The Duties of an Inspector
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Transcript of The Duties of an Inspector
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Frosio course hand-out: Section 03 The duties of an inspector
Frosio 03 Inspector duties slide # 1
The duties of an inspector
Frosio 03 Inspector duties slide # 2
What characterises a qualified inspector?
• Basic training / knowledge / experience
• Straight & Honest approach à Reliable
• Communication
• Strict, but à Friendly à Humble
• Makes the correct decisions
• Has tidy routines
• Is quality conscious
• Use common sense à Comfortable worksituation
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Frosio course hand-out: Section 03 The duties of an inspector
Frosio 03 Inspector duties slide # 3
Inspection Work
• The duties/responsibilities of the inspector (ISO12944-7)
• The role(s) of the inspector
• The different parties in a project
• The inspectors attitude and behaviour
• Reporting, documentation
• Verification of specified quality (section 17)
• Inspection planning (section 17)
• Inspection (section 17)
• Use of instruments (section 17)
• Reference areas (section 17)
Frosio 03 Inspector duties slide # 4
ISO 12944
Part 1 General introduction.
Part 2 Classification of environments.
Part 3 Design considerations.
Part 4 Types of surface and surfacepreparation.
Part 5 Protective paint systems.
Part 6 Laboratory performance test methods.
Part 7 EXECUTION AND SUPERVISION OFPAINT WORK.
Part 8 Development of specifications for newwork and maintenance.
Paints and varnishes - Corrosion protection
of steel structures by protective paints systems.
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Frosio course hand-out: Section 03 The duties of an inspector
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Extracts from ISO 12944-7
6.1 General
• The execution of the work shall be supervised at allstages. Supervision shall be undertaken by suitablequalified and experienced people. The contractor shall beresponsible for carrying out this supervision himself, butadditional supervision by the client – even for corrosionprotection in the workshop – is advisable.
• When coating material with which the contractor isunfamiliar are to be applied, the manufacturer of thecoating material shall be consulted.
• The level of supervision will depend on the type andimportance of the project, the degree of difficulty of thework and local conditions, and on the type of coating andits intended service life. This supervision will requireappropriate technical knowledge and experience.
Frosio 03 Inspector duties slide # 6
Extracts from ISO 12944-7
6.2 Measurement and test instruments
• The instrument manufacturer’s instructionfor the use of their equipment shall becomplied with. The instruments used shallbe checked, calibrated and maintained atregular intervals and the results shall berecorded.
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Frosio course hand-out: Section 03 The duties of an inspector
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Extracts from ISO 12944-7
6.3 Checking the paint coating
• Coatings shall be checked for compliance withthe specification, for example:– By visual assessment, e.g. for uniformity, colour, hiding
power and defects such as holidays, wrinkling, cratering, airbubbles, flaking, cracks and curtains
– By means of instruments for compliance with the followingcharacteristics of the dry film, if required:
• DFT: generally by non-destructive methods
• Adhesion: by destructive methods
• Porosity: by low or high-voltage detectors
Frosio 03 Inspector duties slide # 8
Extracts from ISO 12944-7
6.3 Checking the paint coating (cont’d)
• For DFT measurements, the parties concerned shall agreeon the following:– The method to be used (instrument, calibration, surface profile, etc.)
– The sampling plan (how and how many measurements)
– How the results are to be reported and how they are to be comparedwith acceptance criteria
• Dry film thicknesses (including the nominal and maximumthicknesses) shall be checked at each critical stage, andwhen the complete system has been applied. A criticalstage is, for example, when there is a change in theresponsibility for the paint work or when a long timeelapses between application of priming coats andsubsequent coats.
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Frosio course hand-out: Section 03 The duties of an inspector
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An inspector deals withseveral parties
• The customer / owner’s rep.
• The yard
• The contractor / sub-contractor
• The paint supplier
• Suppliers of equipment
• The classification society (DnV,ABS etc)
Frosio 03 Inspector duties slide # 10
The inspector’s role
At the yard the inspector may be seen as:
• Advisor or Consultant
• Mediator or Arbitrator
• ”Policeman”
• Paint seller
• *&$%*£” (too rude to print)
• Which role shall he take?
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Frosio course hand-out: Section 03 The duties of an inspector
Frosio 03 Inspector duties slide # 11
The inspector’s role
• The paint inspector is a key person in the QAsystem.
