri y purchase orders to assure that welding !aterials and consu!a#les have #een properly speci ied" 347 >eri y and identi y !aterials$ as they are received$ against the purchase speci ication" 3?7 >eri y the che!ical co!positions and !echanical properties shown on !ill test reports against speci ied re(uire!ents" 3@7 Investigate #ase !etal i!per ections and deviations" 3A7 >eri y storage o iller !aterials" 357 >eri y e(uip!ent to #e used" 3B7 >eri y weld =oint preparations" 3C7 >eri y =oint it&up"

3/D7 3//7 3/67 3/47 3/?7 3/@7

>eri y the application o the approved welding procedure" >eri y the (uali ications o the welders and welding operators" Select production test sa!ples" :valuate the test results" Maintain records" ;repare reports"

In !any instances$ the shop inspector !ay not #e re(uired to per or! all o the duties listed a#ove" However$ i he or she is not responsi#le or this personally$ so!eone else in the organi'ation 3 or e8a!ple$ the receiving inspection depart!ent7 is responsi#le$ and it is a reasona#le assu!ption that another (uality assurance inspector 3such as an outside inspector7 will #e responsi#le or e8a!ination o !ost o these areas" Let us e8a!ine those responsi#ilities listed one at a ti!e" /" Enowledge o drawings and speci ications" You should study the drawings and designs in advance to a!iliari'e yoursel with the construction details$ the proposed use o su#asse!#lies$ and the speci ics o the welding operation" 2ote what !aterials are to #e used in the welded structure and whether any o the! re(uire special treat!ent or satis actory welding" You should ind this in or!ation clearly stated in the speci ications or welding procedures" I it is not there$ consult the pro=ect engineer or liaison engineer" .uring a#rication o a&welded structure$ you will #e called upon to read and understand drawings and speci ications" O#viously$ you !ust #e a#le to read #lueprints and drawings" ;rior study o the drawings and design will increase your a#ility to !a*e clear and concise decisions" ,lear and concise decisions will speed proper co!pletion o the wor* under contract$ increase your pro essional i!age$ and greatly aid in e8ercising your authority" In addition to #eing a#le to interpret di!ensions in drawings$ you !ust #e a#le to read and interpret welding sy!#ols" Situations that re(uire a change ro! the drawing or detailed speci ication !ay arise during the receiving inspection unction$ a#rication$ or erection o any structure" It is your responsi#ility to see that the change or deviation in (uestion is authori'ed #y the pro=ect engineer on #ehal o the owner or purchaser" So!eti!es acceptance or re=ection o a large welded structure is involved" The

engineer !ay decide that the error can #e corrected and that the !ethod o correction to #e used will still ensure a satis actorily co!pleted product" You will inspect the repair in accordance with the drawings and speci ications" In all cases$ you should e8ercise e8tre!e caution in accepting deviations" .eviations ro! drawings usually !ust #e re erred to the design agency or approval" It is not always possi#le to write an all&inclusive speci ication containing all the detailed in or!ation needed to provide an answer or any (uestion that !ight arise" I the speci ications have re(uire!ents that are not ully de ined$ the inspector is o ten responsi#le or deter!ining the !eaning and intent o the speci ication" In case o disagree!ent$ turn the (uestion #ac* to the engineering depart!ent" I design changes and !anu acturing process deviations #eco!e necessary during !anu acturing or erection$ it is desira#le to have a or!ali'ed !ethod o handling such deviations to assure e icient correction o the noncon or!ing ite! or acceptance o the deviation #y the appropriate engineering and contract group" This procedure will also provide a record o the occurrence$ and protect you ro! so!eone+s su#se(uent lapse o !e!ory that the deviation did occur" 6" ;urchase speci ications" The speci ications or the =o# should identi y all the !aterial that will #e used" This list should include all consu!a#le !aterial$ such as welding electrodes$ welding or #ra'ing lu8es$ shielding gases$ and #ac*ing #ars and rings" I you per or! the receiving inspection$ you should e8a!ine the purchase speci ications to see that the !aterials that were ordered are the re(uired !aterials" For e8a!ple$ co!!ercial speci ications or steel$ such as ASTM A@56$ re(uently include !ore than one grade o the product which !ust #e individually identi ied on the purchase order to o#tain the correct grade" As another e8a!ple$ speci ications or welding electrodes$ such as A-S A@"/$ will cover a do'en or !ore electrode grades in the one docu!ent" In A@"/$ the si8 :5DFF electrodes are all e(uivalent in strength$ #ut they are not interchangea#le when low hydrogen grades are re(uired" In that event$ :5D/@$ :5D/A$ :5D/B$ or :5D6B !ust #e speci ied on the purchase order" 4" Go# !aterial veri ication" Mista*es do happen" Many !etals loo* ali*e$ leading to the possi#ility o inadvertent !i8&ups" To prevent this$ you !ust #e a#le to veri y that the !aterials supplied to !atch a

