Duties & Responsibilities

Personal Attributes

Honesty
Integrity
Knowledgeable
Good communicator
Physically fit.

Duties & Responsibilities

Supervise
Planning
Organisation
Auditing

DUTIES OF SENIOR WELDING INSPECTOR

What are the Duties of the Senior Welding
Inspector?
The senior welding inspector will be required to: manage and control.
provide guidance and advice on subjects of a
technical nature.
show leadership skills in addition to technical skills
and experience.

DUTIES OF SENIOR WELDING INSPECTOR

Technical skills required for the Senior

Welding Inspector?
1.
2.
3.
4.
5.

Knowledge of technology.
Knowledge of normative documents.
Knowledge of planning.
Knowledge of organisation.
Knowledge of auditing.

DUTIES OF SENIOR WELDING INSPECTOR

1. Knowledge of technology.
Similar to that required for a welding inspector. Additional
knowledge would include;
Commonly used NDT techniques.
Radiographic interpretation.
QA/QC knowledge.
Basic metallurgy of commonly welded
materials.
Assessment of fracture surfaces.

DUTIES OF SENIOR WELDING INSPECTOR

2. Knowledge of normative documents.

Specified normative documents should be
available at the work place. The SWI would be
expected to read, understand and apply them with
the necessary level of precision and direction.
The SWI should be aware of common standards
applied in the welding industry.

DUTIES OF SENIOR WELDING INSPECTOR

3. Knowledge of planning.

Planning will be required for all phases of a project,

from start to completion.

Planning for inspection would usually relate to the

following areas as a minimum;

Pre - contract

In - contract

Post - contract

DUTIES OF SENIOR WELDING INSPECTOR

4. Knowledge of organisation.
Organisational skills are necessary to ensure that the
inspection requirements of any plan can be met on
time using the correct personnel for the job.
This may include assessment of;

Availability of inspectors.

Competence of inspectors.

Supervision / monitoring of inspectors.

DUTIES OF SENIOR WELDING INSPECTOR

5. Knowledge of auditing.

Auditing may take place at any stage

in a project or contract.
It is basically checking against
documented criteria.
There are three areas of audit;
Pre - production
In - production
Post - production

Supervision

Personality
Professional
Responsible
Impartial
Tolerant
Factual
Decisive
Diplomatic
Communicator

Technical
Knowledgeable
Qualification
Experience
Problem solver
Advisory

Supervision

What is a supervisor?
Supervisor a person who supervises
another person(s),task, etc; manager, a
superitendant,an on looker, a reviser,
senior inspector,etc
To understand and what is a supervisor, put
yourself those questions:
What expected of me?
Where do I fit in?
What are my responsibilities?

Duties & Responsibilities

What is expected of me?

Be knowledgeable of your job
Be a leader
Set a good example
Do your best and expect other to do the
same
Be a team player
Be fair but firm, earn respect

Supervision

Where do I fit in?

Manager

Welding
supervisor
production
Welding foremen

Welders

Welding
supervisor
Inspection
Welding inspector

Welders

Welding
supervisor
NDT
NDT Technician

Welders

Supervision
What are my responsibilities?

Quality control

Welding

Training

Inspection & training

Safety

Report

Supervision

QUALITY CONTROL

Know the requirements!

Check the materials
Schedule NDE,be first to know results
Calibrated equipment used where required
Maintain current records

Supervision

WELDING

Know the requirements!

Know the WPSS
Know joint fit up and tolerence,clean!
Know the electrode types, heat treatments & any
special storage requirements
Know welder qualification and skill levels
Ability to communicate WPS requirements to welders
Ability to carried out demonstration if needed
Overall check on welders performance and any repair
or defect trends

Supervision

TRAINING

It is the supervisors to aid in recruitment and

qualifying welders when required for the job. He must
help welders to improve their skills and productivity.
He does this by:
Maintain his own proficiency in the various welding
process
Visually inspecting each welders work and progress
Encouraging welders to achieve higher standards of
quality and production
Participating actively in safety awareness and
training

Supervision

INSPECTION & TESTING

Ensure work meets standards and codes

Ensures all testing & NDT is correct and
properly done
All works is completed & signed off when
required
Outstanding repairs are completely in at
timely manner

Supervision

SAFETY

Set the example (always wear safety

equipment/P.P.E)
Participate actively in safety meeting
Highlight any unsafe practices to senior
management
RAP (reconised,avoid & prevent)
Daily safety contact (solve issues with
workforce)

Supervision

REPORTS

Record drawings (numbers,revisions,etc)

Check if NDT is completed and all report
sign and accepted
No safety issues are outstanding
Produce a weekly progress and overall
quality report for management meeting

Planning & organisation

Resources can be:

All planning requires answers to the
five planning questions
What?
Where?
When?
Who?
How?

