WE Visual Inspection

7/28/2019 WE Visual Inspection

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(1) Document control

The manufacturer must define the sequence of each item indicated in

Fig. 4.3 and make it into documents. It should be made clear that these

documents, including the ones from outside like drawings from the customer,

are ofthe latest edition and so controlled that all the related departmentsand sections can use the proper edition.

(2) Secure of management resources

Management resources mean so called 4M (Man, Machine, Material, and

Method) that are necessary for management, implementation ofoperations, and activities for verification. The manufacturer must define

and secure the management resources for welding fabrication. PersonnelThe manufacturer must secure sufficient number ofcompetent personnel

for planning, fabrication, monitoring, inspection, and investigation for

welding fabrication. For the personnel to be equipped with sufficient

competence, education and training must be conducted and the

effectiveness of such education and training must be evaluated.

Furthermore, welders, welding coordination personnel, and non-destructive

testing personnel should be certified by appropriate standards like the JIS

standard.


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EquipmentThe equipment can be classified into manufacturing and testing

equipment and inspection and measuring equipment. Suchmanufacturing, inspection, and testing equipment indispensable and

suitable for welding fabrication must be secured. Such equipment

includes the following.

a) Welding power sources and other machines

b) Equipment forjoint preparation and cutting, including thermalcutting

c) Equipment forpreheating and postweld heat treatment including

temperature indicator

d) Jigs and fixtures

e) Cranes and handling equipment used for welding productionf) Protective devices and other safety equipment for welding

personnel

g) Depository, drying equipment, and portable containerfor

welding consumables

h) Cleaning goods

i) Destructive and non-destructive testing equipment


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The manufacturer must prepare a maintenance plan for equipment,implement maintenance check regularly, and refrain from using

defective equipment.

Especially, inspection and measuring devices must be calibrated at a

designated interval and records of calibration must be maintained.

In case calibration proves that the equipment is inaccurate, the results of

measurement made by the equipment since the last calibration must be

reviewed for reevaluation of their validity and corrective action must betaken.


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Examples ofitems of maintenance check are as follows:

a) Condition of the guiding device of thermal cutting equipment and

the fixing jigs for welding mechanization.

b) Condition ofammeter, voltmeter, and flow meterfor operation ofwelding equipment

c) Condition ofelectric cables, hoses, and connectors

d) Condition of the control system of mechanized and automatic

welding equipment

e) Condition ofinstruments for temperature measurement such as athermocouple

f) Condition ofwire feeder and wire conduit

The manufacturer must prepare and maintain a list of the equipment

that contains the following items.

a) Name of equipmentb) Identification of equipment such as manufacturing number

c) Specifications of equipment such as capacity, shape, and dimensions

d) Date of maintenance check (calibration date or validity of inspection

and measuring instruments)


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Welding consumablesThe manufacturer must secure a place forstorage of welding

consumables needed for welding production in order to avoid moisture

absorption, oxidization, and damage.

Welding sequence and welding procedureThe manufacturer must prepare the sequence documents indicated in (1)

Document control.

Such sequence documents are generally called a fabrication standard

or working standard.

Fora new welding procedure, a prior verification test must beconducted to verify its appropriateness.

Especially, approval of the welding procedure regulated by legislation must

be acquired in advance.


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(3) Contract reviewThe manufacturer must confirm the contractual requirements indicated by

specifications, design drawings, and other means prior to acceptance of

the order.

This is for the purposes of ensuring that the manufacturer has capabilityof fulfilling the contractual requirements of welding and those requirements

orally given and all the amendments to the contract from tender

documents made prior to contract are clearly documented and accepted

by the purchaser.

The information obtained by the contract review must be conveyed toand used by all the related departments such as the design

department and manufacturing department.


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(4) Design review

When the manufacturer designs by themselves, a set of management

activities are to be performed, which consist ofplanning of design, review

of appropriateness of input, approval of output, design review,verification, review of validity, and design amendment. These

management activities are carried out when the design department works

out the design for the final product including welding design.

Whether the design data are supplied by the purchaser or are made by the

manufacturer himself, the manufacturing department must conduct

design review to confirm the contents of the design, assess capability

of fulfilling the requirements and propose a solution if there is any

problem. When the design data are supplied by the purchaser, such design

review is to be conducted when confirming the contents of the contract.

There are such companies that have a rule of designation of responsible

personnel to conduct design review for each specialized field and of

convening a design review meeting of these responsible personnel for

discussing important matters and the fabrication work to be done for the

first time.


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(5) Purchase control

The manufacturer must carry out the following control activities to

ensure that the purchased products fulfill the requirements.

Assessment of suppliers (subcontractors)

Suppliers must be assessed and selected based on their capability tosupply products that satisfy the requirements of the manufacturer.

