ARC WELDING INSPECTION AND QUALITY CONTROL

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ARC WELDING INSPECTION AND QUALITY CONTROL

• MODULE CODE
• IWLD209

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GENERAL INFORMATION

• WHO IS THE WELDING INSPECTOR?
• A RESPONSIBLE PERSON WHO
• a. Determine weld quality to specification.
• b. maybe an Overseer of others- may not perform
  actual inspection. Responsible for the overall
  inspection operation. Keep records.
• c. maybe a Test Specialist - perform inspection
  process. May or may not work under over seer.
• d. or a combination of the above
• DUTIES OF THE WELDING INSPECTOR
• A. To be familiar with
• 1. welding processes
• 2. terms and definitions
• 3. math and metric conversions
• 4. metallurgy
• 5. welding and NDT symbols

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• DUTIES OF THE WELDING INSPECTOR
• B. Have the knowledge of
• 1. drawings
• 2. codes, standards and specifications
• 3. procedures and welders qualifications
• 4. destructive testing methods
• 5. non destructive testing methods
• C. Have the skills to
• 1. Find and identify weldment discontinuities
  and defects
• 2. Use inspection tools and gages to perform
  Visual Inspection.

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• D. Demonstrated the following abilities
• 1. Keep good records
• 2. Be in good physical condition
• 3. have a good vision, near vision
• 4. take a color perception test
• E. Demonstrate a Professional Attitude
• 1. Fair
• 2. Impartial
• 3. Consistent
• 4. Commitment
• F. Meet and follow requirements of AWS QC1-96
• G. Demonstrate the following ethical
  requirements
• 1. Common sense
• 2. Honesty
• 3. Integrity

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III. PUBLIC STATEMENTS A. Avoid if possible B.
Never for personal publicity C. Get legal advise
IV. COMMUNICATION A. A Good communicator
SPEAKS WRITES ACTS DRAWS WELDS
MESSAGE
SENDER
LISTENS READS OBSERVES INFERS INSPECTS
RECEIVER
FEEDBACK
RESPONSE TO SENDER
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B.LINES OF COMMUNICATION
FOREMAN SUPERVISOR
DESIGN/PROJECT ENGINEER
SUPERINTENDENT
WELDING ENGINEER
WELDER
REPORTING SUPERVISOR
PLANT MANAGER
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• WELD QUALITY ASSURANCE - is defined as the plan
  or systematic actions which provides adequate
  confidence that a product or service will satisfy
  give needs of service requirements.
• WELD QUALITY CONTROL - is defined as the
  operational techniques and activities which
  sustain the quality of the product or service to
  meet service requirements.

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• NDE PERSONNEL
• A. The welding inspector must have
• 1. knowledge of NDE methods
• 2. knowledge of NDE certifications
• a. ASNT
• b. AWS
• VI. EXPERIENCE REQUIRED
• A. SENIOR CERTIFIED WELDING INSPECTOR
• 1. 15 years minimum
• 2. 6 years as CWI
• B. CERTIFIED WELDING INSPECTOR
• 1. 5 years minimum
• C. CERTIFIED ASSOCIATE WELDING INSPECTOR
• 1. 2 years

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• VII. CWI EXAM
• A. Fundamentals 2 hrs
• 1. 150 questions
• 2. closed books
• B. Practical 2 hrs
• 1. 46 questions
• 2. measurement calculations
• C. Codes 2 hrs
• 1. 46 questions
• 2. open book

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• VIII. CODE OPTIONS FOR CWI EXAM
• A. AWS D1.1 --- code for structural
• - 1998, 2000 or 2002 edition
• B. AWS D1.5 --- code for bridges
• - 1995 or 1998 edition
• C. AWS D15.1 --- code for railroad
• - 1993 edition
• D. API 1104 code for pipeline
• EXAMS SUCCESS
• A. Must pass all three parts with
• 1. Fundamentals 108 out of 150 questions
• 2. Practical 33 out of 46 questions
• 3. Code 33 out of 46 questions

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• CERTIFIED WELDING EDUCATOR
• A. must apply for CWE
• B. Pass Part of A of the CWI Exam
• C. Pass Part B of the CWI Exam
• D. Shall have a valid welder qualification
• E. Shall furnace evidence of having met the
  instructional requirements of your school in the
  form of
• 1. written evaluation
• 2. recommendation for CWE by your administrator
• CWI and CWE renewal
• A. CWI every 3 years
• 1. 9 years re-certification
• 2. re-test on part B
• B. CWE every 4 years

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• ETHICAL REQUIREMENTS
• INTEGRITY responsible person with good
  character and common sense. Must be honest.
• RESPONSIBLE TO THE PUBLIC perform duties of
  weld inspection in a conscientious manner with
  well being of public in mind.
• KNOWLEDGE OF WELDING know what defects are most
  likely to occur. Know and monitor welding
  variables.
• KNOWLEDGE OF DRAWINGS, SPECIFICATIONS, AND
  PROCEDURE must be able to read blueprints, NDT
  and welding symbols. Familiar with procedures to
  inspection.
• KNOWLEDGE OF TESTING METHODS should be capable
  of performing a variety of inspections using
  different methods.
• RECORDS clear and concise records must be
  maintained. Good records help protect inspector.
• EDUCATION AND TRAINING requirements will vary.
  The more diversified the job the more training
  that is needed.