THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL

Transcription

1 THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL January 2013 / Vol. 16 / No. 1 Inspector Responsibilities Shear Wave UT Soundness Testing

2 awo.aws.org Online Math for Welders Course Sample seminar at awo.aws.org/seminars/math-for-welders-level-1 aws rs/math-for-welders-leve el-1 Mathematics is a necessary part of a welding professional s s activities. However, math can be complicated and confusing for beginners, and difficult ficult for adults who haven t used math principles awhile. This course provides a combination of clear step-by-step verbal and visual explanations that make each mathematical concept easy to understand and remember. Topics include place value, simplification, estimation, measurement, and the addition, subtraction, multiplication and division of whole numbers, fractions, decimals and mixed numbers. Practical exercises allow welders, welding students, supervisors and inspectors to apply basic math skills to various aspects of the welding process. Eighteen PDHs are provided through this course toward AWS recertification.

3 Vol. 16 / No. 1 Features 19 What Are the Inspectors Roles and Responsibilities? by Neal A. Chapman and Jacqueline Mansfield/ Two inspectors one with plenty of experience and another just starting out offer their perspectives on inspectors roles and responsibilities / 15 What You Should Know about Soundness Testing by Albert J. Moore Jr. / Soundness testing is necessary whether the inspector is qualifying a welder or a welding procedure / 19 INSPECTION TRENDS (ISSN ) is published quarterly by the American Welding Society. Editorial and advertising offices are located at 8669 Doral Blvd., Ste. 130, Doral, FL 33166; telephone (305) Printed by R. R. Donnelley & Sons Co., Senatobia, Miss. Subscriptions $30.00 per year for noncertified, nonmembers in the United States and its possessions; $50.00 per year in foreign countries; $20.00 per year for noncertified members and students; $10.00 single issue for nonmembers and $7.00 single issue for members. American Welding Society is located at 8669 Doral Blvd., Ste. 130, Doral, FL 33166; telephone (305) Periodicals postage paid in Miami, Fla., and additional mailing offices. POSTMASTER: Send address changes to Inspection Trends c/o American Welding Society, 8669 Doral Blvd., Ste. 130, Doral, FL Readers of Inspection Trends may make copies of articles for personal, archival, educational, or research purposes, and which are not for sale or resale. Permission is granted to quote from articles, provided customary acknowledgment of authors and sources is made. Starred (*) items excluded from copyright. AWS MISSION STATEMENT The mission of the American Welding Society is to advance the science, technology, and application of welding and allied processes worldwide, including joining, brazing, soldering, cutting, and thermal spraying. What Is Your Role in Monitoring Shear Wave UT? by David J. Reid / These tips will help you better understand what takes place during shear wave ultrasonic testing / 22 Departments Editor s Note...6 News Bulletins...8 Print and Product Showcase...12 Just the Facts...14 Technology Notes...14 The Answer Is...24 Mark Your Calendar...26 Certification Schedule...27 Advertiser Index...28 Inspection Trends / Winter

4 By Mary Ruth Johnsen Editor s Note Dear Readers, Welcome to a new calendar year and a new year of Inspection Trends. I hope you survived the frenzy of the holiday season and the end of the work year without too much stress. I bet you re among those people who say they never make new year s resolutions, and I also bet that, in fact, you do, even if you don t say them out loud. Now I m not talking about the personal eat more healthfully, lose weight, exercise more type resolutions. I m talking about the ones that relate to our work lives. There s just something about coming back to work after New Year s Day or opening up a blank calendar that compels us to say to ourselves, This is the year things will be different. This is the year I will meet all my deadlines keep all my paperwork in order and up to date keep my office/cubicle/desk/vehicle clutter free take that training class I ve been putting off. I know I make those kinds of resolutions all the time, not just at the new year, but whenever there s some sort of big change that occurs. Sometimes I even keep them. For instance, I m not a clean desk kind of girl. If I haven t finished something I m working on by the end of the day and I know I ll start on it again in the morning, I just leave everything where it lies. But when we moved into the new AWS World Headquarters Building in late August, I told myself I would tidy up my desk every night before I left. Because truth be told, seeing the mess each morning bothered me, and I d end up with piles of stuff that I d lose track of. So far I accomplish it about eight nights out of ten, and I ve found I keep track of my paperwork much better because of it. So what does all that have to do with Inspection Trends? Well, as I was working on this issue and reexamining this year s editorial calendar, I realized a lot of the articles and topics center on the business of being a CWI and offer advice on how to do the job better. Here s the schedule and the editorial deadlines. January (Winter) The CWI s Roles and Responsibilities April (Spring) Tips for Working Overseas Inspection of Pipes, Vessels, and Tanks. Editorial deadline: Feb. 19 July (Summer) The Benefits of the AWS Senior Certified Welding Inspector Program Aids to Visual Inspection. Editorial deadline: May 15 October (Fall) Profiles of Top CWIs Update on Radiography and Radiographic Interpretation. Editorial deadline: Aug. 19 I m excited about this year. It contains some new topics, and we have some new authors submitting articles. My resolution for 2013 is to provide an even more useful magazine. You ll have to let me know in December whether I succeeded. Publisher Andrew Cullison cullison@aws.org Editor Mary Ruth Johnsen mjohnsen@aws.org Associate Editor Howard Woodward woodward@aws.org Associate Editor Kristin Campbell kcampbell@aws.org Production Editor Zaida Chavez zaida@aws.org Senior Production Coordinator Brenda Flores bflores@aws.org National Sales Director Rob Saltzstein salty@aws.org Advertising Sales Representative Lea Paneca lea@aws.org Senior Advertising Production Manager Frank Wilson fwilson@aws.org Subscriptions Representative Tabetha Moore tmoore@aws.org American Welding Society 8669 Doral Blvd., Ste. 130 Doral, FL (800/305) Copyright Copyright 2013 by American Welding Society in both printed and electronic formats. The Society is not responsible for any statement made or opinion expressed herein. Data and information developed by the authors of specific articles are for informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users. 6 Inspection Trends / January 2013