purchase order are !ini!ally identi ied visi#ly on each piece$ pre era#ly at !ultiple locations" Identi ication is lost or the rest o the plate i the irst slice cut o #y the shop re!oves the la#eled end with the grade sta!p on it" 0ood practice calls or re&sta!ping the re!aining pieces produced in cutting operations right then while the identity is still *nown" Huality assurance regulations o the A!erican Society o Mechanical :ngineers re(uire witness and veri ication o this operation #y an inspector" Many !anu acturers re(uire such veri ication as an internal protection against use o the wrong !aterial" Identi ication o low hydrogen welding electrodes is so!eti!es lost when stoc*roo! cler*s re!ove electrodes ro! their containers to store the! in holding ovens" The individual electrodes will still #ear classi ication nu!#ers on their coverings 3at the stu# end7$ #ut the !anu acturer+s control nu!#er only appears on the now discarded container" In nuclear and other critical wor*$ that control identi ication will #e needed or each weld" The pre erred place to store a welding electrode$ #e ore it is used$ is in its original unopened container" I the low hydrogen electrodes are not stored in their original containers$ code re(uire!ents or storage !ust #e ollowed" For iller !etal and lu8 identi ication$ the A!erican -elding Society has developed a syste! that is si!ple$ readily usa#le$ and o considera#le help to the inspector" Figure /&6 descri#es the A-S designation"

A-S

,apa#le o ;roducing
Type o ,urrent

Type o ,overISatis actory -elds in ,lassi ication ;ositions Shown

:AD Series& Mini!u!Tensile Strength o .eposited Metal in As&-elded ,ondition 60 000 psi (or Higher-see Table 4. A5. 1) :AD/D polarity High cellulose sodiu! F$ >$ OH$ Hdc$ reverse

:AD// High cellulose potassiu! reverse polarity :AD/6 High titania sodiu! straight polarity :AD/4 High titania potassiu! polarity :AD6D High iron o8ide H&Fillets" F :AD65 Iron powder$ iron o8ide polarity F

F$ >$ OH$ Hac F$ >$ OH$ Hac

or or

dc$ dc$

F$ >" OH$ Hac or dc$ either ac or dc$ straight polarity ac or dc$ either polarity H&Fillets$ac or dc$ straight ac or dc$ either polarity

E70 Series- MinimumTensile S reng h o! "eposi e# Me al in As-$el#e# %on#4ion 70 000 psi (or Higher-see Table 4& A5. 1) :5D/? Iron powoer$ titaniaF" >" OH$ Hac or dc$ either polarity :5D/@ Low hydrogen sodiu! F$ >$ OH$ Hde$ reverse polarity :5D/A Low hydrogen potassiu! F$ >$ OH$ Hac or dc$ reverse polarity :5D/B Iron powder$ low hydrogen F$ >$ OH$ Hac or dc$ reverse polarity :5D6? Iron powder$ titaniaH&Fillets$ F ac or dc$ either polarity :5D6B Iron powder$ low hydrogen H&Fillets$ F ac or dc$ reverse polarity

