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Inspection Trends - April 2011 - Spring

Checklist for a Systematic Approach to Welder Qualification A successful welder qualification program requires careful consideration of the intended goals of testing the welder. The process should be formalized and systematic. The steps should be well defined and a process followed to ensure the proper test is administered to the welder. The following is a brief outline of the system I employ when qualifying welders. You can use it as a checklist. Organize 1. Determine what welding standard is applicable. 2. Verify a copy of the applicable welding standard(s) is available to the inspector. 3. Determine what performance tests are required, i.e., grooved plate test, fillet break test, pipe test, etc. 4. Determine what test positions are appropriate. 5. Determine what evaluation tests are required, i.e., guided bend tests, fillet break test, NDE, etc. 6. Determine the size of the test pieces required. 7. Determine what base metals and thicknesses are to be welded. 8. Determine what welding process will be used. 9. Develop an appropriate WPS for the test to be administered. 10. Determine what testing equipment is required, i.e., diameter of the bending mandrels, wraparound vs. a plunger and die-type guided bend tester, appropriate press for fillet break test, etc. 11. Complete a welder qualification test request identifying the welder, applicable welding standard, test to be taken, method of evaluation, etc. This may simply entail entering the basic information on the Welder Performance Test Record. It does not have to be a separate document if the test record contains all the required information. Administering the Performance Test 12. Check the welder’s identification. I take the welder’s photograph before testing starts and attach it to the test report. 13. Enter all applicable information and the photograph onto the Welder Performance Test Record. 14. Review WPS, test rules, and acceptance criteria with the welder. 15. Verify the proper materials are being used, including the following: a. Base metal material specification (certified material test report) b. Filler metal c. Proper storage considerations for low-hydrogen shielded metal arc welding covered electrodes. 16. Verify test assembly is properly fitted and tack welded. 17. Verify the test assembly is in the proper test position (check with a spirit level). 18. Verify proper preheat is utilized if it is required. 19. Check root bead for profile, defects, proper interpass cleaning, preheat maintenance, etc. 20. Check welding parameters while the welder is welding. 21. Verify proper interpass cleaning is performed, and when prohibited, that power tools are not used. 22. Perform visual examination of the completed weld. 23. Verify the appropriate identification is applied to the test coupon and the top of the test coupon is marked before removing it from the test position. Evaluation 24. Check the test coupon for proper markings. The type of markings required is not the same for every situation. The following information is usually considered to be the minimum required: a. Welder’s identification b. Test position c. WPS. 25. Perform the final visual evaluation in accordance with the appropriate welding standard or per customer requirements. In many cases, the client has established criteria that are more stringent than that required by the welding standard. For example, ASME Section IX visual criteria can be described as spartan at best. Many clients require the test piece to pass the visual criteria applicable to the appropriate construction code such as Section I, B31.3 high pressure, etc. 26. Lay out the test piece for cutting test specimens that will be subjected to guided bend testing or the fillet break test. 27. Mark each test specimen with appropriate identification before testing. 28. Subject the test specimens to the appropriate destructive or nondestructive tests as required by the applicable welding standard. 29. Record the test results on the Welder Performance Test Record. 30. Return the test specimens to the client when requested to do so or retain the specimens for future review. I typically keep the test specimens for 30 days before I discard them. 31. Inform the client of the test results. 30 Inspection Trends / April 2011


Inspection Trends - April 2011 - Spring
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