5 AWS Conferences & Exhibitions: Weld Cracking Conference March 26-27, 2013 / Las Vegas AWS invites you to join us in Las Vegas to expand your weld cracking knowledge! Our featured presenters will explore the many causes of weld cracking as well as provide information on preventive measures. Gain practical knowledge on the types and causes of weld cracking. Network with industry peers to discuss the best solutions for business growth. AWS Conference attendees are awarded 1 PDH (Professional Development Hour) for each hour of conference attendance. These PDHs can be applied toward AWS recertifications and renewals. For the latest conference information and registration visit our web site at ws.org/conferences or call , ext. 264.

6 News Bulletins TÜV Rheinland Opens NDE Services Operation in Mississippi TÜV Rheinland Industrial Solutions new 3000-sq-ft facility provides testing, inspection, and certification of materials, components, and structures. TÜV Rheinland Industrial Solutions, Inc. (TRIS), recently opened a new testing operation in Richland, Miss. The 3000-sqft facility provides testing, inspection, and certification of materials, components, and structures. The services feature a full range of NDE tests, including computed radiography, film radiography, ultrasonic, magnetic particle, visual, phased array, and positive material identification tests. The new facility is located at 199 Interstate Dr., Suite A, Richland, Miss., and is managed by Daniel Britt. Britt has 11 years of experience in NDE. He is an AWS CWI and holds ASNT Level II certifications in radiography, ultrasonic, magnetic particle, penetrant, and phased array testing. Additional information is available by calling (601) In other news, the company has named Denny A. Stapp, CEO at its Caledonia, Mich., facility. He will be responsible for all operational aspects of TRIS. Most recently, Stapp served as vice president of TRIS where, in addition to operations management, he worked as a senior member of the acquisition team to integrate Woodstock, Ala., based Unified Testing & Engineering Services, Inc., into TÜV Rheinland. Laboratory Testing Names Director of Quality Frank Peszka of Erdenheim, Pa., was recently promoted to the newly created position of director of quality at Laboratory Testing, Inc., Hatfield, Pa. For the past six years, Peszka has held the position of quality assurance manager. This new position was created to oversee the expanding operations of the Quality Assurance and Certification Departments. In his new position, Peszka will continue to implement and maintain the quality management system, oversee preparation of certified test reports and certificates of Opportunity Knocks. AWS agreement with ASNT offers ACCP to qualified CWIs & SCWIs. Do you need visual testing certification which meets the guidelines for Recommended Practice No. SNT-TC-1A as required by some sections of the ASME Code? Through this agreement, qualified SCWIs and CWIs can obtain ACCP Level II VT certification without examination. Enhance your credentials and satisfy work requirements with the addition of an ACCP credential. To apply and for more details visit or call or US/Canada. 8 Inspection Trends / January 2013 Image Longview Inspection For info go to

7 calibration, and administer the company s new program designed to manage industry specifications for testing and calibration. CWI Recertification Group Tours Cowboys Stadium The members of a nine-year CWI recertification class are shown during their tour of Dallas Cowboys Stadium in Arlington, Tex. Members of a CWI nine-year recertification class in New Orleans had the opportunity to travel to Arlington, Tex., to tour the Dallas Cowboys Stadium, the largest domed stadium in the world. It is also the world s largest column-free room. The expansive retractable roof is the largest of its kind in the world and measures approximately 661,000 sq ft. When closed, the roof encompasses 104 million ft 3 of volume, making it the largest enclosed NFL stadium. The CWI seminar class included three 36th-year recertification inspectors, John B. Moore, Bob Johnson, and Michael Carciere. The class was facilitated by Ed Bohnart, an AWS past president and SCWI. For info go to ASNT, Bringing Thousands of Minds To NDT Matters, Including Yours. Join the Professional Society That Brings the NDT Community & Its Resources To You. The American Society for Nondestructive Testing Serving the Profession, Creating a Safer World. For info go to Inspection Trends / Winter

8 Survey Shows Quality Professionals Salaries Flat for First Time in More than 25 Years The average salaries for quality professionals remained steady in 2012, showing no significant change compared to 2011, according to Quality Progress magazine s annual salary survey. This was the first time since the magazine began the annual survey 26 years ago that salaries remained flat from the previous year. The magazine, published by the American Society of Quality (ASQ), conjectured the flat salaries could be a result of lingering effects of the recession. This was the first year since the recession began in December 2007 and ended in June 2009 that quality professionals salaries didn t increase in the United States. From 2008 to 2011, salaries increased an average of 2.24% per year. Like salaries, the number of unemployed quality professionals remained steady. In 2012, 2.5% of respondents said they were unemployed, retired, or laid off; in 2011, 2.7% claimed the same employment status. Quality professionals in the United States made an average of $86,743 in 2012, down from $87,086 in While quality professionals fared well during the recession, the flat salaries are likely indicative of the still-recovering economy, said ASQ CEO Paul Borawski. And even though salary increases slowed this year, there are factors quality professionals can control to earn a higher salary, like earning certifications or pursuing further education. The salary survey ran in the magazine s December issue. ASQ members can view the entire salary survey results by visiting qualityprogress.com/salarysurvey. For info go to continued on page Inspection Trends / January 2013