?" ,he!ical analyses and !echanical properties tests" So!e HA progra!s call or con or!ing tests on inco!ing !aterials to provide ade(uate assurance that they !eet purchase speci ications" Mista*es do happen" A case in point !ay #e a purchase that !ay not !eet the ull re(uire!ents or the =o#" -as the ir! (uali ied to #e supplier1 The nu!#er o tests re(uired will depend on the inspector+s =udg!ent and past e8perience$ unless the steps to #e ta*en have already #een progra!!ed in the contractor+s (uality assurance procedure" The inspector should re(uest tests on representative sa!ples o critical inco!ing !aterials to veri y che!ical co!position and !echanical properties" @" >eri ication o #ase !etal (uality" The (uality o !ill products supplied or a =o# !ust !atch the (uality speci ied or the inal weld!ent or structure" <ase !etals al!ost always contain !any s!all discontinuities" Their e ect depends on the thic*ness o the !etal" Heavy plate$ structural shapes$ orgings$ and pipe are particularly su#=ect to such de ects" In so!e instances$ they !ay #e cause or re=ectionJ in others$ they !ay not" For e8a!ple$ when a steel !ill uses less rolling to reduce an ingot to plate$ it has less opportunity to #rea* up cast structures$ to re#ond shrin*age crac*s$ and to spread out la!inations than when rolling a thin plate or sheet" Forgings o all si'es !ay show splits$ tears$ and sur ace irregularities" Any product !ay have o#=ectiona#le sur ace irregularities" This includes deviations ro! latness$ which !ust #e within certain li!its to !eet the re(uire!ents o so!e codes and speci ications" As the welding inspector$ you have responsi#ility to see that discontinuities in the #ase !etal are detected$ identi ied$ evaluated$ and repaired$ where necessary$ so that they will not #e incorporated into the welded product" At ti!es you !ay need to co!!unicate with the responsi#le engineer in deciding what to do a#out a !a=or de ect" Re!e!#er$ all speci ications state that a de ective piece !ust #e re=ected and replaced unless it can #e repaired" In act$ so!e de ects !ay re(uire re=ecting the piece altogether" On the other hand$ la!e straightening o #ea!s accidentally #ent in shipping or handling is co!!only per!itted" As another e8a!ple$ la!inations will rule out placing a plate where it !ust withstand tensile stresses in the through&thic*ness direction$ #ut other locations !ay #e ound where the sa!e plate !ay #e used with co!plete sa ety" Manage!ent will !a*e that decision" As the inspector$ you !ust then certi y that the original de ect is not har! ul in the new location"

A" Storage o iller !aterials" An i!portant welding inspection responsi#ility is to investigate how welding electrodes and iller !aterials are #eing stored" Low hydrogen electrodes out o their containers !ust #e *ept in holding ovens" Eeep in !ind the necessity or preserving lot identi ication or nuclear =o#s" Also$ re!e!#er that lu8es and lu8 cored electrodes need protection ro! !oisture$ whether present as rain or high hu!idity" 5" -elding e(uip!ent" All welding e(uip!ent$ including that to #e used or testing$ should #e chec*ed or operational capa#ility$ cali#ration$ and sa ety" For e8a!ple$ always chec* the a!!eters and volt!eters" These !eters on welding !achines !ay not #e accurate #ecause o !istreat!ent$ dirt$ gri!e$ and overloads" ;eriodic cali#ration !ay #e necessary" B" -eld =oint preparation" Speci ic tolerances are listed or weld =oint preparations in all codes and speci ications" The pre(uali ied =oints o A-S ./"/$ Structural -elding ,ode & Steel$ are typical e8a!ples" Your responsi#ilities as inspector include e8a!ination o the unwelded =oint or edge preparation$ including root ace di!ensions and #evel angle3s7" C" Goint it&up" Again loo*ing at the unwelded =oint$ you should o#serve the it&up o the parts" For #utt =oint welds$ align!ent 3high&low7 and root opening are !ost i!portant" Eeep in !ind that pre&stressing or ca!#ering !ay #e needed or welds that will #e su#=ect to distortion as a result o shrin*age stress" The a#ricator should not atte!pt such welds without the necessary *now&how" ;rocedure !odi ications !ay give an accepta#le weld$ #ut o er your suggestions to the pro=ect engineer$ not to the ore!an" I the ore!an later says$ %You told !e to do it this way$% you will have !ore di iculty in turning down an unaccepta#le result" The it&up o #ac*ing preparations needs particular attention" <ars and straps should it snugly" 2o unwelded transverse =oints #etween seg!ents o a long #ac*up #ar are per!issi#le$ #ecause they induce crac*s in the root pass" 2ote that A-S ./"/$ Structural -elding ,ode & Steel$ re(uires that steel #ac*ing on all groove welds #e !ade continuous #y co!plete penetration welds in #utt =oints or the ull length o the weld"

