Understanding the Challenges Associated with Weld Inspection
Weld inspection is a critical stage in industrial processes where an assessment of pipeline welds is carried out against project standards. Each individual weld plays a significant role in ensuring the usability of different components of a machinery or structure. Welds that are not fit for the purpose are extremely likely to lead to serious consequences related to industrial safety, the bottom line of the factory, and the environment.
Some of the most common inspection techniques used for weld quality assessment are summarised here.
- Visual inspection is the most common, least expensive, and easiest weld inspection technique. However, this method is extremely effective, if it is performed correctly.
- Surface crack detection is done to detect seams, porosity, surface cracks, and other types of discontinuities. Liquid penetrant inspection or magnetic particle inspection are two most used techniques for performing these inspections.
- Non-destructive testing is extremely popular because it determines weld quality without destroying the welded component. Radiographic and ultrasonic inspections are two common examples of NDT methods.
- Destructive weld testing methods require the welded component to be destroyed and hence have limited applications.
- Sound welding inspection is another method for weld quality evaluation.
Inspection of welds is carried out at several stages and the findings are compared against a series of safety standards. Over the years, there have been serious advances in both inspection and welding technology. In spite of these developments, the process of weld inspection still involves several challenges that can make lives difficult for welding inspectors.
One of the foremost challenges faced by weld inspectors involves working in areas that are difficult to reach. In harsh industry environments, accessing the right areas with the required inspection equipment is not easy. In case of welds that are located long distance apart from all entry points, complex systems comprising of multiple elbows and bends are used to gain access.
In many instances, weld inspection is performed under serious time constraint. Naturally, maintaining time efficiency is critical in these circumstances. For example, while laying pipeline from a barge or vessel, every moment counts. It can be seriously expensive to hold up the process of welding for inspection. At the same time, quick and early identification of defects is critical to effective production.
Welding inspectors play a pivotal role in successful inspection of welds. This inspection process requires inspectors that have thorough knowledge in all aspects of welding and fabrication including inspection and testing techniques, code and standard requirements, welding joint design, and welding drawings, symbols and procedures. They should also undergo proper training and obtain appropriate certification.
To perform weld inspections successfully, it is important to use equipment that are robust enough to deal with harsh environments. Although the process involves several challenges, CMS has been working relentlessly on new solutions capable of addressing these challenges. Our team of certified experts have a wealth of experience in delivering welding, testing, and quality management solutions as per Australian as well as international standards. Please contact us today for all your welding inspection related requirements.