I agree, the third party inspector was playing the part of a clod. Arrogance isn't becoming of any third party inspector. In this case, it would be reasonable to ask the welder how he knew what electrode/filler metal to use, where would he obtain information about preheating requirements, welding parameters, etc., but it is unreasonable to expect the welder or the QC inspector to know what the acceptable ranges were from memory.
Any inspector that is a CWI should have learned that memorizing a code or any working documents, i.e., drawings, NDT procedures, etc., that are subject to revision isn't a smart thing to do and to expect someone else to memorize similar documents is the height of arrogance and ignorance.
I have had auditors try to pull the same "stunt" on welders, but I was quick to step in and tell the auditor that I discourage "memorization" because it is an invitation to making mistakes. I encourage the welder to review the appropriate WPS before starting a new work order because the WPS may have been revised during the interim since he last used it. That usually is sufficient to stop the auditor from asking unreasonable questions.
It is reasonable to expect the welder to know where to find the information and the auditor may have been looking for the response, "I don't know off the top of my head, but I know I can find it in this WPS."
That doesn't sound like the case in the situation you are telling us about.
I've had auditors ask the question, "What is the acceptable amperage range for the electrode diameter you are (now) using?"
The welder should know that it is within the range listed in the WPS. In such a situation it is reasonable for the welder to simply say that he is working within the permitted range when he last checked the WPS. That is not the same as expecting the welder to recite the permitted ranges of each welding parameter listed on the WPS. However, if the question isn't related to something the welder is actually doing, such as a question about a procedure the welder isn't using at that time, it is appropriate for the welder to simply say, "I would have to look at the WPS to answer the question."
I have clients with many WPSs, in one case over 350 WPSs, and it is absolutely unreasonable to expect the welder to have each of them committed to memory.
You were dealing with an individual that had a "God complex" and it is unfortunate they get away with their actions. I encountered an Authorized Inspector once that pointed to his computer's screen saver during a conversation, it simply read: "The AI is God". My response was, "A very good reason to change to another insurance carrier". For some reason he didn't laugh, but I noticed the screen saver was changed the next day.
Best regards - Al
I disaagree with you, most of the welders just perform their welds as they fill the settings good, memorizing the WPS is not the solution of course; the welder shall read the WPS see all data, setting and verify their variables and follow the welding sequece; If the welder do that, they can answer the TPI answers anytime, but as you said, TPI could find deviations to the WPS like polarity, amperage, travel speed, etc. How you ensure that the produced welding will have the mechanical properties demonstated by PQR?; the welder shall maintain, know and follw the essential variables period.
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