Purchase documentsThe manufacturer must prepare purchase documents that contain the

items mentioned below, confirm adequacy of the specified requirements

and place an order.a) Identification of model, kind, and grade

b) Such technical data as specifications, drawings, process

requirements, and inspection instructions

c) The name, number, and version of the standard of applied quality

systemVerification of purchased productsThe manufacturer must define the activities to verify the purchased

products and put them into practice. In a case where such verification

activities are done at the supplier by the manufacturer or the customer of

the manufacturer, the procedures of verification must be provided in the

purchase documents.


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(6) Welding fabrication Manufacturing plansThe manufacturer must define and plan the manufacturing processes that

directly affect the quality of the product. In the plan, the following items

must be contained at least.a) Procedures of manufacturing welded constructions and the

sequence of final assembly (preparation, approval, and issuance of so

called fabrication sequence drawings)

b) Identification of individual processes for manufacturing welded

constructionsc) Reference to appropriate procedure specifications for welding and

related processes

d) Sequence of welding fabrication

e) Sequence and schedule of practicing each process

f) Inspection and testing specifications including those for

independent inspection organizations

g) Environmental conditions (e.g. protection from wind and rain)

h) Identification of batches of materials, components, and parts per

an appropriate unit


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(7) Inspection and testing

Inspection and testing are conducted at appropriate points in the

manufacturing process based on the manufacturing plan in order to assure

compliance with the contractual requirements.

Inspection and testing prior to weldingPrior to welding, the following matters must be checked where

necessary.

a) Conformity and validity of certificates of qualification of thewelding personnel

b) Conformity of the welding procedure specifications (WPS)

c) Identification of the base metals and welding consumables.

d) Groove preparation (configuration and dimensions)

e) Conditions offit-up, fixing by a jig, and tack welding

f) Special requirements in the welding procedure specifications (e.g.

prevention of distortion)

g) Preparation for manufacturing production tests

h) Conformity of working conditions including environment for

welding


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Inspection and testing during weldingDuring welding, the following matters must be checked at appropriateintervals or by continuous parameters, where necessary.

a) Indispensable welding parameters (e.g. welding current, arc

voltage, and travel speed)

b) Preheating and interpass temperature

c) Perfection ofcleaning and shape of runs and layers of weld metal

d) Back gouging

e) Welding sequence

f) Correct use and handling ofwelding consumables

g) Control ofdistortion

h) Intermediate inspection (e.g. checking of dimensions)


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Inspection and testing after weldingAfter welding, the compliance with relevant acceptance criteria must

be checked, when necessary.

a) Visual inspection testingb) Non-destructive testing

c) Destructive testing

d) Shape and dimensions of welds and welded constructions

e) Results and records ofpostweld treatment (e.g. grinding,

postweld heat treatment, and aging)

Inspection and testing statusWhether or not the welded construction has been inspected and tested

and the status of judgment (accepted or rejected) must be either

marked on the weld construction or on the routing card foridentification to prevent a welded construction yet to be inspected

and tested or a nonconforming welded construction from being

transferred to the subsequent process.


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(8) Nonconformance and corrective action

Nonconformance controlIn order to prevent inadvertent miss use or delivery of a nonconforming

product, the product that does not conform to the designated requirements

must be identified and controlled.

When repairing or readjusting the nonconforming product, appropriate

repair specifications must be ready for use and the repaired or

readjusted product must be re-inspected in accordance with the

original requirements.

Corrective actionIn order to prevent recurrence of nonconformance, identification of the

cause of nonconformance, assessment of necessity ofpreventive

activities, and necessary corrective action must be determined.


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(9) Identification and traceability

In order to avoid inadvertent miss use of base metals, weldingconsumables and half-finished products, the product must be identified

all through the manufacturing process.

In cases where traceability is in the contractual requirements, the product

must be specifically identified and controlled.

Traceability is a function of tracing back history, use, and location

of the product by means of recorded identification.

It is useful for removal of a nonconforming product and for search ofcauses of the nonconformance when nonconformance is found after

installation of the product.


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(10) Quality records

Quality records must be maintained as the evidence of conformance to

contractual requirements and of effective operation of quality system. Rules

of identification, storage, search, and period of retention must be decided to

control the quality data. Quality records relating to manufacturing by

welding are as follows:

a) Records ofcontract review and design review

b) Certificates ofmaterialsc) Certificates ofwelding consumables

d) Records ofapproval tests of welding procedure specifications

e) Certificates ofwelders or welding operators

f) Certificates ofnon-destructive testing personnel

g) Records ofheat treatment and welding proceduresh) Non-destructive testing and destructive testing procedures and

records

i) Records ofdimensions

j) Records ofrepairand other records


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4.1.4 Preparation, approval and recording of welding procedure

specifications

As described in the foregoing section, it is important in welding as a

special process to determine its procedure specifications in details clearly

and to determine the proceeding of their approval objectively.

ISO 3834 refers ISO 14731/ISO 9606 which regulate certification of

personnel and ISO 9956 in terms of preparation, approval, and

relevant records of welding procedure specifications. These four

standards are called a set of standards with ISO 3834 as the core.

