WELDING INSPECTOR

AWARENESS
TRAINING
Instructor
ETHEM GUNGOR
 Agenda

▪ Main Responsibilities

▪ Terms & Definitions

▪ Welding Processes

▪ Duties

▪ Welding Imperfections

▪ Destructive and Non Destructive Examination

▪ Welding Inspectors Equipment's

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 Main Responsibilities

▪ Documentation Control
▪ Welding Procedure Specification (WPS)
▪ Welder Certificates
▪ Calibration Certificates

▪ Workmanship Control
▪ Right welder working right place

▪ Code Compliance
▪ All data's is matching with code

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 Terms & Definitions

What is the weld ?

A permanent union between materials caused by heat and /or pressure

Consumables

Work piece -1 Work piece - 2

Heat and/or
Pressure

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 Terms & Definitions
Welding

▪ An operation in which two or more parts are united by means of heat or pressure or both, in such a
way that there is continuity in the nature of the metal between these parts.

Joint

▪ A connection where the individual components, suitably prepared and assembled, are joined by
welding or brazing.

Parent metal

▪ Metal to be joined or surfaced by welding, braze welding or brazing.

Filler metal

▪ Metal added during welding, braze welding, brazing or surfacing 5

 Terms & Definitions
Weld metal

▪ All metal melted during the making of a weld and retained in the weld.

Heat-affected zone (HAZ)

▪ The part of the parent metal that is metallurgically affected by the heat of welding or thermal
cutting, but not melted.

Fusion line

▪ The boundary between the weld metal and the HAZ in a fusion weld. This is a non-standard term for
weld junction.

Weld zone

▪ The zone containing the weld metal and the HAZ. 6

 Terms & Definitions
Weld face

▪ The surface of a fusion weld exposed on the side from which the weld has been made.

Root

▪ The zone on the side of the first run furthest from the welder.

Toe

▪ The boundary between a weld face and the parent metal or between runs. This is a very important feature of a
weld since toes are points of high stress concentration and often they are initiation points for different types of
cracks (fatigue cracks, cold cracks). In order to reduce the stress concentration, toes must blend smoothly into
the parent metal surface.

Excess weld metal

▪ Weld metal lying outside the plane joining the toes. Other non-standard terms for this feature: Reinforcement,
overfill 7
Terms & Definitions
BW – Butt Weld FW - Fillet Weld

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 Terms & Definitions

Cap Weld Cap Width

A B

Design Throat
Actual Throat

Thickness
Thickness

C D

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Terms & Definitions

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 Terms & Definitions
Angle of bevel

▪ The angle at which the edge of a component is prepared for making a weld.

For an manual metal arc welding weld on carbon steel plates, the angle is:

➢ 25-30° for a V preparation

➢ 8-12° for a U preparation
➢ 40-50° for a single bevel preparation
➢ 10-20° for a J preparation

Included angle

▪ The angle between the planes of the fusion faces of parts to be welded. In the case of single V or U
and double V or U this angle is twice the bevel angle. In the case of single or double bevel, single or
double J bevel, the included angle is equal to the bevel angle.
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 Terms & Definitions
Root face

▪ The portion of a fusion face at the root that is not bevelled or grooved. It’s value depends on the
welding process used, parent material to be welded and application; for a full penetration weld on
carbon steel plates, it has a value between 1-2mm (for the common welding processes).

Gap

▪ The minimum distance at any cross section between edges, ends or surfaces to be joined. Its value
depends on the welding process used and application; for a full penetration weld on carbon steel
plates, it has a value between 1-4mm.

Root radius

▪ The radius of the curved portion of the fusion face in a component prepared for a single J or U,
double J or U weld. In case of SMAW, GMAW and oxy-fuel gas welding on carbon steel plates, the
root radius has a value of 6mm for single and double U preparations and 8mm for single and double
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J preparations.
Terms & Definitions

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Terms & Definitions

Open Square Single V Single Bevel

Single V Root Face Big Single Bevel Root Face Big Single U

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Terms & Definitions

Single J Double V or X K

Double U Double J

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 Terms & Definitions
Weld A fusion weld, other than a butt, edge or fusion spot weld, which is approximately triangular in
transverse cross section we called fillet weld.