Planning & organisation

It is your responsibility to organize and

allocate resources to task
Those resources can be:
1) PEOPLE
Knowledgeable
Experience
Training
Task and safety
Number

Planning & organisation

Resources can be:

2) MATERIALS
Permanent /contract
Expendable
Drawings
Specifications
Procedures

Planning & organisation

Resources can be:

3) EQUIPMENT
Major equipment:Crane,generator,welding
plant, air compressor ,etc
Tools: welding leads, air
hose,grinders,grinding ,etc
Supplies : welding consumables,gas,etc
PPE : Hardness, grinding shields, ear
plugs,glasses,etc

Planning & organisation

4) Documentation
Specifications: revisions amendments etc.
Manufacturing: job instructions, mill certs etc
Modifications concessions
Quality manual
Procedures: assembly, welding, repair welding, NDT
etc
Welder qualification: approval and history etc
Inspectors: approvals and history etc
Calibration certificates
All reports

Planning & organisation

How much inspection is required?

Total man hours required
Number of personnel required
Estimation of job times
Analysis of job sequences
Preparation requirements & time
Travel and down time (mobilisation/demob)
Leave time for personnel
Ability of staff

Planning & organisation

The amount of planning required depends

upon the company size
Why?
To force people to think things through
To optimise team/individual performance
To provide documentation for traceability
To convert solved problems into recorded
knowledge
To co-ordinate actions between departments
To improve efficiency, Quality and cost
effectiveness

Planning & organisation

Advantages of planning
1. Jobs are planned and issued in correct
sequence, reducing unnecessary work
2. Men and equipment are supplied at the right time
with the correct materials
3. The correct quality standards are achieved for
the minimum cost
4. Completed goods are despatched as promised
5. Adequate stock levels are maintained
6. Greater job satisfaction/security

AUDITING.
Auditing
stage

Actions required
Assess qualifications / ability of staff.

Pre - production

Planned work scheduling.

Assess whether specifications are being

In - production

Post production

worked to.

Assess overall standard of welding and

inspection.

Auditing
Definitions:systematic,independent and
documented process for obtaining evidence it
objectively to determine the extent to which criteria
are fulfilled
a system

Audit

a compliance

Is quite shallow; examines the

system to confirm that if
follows the quality manual and
procedures are in place
It goes in- depth; examines the
compliance with procedures
and quality manual

Auditing
Definitions
Audit program: set of one or more audits planned
Audit criteria: set of policies, procedures or
requirements used as a reference
Audit evidence: records, statements of fact which relate
to audit criteria
Audit findings: results of the evaluation of the

collected

audit evidence against audit criteria

Audit conclusion: outcome of an audit provided by the
audit team, after considerations of the audit findings

Auditing
Assessment of:
Staff
Equipment
Q.A / Q.C and Inspection
Documents
Safety

Auditing
Internal audits
First Party Audits
Conducted for the companies internal purposes
External Audits
Second Party Audits
Conducted by parties having an interest in the
company, such as customers or by other persons
working on their behalf
Third-Party Audits
Conducted by external independent organizations,
which provide certification of conformity

Traceability
Definition: Ability to trace the history, application or location
of that which is under consideration
Traceability
can relate
to:
The origin
of materials
and parts
Traceability - HOW?

The
processin
g history

hard stamping
painting/etching
labelling

WHEN?

The
distribution
and location
of the product
after delivery
Immediately after
the operation!

Conformity
Conformity
Release
fulfilment
Requireme
nt

Repair

Scrap

Concessio
n
SDR

nonfulfilment
Nonconformi
ty

Nonconformit
y report

Corrective
action

Conformity evaluation
Test

determination of one or characteristics

according to a procedure can be nondestructive or destructive

Conformit
y
evaluatio
n
Inspection

evaluation by observation and

judgement can be accompanied
by measurement, testing or
gauging

Inspection - terminology
Discontinuit
y
Detectio
n
Indication
Evaluation
Acceptance
level

Recordabl
e
indication

detectable change in the

material

signal from a discontinuity typical

to the testing method used
prescribed limit below which a
component is accepted

DEFECT

Quality Control & Quality Assurance

Quality

Quality
is a subjective thing
..what is quality to you might not
be quality to me
Quality = degree to which a set of inherent
characteristics fulfills explicit and implicit
requirements

Quality - definitions
Management

Quality

Policy

system

Coordinated activities to
direct control an
organization
Overall intentions and
directions of an
organization related to
quality as formally
expressed by top
management
A system to direct and
control an organization
with regard to quality

Quality management activities

Assurance

Part of quality
management focused on
providing confidence
that quality requirements
will be fulfilled

Why we need QA?

