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Inspector Course Outline

The document outlines the course training for a QC inspector. It discusses the duties and responsibilities of inspectors, qualification requirements, and ethical standards. Key areas of inspection covered include quality assurance, materials inspection, layout and cutting, fit-up, welding, non-destructive testing, and documentation of inspection records. The goal of welding inspectors is to ensure quality while meeting delivery schedules.

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bhingmeh yotal
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121 views

Inspector Course Outline

The document outlines the course training for a QC inspector. It discusses the duties and responsibilities of inspectors, qualification requirements, and ethical standards. Key areas of inspection covered include quality assurance, materials inspection, layout and cutting, fit-up, welding, non-destructive testing, and documentation of inspection records. The goal of welding inspectors is to ensure quality while meeting delivery schedules.

Uploaded by

bhingmeh yotal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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QC INSPECTOR’S

COURSE TRAINING
COURSE OUTLINE
I. INTRODUCTION
A. Duties & Responsilibilities of Inspector
B. Qualification & Requirements
1. Categories of Inspector
2. Ethical Requirements
• II. QUALITY ASSURANCE
A. QA Manuals & Procedures
B. Codes and Standards
C. Project Specification
*III. MATERIAL INSPECTION
A. Material Receiving Inspection
1. Visual
2. Dimensional
3. Verification of Material Specification
4. Preparation of QCIR/NCR (CARE).
B. Material Testing
C. Review of Mill Certificates
IV. LAY-OUT & CUTTING INSPECTION
A. Material Traceability
1. Transfer of Heat Numbers
2. Verify Material Specification
3. Preparation of Mat’l Traceability Report
B. Dimensional Inspection
1. Length, Width & Thickness
2. Edge Preparation(Bevel & Root Landing)
V. FIT-UP INSPECTION
A. Fit-up Dimensions
1. Bevel, Groove, Root Landing & Gap, Alignment
B. Material Verification
1. Material Specification & Thickness
C. Preparation of QC Reports, CARE/Deficiency Report
D. Preparation of CARE and Deficiency Report
VI. WELDING INSPECTION
A. Welding Procedure Qualification
1. Welding Procedure Specification
2. Procedure Qualification Records
3. Welding Procedure Qualification Test
4. Essential and Non-essential Variables
B. Welding Performance Qualification
1. Welding Performance Qualification Records
2. Welder’s Qualification Test
- Preparation of Test Coupons
- Inspection Checklist
- Testing (RT & Mechanical Test)
C. Welding Consumables
1. Specification
2. Treatment
3. Mechanical Properties
- Filler Metal Properties
- Base Metal Properties
D. Welding (In-process) Inspection
1. Welding Terms & Symbols
2. Welder’s Identification
3. Preheat Requirements
4. Welding Process & Welding Parameters
5. Visual Inspection of Welds/Weld Defetcs
VII. NDT
A. Radiographic Testing
B. Ultrasonic Testing
C. Magnetic Particle Testing
D. Dye-Penetrant Testing
E. Visual Inspection
VIII. DESTRUCTIVE TESTING
A. Bend Test
B. Tension Test
C. Charpy Impact Test
IX. DIMENSIONAL INSPECTION
A. Structural Member
B. Pressure Vessel/Tanks
C. Piping/Machine Items
D. Tolerances, Allowances and Clearances
X. POST WELD HEAT TREATMENT
A. Principles and Application
XI. LEAK TESTING (Principles & Application)
A. Hydrostatic Testing
B. Pneumatic Testing

XII. SURFACE PREPARATION &


PAINTING INSPECTION

A. Tools & Equipment


B. Inspection of Surface Preparation
C. Painting Inspection

XIII. DOCUMENTATION

A. Type of Records and Report Forms


B. Preparation
C. Safekeeping of Records
Welding Inspector
Duties & Responsibilities
Responsible for judging the
acceptability of product according to
a written specification.
Must understand both limitation and
intent of the specification.
The goal of welding inspector is to
strive for a required quality, but not
to delay the completion and delivery
schedules without proper cause.
QUALIFICATION & REQUIREMENTS
WELDING INSPECTORS
CLASSIFIED AS FOLLOWS :

