ENGR.

MOHAMMAD SAZID ALAM

Inspection Engineer (AICO-DAMMAM)
E-mail:-alam_sajid@yahoo.co.uk
Mobile:-+966534077860

DATE:-13/05/2011
DAY-1

CSWIP3.1 EXAMINATION MATERIAL

WELDING: - WELDING IS A PROCESS OF JOINING TWO OR MORE PIECES OF THE
SAME OR DISSIMILAR MATERIALS TO ACHIEVE COMPLETE
COALESCENCE (together).
A WELD : - A UNION OF MATERIALS CAUSED BY HEAT OR PRESSURE.
i.e. THE PROCESS OF WELDING.
TYPES OF COMMON WELDS: --(I)
BUTT WELDS (II) FILLET WELDS(III) SLOT WELDS (IV) EDGE WELDS
(V)SPOT/SEAM WELDS
(VI)
PLUG/SLOT WELDS (VII) FLANGE WELD (VIII) SEAM WELD (IX)
SURFACING WELD.
WHAT IS JOINT: ---A CONFIGURATION OF MEMBERS.
i.e. TO BE WELDED
IN A WELDED FABRICATION WELDS ARE USED TO JOIN DIFFERENT
PARTS.SUCH JUNCTIONS OF PARTS ARE CALLED WELD JOINTS AND ARE DEFINED AS
THE LOCATIONNWHERE TWO OR MORE MEMBERS ARE TO BE JOINTED.
NOTE: ---THE LOADS IN A WELDED STRUCTURE ARE TRANSFERRED FROM ONE
MEMBER TO ANOTHER THROUGH WELDS PLACED IN SUCH JOINTS.
TYPES OF COMMON JOINTS:(I)
(VI)

BUTT JOINTS (II) T JOINTS (III) LAP JOINTS (IV) CORNER JOINTS (V)OPEN
CORNER JOINTS
CLOSED CORNER JOINTS (VII) EDGE JOINTS.

BUTT JOINTS: ------IT IS A JOINT BETWEEN TWO MEMBERS LYING

APPROXIMATELY IN THE SAME PLANE.
WELDING POSITION FOR BUTT WELDS: ------------(1) 1G-FLAT POSITION--- FOR PIPE ROTATED
(2) 2G-HORIZONTAL VERTICAL POSITION
(3) 3G-VERTICAL POSITION
(4) 4G-OVERHEAD POSITION
(5) 5 G-VERTICAL POSITION-Pipe axes fixed horizontal.
(6) 6G-INCLIEND POSITION (FIXED)-45DEGREE.
WELD PREPERATION TERMS:--Bevel Angel, Included Angle, Root face, Root

gap, Root radius,

Root landing.

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WELDING INSPECTION
WELDING INSPECTOR SHOULD BE: ---------(1)FAMILIAR WITH THE STANDARDS, RULES AND SPECIFICATION RELEVANT FOR THE
FABRICATION WORK BEING UNDERTAKEN. (THIS MAY INCLUDE NATIONAL
STDS.CLIENT SPECIFICATION/STANDARDS AND THE COMPANY S OWN IN HOUSE
STANDARDS, INTERNATIONAL STDS.).
(2) FAMILIAR ABOUT THE WELDING PROCESSES/PROCEDURES TO BE USED IN
PRODUCTION.
(3)OF HIGH NEAR VISUAL ACUITY, PROFESSIONAL ATTITUDE, IMPARTIAL AND
CONSISTENCE.
(4)GOOD VISION, ABILITY TO MAINTAIN RECORD, KNOWLEDGE OF TESTING
METHODS.
IMPORTANT QUALITIES AND CHARACTERISTICS OF WELDING INSPECTOR:
------------------(1)HONESTY.
(2) A GOOD STANDARD OF LITERACY AND NUMERACY.
(3)A GOOD LEVEL OF GENERAL FITNESS.
(4) SHOULD BE HIGHEST LEVEL OF INTEGRITY, PROFESSIONALISM, COMPETENCE,
CONFIDENCE AND COMMITMENT.
(5) SHOULD BE PRACTICAL EXPERIENCE OF WELDING INSPECTION.
(6)COMMUNICATION SKILLS, RECORD KEEPING SKILLS, SHOULD BE ANALYTICAL,
DEDICATED, RESPECTED, SAFETY CONSCIOUS, DECISIVE, INQUISITIVE.
DUTIES OF WELDING INSPECTOR: ---(1)BEFORE WELDING
(2)DURING WELDING
(3)AFTER WELDING(INCLUDING REPAIR)
(1)BEFORE WELDING:--------------(I)SAFETY (II) DOCUMENTATION:--MATTERIAL TEST CERTIFICATE, DRAWINGS,
SPECIFICATION/REV- DATE, WELDER APPROVALS CERTIFICATES, PROCEDURES, WPS,
CONSUMABLE CERTIFICATES.
(III)CHECK WELDING EQUIPMENT AND ALL RELATED ANCILLARIES, (CABLE,
REGULATORS, OVANS ECT.)
(IV)CHECK PIPE/PLATE/COILS MATTERIALS /STORAGE, WELDING CONSUMABLES FOR
SIZE, CHECK ELECTRODS AND FLUX BATCHE NUMBER, HEAT NO. AND COIL NO. OF
MATTERIALS FOR PIPE.

