In an engineering fabrication industry, the last activity in the sequence of manufacturing is loadout or dispatch. This activity cannot...
In an engineering fabrication industry, the last activity in the sequence of manufacturing is loadout or dispatch. This activity cannot be initiated unless the product is signed off. As a matter of fact, signing the product off is an assurance of quality which is authenticated by a technically competent person such as “Senior Welding Inspector” who makes sure that complete manufacturing of the product has been carried out in accordance with the applicable standard and sound engineering practices.
However, before signing the documents the senior welding inspector should make enquiry which can give him the in sites of the past while product was being manufactured.
Typical questions can be as followed
1. What was the repair rate during production?
2. Whether any difficulties are encountered within the job?
3. Whether any concession or waiver was given, if yes why?
4. How were the weather conditions?
5. Whether there were any safety issues, fatalities, major accidents/incidents etc…?
6. Whether there were any labour problems?
7. What about the general moral and standard of work amongst the inspection team(s)?
Further to this, he can start reviewing of documents and he should make sure that he attaches the following documents as a minimum
1. Quality control plan – ensure all stages are complete and signed off
2. Inspection checklist – ensure all stage are completed and signed off
3. Verify material certificates such as mill test certificates, material traceability records etc…
4. Verify the following procedures which are to be attached and have all been approved
a. Welding
b. Repair
c. NDT
d. PWHT
e. Hardness
f. PMI
g. Hydrotest
h. Coating/Painting
5. Verify the qualification level and validity of the welder and NDT personnel
6. Verify the inspection reports of the following disciplines and ensure that they cover all appropriate joints and structure
a. Visual
b. NDT
c. Dimensional control etc…
7. Verify calibration certificates of equipments and instruments such as pressure gauge, inspection tools, and welding equipments etc…
8. Verify hardness test reports
9. Verify PMI reports
10. Verify PWHT reports
11. Verify Hydrotest reports
12. Verify as-built drawings are completed
13. Verify weld maps are available for traceability
14. Verify nameplate, rubbing details are available when applicable
15. Verify concession request, NCR, site query etc…
16. Verify permit to work
17. Verify painting and coating inspection reports
As a part of his own inspection, he may be obliged to witness the final hydro test, visual inspection of completed parts. As a matter of quality assurance, he may view some radiographs at random and may even conduct a radiograph audit.
Finally, transit and tie-down procedures should all have been approved by the relevant engineer prior to the final acceptance of the product and issue of any signed certificate of conformance.
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