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Welding Inspection Procedure / Checklist

MaintainX
10/24/2021

Welding Inspection Procedure / Checklist

    Stage 1 - Welding Inspection Prior to Welding Work

    Welding symbols and weld sizes clearly specified in drawing and related documents.

    • Pass
    • Flag
    • Fail

    Weld joint designs and dimensions clearly specified in drawings and related documents.

    • Pass
    • Flag
    • Fail

    Weld maps identify the welding procedure specification (WPS) to be used for specific weld joints.

    • Pass
    • Flag
    • Fail

    Dimensions detailed and potential for distortion addressed.

    • Pass
    • Flag
    • Fail

    Welding consumables specified.

    • Pass
    • Flag
    • Fail

    Proper handling of consumables, if any, identified.

    • Pass
    • Flag
    • Fail

    Base material requirements specified (such as the use of impact tested materials where notch ductility is a requirement in low temperature service).

    • Pass
    • Flag
    • Fail

    Mechanical properties and required testing identified.

    • Pass
    • Flag
    • Fail

    Weather protection and wind break requirements defined.

    • Pass
    • Flag
    • Fail

    Preheat requirements and acceptable preheat methods defined.

    • Pass
    • Flag
    • Fail

    Post-weld heat treatment (PWHT) requirements and acceptable PWHT method defined.

    • Pass
    • Flag
    • Fail

    Inspection hold-points and NDE requirements defined.

    • Pass
    • Flag
    • Fail

    Additional requirements, such as production weld coupons, clearly specified.

    • Pass
    • Flag
    • Fail

    Pressure testing requirements, if any, clearly specified

    • Pass
    • Flag
    • Fail

    Competency of welding organization to perform welding activities in accordance with codes, standards, and specifications specified

    • Pass
    • Flag
    • Fail

    Roles and responsibilities of engineers, welding organization, and welding inspectors defined and appropriate for the work.

    • Pass
    • Flag
    • Fail

    Independence of the inspection organization from the production organization is clear and demonstrated.

    • Pass
    • Flag
    • Fail

    WPS(s) are properly qualified and meet applicable codes, standards and specifications for the work.

    • Pass
    • Flag
    • Fail

    Procedure qualification records (PQR) are properly performed and support the WPS(s).

    • Pass
    • Flag
    • Fail

    Welder performance qualifications (WPQ) meet requirements for the WPS.

    • Pass
    • Flag
    • Fail

    NDE examiners are properly certified for the NDE technique.

    • Pass
    • Flag
    • Fail

    NDE procedures are current and accurate.

    • Pass
    • Flag
    • Fail

    Calibration of NDE equipment is current.

    • Pass
    • Flag
    • Fail

    Welding machine calibration is current

    • Pass
    • Flag
    • Fail

    Instruments such as ammeters, voltmeters, contact pyrometers, have current calibrations.

    • Pass
    • Flag
    • Fail

    Storage ovens for welding consumables operate with automatic heat control and visible temperature indication.

    • Pass
    • Flag
    • Fail

    Heat treatment procedure is available and appropriate

    • Pass
    • Flag
    • Fail

    Pressure testing procedures are available and detail test requirements.

    • Pass
    • Flag
    • Fail

    PWHT equipment calibration is current.

    • Pass
    • Flag
    • Fail

    Pressure testing equipment and gauges calibrated and meet appropriate test requirements.

    • Pass
    • Flag
    • Fail

    Material test certifications are available and items properly marked (including back-up ring if used ;).

    • Pass
    • Flag
    • Fail

    Electrode marking, bare wire flag tags, identification on spools of wire, etc. as-specified.

    • Pass
    • Flag
    • Fail

    Filler material markings are traceable to a filler material certification.

    • Pass
    • Flag
    • Fail

    Base metal markings are traceable to a material certification.

    • Pass
    • Flag
    • Fail

    Recording of filler and base metal traceability information is performed.

    • Pass
    • Flag
    • Fail

    Base metal stampings are low stress and not detrimental to the component.

    • Pass
    • Flag
    • Fail

    Paint striping color code is correct for the material of construction.

    • Pass
    • Flag
    • Fail

    PMI records supplement the material traceability and confirm the material of construction.

    • Pass
    • Flag
    • Fail

    Weld preparation surfaces are free of contaminants and base metal defects such as laminations and cracks.

