1. Welder Qualification - use Table 4.9 to see the number of and type of specimens and range of thicknesses and diameter qualified. Also see Table 4.8 for the Welder qualification-production welding positions qualified by plate,pipe, and box tube tests. Note that a CWI/SCWI must stamp the welder's qualification record.
2. The test records are kept in your files to show proof of welder qualifications and must be accompanied by records to show the welder has met paragraph 4.1.2 and paragraph 4.1.3.
3. First, what inspector are you refering to? If you read paragraph 4.1.2.1, it states that proper documentation must be kept. Now, I think if he can't produce properly documented evidence he must retest just like if he had let it run out. Note that this evidence is for the employer so they can prove that his/her qualifications are still good. When we are awarded a new job I have to submit all our welder's qualifications out for approval. If they are rejected, they must retest to satisfy the approver, or show properly documented evidence to back up the qualifcations. Here's where those records will come in handy. I have found through the school of hard knocks to test every welder when he/she is hired, even if he comes to me with papers in hand. This policy will stop alot of questions from the approver.
As for the WPS's you mentioned, if you can use the prequalified joints in Section 3, you can waive the testing and simply mark a check in the prequalified box on your WPS, if not, you must test your WPS's according to Section 4 to qualify them by testing and keep the records on file and submit them for approval when asked.
I hope I haven't rambled too much and answered your concerns properly.
If anyone has something to add, please do, I'm certain I've left something out.
Hope this helps,
John Wright
Ps, Im referring to an old 98 D1.1, so the sections or paragraphs and tables may have been numbered differently in later editions. All I had at the time of this response was an old 98 model. My 2002 is at work on my desk.