MODULE 9.

QUALIFICATION
1.WELDING PERFORMANCE
In Standard Welding Terms and Definition AWS A3.0:2001 . Welding Performance
or Welding Performance Specification means, the demonstration of a welders or
welding operators ability to produce welds meeting prescribed standards.
-An examples of AWS D1.1 Standard Ref. Sec. 4 in Qualification in Part C (4.18)
General. The performance qualification tests required by this code are specifically
deviced tests to determine a welders, welding operators, or tack welders ability to
produce sound welds. The qualification tests are not intended to be used as guides
for welding or tack welding during actual construction. The latter shall be performed
in conformance with a WPS.
-An examples of ASME Sec IX, Article III ( Welding Performance Qualification)QW-300
General, said QW-300.1 This Article list the welding processes separately, with the
essential variables that apply to welder and welding operator performance
qualification.
- In other words welding performance means, Welder. In ISO 9606-1:1994. (3)
Definition
3.1 Welder: Person who perform the welding.
3.1.1 manual welder: Welder who hold and manipulates the electrode holder,
welding gun , torch or blowpipe by hand.
3.1.2 welding operator : Welder who operates welding equipment with partly
mechanized relative movement between the electrode holder, welding gun, torch
or blowpipe and the workpiece.

2.WELDING INSPECTOR

The presence of welding inspector during welding will almost certainly reduce the
number of weld defect and metallurgical problems which could otherwise occur,
which will in turn, reduce the overall number of failures in service. When an item
has failed, it usually means that cracking or fracture has taken place.
There are many types of crack associated with welds, some of which may initiate at
time of welding (process crack) or year later (in-service cracks). In both these cases,
stresses, metallurgical problems and existing weld defects may have contributed to
the cause of the cracking.

Duties of Welding Inspector

The main duty of welding inspector is to ensure that all the welding and associated
actions aare carried out in accordance with the welding specification(s) relevant to
the contract or work being out.
It is important for welding inspector to know where to find relevant information,
interpret the information and understand it.
i.
ii.
iii.

Duties prior to welding

Duties during welding
Duties after welding

Duties prior to welding

1. Obtain all relevant documentation or ensure access to it:
a. Relevant specification(s)
b. Relevant procedures;
c. Copies of welders test certificates(where applicable)
d. Copies of drawings (where applicable)
2. Ensure welder qualification
3. Correct material-type. Condition , size(pipe/plate etc)
4. Correct consumable-type. condition , size(filler material,gas, inserts etc)
5. Correct equipment certified where necessary.
6. Correct preheat (whre applicable)
7. Assess/measure fit-up
a. Root face
b. Bevel angle
c. Root gap
d. Alignment
e. Seam offset (where applicable)
f. Joint cleanliness
8. Ensure no undue stress is applied to the joint
Duties during welding :
1.
2.
3.
4.
5.
6.
7.

Check amperage, voltage, polarity

Ensure correct welding technique welding direction, run sequence.
Check welding time- time laps and/or run out lengths
Ensure adequate cleaning between passes
Correct interpass temperatures minimum and/or maximum
Check root internally (pipes) where access permits.
Check back gouged welds amount gouged,shaped of gouge, cleanliness of
gouge
(where applicable)

Duties after welding

1. Ensure weld is post cleaned

2. Visual inspection of weld for defect e.g. undercut, overlap, surface porosity,
incompletely filled groove etc.
3. Visual check for arc strikes.
4. Check weld contour and weld width.
5. Ensure joint is covered with heat resistant material to retard cooling rate
(where applicable)
6. Inspect/monitor post-heat treatment (where applicable)
7. Report on weld
8. Check NDT reports-tie up with NDT(where applicable)
Welding Inspector Equipment
The equipment a welding inspector will need to carry out inspection will depend
partly on the work which is to be performed. For example, a welding inspector will
not require a fillet weld gauge if only butt welds are being made. The client or
specification will also determine the equipment to be used, e.g a portable arc
monitoring unit (PAM unit) may be used to measure and record amperage and
voltage instead of hand held voltmeter and ammeter. The equipment which may be
used by a welding inspector is listed below :
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
p.

Steel rule
Flexible tape measure.
Temperature indicating crayons or thermocouple(pyrometer)
Bevel angle gauge
Root gap gauge
Fillet weld gauge for leg length and throat thickness
Misalignment gauge
Voltmeter
Ammeter
Polarity indicator
Height/depth gauge
Contour gauge
Torch or other light source
Modelling clay or resin
Magnifying glass- 5X magnification
Marking crayon or paint stick

Weld Inspector Responsibilities

Welding inspection requires a knowledge of weld drawings, symbols, joint design, procedures, code and
standard requirements, and inspection and testing techniques. For this reason, many welding codes and
standards require that the welding inspector be formally qualified, or have the necessary knowledge and
experience to conduct the inspection.
Weld inspection is only as good as the person running the tests. Here are a few things that a welding
inspector should know and tasks he should be able to perform:
1. Welder Performance and Welding Procedure Qualification. Specific procedures must be
followed to qualify welders and welding procedures. The qualification process is an integral part
of the overall welding quality system, and the welding inspector often is required to coordinate
and verify these types of qualification tests.