Actual throat thickness

▪ The perpendicular distance between two lines, each parallel to a line joining the outer toes, one
being a tangent at the weld face and the other being through the furthermost point of fusion
penetration

Design throat thickness

▪ The minimum dimension of throat thickness used for purposes of design. Also known as effective
throat thickness. Symbolised on the drawing with ‘a’

Leg length

▪ The distance from the actual or projected intersection of the fusion faces and the toe of a fillet weld,
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measured across the fusion face. Symbolised on the drawing with ‘z’.
Terms & Definitions

The design throat thickness or nominal throat

thickness ‘a’ and leg length ‘z’
(a = 0.707 × z ) or (z = 1.41 × a)

The effective throat thickness is symbolised with ‘s’

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 Terms & Definitions

Note: The throat thickness is symbolised with ‘b’ instead of ‘s’. 18

 Terms & Definitions
Question 1: The Leg length is 14mm. What is the Design Throat?

Answer: 14mm x 0.7 = 9.8 mm Throat Thickness

Design Throat Thickness = Leg Length x 0.7

Question 2: The Design Throat is 10mm. What is the Leg length?

Answer: 10mm x 1.4 = 14mm

Leg Length Leg Length = Design Throat Thickness x 1.4

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 Terms & Definitions
Question 1: The Leg length is 14mm. What is the Design Throat?

Answer: 14mm x 0.7 = 9.8 mm Throat Thickness

Design Throat Thickness = Leg Length x 0.7

Question 2: The Design Throat is 10mm. What is the Leg length?

Answer: 10mm x 1.4 = 14mm

Leg Length Leg Length = Design Throat Thickness x 1.4

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 Terms & Definitions

Fillet Welds Shape

Miter Fillet Concave Fillet Convex Fillet

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Terms & Definitions

Welding Positions

European Norm American Norm Description

EN ISO 6947 ASME Sec. IX
PA 1G/1F Flat/Downhand
PB 2F Horizontal-Vertical
PC 2G Horizontal
PD 4F Horizontal-Vertical(Overhead)
PE 4G Overhead
PF 3G/5G Vertical-Up
PG 3G/5G Vertical-Down
H-L045 6G InclinedPipe(Upwards)
J-L045 6G InclinedPipe(Downwards)
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Terms & Definitions

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Terms & Definitions

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 Terms & Definitions
PQR (Procedure Qualification Record)

➢ What is the main reason for carrying out welding procedure qualification test ?

➢ What is the test trying to show ?

✓ Answer is to show that the welded joint has the properties (mechanical properties are the main
interest, always strength but toughness and hardness may be important for some application
also test demonstrates that the weld can be made without defects) that satisfy the design
requirements (fit for purpose).

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 Terms & Definitions
PQR (Procedure Qualification Record)

Example codes:

AWS D1.1 : Structural Steel Welding Code

API 1104 : Welding Pipelines

ASME Section IX : Qualification Standard for Welding, Brazing, and Fusing Procedures

EN ISO 15614-1: Specification and qualification of welding procedures for metallic materials - Welding
procedure test - Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys

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 Terms & Definitions
PQR (Procedure Qualification Record)

According to EN standards welding conditions are called welding variables so welding variables are
classified as;

▪ Essential Variables
▪ Non-essential Variables
▪ Additional Variables

According to ASME standards welding conditions (welding variables) are classified as;

▪ Essential Variables
▪ Non-essential Variables
▪ Supplementary Essential Variables

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 Terms & Definitions
PQR (Procedure Qualification Record)

Essential Variables that if changed beyond certain limits may have a significant effect on the properties
of the joint

▪ Welding Process (SMAW,GTAW,SAW etc.)

▪ Post Weld Heat Treatment
▪ Material Type (P Number , Group Number)
▪ Electrode Type, Filler Wire Type (F Number , A Number)
▪ Material Thickness
▪ Electrical Polarity (ACEN,ACEP,DCEN,DCEP)
▪ Pre-Heat Temperature
▪ Heat Input
▪ Welding Position

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 Terms & Definitions
WPS (Welding Procedure Specification)

pWPS: preliminary welding procedure specification before procedure approval the welding engineer
writes for production welding procedure.

WPS: Once a PQR has been produced, the welding engineer is able to write qualified WPSs for the
various production weld joints that need to be made.

▪ The use of qualified WPSs is the accepted method for controlling production welding but this will
only be successful if the welders are able to understand and work in accordance with them.

▪ The welding conditions that are allowed to be written on a qualified WPS are referred to as the
qualification range and this range depends on the welding conditions used for the test piece and
form part of the WPQR.

▪ The WPS must be showing essential variables.

