Inspection Conference Program

Who Should Attend: Welders, Certified Welding Inspectors, and those interested in transitioning into welding inspection.

A reoccurring theme in our inspections world today is inspectors wanting to be their own boss. Many are looking to be ‘INDEPENDENT’ and not answer to others. Others just think that they can make so much more money with their own business. But this is not a decision to be taken lightly.

There is a lot more to starting a business than people take the time to consider. In the Welding Inspections sector, it is definitely something that needs careful attention and a little bit of guidance from someone who has been there before.

This presentation will give you some insight and direction into what goes into starting a SUCCESSFUL Welding Inspections Business.

This has long been evident in many industries, even though Codes invoked by contracts contain very explicit requirements that all inspections and tests be conducted in accordance with a documented procedure. Audits of inspection and testing operations continue to expose a general lack of understanding that any test – visual or other – must be conducted in a very predictable and regulated manner in order to assure both accuracy of the inspection/test, and the thoroughness.

Most sentiments regarding visual inspection procedures regard them as “unnecessary” to a fully trained and certified inspection professional who has likely conducted, “…untold hundreds of similar inspections…”. Those organizations who profess to “do it right”, generally regard the inspection and test report form as the “procedure”. While better than nothing, this practice brings into light the lack of understanding of many between the process of inspection and the collection of data resulting from that process.

In the rare event that a visual inspection procedure is part of a company or individual’s quality management system, the use of this tool is relegated to the book shelf rather than made a part of every-day practice. Similar to Welding Procedure Specifications (WPS), welding inspection procedures simply do not find their way into the hands of those individuals most effected and most reliant on them, and necessary to their day-to-day work activities.

The most effective visual weld inspection procedures are “living documents” that are revised for each assignment, and include detailed information relating to; the items to be inspected, contact information, contract/job references, materials used in fabrication, inspection tools needed, the inspection environment, scope of inspections, reference materials to be used (Code or specification with acceptance criteria), safety hazards anticipated, etc.

AUDIENCE
Employers and inspection personnel regularly engaged in visual weld inspection.

TRAINING IMPLICATIONS
Using procedure formats developed over 40+ years of industry and inspection experience, the author will show the value of including visual inspection procedures for all inspection activities, and improve the training offered by employers to their inspectors in the development and application of project-specific inspection procedures.
As employers embrace the use of documented procedures for all inspections, there will need to be training established for employees to instruct them in the development and use of said procedures.

APPLICABILITY
Documented inspection procedures are applicable wherever visual inspection is conducted, and, if properly developed and implemented, can be used as a selling tool for small contractors and individual inspectors to improve and expand their business base.

POSSIBLE IMPACT TO THE INSPECTION INDUSTRY
The author anticipates a generally positive impact to the inspection industry as employers and individual inspection consultants adopt the process of producing detailed inspection procedures. This action would improve the quality of inspections, demonstrate a high level of commitment to conducting highest quality inspections, and ensuring that inspections are adequately researched prior to being conducted.

Another anticipated improvement in inspection quality would result from inclusion of the “scope of work” within project-specific procedures. This practice would help eliminate follow-up inspections necessitated by poor communication between the inspector and employer resulting in incomplete inspections, additional costs, and schedule impacts.

Another factor affecting the overall cost of a product has to do with the applicable acceptance criteria specified by the design authority. Specification of acceptance criteria more critical than the design warrants only adds cost. Then, if an inspector applies these criteria in an overzealous manner, the cost escalates even further. The bain of the inspector is the “borderline indication”. Since the acceptance criteria is already considered conservative, rejection of the borderline indication adds even more cost.

AWS D14.4, Specification for the Design of Welded Joints in Machinery and Equipment, is one of the best standards produced by AWS. It integrates the design, fabrication, and inspection of components according to the design criteria for a weld joint, or structural component. The design authority specifies a Class of weld joint, which then dictates fabrication requirements, inspection method(s) and frequency, and the applicable acceptance criteria. This presentation will describe this unique approach and some of the inherent benefits. As part of this approach, the visual examination acceptance criteria is greatly simplified, providing an opportunity to improve the consistency and effectiveness of the inspection, thereby reducing the overall cost.

For many years I have heard from inspectors how they fear taking practical exams and how hard it is to get practical experience. In this day and age, we are still experiencing only 50% passing rate on some of the standardized Industry Performance Demonstration Exams. Why is that?

I believe it is most likely linked to lack of adequate preparation. Just because you do it day in and day out doesn’t mean you don’t need a refresher prior to taking an exam.

I will discuss the advantages of having and using realistic flawed specimens to both train on and test with for a variety of industry sectors.