9 Online Welding Safety Certificate Course OSHA estimates that 4 out of every 1,000 welders will experience a fatal injury or accident over their working lifetime Earn PDHs and increase your ability to improve safety and health of your welding operations. Three-hour self-paced course covers electric shock, vision and skin protection, ventilation, fire protection, handling of gases, and much more. Sample seminar at awo.aws.org/seminars/safety

10 Print and Product Showcase Software Documents Pipe Inspections Using Tablet Designed for touch-screen data entry on a tablet PC, WinCan ProTouch software includes everything an operator needs to document pipe inspections with a video crawler, push camera, or zoom survey camera. The data are fully compatible with the company s WinCan v8 software. The software generates reports that include schematics and captured images. It can also export inspections to freely distributable viewer software, so clients can review video along with section detail. It works with all common video inspection hardware. Pipeline Analytics (877) Image Processing Systems Automate Surface Inspections The company s VINSPEC machine vision systems detect surface flaws such as scratches, notches, dents, bubbles, pores, cavities, spots, and changes in transparency, as well as edge defects such as cracks, burrs, bevel, rounding, and leveling errors. The 2D and 3D camera-based systems are generally installed inline and inspect surfaces at production speed. The software learns on the basis of relevant defect patterns and CAD files, and records parts even when they are not properly positioned. Defective parts can be detected automatically and discharged in a timely manner. VITRONIC Machine Vision Ltd. (502) New 12 Inspection Trends / January 2013

11 New Hardware and Software Enhance Flaw Detector strategy to determine the appropriate number of UT, PA, or TOFD beams and angles for a given test. OmniPC is a computer-based software program that provides comprehensive data analysis capabilities for data acquired with the flaw detector. It provides costsaving advantages because analysis of the inspection data can be conducted on a computer rather than on the flaw detector. New phased array and ultrasound modules extend the capabilities of the OmniScan MX2 flaw detector. Included are the PA2 secondgeneration phased array module with a UT channel, UT2 two-channel conventional ultrasound module that can be used for time-of-flight diffraction, NDT SetupBuilder software program specifically designed for the company s line of automated and semiautomated ultrasonic testing instruments, and OmniPC software revision. The SetupBuilder software allows users to simulate an inspection Olympus NDT (781) Flashlights Useful for a Variety of NDE Applications The company offers four models of its OPTI-LUX 365 Series UV-A (365- nm) LED flashlights. High-intensity and standard intensity versions are available, each with or without an internal black light filter. The black light filter reduces the output of wavelengths longer than 400 nm. The high-intensity versions produce a nominal steady-state UV-A intensity of 10,000 μw/cm 2 at 15 in. The standard intensity versions produce a maximum UV-A intensity of 4500 μw/cm 2. The lightweight flashlights come with a lanyard, belt holster, two rechargeable batteries, two-position charging cradle with AC power cord, UV-absorbing spectacles, and padded carrying case. They are useful for a wide variety of inspection applications. Spectronics Corp. (800) Manufacturer of Flawed Specimens OFFERING THE: AWS / CWI VISUAL SPECIMEN KIT In hydrotesting, time is money. We save you both. DESIGN SPECIFICATIONS BASED ON AWS D SPECIMENS - 2 FLAWS EACH CARBON STEEL SPECIMENS USE FOR TRAINING & TESTING CWI s CONTACT FLAWTECH FOR MORE DETAILS The GripTight high pressure test plug uses proven self gripping features to safely, quickly, and effectively test pipe whether it s pipe spools, pipe rack modules or process modules. The greater the test pressure, the greater the grip. Available to ANSI N45.2 and 10CFR50 Appendix B quality requirements. EST Group is ISO-9001 certified. When time equals money, add GripTight to the equation. T F FlawTech EST Concord North Carolina USA For info go to We invite you to see all that we can do for you at For info go to Inspection Trends / Winter

