SO YOU WANT TO BE A WELDING INSPECTOR?

Transcription

1 Title So you want to be a welding inspector? Author Stephen Siu, P Eng., President of SKC Engineering. He is CSA W178.2 level III Inspector #159, AWS QCI, IIW welding engineer and CWB W47.1 & W47.2 welding engineer. He is the recipient of the 2013 Michael Vuchnich Award presented for most achievements in advancing Canadian science, technology, arc welding application in their career. He is experienced in welding inspection, weld quality, weld joint designs, welding processes / weld consumables and welding codes. He specializes in resolution of welding and weld quality issues. He has over 35 years of relevant experience and has worked in Canada, US and Asia. Contact Information: Stephen KC Siu, P Eng., SKC Engineering Website, Address, Telephone, Address ADD PICTURE 1 ( Steve Siu ) So You Want To Be a Weld Inspector by Stephen Siu, CSA W178.2 Level III..Page 1

2 Abstract In the Canadian welding world; there is real need for qualified and well-rounded welding inspectors. This talk will try to be informative, practical and insightful. The author will draw on his 35 years of life experiences in inspection and welding. He will talk about welding inspector qualifications; health and safety concerns related to weld inspection work; needed skill sets for welding inspector performance, inspection work limits and boundaries; delivering clear, precise verbal and written reporting; making sense of welding codes, regulations and specifications; the demands on a welding inspector; communication skills and conflict resolution and acceptable & non-acceptable weld inspector conduct. Further, the author will talk about his cultural insights in overseas inspection work and how to satisfy client and family expectations and demands. Most importantly through out of this, the author will talk about how to keep one s sense of humour. The author s goal will be to encourage interested individuals to consider a career in welding inspection. Weld inspection work can be demanding; it can also be rewarding and satisfying. The welding inspector will meet good people, travel the world, do meaningful work and be well compensated. So You Want To Be a Weld Inspector by Stephen Siu, CSA W178.2 Level III..Page 2

3 INTRODUCTION SO YOU WANT TO BE A WELDING INSPECTOR? I am a CSA W178.2 Level III weld inspector registration #159. The W178.2 weld inspectors programme was launched by the Canadian Standards Association (CSA) in the early years of 1980 under administration by the Canadian Welding Bureau (CWB). I was the 159 th weld inspector in Canada to be qualified under this programme. I believe that I am one of the few remaining weld inspectors of that vintage who are still active in welding work. The W178.2 weld inspectors now number in the 7000s with ~6000 Canadian and ~1000 International inspectors. Further; the W178.2 programme has international recognition and membership. Weld inspection work has allowed me to travel extensively throughout Canada, US and Asia. I have met kind hearted, generous people who have shared their welding knowledge; I have seen breathtaking cityscape and countryside and worked on some pretty amazing welded structures. If this life sounds appealing, allow me to share my experiences with you. Canadian Welding Standards, Regulations and Specifications. The Canadian welding world is pretty big. The two major welding fields are pressure and structural welding. There is also welding specialties; as in aerospace welding application and custom manufacturing. Pressure welding work is essential in water management and distribution; oil and gas extraction, refining, distribution and transporting; and hydro-electric generation and distribution. Generally, pressure welding work falls under the Provincial Boiler & Pressure Vessel Regulations, ASME VIII and IX welding rules [1,2]. Pressure welding work in BC is regulated by the BC Safety Authority (BCSA); in Alberta, the pressure welding work is regulated by the Alberta Safety Authority (ABSA). Structural welding is essential to ship building and refit application, building construction, bridge fabrication, repair and erection, hydro-electric equipment generation and distribution, machinery and equipment manufacture. Canadian Standards Association (CSA) W59 is the structural welding standard called up in the National Building Code (NBC) and CSA Bridge Build Code S6. Companies performing structural welding are qualified to welding certification programmes CSA W47.1 (Steel) and CSA W47.2 (aluminium). Companies performing weld inspection are qualified to CSA W178.1 and individual weld inspectors are qualified to CSA So You Want To Be a Weld Inspector by Stephen Siu, CSA W178.2 Level III..Page 3

