Welding Inspection Procedure / Checklist

Stage 1 - Welding Inspection Prior to Welding Work

1. Welding symbols and weld sizes clearly specified in drawing and related
documents.
2. Weld joint designs and dimensions clearly specified in drawings and related
documents.
3. Weld maps identify the welding procedure specification (WPS) to be used for
specific weld joints.
4. Dimensions detailed and potential for distortion addressed.
5. Welding consumables specified.
6. Proper handling of consumables, if any, identified.
7. Base material requirements specified (such as the use of impact tested
materials where notch ductility is a requirement in low temperature service).
8. Mechanical properties and required testing identified.
9. Weather protection and wind break requirements defined.
10. Preheat requirements and acceptable preheat methods defined.
11. Post-weld heat treatment (PWHT) requirements and acceptable PWHT
method defined.
12. Inspection hold-points and NDE requirements defined.
13. Additional requirements, such as production weld coupons, clearly specified.
14. Pressure testing requirements, if any, clearly specified
15. Competency of welding organization to perform welding activities in
accordance with codes, standards, and specifications specified
16. Roles and responsibilities of engineers, welding organization, and welding
inspectors defined and appropriate for the work.
17. Independence of the inspection organization from the production organization
is clear and demonstrated.
18. WPS(s) are properly qualified and meet applicable codes, standards and
specifications for the work.
19. Procedure qualification records (PQR) are properly performed and support the
WPS(s).
20. Welder performance qualifications (WPQ) meet requirements for the WPS.
21. NDE examiners are properly certified for the NDE technique.
22. NDE procedures are current and accurate.
23. Calibration of NDE equipment is current.
24. Welding machine calibration is current
25. Instruments such as ammeters, voltmeters, contact pyrometers, have current
calibrations.
26. Storage ovens for welding consumables operate with automatic heat control
and visible temperature indication.
27. Heat treatment procedure is available and appropriate
28. Pressure testing procedures are available and detail test requirements.
29. PWHT equipment calibration is current.
30. Pressure testing equipment and gauges calibrated and meet appropriate test
requirements.
31. Material test certifications are available, and items properly marked (including
back-up ring if used ;).
32. Electrode marking, bare wire flag tags, identification on spools of wire, etc. as
specified.
33. Filler material markings are traceable to a filler material certification.
34. Base metal markings are traceable to a material certification.
35. Recording of filler and base metal traceability information is performed.
36. Base metal stampings are low stress and not detrimental to the component.
37. Paint striping color code is correct for the material of construction.
38. PMI records supplement the material traceability and confirm the material of
construction.
39. Weld preparation surfaces are free of contaminants and base metal defects
such as laminations and cracks.
40. Preheat, if required, applied for thermal cutting c. Hydrogen bake-out heat
treatment, if required, performed to procedure.
41. Weld joint is free from oxide and sulfide scales, hydrocarbon residue, and any
excessive build-up of weld-through primers.
42. Weld joint type, bevel angle, root face and root opening are correct.
43. Alignment and mismatch is correct and acceptable.
44. Dimensions of base materials, filler metal, and weld joint are correct.
45. Piping socket welds have proper gap.
 46. Preheat equipment and technique are acceptable.
47. Preheat coverage and temperature are correct.
48. Reheat, if required, applied to thermal cutting operations.
49. Preheat, if required, applied to remove moisture
50. Filler metal type and size are correct per procedure.
51. Filler metals are being properly handled and stored.
52. Filler metals are clean and free of contaminants.
53. Coating on coated electrodes is neither damaged nor wet.
54. Flux is appropriate for the welding process and being properly handled.
55. Inert gases, if required are appropriate for shielding and purging.
56. Gas composition is correct and meets any purity requirements.
57. Shielding gas and purging manifold systems are periodically bled to prevent
back filling with air.

Stage 2 - Welding Inspection During Welding

1. Welder is responsible for quality craftsmanship of weldments
2. Welder meets qualification requirements
3. Welder understands welding procedure and requirements for the work.
4. Special training and mock-up weldments performed if required.
5. Welder understands the inspection hold-points.
6. Essential variables are being met during welding.
7. Filler material, fluxes, and inert gas composition/flow rate.
8. Purge technique, flow rate, O2 analysis, etc.
9. Rod warmers energized or where rod warmers are not employed, the welder
complies with maximum exposure times out of the electrode oven.
10. Preheating during tack welding and tack welds removed (if required).
11. Welding technique, weld progression, bead overlap, etc.
12. Equipment settings such as amps, volts, and wire feed.
13. Preheat and interpass temperatures.
14. Travel speed (key element in heat input).
15. Heat input (where appropriate).
16. Mock-up weldment, if required, meets requirements with welder and welding
engineer.
17. Welder displays confidence and adheres to good welding practices.
18. Tack welds to be incorporated in the weld are of acceptable quality.
19. Weld root has adequate penetration and quality.
20. Cleaning between weld passes and of any back-gouged surfaces is
acceptable.
21. Additional NDE performed between weld passes and on back-gouged
surfaces shows acceptable results.
22. In-process rework and defect removal is accomplished.
23. In-process ferrite measurement, if required, is performed and recorded.
24. Final weld reinforcement and fillet weld size meets work specifications and
drawings.
Stage 3 - Welding Inspection Upon Completion Of
Welding