12 By Lyndsey Deckard Just the Facts GMAW-S: A Little Different Kind of Animal I recently reviewed welding procedures for a fabricator who used constant voltage welding machines. The Welding Procedure Specifications (WPSs) called for multiple passes using rather widely varied voltages, and consequently even more widely varied amperages, in the passes of the same weld. The WPS indicated the weld joint configuration to be prequalified, and the welders were qualified by radiographic testing (RT) of their test weldment coupons. The review of the WPS and its supporting Procedure Qualification Record (PQR) indicated voltages and currents for some passes to be below the globular/short circuit transition range. A change in mode of metal transfer is an essential variable, requiring requalification of the welding procedure. Since short circuit gas metal arc welding (GMAW-S) is not a prequalified process, dropping into the GMAW-S volt/amp range required requalification of both the welds. Welders may not be qualified by RT alone using the GMAW-S process. It is very important to review WPSs for changes in mode of transfer. Following are some excerpts from AWS D1.1/D1.1 M:2010, Structural Welding Code Steel, related to this topic Prequalified Processes. SMAW, SAW, GMAW (except GMAW- S), and FCAW WPSs which conform to all of the provisions of Clause 3 shall be deemed as prequalified and are therefore approved for use without performing WPS qualification tests for the process. For WPS prequalification, conformance with all of the applicable provisions of Clause 3 shall be required (see 3.1) ESW, EGW, GTAW, and GMAW-S. ESW, EGW, GTAW, and GMAW-S may be used, provided the WPSs are qualified in conformance with the requirements of Clause 4. Note that the essential variable limitations in Table 4.5 for GMAW shall also apply to GMAW-S Substitution of RT for Guided Bend Tests. Except for joints welded by GMAW-S, radiographic examination of a welder or welding operator qualification test plate or test pipe may be made in lieu of bend tests described in (2) (see for RT requirements). In lieu of mechanical testing or RT of the qualification test assemblies, a welding operator may be qualified by RT of the initial 15 in. [380 mm] of a production groove weld. The material thickness range qualified shall be that shown in Table LYNDSEY DECKARD (Deckard@pbworld.com) is quality manager of the Vehicle Division of Parsons Brinckerhoff Transit & Rail Systems, Inc. He is an AWS Senior Certified Welding Inspector, an ASQ Certified Quality Auditor, and a member of the AWS Certification Committee, Examination Question Bank Subcommittee, and Ethics Subcommittee. Technology Notes Errata AWS D3.6M:2010 Underwater Welding Code The following errata, in addtion to previously announced corrections (visit have been identified and will be incorporated into the next reprinting of this document. Page 60, Figure 7.2, note 2b. Correct to. Page 63, Figure 7.3, note a. Correct to. Page 63, Figure 7.3, note b. Correct to. Page 75, Figure 8.2, note 3b. Correct to. Page 77, Figure 8.3, note b. Correct to. 14 Inspection Trends / January 2013

13 By Neal A. Chapman and Jacqueline Mansfield Feature What Are the Inspectors Roles and Responsibilities? Inspectors duties are outlined both in respect to what s called for in the standards and what happens in practice What are the roles and responsibilities of the participants in the AWS Certified Welding Inspector programs? You may be surprised to learn that those two terms roles and responsibilities are not found in the AWS documents associated with Senior Certified Welding Inspectors (SCWIs), Certified Welding Inspectors (CWIs), or Certified Associate Welding Inspectors (CAWIs). However, those are the terms we use every day when talking about inspectors duties. Therefore, we will describe some of our personal experiences regarding our roles and subsequent responsibilities that we believe are typical of others in this field. Jacqui and Neal are at the opposite ends of the spectrum regarding this certification. While both are employed as welding engineers, she is a newly tested CAWI, and he is a very experienced inspector first certified in We see the role of welding inspectors much like that of a local justice or judge. Inspectors ensure that welds are inspected to a known standard and that the variables used to make them have been verified and documented. This is much like at a trial presided over by a judge: The evidence is presented, evaluated, and ruled upon. What Do We Mean by Role? In looking for an official definition, we found that Wikipedia distinguishes between two types of roles: social and achieved. The achieved role is a position a person assumes voluntarily that reflects personal skills, abilities, and effort. This definition fits nicely into our understanding as no one is conscripted into being an inspector; one chooses to become one. Typically, a person is hired to perform this role and the duties necessary to accomplish it. Many of us have the inspector role as a part of a larger occupation. Some inspectors are also qualified welders; others may be engineers, managers, NDE examiners, educators, and consultants in welding production. In fact, most certified inspectors do much more in their daily jobs than just inspect welds. Fortunately, for our society, there is a level of qualification needed for the role of welding inspector. These qualifications are addressed in AWS B5.1:2003, Specification for the Qualification of Welding Inspectors, and QC-1:2007, Standard for AWS Certification of Welding Inspectors. Both of these documents can be downloaded for free from the AWS Web site, Neal gained his initial experience as a visual inspector and a NDE examiner with a testing company that served industries such as petrochemical, energy, power, and Dept. of Transportation bridges in numerous states. Currently, he is a leader in nuclear welding programs within his company and through the industry via his positions on the EPRI Welding Research Steering Committee and the AWS Certification Committee. In that experience of more than 30 years, Neal has seen a few inspectors who were of no value to their employers or the public in general. In the same breath, he can state that he has seen inspectors who were nothing less than heroic in their dedication to their products, employers, and the public. According to Neal, I can honestly say that the good outweigh the bad 99 to 1. A common theme among these good inspectors is that they can talk about all aspects of a job and to all of the personnel involved. As an example, good inspectors will not only validate the E7018 used on the job has been properly stored and maintained, but will also inform the welders and foremen why that is a needed practice. This level of involvement ensures the current products are good and also provides tools for all involved as they go forward. Neal s experience in the last 20 years has been to ensure only the best welders are assigned to make welds deemed high risk and high value. This is based on inspection results from his own work and, more typically, that of other inspectors. His inspections are typically made after another inspector has found something and the company needs to evaluate for an engineering assessment to determine if a weld is fit for service (accept as is) or to determine a repair plan. Welding inspections are a part of a company s welding program and yes, an essential part but often inspection does not stand alone in our industry. Neal uses himself as an example as how many people with a CWI credential use it as only part of their job. Jacqui s experience is newly gained, and she works with Neal in a mentor/protégé relationship at a nuclear power plant. She is an AWS CAWI who achieved a high score on the exam and now waits out her time in grade. However, she is also qualified to inspect welds on her own under ANSI N45.2 rules at the plant. According to Jacqui, I have found one of the most difficult-to-grasp aspects of being a welding inspector is Inspection Trends / Winter