Of the series of standards (old edition of ISO 9956) relating to

specification and approval of welding procedures of metallic materials, hereare explained) JIS Z 3420 (ISO 15607-2000)(General Rules), JIS Z 3421-1

(ISO 15609-2000) (Welding Procedure Specification for Arc Welding), and

JIS Z 3422-1 (ISO 15614) (Welding Procedure Test) that were taken into

the JIS standard in 2003.


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As for the JIS standard for welding procedure test, there are JIS Z

3040 (Method of Qualification Test for Welding Procedure) and JIS B

8285 (Welding Procedure Qualification Test for Pressure Vessels) .

These standards are expected to be unified into a new JIS standard

compatible with the ISO standard in the future.

Likewise, the ASME and AWS specify the similar standards.

These standards are desired to be unified into an internationalstandard in the future.


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(1) Procedures of preparation and approval of welding procedure

specifications (pWPS) : (Method of welding procedure test)

Firstly, provisional preliminary welding procedure specification

(pWPS) is made based on the past experience, expertise, and results

of research.

Then, test assembly is welded in the same conditions (regarding materials

and welding parameters, for instance) as those written in the

specification, and designated test is performed.

If all the results of non-destructive testing (including visual inspection) and

destructive testing are satisfactory, the pWPS is approved andbecomes an approved welding procedure specification (WPS).


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In case the weld test assembly fails to satisfy the requirements of either

visual inspection or non-destructive testing, one additional test assembly

may be is welded and the same tests are performed.

In case the additional weld test assembly does not fulfill the relevant

requirements, the provisional preliminary welding procedure specification

(pWPS) cannot be regarded as satisfying the requirements of this

standard unless it is changed.

In destructive tests, if any test specimen does not satisfy the

requirements because of imperfection of weld, 2 additional test

specimens can be taken either from the same weld test assembly if

possible or from a new weld test assembly, and the same tests can be

performed.

If any of the additional test specimens does not fulfill the relevant

requirements, the provisional preliminary welding procedures

specifications (pWPS) cannot be regarded as satisfying the requirements

of this standard.


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(2) Method of approval of welding procedures

In order to approve a provisional preliminary welding procedure

specification (pWPS) as a WPS and make a welding procedure approvalrecord (WPAR, or PQR as per the ASME and AWS), other methods than

the welding procedure qualification test described in the previous

article are also allowed. They are as follows:

(a) Approval by use of tested (approved) welding consumables

Approved welding consumables mean the welding consumables or their

combinations tested and approved by an independent inspector or

inspection agency (a third party body).

Provided the welding heat input is maintained within a limited range,

approval of the welding procedures that use such approved weldingconsumables is allowed for materials whose heat-affected zone is not

deteriorated considerably.

But this approval method is allowed only for arc welding and gas welding.


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(b) Approval by past previouswelding experiences

This method allows welding procedures to be approved by referring to

the past previous welding experiences.

The manufacturer may obtain approval of a provisional preliminary

welding procedure specification (pWPS) by referring to the past previous

welding experience on condition that it can be proved by an independentdocument with an appropriate ground that the same kinds of joint

and material were satisfactorily welded in the past.

In this case, only those welding procedure specifications should be used

that can be associated with consistent acceptable quality test dataobtained for a certain period and proven reliable from such past results.


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(c) Approval by use of standard welding procedures

This is a method of approval of welding procedures using the standard

welding procedures.

The provisional preliminary welding procedure specifications (pWPS)

prepared by the manufacturer are approved if the range of all the

matters to be verified are within the range permitted by the standard

welding procedures.

The standard welding procedure must be issued in the form of WPS or

WPAR based on the same proceeding as that for the approval of the

welding procedure qualification test.

The inspector or inspection agency responsible for the first approval ofthe standard welding procedure must issue or revise this standard

Furthermore, application of the standard welding procedure is allowed

only under the conditions that the user is satisfied with.


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(d) Approval by pre-production welding test prior to manufacturing

This welding test has the same functions as the welding procedure

qualification test but the test assembly is prepared in conditions moresimilar to actual fabrication welding.

The standard test assembly shown on the next page does not have to be

used.

The test assembly must be so prepared that the joint in actual

fabrication is simulated.

Furthermore, the welding test must be conducted prior to fabrication

welding in the same conditions as used in actual fabrication welding.

The inspections and tests of the test assembly must be done within therange of the requirements.

This welding test may require special tests additionally or some other

substitute tests depending on the kind of the joint, which must be agreed to

by the inspector or inspection agency.


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(3) Contents of welding procedure qualification test

(a) Shape and dimensions of test assembly piece

Fig. 4.4 shows the shape and dimensions of the test plate piece for butt

welding (full penetration).

Conduct groove preparation and groove alignmentper provisional welding procedure specification pW PS)

W here, a = 3t : minimum value 150mmb = 6t : minimum value 350mm

Fig. 4.4 Test plate for full penetration butt welding joint

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