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 Terms & Definitions
WPS (Welding Procedure Specification)

Example codes:

AWS D1.1 : Structural Steel Welding Code

API 1104 : Welding Pipelines

ASME Section IX : Qualification Standard for Welding, Brazing, and Fusing Procedures

EN ISO 15609-1: Specification and qualification of welding procedures for metallic materials - Welding
procedure specification - Part 1: Arc welding

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 Terms & Definitions
Welder Qualification

➢ What is the main reason for qualifying a welder ?

✓ Answer is to show that the welder has the skill to be able to make production welds that are
free from defects.

Example codes:

AWS D1.1 : Structural Steel Welding Code

API 1104 : Welding Pipelines

ASME Section IX : Qualification Standard for Welding, Brazing, and Fusing Procedures

EN ISO 9606-1 : Qualification testing of welders — Fusion welding — Part 1: Steels

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Terms & Definitions
Welder Qualification Schedule

• WPS for welder qualification test piece

• The welder makes the test weld in accordance with the WPS
• A welding inspector monitors and witnessed the welding to ensure that the welder is
working in accordance with the WPS

• The test coupon is subjected to NDE in accordance with the methods specified by the
Standard

• A welder’s Qualification Certificate is prepared showing the welding conditions used for the
test piece and the range of qualification allowed by the Standard for production welding.

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 Terms & Definitions
Welder Qualification

According to EN ISO 9606-1

The welder shall be retested every 3 years.

The certificate needs to be confirmed every 6 months otherwise the certificate(s) become(s) invalid.

Every 2 years, two welds made during the last 6 months of the validity period shall be tested by
radiographic or ultrasonic testing or destructive testing and shall be recorded.

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 Terms & Definitions
Welding Symbols

If the arrow show the weld here you can weld as the follow ;

So needs to specify weld. We are using arrow line.

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 Terms & Definitions
Welding Symbols

In the ISO system there are two parallel reference lines, one solid and one dashed. In the AWS system a
solid reference line is used.

▪ Apart from weld symbols placed on the reference line, additional information can be supplied
adjacent to the tail which is generally omitted when not required.

▪ The arrow line can point in any direction

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 Terms & Definitions
Welding Symbols

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 Terms & Definitions
Welding Symbols

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 Terms & Definitions
Welding Symbols

5
80 80 80
5

6 90 90 90

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 Terms & Definitions
Welding Symbols

Please fill in the relevant places.

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 Terms & Definitions
Welding Symbols

6
80 80 80
6

8 90 90
90

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 Welding Processes

Process Name EN AWS Characteristics Applications

Arc welding Carbon arc welding 181 CAW Carbon electrode, historical Copper, repair (limited)
Arc welding Flux cored arc welding 136 FCAW Continuous consumable electrode filled with flux Industry, construction
Arc welding Gas metal arc welding 131 GMAW Continuous consumable electrode and shielding gas Industry
Arc welding Gas tungsten arc welding 141 GTAW Nonconsumable electrode, slow, high quality welds Aerospace,Construction(piping),Tool and Die
Arc welding Plasma arc welding 15 PAW Nonconsumable electrode, constricted arc Tubing, instrumentation

Shielded metal arc welding 111 SMAW Consumable electrode covered in flux, can weld any metal as long as
Arc welding they have the right electrode Construction, outdoors, maintenance
Arc welding Submerged arc welding 121 SAW Automatic, arc submerged in granular flux

Magnetically Impelled Arc Butt 185 MIAB both tube ends are electrodes; no protection gas; arc rotates fast
Arc welding along edge by applied magnetic field Pipelines and tubes

Oxyacetylene welding 311 OAW Combustion of acetylene with oxygen produces high-temperature
Oxyfuel gas welding flame, inexpensive equipment Maintenance, repair

Resistance spot welding 21 RSW Two pointed electrodes apply pressure and current to two or more
Resistance welding thin workpieces Automobile industry, Aerospace industry

Ultrasonic welding 41 USW High-frequency vibratory energy is applied to foils, thin metal sheets
Solid-state welding or plastics. Solar industry. Electronics. Rear lights of cars.
Other welding Electroslag welding 72 ESW Welds thick workpieces quickly, vertical position, steel only, Heavy plate fabrication, construction,
Other welding Laser beam welding 521 LBW Deep penetration, fast, high equipment cost Automotive industry
Exothermic reaction between alumnium powder and iron oxide
Thermite welding 71 TW
Other welding powder Railway tracks
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 Welding Processes
Manual Arc Welding

MMA,111,SMAW

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 Welding Processes
Manual Arc Welding

1) Power source transformer/rectifier (constant current type)

2) Holding oven (holds at temperatures up to 150°C)
3) Inverter power source (more compact and portable)
4) Electrode holder (of a suitable amperage rating)
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5) Power cable (f a suitable amperage rating)
6) Welding visor (with correct rating for the amperage/process)
7) Power return cable (of a suitable amperage rating)
8) Electrodes (of a suitable type and amperage rating)
9) Electrode oven (bakes electrodes at up to 350°C)
10) Control panel (on/off/amperage/polarity/OCV)

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 Welding Processes
Manual Arc Welding

▪ When an arc is struck between the coated electrode and workpiece, both the electrode and
workpiece surface melt to form a weld pool.