• He performs the practical QC work at the yard.
• However, the inspector’s prime role is to protect hisemployer’s interests. The inspector must neverforget whom he works for (who pays his salary)
• Usually the inspector has no formal authority inrelation to the yard and contractor
Frosio 03 Inspector duties slide # 12
What is QA - QC ?
QA = Quality Assurance
(A documented company managementsystem)
QC = Quality Control
(Inspection and testing routines)
QC is a part of the QA system
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Frosio course hand-out: Section 03 The duties of an inspector
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Why QA and QC ?
• The purpose is to make sure that one getswhat one wants
• A good QA system makes the futureresults predictable:– The object / structure / ship is delivered on time
– It is made according to specification
– The quality of the work is satisfactory
Frosio 03 Inspector duties slide # 14
Quality Assurance standards
• The ISO 9000 series ofstandards:
Requirements and guidelinesto establish a QA system in anorganization and keep iteffective
Deals with managementroutines, organisation, controlof activities, verification,reporting etc
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Frosio course hand-out: Section 03 The duties of an inspector
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The challenge for the paint inspectorThe challenge for the paint inspector
• To ensure that the coatingspecification is met
• To verify the quality ofwork carried out by thecontractor/yard.
• To prepare written recordsfor the standard work– Approval (Good enough?)
– Not acceptable (non-conformance)
Frosio 03 Inspector duties slide # 16
An inspector’s work includes:
• Be capable of interpreting
the specifications
• Understand the objective
of the inspection
• Inspect all structures to be painted
• Ensure that all specifiedrequirements are met
• Document the results from theinspections
• In case of non-conformance: Issuewritten reports
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Frosio course hand-out: Section 03 The duties of an inspector
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• All paints that will be used
• All relevant inspection methods andinspection tools
• Relevant standards
• Relevant TDS and MSDS
• Methods used for pre-treatment andpaint application
• The equipment used for pre-treatment and application: Benefitsand limitations
An inspector needs to know
Frosio 03 Inspector duties slide # 18
What needs to be inspected ?
• Shop-priming of the steel
• The steel work
(Pre-blasting preparation)
• Cleaning and surface preparationprior to paint application
• Application of paint
• The applied paint film and itscuring/drying conditions.
If relevant, the following stages
of the production need to be inspected
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Frosio course hand-out: Section 03 The duties of an inspector
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Inspection of steel work (Pre-blasting preparation)
• Rounding of sharp edges.
• Smoothing of rough welding
seams.
• Removal / grinding of weld spatter
and beads.
• Cracks and pittings.
• Surface faults like laminates etc.
• ISO 12944 - 3 , or ISO 8501 - 3
The following items need to
be inspected during construction
Frosio 03 Inspector duties slide # 20
Inspection of cleaning and surface preparationprior to application
• Cleanliness (salt, oil, grease and dust/dirt)
• Evaluation of present condition (rust grade)
• Surface preparation (e.g. blast cleaning)
• Cleanliness of prepared surface
(salts, oil, grease, dust and dirt)
• Climatic conditions
(temperature, relative humidity etc.)
If relevant, the following conditions
must be inspected / verified
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Frosio course hand-out: Section 03 The duties of an inspector
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Inspection during application
• Record name of coating and batch no.
• Ensure proper mixing of 2-pack paints
• Ensure use of the correct thinner
• Measuring the wet film thickness (WFT)
• Number of coats as given in the specification
• Cleanliness between coats (salts, dust, oil etc.)
• Drying time / recoating intervals
• Control of equipment: Pressure, nozzle etc.
