Visual Inspection/Visual testing (VT)

As I pointed out, there are three phases to consider in developing a visual inspection and testing
program/checklist; what happens before welding, during welding, and after welding.
In some of the phases, the inspector will have to use tools to measure for instance: fit-up dimensions (root
opening, root face, groove angle) and fusion type discontinuities like porosity to determine if they are in
compliance with specifications.
Visual observation that the welding procedure specification (WPS) is adhered to is an essential component of
visual inspection/visual testing. In fact before any welding proceeds, the welding inspector must verify that
there is a WPS and welding personnel are qualified to use the WPS in production welding. By the way is the
joint you are using in the design prequalified? If not it will have to be qualified by testing.
AWS D1.1 Chapter 6 covers INSPECTION, outlines responsibilities of verification (QA) and contractor's (QC)
inspector as well as those of the contractor. It then delves into acceptance criteria for VT and NDT, followed
by procedures for primarily RT and UT.
AWS D1.1 chapter 6 does not spell out a detailed checklist and set of procedures for visual inspection but it
does provide acceptance criteria for welds. AWS has other publications that deal with this. For instance,
Figure 10.1 of the AWS WIT is an example of a welding inspection checklist and covers what is to be done by
the inspector before welding, during welding, and after welding. I recommend getting a copy of it.
After welding the inspector has to check the weld. D1.1 has a table dealing with this. Discontinuity Category
and Inspection Criteria items enumerated in AWS Table 6.1 Visual Inspection (VT) Acceptance Criteria are as
follows: 1. Crack prohibition, 2. Weld/Base-Metal Fusion, 3. Crater Cross Section, 4. Weld Profiles (refers to fig
5.4), Time of Inspection, 6. Undersized welds, 7. Undercut, and 8. Porosity.
Item 4 in the preceding paragraph directs us to Figure 5.4 Acceptable and Unacceptable Weld Profiles. Figure
5.4 deals with fillet welds and groove welds. The butt welds (groove welds in butt joints) will have to be
checked with appropriate tools to make sure reinforcement is not excessive, there is no underfill, no
excessive undercut, and no overlap.
Regarding frequency of visual inspection, if I were you I'd specify continuous VT from start to finish.
NDT
This can get very expensive but is imperative in order to supplement VT. Therefore, I recommend that you to
talk to an NDT expert prior to specifying required tests and frequency of testing.
Methods to consider include: RT (x-ray testing...very expensive), UT (ultrasonic testing), LT (leak test), PT,
and MT.
Dye penetrant testing (PT) and MT (magnetic particle testing) are relatively inexpensive but have
limitations.
IMO in addition to performing NDT when fabrication is complete, there should be hold points during the
fabrication process for NDT to be carried out.
To the best of my knowledge D1.1 does not recommend an NDT frequency of testing but ASME Section VIII
does.