1. Size, length and location of all welds conform to the drawings / specifications
/ Code.
2. No welds added without approval.
3. Dimensional and visual checks of the weld don’t identify welding
discontinuities, excessive distortion, and poor workmanship.
4. Temporary attachments and attachment welds removed and blended with
base metal.
5. Discontinuities reviewed against acceptance criteria for defect classification.
6. PMI of the weld, if required and examiner’s findings indicate they comply with
the specification.
7. Welder stamping/marking of welds confirmed.
8. Perform field hardness check.
9. Verify NDE is performed at selected locations and review examiner’s findings.
10. Specified locations examined.
11. Specified frequency of examination.
12. NDE performed after final PWHT.
13. Work of each welder included in random examination techniques.
14. RT film quality, IQI placement, IQI visibility, etc. complies with standards.
15. Inspector is in agreement with examiners interpretations and findings.
16. Documentation for all NDE correctly executed
 17. Verify post-weld heat treatment is performed to the procedure and produces
acceptable results.
18. Paint marking and other detrimental contamination removed.
19. Temporary attachments removed.
20. Machined surfaces protected from oxidation.
21. Equipment internals, such as valve internals, removed to prevent damage.
22. Equipment supported to prevent distortion.
23. Thermocouples fastened properly.
24. Thermocouples adequately monitor the different temperature zones and
thickest/thinnest parts in the fabrication.
25. Temperature monitoring system calibrated.
26. Local heating bandwidth is adequate.
27. Insulation applied to the component where required for local heating.
28. Temperature and hold time is correct.
29. Heating rate and cooling rate is correct.
30. Distortion is acceptable after completion of the thermal cycle.
31. Hardness indicates an acceptable heat treatment
32. Verify pressure test is performed to the procedure
33. Pressure meets test specification.
34. Test duration is as specified.
35. Metal temperature of component meets minimum and maximum
requirements.
36. Pressure drop or decay is acceptable per procedure.
37. Visual examination does not reveal defects.
38. Perform a final audit of the inspection dossier to identify inaccuracies and
incomplete information.
39. All verifications in the quality plan were properly executed.
40. Inspection reports are complete, accepted and signed by responsible parties.
41. Inspection reports, NDE examiners interpretations and findings are accurate.

We as welding inspection company utilize many instructions, procedures, welding

inspection forms to check above point precisely that refer to inspection after welding
process.
Welding Inspection @ ASME Section IX
Here are some important points in the ASME Section IX that are necessary to be
taken in account for any welding inspection company that conducts welding
inspection on fix equipment, process and power piping and above ground storage
tank.

1. A WPS is a written document that provides direction to the welder or welding

operator for making production weld in accordance code requirement. It
must be check by welding inspection company.
2. The PQR documents what occurred during welding the test coupon and the
result of testing of the coupon. It must be checked by welding inspection
company.
3. Procedure qualifications give suitability of weld for required mechanical
properties (i.e., strength, ductility), while performance qualifications show the
ability of the welder to deposit sound weld. This must be checked by welding
inspection company.
4. Each manufacturer or contractor shall maintain a record of the result obtained
in welding procedure and welder/operator performance qualifications. The
records shall be certified by manufacturer or contractor and accessible to the
authorized inspector
5. Tension test gives tensile value, while bend test shows ductility and
soundness. Radiography also indicates soundness.
6. Thus, Procedure Qualification: Tension test + Bend test
7. Performance Qualification: Bend test or Radiography
8. Tensile test for procedure qualification is passed if failure is in a) Weld metal
at strength>= Base metal SMTS or b)Base metal at strength>= 95% of base
metal SMTS. This must be checked by welding inspection company.
9. When the welder or welding operator is qualified by radiography, the
minimum length of coupon to be examined shall be 6 inch and shall include
the entire weld circumference for pipe
10. Production test with some condition is acceptable
11. Bend test crack shall not exceed 1/8” in any direction. Radiography criteria
are stricter than radiography for the job.
12. P-numbers represent parent metal classification of similar composition and
properties, i.e., similar strength and ductility.
13. F-number gives similar usability aspects of filler material.
14. A-number gives similar chem. comp. In “as welded” condition.
15. Essential variables (EV), if changed require new procedure qualification. Non-
essential variables (NEV) may be changed without new procedure
qualification. But the procedure must be revised.
16. Supplementary essential variables (SEV) are considered as (EV) only if there is
impact strength requirement. Otherwise, they are “non-essential” variables.
17. EV and SEV are included in PQR document. EV, SEV, and NEV are included in
WPS document.
18. PQR document gives data used in PQR test and test results and cannot be
revised.
19. WPS gives parameters to be used in the production job and must be within
ranges qualified by the PQR test.
20. WPS may be revised within the EVs qualified. The NEVs can always be
revised without affecting the validity of PQR.
21. Only in SMAW, SAW, GTAW, PAW and GMAW (except short-circuiting) or the
combination of them Radiography test can be used for welder performance
qualification test, but there is an exception, except P-No.21 through P-No.25
and P-No.51 through P-No.53 and P-No.61 through P-No.62, welder making
groove welds P-No.21 through P-No.25 and P-No.51 through P-No.53 metals
with GTAW process may also be qualified by radiography.
22. For welder performance qualification when the coupon has failed the visual
examination, and immediate retest is intended to be done, the welder shall
make two test coupons for each position which he has failed. If both test
coupons passed the visual inspection, one may be selected by the examiner
for mechanical, in a similar way if mechanical test coupon has failed, two test
coupons shall make by the welder, both test coupon shall pass the test.
23. For welder performance qualification by radiography for immediate retest,
two 6-inch plate and pipe examination shall include two pipes for a total of 12
inch of weld which shall include entire weld circumference
24. When the welder has not welded with a process during a period of 6 months
or more, his qualification for that process shall expire
25. Article IV should not be read directly, during the study of other articles
specifically “welding variables procedures specifications” (QW-252 through
265) should refer to a specific paragraph in this article.
26. For performance, 1G is flat, 2G is horizontal, 3G is vertical, and 4G is the
overhead position. Pipe 5G qualifies 1G, 3G, and 4G, but pipe 6G qualifies all
positions.