4 W The Canadian Welding Bureau (CWB) are the regulators and administrators for the CSA W47.1, CSA W47.2, CSA W178.1 and CSA W178.2 welding certification programmes. For structural welding work in Canada; owners and end-users specify that welding and inspection companies doing their welding work meet these welding certification programme requirements. Further; the owners and end-users specify that the welded structures and products shall meet the requirements of welding product codes and standards. Owners and end-users may further specify that all welding shall be inspected by CSA W178.2 welding inspectors. For structural welding work done outside Canada; these same welding rules generally are specified by the owners and end-users. These welded structures and products shall meet CSA W47.1, CSA W47.2, CSA W178.1 and CSA W178.2 welding rules before entry into Canada CSA W178.1 Inspection Company and CSA W178.2 Weld Inspector Programmes Canadian inspection companies qualify to CSA W This programme requires that inspection companies have written inspection and testing procedures, the company facilities and test equipment are in order, their inspectors are qualified to CSA W178.2 and nondestructive technicians are qualified to Canadian General Standards Board (CGSB) for Nondestructive examination (NDE). Inspection companies must have a designated W178.2 Level III inspector and CGSB Level III (NDE) person responsible for the company s inspection and nondestructive examination work. The inspection companies are audited annually by the CWB for compliance and the individual weld inspectors are examined periodically. CSA W178.2 weld inspector candidates can qualify under three levels. Level I inspectors shall pass welding study modules and code book examinations. Level II inspector inspectors shall pass welding study modules, code book of choice examinations, practical examinations and shall have the welding related experience. Level III inspectors shall pass level III examinations and are responsible for the W178.1 inspection company programme. Again, the CSA W178.2 weld inspectors are periodically examined by the CWB. So You Want To Be a Weld Inspector by Stephen Siu, CSA W178.2 Level III..Page 4

5 Inspector Skills The welding inspector shall be a good communicator, shall be self-motivated, have a good personal attitude and really present well. Generally, the inspection work proceeds well if the inspector is confident, disciplined, neat in his appearance and his approach to the inspection work. The welding inspector shall have good eyesight and be in good physical health. The welding inspector shall acquire good welding knowledge and truly like welding. The welding inspector shall be comfortable working in a shop or site environment. Special knowledge gained working in a machine shop, drawing office, paint shop, mechanical assembly shop, fabrication shop, construction site, engineering office or laboratory will only enhance the welding inspector skills. Health & Safety Fabrication shops and construction sites can be large, complex and busy with movement. Working in fabrication shops and construction sites can be demanding, dirty, noisy and dangerous work. Generally, companies require health and safety training to work in these environments. Some work environments require special lockout procedures, evacuation procedures and environment protection training. Further, the welding inspector may need special personal trainings for working in confined space, working at heights, special work site training, and operating specialized equipment. The welding inspector shall know evacuation procedures, locations of first-aid, bathrooms, lunchrooms and restricted areas; and how to contact help when needed. In fabrication shops and construction sites abroad; spoken and written English may not the first language or language of choice. The inspector shall dress appropriately for his work environment. The inspector shall recognize unsafe acts, situations, and behavior and respond accordingly. The weld inspector is responsible for his own personal safety. The weld inspector shall not do acts that jeopardize the safety of others. Towards that end; the work may require the weld inspector to wear safety glasses with side screens, hard hat, respirators, safety vest, hearing protection, kneepads, gloves and safety boots in order to work safe. For personal comfort; water bottles, wipes & towels may be needed. In a welding environment; it is advisable to have sunblock; wear long-sleeved clothes or fire-retardant overalls to protect from burns and hurt to the body. So You Want To Be a Weld Inspector by Stephen Siu, CSA W178.2 Level III..Page 5