14 when to reject a weld and when to accept it. Under time pressure, if you do not correctly interpret the code you are working with, you may make the wrong call. I feel this is why so many struggle with the Part B portion of the AWS CWI exam. I was told one time, It doesn t have to be pretty to pass. This may be true depending on the code you are inspecting to. Learning the steps to an inspection can be challenging at first depending on the industry. It could be as simple as checking the inside and outside surfaces of the weld, and if those elements are satisfactory, then the weld is acceptable. In some industries, it s not just the size and quality of the weld that must meet a particular code that the inspector must examine, but was all appropriate paperwork included, were the referenced procedure(s) followed, and were the base material and filler metal slips checked. In particular, some industries and companies use software and standardized forms to specify the weld criteria. If these procedures and forms are not kept up to date with the codes, mistakes on weld size can be missed. In cases such as this, the SCWI and/or CWI must stay up to date on the changes to codes. Code hierarchy in some industries is a challenge the first few years as a new-to-the-industry CAWI. The question of how did they choose that specific code is always floating in our heads. Just when we think we ve got the majority of it down, there is an exception to the rule or a code change. For CAWIs who are not provided a code to follow by the owner, the question is then what do I do if they don t provide a code? So far, in my experience as a CAWI in the nuclear industry, I notice the minor mistakes such as preheat and purge hold points. Neal will direct us to use ASME Section VIII because the welding is on a pressure vessel, not ASME B31.1, which is applied to pipe. Learning this demarcation is especially important in the transition areas. Responsibilities The definition of responsibility according to dictionary.com is a Table 1 Welding Inspection Capabilities Based on Qualification Level Knowledge and Skills AWI WI SWI 1) prepare reports X X X 2) communicate effectively orally and written X X X 3) understand the fundamentals of SMAW, SAW, OFW, RW, GTAW, FCAW, GMAW, PAW, X X X SW, ESW, and Thermal Spraying, Soldering, Mechanical Cutting, Thermal Cutting/Gouging, Brazing/Braze Welding 4) understand the fundamentals of VT, MT, AET, UT, PT, ET, RT, LT, quality procedures X X X and quality audits/surveillance 5) understand the fundamentals of welding metallurgy X X 6) understand welding symbols and drawings X X X 7) interpret drawings X X Standards AWI WI SWI 1) verify base material compliance X X X 2) verify filler metal compliance X X X 3) verify filler metal storage/handling compliance X X X 4) verify inspection records compliance X X X 5) verify proper documentation compliance X X X 6) verify base material and filler metal compatibility X X 7) certify documented results compliance X X 8) verify procedure qualification records compliance X X 9) verify welding procedure compliance X X 10) verify NDE procedures compliance X X Procedure Qualification AWI WI SWI 1) verify welding equipment appropriateness X X X 2) verify edge preparation compliance X X X 3) verify joint geometry compliance X X X 4) witness procedure qualification X X 5) verify welding procedure qualification compliance X X 6) review and approve welding procedures X X 7) develop welding procedures X Performance Qualification AWI WI SWI 1) witness welder performance qualification X X 2) verify welder qualification compliance X X 3) verify welder qualification records compliance X X 4) request welder performance requalification X X Production AWI WI SWI 1) verify welder qualification appropriateness X X 2) verify production welding compliance X X 3) verify personnel qualifications X X Inspection AWI WI SWI 1) perform visual examinations X X X 2) verify examination procedure compliance X X 16 Inspection Trends / January 2013

15 particular burden of obligation upon one who is responsible. The welding inspector s responsibilities are to perform the following listed duties to reach his or her conclusion regarding the acceptance of a weld. Activities of the CAWI Remember that CAWIs are limited in responsibility; therefore, one of the CAWI s main responsibilities is to learn from CWIs and SCWIs. Learning from other resources such as welders, foremen, engineers, and other professionals they work with is important as well. Some of the CAWI s other responsibilities follow: Perform visual inspections under the direction of a CWI or SWCI Learn the logic behind how to make their decisions and the process to document the results Learn their rights as an inspector Understand code hierarchy Understand welding in general and WPS compliance Learn the differences between the various NDE and welding techniques and processes. Activities of the CWI Following are some of the responsibilities of a CWI: Perform visual inspections Supervise CAWIs Learn from and question the SCWI Share knowledge by serving as a mentor Model ethical behavior. Activities of the SCWI Following are some of the duties of SCWI: Supervise CWIs and CAWIs Assist CWIs and CAWIs with regard to their questions and concerns Perform visual inspection Share knowledge as a mentor Model ethical behavior. Different industries utilize welding inspectors in a variety of positions and in various ways. In some code fabrication shops, the CWI may be the entire quality (Table 1 Continued) (Inspection continued) AWI WI SWI 3) review examination results compliance X X 4) develop visual inspection procedures (before, during, and after welding X X 5) provide NDE inspection planning and scheduling (before, during, and after a project) X X 6) review welding inspection reports X X 7) verify implementation of nondestructive and destructive evaluation methods X X 8) prepare visual inspection requirements X 9) prepare NDE requirements X 10) report investigation results of quality inspection disputes X 11) prepare destructive testing requirements X Safety AWI WI SWI 1) verify safety requirements compliance X X X 2) develop safety procedures and policies X Quality Assurance AWI WI SWI 1) perform audits and surveillance X X 2) develop quality assurance plans X 3) prepare base material control requirements X 4) prepare weld consumable control requirements X 5) prepare audit and surveillance plans X 6) prepare documentation control requirements X Project Management AWI WI SWI 1) review contract requirements X X 2) review vendor proposal compliance X X 3) prepare weld inspection bid specifications X 4) prepare purchase specifications X 5) determine vendor capacity and capability X 6) select vendor X Training AWI WI SWI 1) develop and provide a training program for the AWI X X 2) develop visual inspection training X X 3) verify implementation of visual inspection training X X 4) develop and provide a training program for the WI X 5) provide technical leadership for welding inspectors X 6) develop quality assurance training program X 7) verify implementation of quality assurance training X 8) provide guidance and direction to inspectors for maintaining and upgrading their individual qualifications X Evaluation AWI WI SWI 1) evaluate AWI s performance X X 2) evaluate WI s performance X 3) perform inspection results trend analysis X Inspection Trends / Winter