/D" Huali ication o a welding procedure" The a#ricator !ust prescri#e the details o the welding procedure that will #e ollowed in producing weld!ents" The procedure should produce welded =oints with accepta#le !echanical properties as re(uired #y the particular speci ication or code" //" Huali ication o welders and welding operators" ,odes and speci ications that apply to the a#rication o weld!ents usually re(uire (uali ication o all welders and welding operators" It is your duty to veri y that every welder and welding operator who wor*s under the code or speci ication has #een properly (uali ied according to the code" Again$ veri ication is o#tained either #y your personal witness o each test or your review o veri ied results o tests" As you can see$ an i!portant duty you will have is to li!it welders and welding operators to wor* within their (uali ications" -elding codes or speci ications do not nor!ally re(uire re(uali ication o procedures$ welders$ or welding operators or each new contract or change o design" You !ust read and understand the re(uire!ents o the speci ication or code to !a*e this deter!ination" Re!e!#er that the !ain o#=ective o (uali ication tests is to ensure that (uali ied procedures and welders or welding operators are #eing used properly" To #e air to the a#ricator and purchaser$ !a*e every e ort within reason to avoid unnecessary (uali ication tests" /6" Selection o production test sa!ples" In a welded asse!#ly$ inspection o the product is o ten per or!ed on sa!ples ta*en ro! the production line" These sa!ples !ay #e selected #y chance or according to an esta#lished order" In case$ witnessing their selection and testing is one o your i!portant duties" So!eti!es selection o sa!ples is le t to your =udg!ent and discretion" .o not ta*e !ore sa!ples than will #e reasona#ly needed to deter!ine con or!ance" Typical tests include radiography and other nondestructive tests$ hydrostatic tests$ che!ical analysis$ !etallurgical e8a!ination$ and !echanical testing to destruction" You !ust see that such wor* is properly carried out" /4" :valuation o test results" So!eti!es it will not #e practical or you as an inspector to witness all tests" However$ you should witness enough to satis y yoursel that the tests are #eing per or!ed in the proper !anner and that the results are accurate" Ma*e sure that the testing e(uip!ent has #een cali#rated and is accurate" -hen the tests have #een per or!ed$ you !ust evaluate the results and decide whether the product !eets the speci ication" I the product does not !eet the standards or acceptance in certain details$ you should consider the overall results against the re(uire!ents #e ore deciding on acceptance or re=ection" That inal

decision$ unless otherwise speci ied$ is !ade #y you$ the welding inspector" /?" Maintaining records" ,ode wor* always re(uires record *eeping" -hether other =o#s call or it or not$ co!plete records should #e *ept #y every inspector" These can #e in the or! o detailed notes" It will also #e your duty to chec* o icial records or co!pleteness and accuracy and to !a*e certain that they are availa#le" Records that re(uire the a#ricator+s signature should #e prepared #y the a#ricator$ not #y you" Records should #e as detailed as necessary and entered in in*" :rrors are to #e crossed out and not erased" /@" ;reparing Reports" Reporting your decisions is your inal responsi#ility" Report or!s will #e provided #y so!e codes" In or!al reports !ay #e prepared in other cases" So!ewhere in your inal report you should co!!ent on the general character o the wor*$ how well it stayed within prescri#ed tolerances$ di iculties that occurred$ and any de ects" Repairs should #e e8plained" .istri#ute the necessary copies$ and *eep a copy in your own ile"

SAF:TY ,O2SI.:RATIO2S
"Sa ety in -elding and ,utting% is the title o an A!erican 2ational Standard$ ASM: K?C"/&54$ which has #een incorporated into OSHA regulations and so is now Federal law" You !ust #eco!e a!iliar with the re(uire!ents o this standard$ even though you are not an OSHA inspector$ #ecause those sa ety rules protect you and everyone on the =o# ro! several welding and cutting ha'ards" -elding is a sa e operation when the rules are o#served" The ha'ards relate to the use o co!pressed uel gases$ inert gases$ and o8ygenJ the dangers o ire and #urns ro! welding and cutting la!es and electric arcsJ the possi#ility o electric shoc* ro! arc welding and resistance welding e(uip!entJ eye protection$ radiation protection$ and ventilation or health protection" ;ac*ages o welding iller !etals and usi#le granular !aterials all carry a caution notice$ stating that welding !ay produce u!es and gases ha'ardous to health" The welders and you should avoid #reathing these u!es and gases"