    • Pass
    • Flag
    • Fail

    Preheat, if required, applied for thermal cutting c. Hydrogen bake-out heat treatment, if required, performed to procedure.

    • Pass
    • Flag
    • Fail

    Weld joint is free from oxide and sulfide scales, hydrocarbon residue, and any excessive build-up of weld-through primers.

    • Pass
    • Flag
    • Fail

    Weld joint type, bevel angle, root face and root opening are correct.

    • Pass
    • Flag
    • Fail

    Alignment and mismatch is correct and acceptable.

    • Pass
    • Flag
    • Fail

    Dimensions of base materials, filler metal, and weld joint are correct.

    • Pass
    • Flag
    • Fail

    Piping socket welds have proper gap.

    • Pass
    • Flag
    • Fail

    Preheat equipment and technique are acceptable.

    • Pass
    • Flag
    • Fail

    Preheat coverage and temperature are correct.

    • Pass
    • Flag
    • Fail

    Reheat, if required, applied to thermal cutting operations.

    • Pass
    • Flag
    • Fail

    Preheat, if required, applied to remove moisture

    • Pass
    • Flag
    • Fail

    Filler metal type and size are correct per procedure.

    • Pass
    • Flag
    • Fail

    Filler metals are being properly handled and stored.

    • Pass
    • Flag
    • Fail

    Filler metals are clean and free of contaminants.

    • Pass
    • Flag
    • Fail

    Coating on coated electrodes is neither damaged nor wet.

    • Pass
    • Flag
    • Fail

    Flux is appropriate for the welding process and being properly handled.

    • Pass
    • Flag
    • Fail

    Inert gases, if required are appropriate for shielding and purging.

    • Pass
    • Flag
    • Fail

    Gas composition is correct and meets any purity requirements.

    • Pass
    • Flag
    • Fail

    Shielding gas and purging manifold systems are periodically bled to prevent back filling with air.

    • Pass
    • Flag
    • Fail

    Stage 2 - Welding Inspection During Welding

    Welder is responsible for quality craftsmanship of weldments

    • Pass
    • Flag
    • Fail

    Welder meets qualification requirements

    • Pass
    • Flag
    • Fail

    Welder understands welding procedure and requirements for the work.

    • Pass
    • Flag
    • Fail

    Special training and mock-up weldments performed if required.

    • Pass
    • Flag
    • Fail

    Welder understands the inspection hold-points.

    • Pass
    • Flag
    • Fail

    Essential variables are being met during welding.

    • Pass
    • Flag
    • Fail

    Filler material, fluxes, and inert gas composition/flow rate.

    • Pass
    • Flag
    • Fail

    Purge technique, flow rate, O2 analysis, etc.

    • Pass
    • Flag
    • Fail

    Rod warmers energized or where rod warmers are not employed, the welder complies with maximum exposure times out of the electrode oven.

    • Pass
    • Flag
    • Fail

    Preheating during tack welding and tack welds removed (if required).

    • Pass
    • Flag
    • Fail

    Welding technique, weld progression, bead overlap, etc.

    • Pass
    • Flag
    • Fail

    Equipment settings such as amps, volts, and wire feed.

    • Pass
    • Flag
    • Fail

    Preheat and interpass temperatures.

    • Pass
    • Flag
    • Fail

    Travel speed (key element in heat input).

    • Pass
    • Flag
    • Fail

    Heat input (where appropriate).

    • Pass
    • Flag
    • Fail

    Mock-up weldment, if required, meets requirements with welder and welding engineer.

    • Pass
    • Flag
    • Fail

    Welder displays confidence and adheres to good welding practices.

    • Pass
    • Flag
    • Fail

    Tack welds to be incorporated in the weld are of acceptable quality.

    • Pass
    • Flag
    • Fail

    Weld root has adequate penetration and quality.

    • Pass
    • Flag
    • Fail

    Cleaning between weld passes and of any back-gouged surfaces is acceptable.

    • Pass
    • Flag
    • Fail

    Additional NDE performed between weld passes and on back-gouged surfaces shows acceptable results.

    • Pass
    • Flag
    • Fail

    In-process rework and defect removal is accomplished.