• Climatic conditions (Ventilation, Air and steel temperatureand the relative humidity)
The following must be verified, inspected or tested:
Frosio 03 Inspector duties slide # 22
Inspection after application
• Climatic conditions (Ventilation,
Temperature and humidity)
• Curing / drying of the film
• Dry film thickness (DFT)
• Adhesion
• Holiday detection (if required)
After application
the following must be checked
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Frosio course hand-out: Section 03 The duties of an inspector
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Joining a new project
• First impression – Company Representative
• Correct presentation à Confidence
• Prepare yourself, read and understand applicablespecifications
• Obtain site work procedures
• Do a round trip on site / familiarisation / say hello
• Make a short list of personnel who are mostimportant in your job
• Get phone numbers and locations
• Establish a proper filing system
Frosio 03 Inspector duties slide # 24
Proceedings on site
• Make use of your personal logbook and write theinformation in a report when required
• Make a priority list à Effectiveness
• Make up progress plan and monitor activities
• Establish weekly inspection plan with the contractor
• Formalise “Mutual agreements” and disagreements
• Beware of the responsibility, both towards theCompany and the Contractor
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Frosio course hand-out: Section 03 The duties of an inspector
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Inspection planning
• Preparations
• Your daily work
• Meetings
• Reporting
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Preparations
• Read and understand relevantspecifications
• Get hold of work procedures at site
• Make a round-trip on site – establishcontact with people who will be importantfor you
• Organize your office – make a suitablefiling system for documents
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Frosio course hand-out: Section 03 The duties of an inspector
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Your daily work
• Establish a weekly inspection plan with thecontractor
• Use a daily log book and transferinformation into reports as required
• Formalize ”mutual agreements” anddisagreements (i.e. write down and sign)
• Maintain a close contact with youremployer
Frosio 03 Inspector duties slide # 28
Meetings
• Always prepare yourself
• Bring up relevant issues– skip minor subjects
– don’ t bring up repeats
• Accept a decision – end of case. Makea report if required
• Follow up pending issues
• Write down important things yourself,and ask the chairman for Minutes ofMeeting
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Frosio course hand-out: Section 03 The duties of an inspector
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Reporting
• The inspector shall be able to prepareinspection reports and ensure properdistribution of such reports
Different types of reports:
• Daily logs, Weekly report– (reporting progress)
• Inspection reports– (reporting findings during a visit)
• Consultant report– (3rd party report)
Frosio 03 Inspector duties slide # 30
Routine Reports to be made by the paintinspector
• Daily reports, weeklyreports, final reports
(Do not camouflage yourfindings!)
• Non conformance reports:To be signed by theresponsible contractor, andbrought forward to youremployer
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Frosio course hand-out: Section 03 The duties of an inspector
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Content of the daily reports
• Steel temperature
• Air temperature
• % Relative Humidity
• Dew point
• Object no. and name
• Exact specification
• Pre-treatment, specified andactually conducted
• Film thickness (to be measuredalso at spot repair)
• Area, m²
• Product name, place ofproduction and batch no.
• Name of relevant personnel
• What was discussed
• Non conformance report(remember signatures)
• Other comments
Frosio 03 Inspector duties slide # 32
Inspection report (made during a visit)
Purpose:
• Establish condition of a ship / structurebefore preparation of a specification /quotation
• Routine follow-up of a guarantee
• Technical service in order to assist with aproblem
• Investigation in connection with a productcomplaint
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Frosio course hand-out: Section 03 The duties of an inspector
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Inspection report
The report shall contain– General surface condition
– Specific areas deviating has to be evaluated and specified
• When evaluating the general surface conditionand/or a specific area – the stated conditionshould be further described with reference tothe coating being:– Intact
– Blistering
– Peeling off
– Spot rusting
– Etc.
Frosio 03 Inspector duties slide # 34
Inspection report
Ballast tanks, etc.
• Blistered surfaces:– Fluid inside the blisters
– Inspection result should be reported
– Use photos for documentation
Complete surface condition report:
• Clearly state and define both location and size ofdamaged areas
• Severe corrosion / pitting and loss of materialmust be investigated and measured. Thecondition must be included in the report
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Frosio course hand-out: Section 03 The duties of an inspector
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Consultant report (neutral / 3rd party)
• Title
• Summary
• Observations
• Investigations
• Discussion, assessment
• Proposal for repair procedure
• Conclusion, date and signature
Frosio 03 Inspector duties slide # 36
A First Class Professional Inspector will:
• be one of the best assets a company can have in terms ofpromoting its products and services
• be polite and respectful, calm and firm, reliable andhonest, and represent his employer in a diplomatic way
• communicate extensively with all parties to a project
• perform his duties in such a way that he contributes toconstructive measures to be taken, instead of taking anindifferent (or negative) approach (i.e. seek a solution)
• whenever circumstances force compromises to be the onlysolution, he ensures that this is properly authorised,recorded and reported