16 control department. In other industries, a CWI certification is the entry-level requirement along with possible NDE qualifications. None of these is wrong or better; they are just different. Responsibilities or duties are welldefined in AWS B5.1, Specification for the Qualification of Welding Inspectors. Following is an excerpt from that document. 4.1 Duties. The employer shall define the welding inspector s specific duties AWI. The AWI shall be able to perform inspections, under the active supervision of a SWI or WI. Supervision should be within visible and audible range. The SWI or WI shall maintain the responsibility for determining if welded assemblies conform to workmanship and acceptance criteria WI. The WI shall be able to supervise and train AWIs. The WI shall be able to perform inspections to applicable procedures and processes. The WI shall be able to conduct audits of suppliers and organizations providing materials or services to the project. The WI shall ensure the work performed and associated records are maintained and conform to the requirements of the applicable standards or other contract documents SWI. The SWI shall be able to train, supervise, and evaluate WIs and AWIs. In addition to being able to perform the duties of the WI, the SWI shall be able to develop inspection requirements, safety procedures, quality assurance plans, project plans, and training programs. 4.2 Capabilities. As specified by qualification level, the welding inspector shall be able to perform the tasks listed in Table 1. Conclusions CWIs and SCWIs need to share their experiences including mistakes they have made and how they learned from them openly with their subordinates. These individuals should take their mentorship seriously and teach the succeeding generations of inspectors the how and why of performing the steps toward a good inspection. SCWIs and CWIs must also have patience with new CAWIs. Weld inspection is not an everyday practice; it takes time to thoroughly understand the codes and acceptance criteria. All levels of inspectors need to maintain a strong conviction that their real responsibility is to ensure the welds they inspect meet all of the applicable standards, knowing that the safety of the public depends on them. NEAL A. CHAPMAN (weldingengineer@inbox.com) is lead welding engineer, Entergy Nuclear Northeast, and JACQUELINE MANSFIELD is site welding engineer, Entergy Nuclear, Oswego, N.Y. CHAPMAN is an AWS CWI, a member of the AWS Certification Committee, and chair of the Subcommittee on the Code of Ethics and the Subcommittee on Supplemental CWI Inspection Programs. 18 Inspection Trends / January 2013

17 By Albert J. Moore Jr. Feature What You Should Know about Soundness Testing Review the applicable welding standard before performing soundness tests because the various standards may require different tests, specimen dimensions, and number of specimens Soundness tests verify that welded samples are free of unacceptable surface-breaking and subsurface discontinuities such as incomplete fusion, incomplete joint penetration, inclusions, cracks, porosity, etc. Nondestructive or mechanical tests can be used to verify soundness. Soundness tests are required whether the inspector is involved in qualifying a welder or a welding procedure. These tests can consist of nondestructive or destructive tests; the applicable welding standard will stipulate what tests are required. It is presupposed that the test sample has already passed the requisite visual examination. Radiographic testing (RT), or in some cases ultrasonic testing (UT), can be used when permitted by the welding standard, but most standards require mechanical (destructive) tests for evaluation of test coupons. Mechanical tests include guided bend and fillet break tests. If testing is per API 1104, Welding of Pipelines and Related Facilities, the nick break, tensile, and guided bend tests may be required. It is important to review the applicable welding standard to verify what soundness tests are required. Different welding standards require different tests, different specimen dimensions, and possibly different numbers of test specimens. Fig. 1 A longitudinal guided root bend. The base metals are CuNi and HY80. Incomplete fusion between the weld and CuNi base metal is shown. Welder Performance Qualification Welding standards often list both RT and guided bend testing as options that can be used to evaluate a welder performance test coupon consisting of a grooved butt joint in either plate or pipe. Once a test method has been selected, only that method is used to evaluate the test coupon. Welding standards do not offer provisions for Fig. 2 A typical transverse root bend for pipe. Notice the corner tears. Inspection Trends / Winter