<ra'ing or welding iller !etals containing cad!iu! carry a notice not to #reathe those u!es$ which are poisonous" <ra'ing and welding lu8es containing luorine co!pounds have a cautionary la#el noting that the u!es !ay irritate eyes$ nose$ and throat" The ilter shades that welders use in their hel!ets and goggles have the densities shown in Ta#le 6&/" You !ust not loo* steadily at a welding arc without the prescri#ed protection" -elders should warn you to cover up or turn your #ac* #e ore they stri*e an arc in your vicinity" .istance reduces the danger"

'E(S SHA"E SE'E%T)*

Operation Shade nu!#er Soldering Torch #ra'ing O8ygen cutting Up to 6@"? !! 3I in$7 6@"? !! to /@6"? !! 3I to A in"7 /@6"? !! 3A in"7 and over 0as welding Up to 4"6 !! 3/)B in"7 4"6 !! to /6"5 !! 3/ )B in" to /)6 in"7 /6"5 !! 3/)6 in"7 and over Shielded !etal arc welding /"A !! 3/)/A in"7$ 6"? !! 34)46 in"7$ 4"6 !! 3/)B in"7$ ?"D !! 3@)46 in"7 electrodes 0as tungsten arc welding 3non errous7 0as !etal arc welding 3non errous7 l"A!!3/)/Ain"7$6A!!34)46in"7$ 4"6 !! 3/)B in"7$ ?"D !! 3@)46 in"7 electrodes 0as tungsten arc welding 3 errous7 0as !etal are welding 3 errous7 /"A !! 3I ) /A in"7$ 6"? !! 34 )4 6 in"7$ 4"6 !! 3/)B in"7$ ?"D !! 3@)46 in"7 electrodes Shielded !etal arc welding ?"5 !! 34)/A in"7$ @"A !! 35)46 in"7$ A"? !! 3/ )? in"7 electrodes 5"C !! 3@)/A in"7$ C"@ !! 34)B in"7 electrodes Ato!ic hydrogen welding ,ar#on arc welding

6 4 or ? 4 or ? ? or @ @ or A ? or @ @ or A A or B /D

//

/6 /6 /? /D to /? /?

-elders and cutters wear gloves and special clothing or protection ro! spatter and radiation" Eeeping your distance will protect you" You should wear sa ety glasses with side shields when welders are chipping slag ro! their welds or *noc*ing the errules ro! stud welds and testing the studs" LThere are also radiation ha'ards or you to #eware o when welds are #eing radiographed" The radiographer should #e a (uali ied operator who will post signs and arrange the e(uip!ent so that no one is e8posed" .o pay attention to the signs" Your responsi#ilities as inspector do not include your #eing irradiated"

SUMMARY
A welding inspector is a privileged person$ authori'ed to wor* in al!ost every area o a a#ricating plant" 2evertheless$ his authority is li!ited #y speci ic re(uire!ents stated in codes and #y policies esta#lished #y his e!ployers" The welding inspector inspects not only the welding$ #ut also the preparations or welding and the results o the welding" Thus$ your responsi#ilities and duties when you are assigned to a welding pro=ect as inspector start with the paper wor* 3the =o# speci ications and drawings$ the purchase orders$ and the properties$ identity$ storage$ and (uality o the !aterials received7J the e(uip!entJ and the proposed welding procedure and the (uali ications o the prospective welders and welding operators" Your duties continue during the preparation o the weld =oints and their it&up" You are concerned with the welders and their procedures during the actual weldingJ as you !ust veri y that the (uali ied steps are #eing ollowed" Finally$ you !ust inspect the product$ select and evaluate test sa!ples as needed$ and record and report your decisions" For your own sa ety you !ust not watch an open electric arc without the protection o a no" /D or /6 ilter lens 3no" /? i the welder is using !ore than ?DD a!peres7" Other sa ety precautions in A2SI K?C"/ 3now part o OSHA regulations7 have #een highlighted in this !odule"