CHECK MARKING OUT PREPARATION & SET UP: ----

CORRECT METHODS OF CUTTING WELD PREPARATION, METHOD OF PRE HEATING,

RELEVENT BEVEL ANGLE, ROOT FACE, ROOT GAP, ROOT RADIUS, AND CORRECT
PRE-WELDING DISTORTION CONTROL.
ALL TACK WELDING TO BE MONITORED AND INSPECTED, CHECK INSIDE T-/CROSS
JOINT FOR WELD.

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(2)DURING WELDING:--------------(I)WEATHER CONDITIONS (MAINLY FOR SITE WORK)
(II)PRE-HEAT VALUE-HEATING METHOD, LOCATION AND CONTROL METHOD.
(III)IN PROCESS DISTORTION CONTROL (SEQUENCE OR BALANCED WELDING).
(IV)CONSUMABLE CONTROL (SPECIFICATION, SIZE, CONDITION, AND ANY SPECIAL
TREATMENTS).
(V)WELDING VARIABLE PARAMETERS (TRAVEL SPEED, VOLTAGE, CURRENT,
AMPERAGE ETC.)
(VI)WELDING GASES/PURGING GASES (PRESSURE FLOW AND CONTROL METHOD)
(VII)WELDING CONDITION FOR ROOT RUN/HOT PASS AND ALL SUBSEQUENT RUN
AND INTER-RUN CLEANING.
(XI)MINIMUM AND MAXIMUM INTER-PASS TEMPERATURE (TEMPERATURE AND
CONTROL METHOD).
(X) FULL COMPLIENCE WILL ALL ELEMENTS GIVEN ON THE WPS.
(3)AFTER WELDING: --------------------(I)PRIMARY VISUAL INSPECTION/VISUAL INSPECTION.
(II)NONDESTRUCTIVE TESTING/MANUAL UT/RADIOGRAPHIC TESTING.
(III)REPAIRS/REPAIRS PROCEDURES (NDT, WELDING, WELDER APPROVAL)
(IV)PWHT, HYDRO-FOR SAW PIPES.
(V)OFFLINE ULTRASONIC TESTING-FOR SAW PIPES.
(VI)ENDS BEVEL/ROOT FACINGFOR SAW PIPES.
(VII)RE-INSPECTION OF REPAIR AREA/FINAL VISUAL INSPECTION.
(VII)SUBMISSION ALL INSPECTION REPORT TO QC DEPARTMENT.

Inspector

Responsibilities of a Welding
TO OBSERVE---TO RECORD-----TO

COMPARE
TO OBSERVE ALL RELEVANT ACTIVITIES/ACTIONS RELATED TO WELD QUALITY
THROUGHOUT PRODUCTION

PRODUCTION TO
-------------------------------------------------------------------------------------------FINAL V
STATION
TO RECORD ALL PRODUCTION POINTS RELEVANT TO QUALITY, INCLUDING A FINAL
MAP AND REPORT SHEET SHOWING ALL IDENTIFIED WELDING IMPERFECTIONS,
ETC.
PRODUCTION TO
-------------------------------------------------------------------------------------------FINAL V
STATION
TO COMPARE ALL INSPECTION REPORTED INFORMATION WITH THE ACCEPTACE
LEVELS/CRITERIA AND CLAUSES WITH IN THE APPLIED APPLICATION STANDARD.
SUBMIT A FINAL INSPECTION REPORT OF YOUR FINDINGS TO THE QA/QC
DEPARTMENT FOR ANALYSIS AND ANY REMEDIAL ACTION.

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