18 Fig. 3 Once the sample is welded, it is loaded so that the root is in tension and the weld fails through the throat. test coupons that have failed RT to be subjected to bend testing. Once a coupon has been tested with the selected method, it either passes or fails. No additional testing is permitted, i.e., the test coupon cannot be subjected to guided bend tests to override the failed RT. There are situations for which guided bend tests are required, and radiography is not an option. Such is the case when the applicable standard is ASME B31.3, Process Piping, and the fluid service is specified as high pressure. Likewise, many welding standards require guided bend tests when the welding process used is gas metal arc welding with short circuiting transfer. API 1104 is unique in that it allows the welder to be qualified using nick break tests or tensile tests when the test coupon consists of grooved plates or pipe nipples. In both cases, the goal is to fracture the weld so the cross section can be examined to verify the absence or presence of defects. Fillet welds are typically evaluated by the break test. The fillet weld is loaded such that it should fail along the throat so the fractured surfaces can be examined. Unacceptable defects such as incomplete fusion to the root, slag inclusions, etc., are causes to reject the weld. AWS D1.1, Structural Welding Code Steel, offers an option that consists of a square groove with a wide root opening that requires the welder to deposit a fillet weld in each corner. The remaining groove is welded and the coupon subjected to guided bend tests as a means of determining weld soundness. Welding Procedure Qualification The testing regimen for qualifying a welding procedure is more involved than that for qualifying a welder. Procedure qualification may require nondestructive testing before the destructive tests are performed. AWS D1.1 requires the test coupons, consisting of grooved plate or pipe, to be examined using a volumetric test method, i.e., radiographic or ultrasonic test. If the NDE method deems the test coupon is sound, the coupon then undergoes additional destructive tests. In addition to tensile testing, the coupon is subjected to guided bend testing. API 1104 requires nick break testing in addition to guided bend testing when qualifying a welding procedure. Tensile tests are also required, but not for the purpose of determining weld soundness. Section IX of the ASME Boiler and Pressure Vessel Code does not require volumetric NDE, but there is nothing in the code prohibiting the contractor from using NDE to determine whether it is worthwhile to subject the test coupon to destructive testing. When RT or UT is performed, the test is not used as a means to determine where the test specimens are to be removed from the test coupon. The applicable code stipulates the locations at which the various test specimens are to be removed. Nondestructive Testing Individuals with the proper qualifications and certification must perform the RT and UT. While some CWIs possess the necessary credentials to perform those tests, a CWI is not required to perform them. A detailed discussion of how those tests are performed and evaluated is a topic for another article. Guided Bend Tests Most welding standards utilize guided bend tests to evaluate welder performance test coupons and welding procedure qualification coupons. There are two types of guided bend tests, each requiring a different preparation for the test coupon. One type is a longitudinal guided bend test, and the other is the transverse guided bend test. The longitudinal guided bend test is used when dissimilar metals are joined or when the mechanical properties, i.e., yield strength or elongation, of the two base metals being joined are different. The transverse guided bend test is used when the same base metals are being welded together or when the mechanical properties are similar. The longitudinal guided bend test can be either a guided face bend or a guided root bend Fig. 1. The sample is called a longitudinal face bend when the bending fixture places the weld face of a single-sided weld into tension. The convex surface of the bend specimen is the face of the weld. When the weld root is placed into tension by the bending fixture, the convex face of the bent specimen is the root of the weld and the sample is called a longitudinal root bend. The transverse guided bend test can be a guided face bend, a guided root bend, or a guided side bend Fig. 2. Either the weld face, root, or cross section is placed into tension. In each case, the convex surface is evaluated for open discontinuities. The guided bend test places the face, root, or cross section of the weld in tension, and causes the convex surface to yield and elongate. Any unacceptable discontinuities near the convex surface will cause a surface tear (open discontinuity) that will be measured and compared to the acceptance criteria of the applicable standard. The bend radius and the thickness of the test specimen determine the amount of elongation the convex surface will experience. The applicable welding standard will specify the bend radius or it will provide a formula to calculate the required bend radius. Most welding standards, API 1104 excluded, require the bend test to produce an elongation that is equal to the specified elongation of the base metal. When dissimilar base metals are 20 Inspection Trends / January 2013

