Weld Inspector Duties

Weld inspector duties vary depending on the industry but generally consist of activities before, during, and after welding occurs. Common duties include verification of welding procedures and certifications before welding begins, visual inspection of welds during and after welding is complete, and documentation of inspections performed.

The phases of weld inspection are broken down into the following categories:

• Job Setup

• Before Welding

• During Welding

• After Welding

• Inspection Paperwork

Good written and verbal communication is also essential for a weld inspector to work effectively with engineers, welders and management.

To be an effective weld inspector it is crucial to become familiar with the different industries and the welding codes aligned with them. It is also essential to be able to know the difference between the owner requirements detailed in their specifications, common industry practices, and what is actually a code requirement.

Job Setup

• Contractual Documents

  • Specifications

  • Drawings

• Submittals

  • Welding Procedure (WPS & PQR)

  • Welder Qualification (WPQ)

  • NDE Procedures (VT, MT, PT, RT, etc…)

  • Quality Procedures

  • Others depending on project requirements

• Equipment

  • Welding machines & related peripherals

  • Calibration of Measuring and Testing Equipment

    • Torque wrenches

    • Pressure gauges

    • Measuring tapes

Before Welding

• Materials

  • Base metal

    • MTR’s (as required)

    • Material markings (Specification and Grade)

    • P-Number matches accepted WPS

    • Transfer of heat numbers or material identification when cut or divided

    • Material irregularities; deformation, gouges, mechanical wear, corrosion, cracks

  • Filler metals

    • MTR’s (as required)

    • Material markings (Specification and Classification)

    • Filler metal matches accepted WPS

    • Storage and method of handling and distribution

• Rod Ovens

  • for SMAW low-hydrogen electrodes

• Weather / Environmental Protections

  • Proper shelter from weather, wind or draft to avoid detrimental affects

• Welding Procedure

  • Available to the welders performing the work, welders know how to access, and comply with variables

• Weld Preparation

  • Joint configuration such as root opening, misalignment, root face, items that can’t be checked once welding has begun

  • Internal Cleanliness

• Tack Welding properly performed by qualified welders

• Fit-up Checks

  • Dimensional checks

  • Configuration checks

During Welding

• WPS Variables

  • Joint Configuration, Base Metal, Filler Metal, Preheat, Interpass Temperature, Shielding Gas or Backing Gas, Electrical Characteristics (Amps, Volts, Wire Feed Speeds), Welding Technique, etc.

• Welding Equipment settings and condition, including welding consumables, connections related to welding leads, integrity of shielding gas lines and distribution systems

• Grounding: secured near the welding, and does not have a path through equipment that may have its own wiring systems

• In process welding inspection; free of weld defects, proper interpass cleaning, properly placed weld layers, free of arc strikes, if the ID of open roots are visible check for proper ID reinforcement

• Dimensional surveillance and checks

• Monitor for heat distortion and distortion controls, proper weld stepping or sequencing, clamping, counter bowing, interpass temperature

• Proper ventilation is available in the welding area

• Ensure draft or wind protection is in place, including prevention of fans meant for cooling are not interrupting proper weld shielding.

After Welding

• Welds cleaned: spatter and/or slag removal, wire brushing, removal of smoke residue

• No excessive slag chipping marks in the base metal as applicable

• VT

  • Inspect for: Size, profile, reinforcement, undercut, porosity, cracking, craters, slag removal, proper cleaning, arc strikes, external slag inclusions, underfill, lack of fusion, incomplete penetration on ID of open roots where visible, surface finish, welder ID markings - stencil/stamps

  • Use visual aids or tools such as measuring tape, calipers, groove weld gauges, fillet weld gauges, temperature measuring tools,

• Monitor or Perform NDE

  • MT : Magnetic Particle Testing

  • PT : Dye Penetrant Testing

  • RT : Radiographic Testing

  • UTSW : UT Shear Wave - Ultrasonic

  • PAUT : Phased Array UT - Ultrasonic

• Monitor PWHT

  • Target temperatures at required durations

  • Heating and cooling ramp rates

  • Proper soak band (SB), heating band (HB), and gradient control band (GCB), and insulation thickness

  • Thermocouples: proper quantity placed in the correct locations

• Bolting

  • Correct bolting materials (bolting assembly - bolt, nut, washer, lubrication), diameter, length

  • Proper alignment of bolted items before tightening

  • Correct tightening sequence

  • Torque or tension requirements complied with as applicable

  • Torque checks or hammer/ping testing to confirm proper tightening

• Pressure Testing (Pipe & Vessels)

  • Confirm welding and NDE are complete before testing begins

  • If required welds are not coated for pressure testing

  • Pressure sensitive valves or instrumentation are removed for testing

  • Correct pressure testing medium is used (Water/Hydro or Air/Pneumatic

  • Required testing pressure was achieved for the necessary duration

  • Calibrated test gauges were used during the test

  • Proper flushing and drying occurred post test

Inspection Paperwork

• Fill out inspection paperwork in an accurate and timely manner

• Utilize computer generated reports, or handwritten hard copies, using legible handwriting, and permanent ink

• Attach photos if permitted and appropriate for the work scope

• Compile the inspection reports, and other documentation generated during the process into a final package