Bernardo Cuervo is a Senior Pipeline Integrity Consultant for G2 Integrated Solutions with 30 years of experience in pipeline design, construction, and in-line inspection (ILI). Cuervo graduated as a Civil Engineer in 1989 and is a Master Trainer of the National Center for Construction, Education, and Research (NCCER). He is co-chair of the Corrosion Control Course of the University of Oklahoma and a PHMSA associate instructor for the ‘Safety Evaluation of In-line Inspection Programs’. Cuervo has co-presented the workshop ‘Practical Pigging Operations’ for Clarion Technical Conference and has trained and certified analysts and pipeline operators in various ILI technologies in the USA and Canada.

(8:45 – 10:00am) Inspection of Crack Repairs in Large Castings and Forgings
Presenter: George Fairbanks, Fairbanks Inspection & Testing

AWS D1.1 allows for using modern fracture mechanics as a basis for justifying alternative flaw acceptance criteria in structural steel welds, but it does not provide any recommendations for executing this practice. The intent of this presentation is to provide recommended best practices for planning and implementing
alternative flaw acceptance criteria programs. The emphasis is placed on the interaction of different technical specialists, workflow, material procurement requirements, and schedule. Consensus fracture mechanics procedures, fracture toughness testing standards, non‐standard fracture mechanics tests,
other necessary material testing, and inspection capabilities are reviewed. Similar to any other engineering method, there are multiple options for level of effort and technical sophistication.

The multiple options, each with its respective pros and cons, are provided. Current and anticipated future research and development trends for fracture mechanics in alternative flaw criteria are briefly discussed.

Quality Auditing vs Inspecting, Can they work hand-in-hand? Identifying types of audits, possible conflicts, and misconceptions about auditing as we explore some practical methods used and hoping to allow time for questions and answers. The target audience for QA/QC and executive management.

This paper provides an overview of the existing federal and state legislation regulating the themed park industry and the means, methods, and technologies existing and being developed to effectively inspect amusement rides. Actual ride components with examples of existing inspection methods are described.

At the same time, the relatively high strength of downhole 13Cr stainless steel grades (80-110 ksi specified minimum yield strength) requires tempering temperatures that limit how high the PWHT temperature can go without compromising strength. This article presents experimental work that was done to determine how post-weld heat treatment affects yield strength of 13Cr grades and establish a suitable post-weld heat treatment time and temperature for these alloys.

A typical project requires the inspector to provide information to the Project Manager during site preparation, excavation, subsurface utility and drainage systems, foundations for pipe racks and equipment, as well as the piping and equipment to be placed on those foundations. Inspecting welding is only a small part of a “Welding Inspector’s” day.
Each of these areas of construction are guided by multiple standards with which the inspector must be familiar, if not expert. On a typical refinery or chemical plant project, the inspector of record may find more than 30 standards invoked as part of the contract. If that inspector is employed by the design engineer, there will be additional standards to be knowledgeable of that relate to design, fabrication, and construction.

At times, U.S.-based inspectors are asked to inspect projects in foreign countries (Europe, China, Southeast Asia, South America, etc.) where additional codes and standards will apply to the work being performed. On a project the author was assigned for a Client in Singapore, the Ministry of Manpower in Singapore insisted that mechanical systems (piping and pressure vessels) be designed, fabricated, and tested (NDE) to the Ministry of Manpower Standard. Engineers unfamiliar with the requirements of that standard failed to stipulate to the NDE requirements of the standard which cost the Owner significant money to have piping system insulation removed for additional NDE after delivery to Singapore.

This presentation will investigate the myriad codes and standards which an inspector must become familiar with in order to ensure proper compliance for their projects. At times, the inspector will have very little time with which to educate themselves in the new standards and to figure out how to apply unfamiliar requirements.

AUDIENCE
Inspection personnel regularly engaged in visual weld inspection in fabrication and construction of refineries, process, and other industries where multiple standards apply. Inspection personnel who are considering or could possibly find themselves assigned to projects where foreign standards are used in lieu of U.S. standards.

TRAINING IMPLICATIONS
Using experiences developed over 40+ years of industry and inspection experience, the author will discuss the process of identifying relevant standards that apply to all aspects of projects, not only those that are most comfortable (familiar) for the inspector. Standards for all project activities are critical and having a strong knowledge of these is crucial to the success of any project inspector.

As inspectors begin to understand their responsibilities as it regards multiple standards, there will continue to be a need for training to instruct them in the application of unfamiliar standards.

APPLICABILITY
Standards are applicable wherever design, fabrication, construction, and plant operations are conducted. If inspectors are properly trained in their content and use, this expertise can be used as a selling tool for small contractors and individual inspectors to improve and expand their business base.