These qualifications typically involve producing welded samples representative of the welds that
will be used in production welding. These welded samples usually are required to be tested after
completion. Radiographic, microetching, guided bends, transverse tension, and nick-break
fracture are some of the tests that are used. The test results must meet or exceed the minimum
requirements as stipulated in the welding code or standard before the procedure can be qualified.
2. Visual Inspection. This is often the easiest, least expensive, and most effective method of
welding inspection for many applications if performed correctly. The welding inspector must be
capable of identifying all of the different welding discontinuities during visual inspection. He also
must be able to evaluate, in terms of the relevant welding code or standard, the significance of
identified discontinuities to determine whether to accept or reject them during testing and
production.
A welding inspector with good eyesight can be trained relatively quickly by a competent instructor
and can prove to be a major asset to the welding quality system (good vision is obviously
essential for visual inspection).
3. Surface Crack Detection. A welding inspector sometimes is required to conduct weld testing by
surface crack detection methods. He also may have to evaluate the test results of these testing
methods. The inspector should understand testing methods, such as liquid penetrant and
magnetic particle inspection. Additionally, he must know how the tests are used and what they will
find.
4. Radiographic and Ultrasonic Weld Inspection. These two inspection methods are in a group
known as nondestructive testing (NDT). These inspection methods are used to examine the
internal structure of the weld to establish the weld's integrity, without destroying the welded
component. The welding inspector may be required to understand this type of testing and be
competent in the interpretation of the results. Radiographic and ultrasonic weld inspection are the
two most common methods of NDT used to detect discontinuities within the internal structure of
welds. The obvious advantage of both methods is their ability to help establish the weld's internal
integrity without destroying the welded component.
Radiographic testing makes use of X-rays produced by an X-ray tube or gamma rays produced
by a radioactive isotope. The basic principle of radiographic inspection is the same as that for
medical radiography. Penetrating radiation is passed through a solid object, in this case a weld,
onto a photographic film, resulting in an image of the object's internal structure. The amount of
energy absorbed by the object depends on its thickness and density. Energy not absorbed by the
object will cause exposure of the radiographic film. These areas will be dark when the film is
developed. Areas of the film exposed to less energy remain lighter.
Therefore, areas of the weld where the thickness has been changed by discontinuities, such as
porosity or cracks, will appear as dark outlines on the film. Inclusions of low density, such as slag,
will appear as dark areas on the film, while inclusions of high density, such as tungsten, will
appear as light areas. All discontinuities are detected by viewing shape and variation in density of
the processed film.
Ultrasonic testing makes use of mechanical vibrations similar to sound waves but of higher
frequency. A beam of ultrasonic energy is directed into the weld to be tested. This beam travels
through the weld with insignificant loss, except when it is intercepted and reflected by a
discontinuity. The ultrasonic contact pulse reflection technique is used. This system uses a
transducer, which changes electrical energy into mechanical energy. The transducer is excited by
a high-frequency voltage, which causes a crystal to vibrate mechanically. The crystal probe
becomes the source of ultrasonic mechanical vibration.
These vibrations are transmitted into the test piece through a coupling fluid, usually a film of oil,
called a couplant. When the pulse of ultrasonic waves strikes a discontinuity in the test piece, it is
reflected back to its point of origin. Thus, the energy returns to the transducer. The transducer
now serves as a receiver for the reflected energy. The initial signal or main bang, the returned

echoes from the discontinuities, and the echo of the rear surface of the test piece are all
displayed by a trace on the screen of a cathode-ray oscilloscope.
5. Destructive Weld Testing. Destructive methods to establish weld integrity or performance
include sectioning, bending, or breaking the welded component and evaluating various
mechanical or physical characteristics. Some of these tests are the guided bend test, macroetch
test, reduced section tensile test, fracture test, and Charpy V-notch impact test. These tests are
used during welding procedure or welder performance qualification testing. The welding inspector
often is required to conduct, supervise, or evaluate these testing methods.
6. Interpretation of Welding Details and Weld Symbols. The welding inspector should be
competent in the ability to read engineering and manufacturing drawings, and be able to interpret
all details and symbols that provide information about the welding requirements.
3.Report and Record

Completing and Maintaining Inspection Records.

A final attributed, which is not to be taken lightly, is the welding inspectors ability
to complete and maintain inspection records. The welding inspector must be
capable of accurately communicating all aspects of the inspection, including the
results.
The records should be legible and understandable to anyone familiar with the work,
therefore, neatness is important. The welding inspector should also consider these
records as protection should questions later arise. Reports should contain sufficient
information regarding how the inspection was performed so that similar result can
be obtained later by someone else.
Once records have been developed, the welding inspector should be capable of
maintaining all necessary information in an orderly fashion to facilitate easy
retrieval. Accordingly, there are a few rules of etiquette relating to inspection
records. First, records should be completed in ink; if incorrect entries are noted, they
can be lined out and corrected. This corrective action should then be initialed and
dated for explanation. Next, the report should accurately and completely state the
job name and inspection location in addition to specific test information. The use of
sketches and pictures may also help to convey information regarding the inspection
result. Finally, the completed report should then be signed and dated by the
inspector who actually performed the work.
Report is any information work made with specific intention of relaying information or
recounting certain events in a widely presentable form. And record is collection of data.