    • Pass
    • Flag
    • Fail

    In-process ferrite measurement, if required, is performed and recorded.

    • Pass
    • Flag
    • Fail

    Final weld reinforcement and fillet weld size meets work specifications and drawings.

    • Pass
    • Flag
    • Fail

    Stage 3 - Welding Inspection Upon Completion Of Welding

    Size, length and location of all welds conform to the drawings / specifications / Code.

    • Pass
    • Flag
    • Fail

    No welds added without approval.

    • Pass
    • Flag
    • Fail

    Dimensional and visual checks of the weld don’t identify welding discontinuities, excessive distortion and poor workmanship.

    • Pass
    • Flag
    • Fail

    Temporary attachments and attachment welds removed and blended with base metal.

    • Pass
    • Flag
    • Fail

    Discontinuities reviewed against acceptance criteria for defect classification.

    • Pass
    • Flag
    • Fail

    PMI of the weld, if required and examiner’s findings indicate they comply with the specification.

    • Pass
    • Flag
    • Fail

    Welder stamping/marking of welds confirmed.

    • Pass
    • Flag
    • Fail

    Perform field hardness check.

    • Pass
    • Flag
    • Fail

    Verify NDE is performed at selected locations and review examiner’s findings.

    • Pass
    • Flag
    • Fail

    Specified locations examined.

    • Pass
    • Flag
    • Fail

    Specified frequency of examination.

    • Pass
    • Flag
    • Fail

    NDE performed after final PWHT.

    • Pass
    • Flag
    • Fail

    Work of each welder included in random examination techniques.

    • Pass
    • Flag
    • Fail

    RT film quality, IQI placement, IQI visibility, etc. complies with standards.

    • Pass
    • Flag
    • Fail

    Inspector is in agreement with examiners interpretations and findings.

    • Pass
    • Flag
    • Fail

    Documentation for all NDE correctly executed

    • Pass
    • Flag
    • Fail

    Verify post-weld heat treatment is performed to the procedure and produces acceptable results.

    • Pass
    • Flag
    • Fail

    Paint marking and other detrimental contamination removed.

    • Pass
    • Flag
    • Fail

    Temporary attachments removed.

    • Pass
    • Flag
    • Fail

    Machined surfaces protected from oxidation.

    • Pass
    • Flag
    • Fail

    Equipment internals, such as valve internals, removed to prevent damage.

    • Pass
    • Flag
    • Fail

    Equipment supported to prevent distortion.

    • Pass
    • Flag
    • Fail

    Thermocouples fastened properly.

    • Pass
    • Flag
    • Fail

    Thermocouples adequately monitor the different temperature zones and thickest/thinnest parts in the fabrication.

    • Pass
    • Flag
    • Fail

    Temperature monitoring system calibrated.

    • Pass
    • Flag
    • Fail

    Local heating bandwidth is adequate.

    • Pass
    • Flag
    • Fail

    Insulation applied to the component where required for local heating.

    • Pass
    • Flag
    • Fail

    Temperature and hold time is correct.

    • Pass
    • Flag
    • Fail

    Heating rate and cooling rate is correct.

    • Pass
    • Flag
    • Fail

    Distortion is acceptable after completion of the thermal cycle.

    • Pass
    • Flag
    • Fail

    Hardness indicates an acceptable heat treatment

    • Pass
    • Flag
    • Fail

    Verify pressure test is performed to the procedure

    • Pass
    • Flag
    • Fail

    Pressure meets test specification.

    • Pass
    • Flag
    • Fail

    Test duration is as-specified.

    • Pass
    • Flag
    • Fail

    Metal temperature of component meets minimum and maximum requirements.

    • Pass
    • Flag
    • Fail

    Pressure drop or decay is acceptable per procedure.

    • Pass
    • Flag
    • Fail

    Visual examination does not reveal defects.

    • Pass
    • Flag
    • Fail

    Perform a final audit of the inspection dossier to identify inaccuracies and incomplete information.

    • Pass
    • Flag
    • Fail

    All verifications in the quality plan were properly executed.

    • Pass
    • Flag
    • Fail

    Inspection reports are complete, accepted and signed by responsible parties.

    • Pass
    • Flag
    • Fail

    Inspection reports, NDE examiners interpretations and findings are accurate.

    • Pass
    • Flag
    • Fail

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