▪ The average temperature of the arc is approximately 6000°C.

▪ The flux forms gas and slag, which protect the weld pool from atmosphere effects.

▪ A new electrode needs to be inserted in the holder.

▪ Manual metal arc welding can be carried out using either direct (DC) or alternating (AC) current.

▪ A suitable current range, typically 30-350 amps.

▪ The arc during welding, between 20 and 30 voltage.

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 Welding Processes
Manual Arc Welding

Welding variables which affect the final quality of the process.

➢ Current (Amperage)

➢ Voltage

➢ Travel Speed

➢ Polarity

➢ Type of Electrode

Note: Current , voltage and travel speed directly affects heat input.
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 Welding Processes
Manual Arc Welding

➢ Current (Amperage)

▪ Amperage too low: Poor fusion or penetration, irregular weld bead shape, slag inclusion unstable
arc, arc stumble, porosity, potential arc strikes.
▪
▪ Amperage too high: Excessive penetration, burn through, undercut, spatter, porosity, deep craters,
electrode damage due to overheating, high deposition making positional welding difficult.

➢ Voltage

▪ Arc voltage too low: Poor penetration, electrode stubbing, lack of fusion defects, potential for arc
strikes, slag inclusion, unstable arc condition, irregular weld bead shape.

▪ Arc voltage too high: Excessive spatter, porosity, arc wander, irregular weld bead shape, slag
inclusions, fluid weld pool making positional welding difficult.
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 Welding Processes
Manual Arc Welding

➢ Travel Speed

▪ Travel speed too fast: Narrow thin weld bead, fast cooling, slag inclusions, undercut, poor
fusion/penetration.

▪ Travel speed too slow: Cold lap, excess weld deposition, irregular bead shape undercut.

➢ Polarity

▪ Polarity will determine the distribution of heat energy at the welding arc.

➢ Consumable

▪ For manual arc welding there are three generic types of flux covering. Rutile, Basic, Cellulosic.
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 Welding Processes
Manual Arc Welding

1 2 3 4 5 6 7

1-Normal
2-Current Low 4-Arc Short 6-Travel Speed Slow
3-Current High 5-Arc Long 7-Travel Speed High
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 Welding Processes
Manual Arc Welding

Advantages:

✓ Shop or field use

✓ Range of consumables
✓ All positions
✓ Portable
✓ Simple equipment

Disadvantages:

× High welder skill is required

× High levels of fume
× Hydrogen control
× Stop/start problems
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 Welding Processes
Tungsten Arc Welding

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 Welding Processes
Tungsten Arc Welding

TIG is also called GTAW (gas tungsten arc welding) is a process where melting is produced by heating
with an arc struck between a non-consumable tungsten electrode and the workpiece .

An inert gas is used to shield the electrode and weld zone to prevent atmospheric contamination of the
weld and hot filler wire.

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 Welding Processes
Tungsten Arc Welding

The main variables in TIG welding are:

➢ Welding current Pure Tungsten

%2 Serum
➢ Current type and polarity
%1.5 Lantin

➢ Travel speed %0.8 Zirconium

%2 Thorium

➢ Shape of tungsten electrode tip and vertex angle

➢ Shielding gas flow rate

➢ Electrode extension

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 Welding Processes
Tungsten Arc Welding

▪ Electrode extension is the distance from the contact tube to the tungsten tip.
▪ If the electrode extension is too small, low electron emission and unstable arc.
▪ If the electrode extension is too large overheating and tungsten inclusions.
▪ As a general rule, stick out length should be 2 to 3 times the electrode diameter.

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 Welding Processes
Tungsten Arc Welding

Advantages:

✓ Weld quality is high, with very low levels of diffusible hydrogen so there is less danger of cold
cracking.
✓ Does not give either weld spatter or slag inclusions.
✓ Can weld almost all weldable metals.
✓ The process does not have any cleaning action.