19 welded, the elongation must typically match that of the weaker component, i.e., base metal or filler metal. As such, the individual performing the bend test must know the following: Base metals Minimum elongation Coupon thickness Filler metal. The thickness of the test coupon and bend diameter used have been standardized in some welding standards. This is the case with the AWS Structural Welding Codes and ASME Section IX. However, they make provisions for job-sized pipe or plate having different thicknesses. When nonstandard thicknesses are used, the standard bend diameter is inappropriate. The applicable welding standard will usually provide a formula that can be used to determine the required Diameter ( 100 t ) bend diameter. = The following formula is typical: E t where t is the thickness of the test specimen, E is elongation as a percentage, and Diameter is the diameter of the bend mandrel. For example, given the following, Base metal: carbon steel Elongation: 20% Thickness: 3 8 in. Diameter = (( )/20) 3 8 = 1½ in. As shown by the example, the diameter of the bending fixture varies for different materials with different elongation properties and material thicknesses. The testing facility must have the proper bend mandrel or have it made if the test is to meet the applicable welding standard. A word of caution is warranted before continuing. If AWS B4.0, Standard Methods for Mechanical Testing of Welds, is the working document, an elongation of 20% is the maximum required unless the customer specifies an elongation that is greater. API 1104 is an exception to the protocol given in the preceding. It specifies one bend mandrel diameter for all thicknesses and all carbon steel and high-strength, low-alloy-steel line pipe. Evaluation When guided bend tests are evaluated, only the convex face is examined. Different welding standards list different acceptance criteria. The inspector should always review the acceptance criteria provided by the appropriate welding standard. A case in point is the difference between ASME Section IX and AWS D1.1. ASME limits the maximum open discontinuity on the convex face of the bent sample to 1 8 in. or less. There is no maximum to the number of open defects. In comparison, AWS D1.1 limits the maximum open discontinuity to 1 8 in., and the sum of discontinuities cannot exceed 3 8 in. This difference in acceptance criteria means a guided bend sample that is acceptable per ASME Section IX may not be acceptable per AWS D1.1. Cracks extending from the corners of the bent sample are more liberal provided there is no evidence of incomplete fusion or slag inclusions. Discontinuities observed on the concave face of the bend samples are not subject to evaluation. When a fillet weld is evaluated by fracturing the weld, the method of breaking the weld is not specified. The welded T-joint can be clamped to a column and the butting member struck several times with a sledge hammer Fig. 3. An alternative is to break the coupon in a press, but be forewarned: The press may fail before the fillet weld fails if the capacity is insufficient. A third method for breaking the welded coupon is to fabricate a robust hickey bar to apply a load to the butting member while securing the nonbutting member to a strong work bench or column. The fractured surfaces of the two pieces (butting and nonbutting members) are examined to see the following: Evidence of incomplete fusion to the root (but not necessarily beyond the root) Incomplete fusion, especially where the welder stops and restarts the weld bead near the middle of the weld Porosity, etc. Of all the soundness tests used to evaluate welds, the fillet break test is probably the easiest and fastest to perform. When the weld coupon consists of plates, the ends of the weld are trimmed back an inch. One of the ends removed from the weld is ground smooth and subjected to macroetching with a suitable etchant. Of the soundness tests described, the transverse guided bend test is performed more frequently than the fillet break test or the nick break test. However, keep in mind that the inspector should check the requirements of the specific welding standard to verify the welded coupon has been prepared properly and the correct procedures are followed when evaluating the samples. ALBERT J. MOORE JR. (AMoore999@comcast.net) is vice president, Marion Testing & Inspection, Canton, Conn. He is an AWS Senior Certified Welding Inspector and an ASNT ACCP NDT Level III. He is also a member of the AWS Certification Committee and the Committee on Methods of Inspection of Welds. AWS Expands International Services With international membership on the rise, the American Welding Society (AWS) launched a series of countryspecific Web sites known as microsites for members to access information in their native languages. Multilingual microsites are now live for Mexico at China at and Canada (English/French) at They feature information on services offered by AWS in each country, membership benefits, exposition information, online education, and access to AWS publications and technical standards. Other countries will be added later. Inspection Trends / Winter

20 By David J. Reid Feature What Is Your Role in Monitoring Shear Wave UT? Here s advice from an experienced CWI to help you understand what s happening during shear wave ultrasonic testing One of the responsibilities of AWS Certified Welding Inspectors is to monitor nondestructive examinations (NDE). Most CWIs know enough about magnetic particle testing (MT) and liquid penetrant testing (PT) to feel comfortable monitoring these NDE methods. And some know enough about radiographic testing (RT) that they can review X-ray film. But how many CWIs know enough about ultrasonic shear wave inspections (UT SW) to have that same warm fuzzy feeling of confidence? Ultrasonic shear wave inspections are voodoo and witchcraft. I don t care what your magic box says, show me something I can believe in like an X- ray film or a red line from a PT indication. How many times have you heard someone say that or even said something like it yourself? With that in mind, the goal of this article is to give you a little inside information about ultrasonic shear wave inspections. This is not going to be another rehash of basic ultrasonic theory there are plenty of other resources for that but some practical information from a practicing CWI and UT technician. Most of the rejectable indications I have seen were incomplete fusion or slag inclusions just above the root pass, along the square edge of a single-bevel groove weld. I recommend making this part of a complete-joint-penetration (CJP) weld a quality control (QC) hold point to minimize welds being rejected. What about that equipment the UT SW tech is using? If inspection is to AWS D1.1, Structural Welding Code Steel, make sure the technician is using code-approved equipment. Shear transducers typically are rectangular and are attached to a wedge that together makes the search unit (Ref. 1). Straight beam transducers typically are Fig. 1 UT shear wave legs. What are you going to see in the third leg that could not be seen in the first or second leg? round (Ref. 2). They do make round transducers that can be attached to a wedge, but they are not AWS D1.1 Code approved. Don t let the UT SW tech try to tell you that his or her round transducer is prequalified for AWS D1.1 shear wave inspections. If the inspection is to the requirements of the ASME Boiler and Pressure Vessel Code, make sure the technician is using the code-approved calibration block (Ref. 3). Make sure an IIW (Ref. 4) or DSC block (Ref. 5) is not going to be used instead. How clean is the inspection area? You can get by with minimal surface prep and a bucket of dirty, nasty couplant (a.k.a. gel) when taking thickness measurements, but I would not recommend it for shear wave inspections. Ask the shear wave UT tech to do a straight beam examination of the base metal next to the weld (Ref. 6). Ask the technician to do this after the normal surface prep and using that bucket of dirty, nasty gel. Take note of how much gain had to be used to get a good signal at 75% full screen height (Ref. 7) and what it took to keep it up there during scanning. Now, ask the technician to do the same examination on a surface wiped clean with a solvent such as acetone and using clean couplant. You should notice a difference in the amount of gain that is needed and that it is much easier to keep it up there during scanning. So, what do you think happens when the technician calibrates for the shear wave exam on a clean calibration block but does an inspection on a dirty surface? If you guessed that some sensitivity was lost, you are right. The D1.1 Code mentions legs and faces (Ref. 8). I address legs first since they also apply to inspections done according to the ASME Code Fig. 1. Most of the rejectable indications I have seen were in Leg I, although there have been a few in Leg II. However, if you hear something said about Leg III (Ref. 8), you may want to question why it could not be seen in Legs I or II. This might be something that should be inspected using a different test angle 22 Inspection Trends / January 2013