- Code or governing agency inspector


- Purchaser’s, customer’s or owner’s
inspector
- Fabricator’s, manufacturer’s, or
contractor’s inspector
- Architect’s or engineer’s inspector
QUALIFICATIONS OF WELDING
INSPECTOR
Physical Condition
Good Vision
Professional Attitude
Knowledge of Welding & Inspection
Terminology.
Knowledge of Drawings & Specification
Knowledge of Testing Methods
Ability to Produce and Maintain Records
Knowledge of Welding Process
Ability to be trained
Inspection Experience
ETHICAL REQUIREMENTS OF
WELDING INSPECTOR
Integrity
Responsibility to the Public
Public Statements
Conflict of Interest
Unauthorized practice
Establishing lines of communication
Establishing Lines of
Communication
Welder
Reporting Supervisor
Welding Foremen or Supervisors
Shop or Field Superintendent
Plant Managers
Design/Project Engineers
Welding Engineers
II. QUALITY ASSURANCE
QUALITY ASSURANCE
(Definition)
QUALITY CONTROL
(Definition)
IMS 9001:2000 (QUALITY
MANAGEMENT SYSTEM–QMS
MANUAL )
ISO PROCEDURES
ISO 9001:2000
CODES & STANDARDS
ASME
ASME I - Power Boilers
ASME II – Materials Specification
Part A – Ferrous Material Specification
Part B – Nonferrous Mat’l Specification
Part C – Specification for Welding Rods,
Electrodes, and Filler Materials
ASME V – Non Destructive Testing
ASME VIII - Pressure Vessel
ASME IX - Welding & Brazing Qualification
ASTM, AISC. ANSI, API, SAE,
AS/NZS ,
JIS,
DIN, EN, ISO, BS , etc.
What is welding?

Welding – is a process that results in joining of metals through


melting together by application of heat.
- fusion or melting of edges.

* How about brazing or soldering ?

Brazing – is a joining process that produces coalescences


of mat’ls by heating them in the presence of
filler metal having a melting point above 840 ºF
and below the melting point of the base metal.

Soldering – heating the filler metal (lead) at 350 ºF .


WELDING PROCESSES

SMAW – Shielded Metal Arc


Welding
GTAW – Gas Tungsten Metal Arc
Welding
GMAW – Gas Metal Arc Welding
FCAW – Flux- Cored Arc Welding
SAW - Submerged Arc Welding
ESW – Electroslag Welding
PAW – Plasma Arc Welding
SW – Stud Welding
What is arc welding ?

Electric Arc – is a spark produced in


an electric circuit when electric
current stops.
Arc length – distance between the
electrode and base metal.
Current – measured in ampere.
Voltage – measured in volts
Polarity – positive (+)/ negative (-)
Guide for Selecting a Welding
Machine
150-200 ampere – For light to medium duty welding.
Excellent for all fabrication purposes and rugged enough for
continuous operation on light or medium production work.

250-300 ampere – For average welding requirements. Used


in plants for production, maintenance, repair, toolroom
work, and all general shop welding.

400-600 ampere – For large and heavy duty welding.


Especially adaptable for structural work, fabricating heavy
machine parts, pipe and tank welding.
SHIELDED METAL ARC WELDING
Power Supply – for effective shielded
metal-arc welding constant-current type
of machine is required. This welding
machine is characterized by a dropping
volt-ampere curve in which a relatively
constant supply of current is produced
with only a limited change in voltage load.

Equipment – the basic units of any


shielded metal arc-welding system consist
of power supply, an electrode holder, a
ground clamp, and a protective shield.
SHIELDED METAL ARC WELDING
Power Supply – for effective shielded metal-arc
welding constant-current type of machine is
required. This welding machine is characterized
by a dropping volt-ampere curve in which a
relatively constant supply of current is produced
with only a limited change in voltage load.

Equipment – the basic units of any shielded metal


arc-welding system consist of power supply, an
electrode holder, a ground clamp, and a
protective shield.

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