Study Material Contents

Function and responsibilities of a senior welding inspector Defects in welds Weld symbol interpretation Interpretation of NDT reports Documentation of welding Approval and certification procedures General principles of supervision Case studies Planning Organisation Interpretation of fractured surfaces Auditing Practice in typical examination questions Course assessments

Low Morale
Monday 31 December 2012 7:43 PM Posted by Cswip Questions , 0 Comments Labels: CSWIP 3.2 , CSWIP 3.2 Question and Answers , cswip 3.2 welding inspector study material , Senior Welding Inspector

IT HAS COME TO YOUR ATTENTION THAT THE MORALE OF YOUR INSPECTION TEAM APPEARS TO BE LOW, a. WHAT COULD YOU HAVE OBSERVED TO DETERMINE THIS? b. WHAT WOULD OCCUR IF THIS WAS NOT RECTIFIED QUICKLY? c. WHAT COULD YOU DO TO LIFT LOW MORALE? Low morale can be identified by the following symptoms 1. lack of diligence 2. taking short cuts 3. ignoring safety procedures 4. not starting work promptly 5. taking long breaks 6. talking in groups and grumbling about minor matters 7. higher levels of absenteeism 8. Negligence (poor record keeping, not inspecting the weld etc..) 9. complaints from TPI/Client Low morale may be result in the following 1. lack of control over production activities from quality point of view 2. poor productivity 3. substandard work output 4. delay in work schedule 5. lack of credibility to the organization

Observing all above, it is imperative that lifting the low morale this can be done as follows 1. Arrange the meeting of entire sub coordinates staff for discussion on the subject matter. 2. From their response I can form a collective opinion for low morale 3. Further to this I may have private discussion with each individual which can help me to zero in on his problems. 4. This problem is then sorted out as general problem and individual problems. 5. As regard to the personal problems I can assure the team that I will do everything possible in my capacity to rectify it. 6. I should bring to the attention of the employees in gentle but firm manner that, their individual problems must not affect the morale. 7. I will try to seek companys help for their personal problem. 8. These they should be noticed that the high morale will reflect in good salary rise, better facilities etc. 9. If low morale continues then the management will be obliged warning letters, demotions and worst case termination also

Signing Off a Prouduct

Monday 31 December 2012 7:39 PM Posted by Cswip Questions , 0 Comments Labels: CSWIP 3.2 , CSWIP 3.2 Question and Answers , cswip 3.2 welding inspector study material , Senior Welding Inspector , Welding Inspector

In an engineering fabrication industry the last activity in the sequence of manufacturing is load out or dispatch. This activity cannot be initiated unless the product is signed off. As a matter of fact signing the product off is assurance of quality which is authenticated by a technically competent person such as Senior Welding Inspector who makes sure that complete manufacturing of product has been carried out in accordance with applicable standard and sound engineering practices. However before signing the documents the senior welding inspector should make enquiry which can give him the in sites of the past while product was being manufactured. Typical questions can be as followed 1. What was the repair rate during production? 2. Whether any difficulties are encountered within the job? 3. Whether any concession or waiver were given, if yes why? 4. How were the weather conditions? 5. Whether there were any safety issues, fatalities, major accidents/incident etc? 6. Whether there were any labour problems? 7. What about the general moral and standard of work amongst the inspection team(s)? Further to this he can start reviewing of documents and he should make sure that he attaches the following documents as a minimum 1. Quality control plan ensure all stages are complete and signed off 2. Inspection check list ensure all stage are completed and signed off 3. Verify material certificates such as mill test certificates, material traceability records etc

4. Verify the following procedures which are to be attached and have all been approved a. Welding b. Repair c. NDT d. PWHT e. Hardness f. PMI g. Hydrotest h. Coating/Painting 5. Verify the qualification level and validity of the welder and NDT personnel 6. Verify the inspection reports of following disciplines and ensure that they cover all appropriate joints and structure a. Visual b. NDT c. Dimensional control etc 7. Verify calibration certificates of equipments and instruments such as pressure gauge, inspection tools and welding equipments etc 8. Verify hardness test reports 9. Verify PMI reports 10. Verify PWHT reports 11. Verify Hydrotest reports 12. Verify as built drawings are completed 13. Verify weld maps are available for traceability 14. Verify name plate, rubbing details are available when applicable 15. Verify concession request, NCR, site query etc 16. Verify permit to work 17. Verify painting and coating inspection reports As a part of his own inspection he may be obliged to witness final hydrotest, visual inspection of completed parts. As a matter of quality assurance he may view some radiographs at random and may even conduct radiograph audit. Finally, transit and tie down procedures should all have been approved by the relevant engineer prior to the final acceptance of the product and issue of any signed certificate of conformance.