Quality

prevent defective work

ensure programme commitment
are achieved
provide feedback to the
management

Control

Part of quality
management focused on
fulfilling quality
requirements

Quality assurance documents

Quality
assurance
documents

specification

Document stating
requirements (related to
activities or products)

Quality
manual

Document specifying the

quality management
system of an organization

Quality plan

procedure
Code of
practice

Document specifying
which procedures and
resources shall be applied
by whom and when to a
specific project
Specified way to carry out an
activity
Set of rules for
manufacturing a specific
product or activity

Quality plan

Is a check list specifies which procedures and associated

resources shall be applied, by whom and when to a specific
project,product,process or contract

Is a list with the main operation following manufacturing

sequences
Stop/hold point with specific requirements (e.g. document
check,NDT witnessed by customer representative,
independent body supervision, procedure used, acceptance
standards,etc)
Type and number of document issued (NDT
report,WPAR,welder qualification , dimensional check
list,etc)
Name and signature of welding coordinator in charge with
each operation ( if required)
Date of completion for each step

Quality plan
Process
descriptio
n activity

Responsibl
e person

Process
reference
document

Approva
l
/remark
H
s
W
R
A
M

H - Hold point: work shall stop until

representative are present to
monitor/observe
activity
W
- Witness point:
notifiable point; should
representative fail to attend, work may
proceed
R - Document review
A - Document approval
M - Monitor/periodic control of activity

Welding map
N1

N2

L1

C3

L3

N3
N4

C5
L4

C2
C1

C6
S1

Information's to be
weld type and
supplied:
position
WPS and PQR
number
type and extent of

L2

C4

L5

S2

welders stamp
number
type of PWHT

Quality pack
a.k.a. doc pack, history
docket
Quality pack
content

Documents supplied
before
commencement of
manufacture

Documents
supplied on
completion of
construction

Quality pack content

Documents supplied
before manufacture

certificate of conformance with

different codes/standards
design calculations (optional)
manufacturing drawings
WPS with supporting WPQR
(copies)
welder qualifications
qualification of NDT personnel
NDT procedures
PWHT oven calibration record
(optional)

Documents supplied
after manufacture
material test certificates (list!)
welding production tests (if
required)
PWHT record (if required)
NDT test reports: dimensional,
pressure test and coating thickness
are included
quality plan and weld map
as-built drawings
non-conformity reports (SDR)
operating/mounting instructions

QA Vs - QC

QA applies to all
areas which have
an affect on quality

has the work been performed

correctly?

QC deals with the

actual measurement
of quality performance

is the work/action been performed

correctly?

QA Vs - Inspection

QA is mainly about
documentation
And must see the
whole picture

quality assurance is not

inspection

Inspection is mainly
about physical reality,
monitoring and
measuring, a QC tool

comparing the results against

documented criteria

Definitions Relating to Quality

Quality Assurance: All those planned and systematic actions
necessary to provide adequate confidence that a product or
service will satisfy given requirements for quality or that quality
requirements will be fulfilled
Quality Control: The operational techniques and activities that are
used to fulfil the requirements for quality
Inspection: Activities such as measuring, examining, testing,
gauging one or more characteristics of a product or service and
comparing these with specified requirements to determine
conformity. Inspection is a tool used for quality control
Testing: Determination of one or more characteristics according to
a procedure

Concepts Relating to Quality Management

top management
quality management

quality planning quality assurance

quality control
Inspection

Concepts Relating to Quality Management

Requirements

Quality
Degree to which a set of
inherent characteristics
fulfils requirements

Customer satisfaction
Customers requirements
have been fulfilled

Grade

CSWIP 3.2 Mandatory Question

You are required to visit a site on which your welding

inspectors have been involved
The work concerns the inspection of a welded
fabrication to a specific application standard and is
now ready for final approval
What question do you ask?
What documents do you review and what inspections
do you require before submitting an inspection report
to the authorities concerned?

CSWIP 3.2 Mandatory Question

Prior to your visit on site it is important to spend time planning
and organizing the visit, in order that all the vital details are not
overlooked.
Knowledge of the product with regards to the specification and
codes and standards from which it has been fabricated and the
service life and service conditions of the product are beneficial in
assessing the fitness of the product for service.
A list of the inspection team will ensure that those involved with
the fabrication and inspection of the product are at hand to answer
any question.
The following documents should be reviewed as a minimum prior
to the final approval of the product.

CSWIP 3.2 Mandatory Question

1. Review the quality plan and inspection check lists ensuring all
stages have been completed and signed.
2. Review the client specification as to ensure weld and materials
suitability.
3. Check material/mill certs, ensuring all heat numbers have been
transferred where applicable.
4. Review procedure and qualification test certs for bending,
rolling and all other cold forming operations.
5. Review all welding procedure specifications, repair welding
procedure.
6. Review all NDT procedures
7. Review all NDT personal, checking qualifications against clients
requirements.
8. Review PWHT records, check calibration certs of equipment
used where applicable.

CSWIP 3.2 Mandatory Question

9. Check the technical data sheets of all welding consumables used,
storage conditions and heat treatments where applicable.
10. Check welder approval certs, check all welding operations carried
out by qualified welders only.
11. Check that all production tests on parent material and welds
have been carried out, where applicable.
12. Check and review all NDT reports.
13. Review all technical drawings, showing materials and weld maps
tractability.
14. Dimension checks.
15. Check all painting/coating procedures.
16. Check all painting/coating reports.
17. If applicable, check the final as-build drawings, locating all
material used in the fabrication, cross-referencing the weld
identification numbers to the NDT reports.

Missing
Documents

Weld
Procedures

Material
Traceability &
Mill Certs
Coatings

& Welder Quals

Pressur
e
testing

Distortion
&
Dimension
s

Inspection
Reports,
Inspection
personnel,

Any Questions