6 Looking back; I wished I was more vigilant in protecting my hearing and joints in my younger working years. Inspection Tools and Equipment The welding inspector, in addition to having his safety gear; shall acquire and safeguard his own weld inspection tool box. His working tools shall be identified so that tools can be returned if mislaid. Typically, this tool box includes tape measure, measuring rules, lighting, stainless brushes and picks, fillet weld gauge, bridge-cam weld gauge, tags and locks, welding helmet, paint markers, soapstone and magnifying glass. Further, he shall have access to welding codes, notebooks for recording and preferably, a digital camera for low-light macro work. A serious weld inspector may have his own amp-probe, tempstiks, and grinding kit to conduct welder and procedure tests. Any borrowed tools used during inspection work shall be returned in good condition to the lender. The welding inspector shall acknowledge and thank the lender for the borrowed tools. After working in an area; the welding inspector shall gather up his tools and leave the working area in clean or as-found condition. This is the right way to maintain working tools and do inspection work. Acceptance & Rejection of Welds When inspection work is done; the weld inspector is faced with accepting or rejecting welds and his declaration is always required. A weld inspector needs to be decisive and confident in his declaration. He shall base this decision on his welding knowledge and his understanding of the welding code, specifications and his tasking. Some related questions that may need to be asked and answered beforehand are: Is the welding facility certified or qualified to do the welding?; Were acceptable weld procedures used during welding?; Did a qualified welder do the welding? Does the company have a qualified welding supervisor? Does the general overall workmanship and weld quality meet welding standards? Has the part been fabricated and welded to drawings? Have right materials and consumables been used during fabrication?; Are the weld profiles and weld presentation acceptable to the declared welding code? It is really hard for a welding inspector to accept found welding based upon personal knowledge and conviction. It is really easy to find reason to reject the found welding and walk away. A welding inspector may find these decisions hard to make on his own and may need a So You Want To Be a Weld Inspector by Stephen Siu, CSA W178.2 Level III..Page 6

7 supervisor to intervene. As he becomes more experienced, the weld inspector will find that these decisions come easier. Eventually; a weld inspector will realize that the acceptance / rejection of welds becomes pretty straight forward. Fundamental to all of this is the weld inspector s welding knowledge. He must know fabrication and welding, he must know welding language; he must be comfortable in a welding environment; he must know welding code; he must know how to use his inspection tools and weld gauges accurately and confidently. He must be really comfortable talking to fabricators, welders, owners and supervisors about the welding, his findings and his declaration. Communication & Conflict Resolution I feel that the most important weld inspector skill is his ability to understand and communicate welding issues and minimize conflicts. During a shop visit; if welding discrepancies come up, the weld inspector shall gather his thoughts, know his position and frame up what needs to be said and done. Further, the weld inspector shall identify and document discrepancies before initiating discussions with the fabricating / welding representative. The fabricating / welding representative shall be allowed to make his response in turn. If the welding is truly unacceptable; the welding inspector shall reject the welding. If the welding representative s responses are reasonable; the welding inspector shall accept the welding. The welding inspector shall then be accepting of the consequences of his actions. There will be other times, when the weld inspector notices that situations, workmanship and conduct in the fabricating / welding shop are exceptional and praiseworthy. This shall also be told to the shop representatives. During shop time, the weld inspector shall speak to work concerns. Outside of shop time; if given the chance; share welding and inspection knowledge and experiences. Try to make new friends in the welding community! Inspector Conduct The welding inspector is a visitor to a welding shop or construction site. The inspector shall respect the shop / site safety and conduct rules. Initially, he shall introduce himself to the shop / site representatives. He shall declare his intentions to his shop / site contact. The inspector shall arrange all inspection work with shop / site contact; he shall do his work and verbally report findings to the shop/site contact. The welding inspector does not own the work and does not speak to unauthorized people about the work. He does not carry out unsafe acts while he So You Want To Be a Weld Inspector by Stephen Siu, CSA W178.2 Level III..Page 7