Disadvantages:

× Tungsten inclusions can occur if the electrode is allowed to contact the weld pool.
× There is a need for higher qualified welders.
× Is difficult to fully shield the weld zone in draughty conditions and so may not be suitable for
site/field welding.
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 Duties
Inspection Personnel

ISO 17637 states that welding inspectors should ;

▪ Be familiar with relevant standards (may be National or Client) , rules and specifications for the
fabrication work that is to be undertaken

▪ Be informed about the welding procedure(s) to be used

▪ Have good vision – in accordance with EN 9712 and should be checked every 12 months

Note: ISO 17637 does not give or make any recommendation about a formal qualification for visual
inspection of welds

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 Duties
Visual Inspection min Conditions Requirement

ISO 17637 states that ;

▪ The minimum illumination shall be 350 lux but recommends a minimum of 500 lux (normal shop or
office lighting ).

Access to the surface, for direct inspection, should enable the eye to be:

▪ Within 600mm of the surface being inspected

▪ In a position to give a viewing angle of not less than 30°

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 Duties
Visual Inspection min Conditions Requirement

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 Duties

Visual Inspection min Conditions Requirement

Inspector should be read the following word min minimum Jaeger number 1 or Times New Roman N4.

CAN YOU READ THIS WORD

Also Inspector should be pass the Ishihara Test as well

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 Duties

Stages of Visual Inspection

Extent of examination and when required should be defined in the application standard or agreement between
the contracting parties.

For the process following steps control are highly recommended

➢ Before Welding
▪ Before Assembly
▪ After Assembly

➢ During Welding

➢ After Welding

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Duties
Before Welding

Check Point Action by Inspector

Material In accordance with drawing/WPS Identified and can be traced to a test certificate In
suitable condition (free from damage and contamination
WPSs Have been approved and are available to welders (and inspectors)
Welding equipment In suitable condition and calibrated as appropriate
Weld preparations In accordance with WPS (and/or drawings)
Welder qualifications Identification of welders qualified for each WPS to be used. All welder qualification
certificates are valid (in date)
Welding consumables Those to be used are as specified by the WPSs are being stored/controlled as
specified by the QC Procedure
Joint fit-ups In accordance with WPS/drawings tack welds are to good workmanship standard and
to code/WPS
Weld faces Are free from defects, contamination and damage
Preheat (if required) Minimum temperature is in accordance with WPS
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Duties
During Welding

Check Point Action by Inspector

Site/field welding Ensure weather conditions are suitable/comply with Code (conditions will not affect
welding)
Welding process In accordance with WPS
Preheat (if required) Minimum temperature is being maintained in accordance with WPS
Interpass temperature Maximum temperature is in accordance with WPS
Welding consumables Accordance with WPS and being controlled as Procedure
Welding parameters Current, volts, travel speed are in accordance with WPS
Root run Visually acceptable to Code (before filling the joint) (for single sided welds)
Gouging/grinding By an approved method and to good workmanship standard
Interrun cleaning To good workmanship practices
Welder On the approval register/qualified for the WPS being used

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Duties
After Welding

Check Point Action by Inspector

Weld identification Each weld is marked with the welder's identification and is identified in
accordance with drawing/weld map
Weld appearance Ensure welds are suitable for all NDT (profile, cleanness etc) Visually inspect
welds and sentence in accordance with Code
Dimensional survey Check dimensions are in accordance with drawing/Code
Drawings Ensure any modifications are included on as-built drawings
NDT Ensure all NDT is complete and reports are available for records
Repairs Monitor in accordance with the Procedure
PWHT (if required) Monitor for compliance with Procedure (check chart record)
Pressure/load test (if required) Ensure test equipment is calibrated Monitor test to ensure compliance with
Procedure/Code. Ensure reports/records are available
Documentation records Ensure all reports/records are completed and collated as required
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 Duties
ORC (Observe Record Compare)

Inspector to ensure all the actions are carried out in accordance with the specification and/or applicable
client procedures.

Observe
▪ To observe all relevant actions related to weld quality throughout production.

Record
▪ To record, or log all production inspection points relevant to quality, including a final report showing all
identified imperfections

Compare
▪ To compare all recorded information with the acceptance criteria and any other relevant clauses in the
applied application standard
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 Welding Inspectors Equipment's

➢ Flexible tape, steel rule

➢ Temperature indicating crayons

➢ Welding gauges
➢ Voltmeter

➢ Amperemeter

➢ Magnifying glass
➢ Torch / flash light

➢ Gas flow-meter

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 Welding Inspectors Equipment's
How to use welding measurement devices

Weld Gauge

Hi-Lo Gauge

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