8 is visiting. How the welding inspector conducts himself is what he will be known for; that is his reputation. In the welding community; that is everything. The welding inspector shall strive to be fair-minded, respectful and present himself well. On conclusion of his work and reporting; the welding inspector shall thank the shop / site contact for the visit and say his good-byes. The inspector may have a good chance of being asked to visit again to do inspection work. Verbal and Written Reporting Before verbal reporting; the welding inspector shall have identified and documented the inspected parts and status. If rework is required; locations on the inspected parts shall be clearly marked and this information conveyed to the shop / site contact. Unsolicited speculation as to cause of rejection and rework shall not be discussed. The shop / site contact shall be made aware that the inspected parts were accepted or rejected based on the relevant welding code and clauses. The client shall be advised that a written report of findings will be forthcoming before an agreed upon date. Written reports shall be brief, accurate, clean and to the point and delivered in a timely manner. The written report framework shall include client and contact; reporting and inspection dates; work order identification; reference documents, assumptions; inspection methods and welding code. Further; quantities, part numbers, locations shall identify and trace the reporting to the inspected parts. Welding code and acceptance / rejection criteria shall be described. Most importantly, the pass / fail status of inspected parts reporting shall be clearly stated and signed by the qualified welding inspector. There shall be a few images of good quality and these images shall only be used to aid the presentation. Subject matter irrelevant to the written reporting shall be omitted. Written reports shall be reviewed by senior welding inspector / manager prior to releasing to client. Personal Demands on Welding Inspectors Local inspection work can be tough and demanding and can lead to long busy days. The individual pushes himself to improve his work skills, maintain a home and raise a family. More money can be made for out-of-town work; but site work means working away from home, living in camp; working long hours and being away from home three out of four weeks for the duration of a project. So You Want To Be a Weld Inspector by Stephen Siu, CSA W178.2 Level III..Page 8

9 Working abroad is tougher still. The individual can expect to be away from home continuously for weeks and months at a time. Weather, food, language, people, and customs and living arrangements can be different. I have some experience working abroad in Chinese fabrication shops, mills and shipyards for extended time. I believe that the Chinese feel that working away from home and family is expected, is a necessity and the worker is doing this for the greater good of his extended family and home. Many visit their families one weekend a month if their homes are within a one-day car / train ride of their work. China has two national holidays; during New Year and Harvest Moon Festival, everything shuts down and everyone goes home for visits. I have found that the Chinese workers have resolved that this is the way life is; they enjoy work, eat and drink well, have good friendships, are active and remain reasonably happy. It is up to the individual to decide what is best for himself and his family. Will it be doing local work and spending quality time with family; or doing site work spending less time with family but making more money; or working abroad gaining new experiences and being exposed to new opportunities? Closing & Challenges and Opportunities If after all of this; the life of a welding inspector is still looking attractive; I have done what I have to do. If one is starting out; be flexible, consider working in an entry level position in a welding shop, fabrication shop, drawing office, steel plate shop or do construction work. Learn about welding and be really passionate about welding. I suggest: Take an NDE course, Take up a welding course, Take up the CWB welding study modules, Challenge a W178.2 inspector course Attend local AWS, CWS chapter meetings Talk up welding with welders, inspectors, technicians, engineers Check out the CWB website and W178.2 weld inspector programme. If working abroad in the welding field is of interest; take up a language course. Continue to be real passionate about welding. End So You Want To Be a Weld Inspector by Stephen Siu, CSA W178.2 Level III..Page 9

10 References & Copyright [1] BPVC Section VIII-Rules for Construction of Pressure Vessels, 2013 [2] BPVC Section IX-Welding, Brazing, and Fusing Qualifications, 2013 [3] CAN/CSA W59-13: Welded steel construction (metal arc welding) [4] CAN/CSA-S6-06: Canadian Highway Bridge Design Code [5] CAN/CSA W : Certification of companies for fusion welding of steel [6] CAN/CSA W : Certification of Companies for Fusion Welding of Aluminum [7] CAN/CSA W : Certification of Welding Inspection Organizations [8] CAN/CSA W : Certification of Welding Inspectors Search Phrases & Keywords Welding Inspector, Welding Inspection, Non-destructive Testing, Training End So You Want To Be a Weld Inspector by Stephen Siu, CSA W178.2 Level III..Page 10