Navy Spec Welding Audits Common Areas of Findings & Common NDT Qualification Problems
navsea technical publication
T9074-AS-GIB-010/ 271 REQUIREMENTS FOR NONDESTRUCTIVE TESTINGTEST METHOD
MIL-STD- 2035 A(SH) DEPARTMENT OF DEFENCE TEST METHOD NONDESTRUCTIVE TESTING ACCEPTANCE CRITERIA
S09074-AR-GIB-010/ 278 REQUIREMENTS FOR FABRICATION WELDING AND INSPECTION, AND CASTING INSPECTION AND REPAIR FOR MACHINERY, PIPING, AND PRESSURE VESSELS
S9074-AQ-GIB-010/ 248 D REQUIREMENTS FOR WELDING AND BRAZING PROCEDURE AND PERFORMANCE QUALIFICATION
Navy Spec Welding Audits Common Areas of Findings
Welding Filler Metal:
Common Audit Finding
Requirement
Correction
Ensure only compliant filler metals are used, matching MIL- SPEC requirements.
Use of non-compliant filler metal
S9074-AQ-GIB-010/248 4-7.2.a
- Commercial specifications are not equivalent to MIL-SPEC
Verify equivalency and obtain approval before use.
S9074-AQ-GIB-010/248 4-7.2.a
- Where AWS grade is allowed, additional lot-specific testing and certification required
S9074-AQ-GIB-010/248 4-7.2.a, 5.2.1, 5.2.2
Conduct required testing and certification for each lot.
- EB Submarine compliant MIL- 100S wire does not meet NNS aircraft carrier requirements
Use wire that meets specific requirements for NNS aircraft carriers.
S9074-AQ-GIB-010/248 Table 7-2 footnote 13, 20
Welding Filler Metal:
Common Audit Finding
Requirement
Correction
Packaging and/or product not marked properly
Ensure proper marking and packaging as per specifications.
S9074-AR-GIB-010/278 5.3
Losing traceability before the point of use
Maintain traceability of materials up to the point of use.
S9074-AR-GIB-010/278 5.3
Level-1 applications require specific documentation for each weld joint
Provide detailed documentation for each weld joint in Level-1 applications.
S9074-AR-GIB-010/278 5.3
Receipt inspection not comparing MTR data for mechanical properties and chemical composition compliance to the filler metal specification
Perform thorough receipt inspections to compare MTR data with specifications.
S9074-AQ-GIB-010/248 4-7.2.a
Welding Filler Metal:
Common Audit Finding
Requirement
Correction
Additional testing requirements of fabrication standards not being performed (diffusible hydrogen, chemical composition over check, etc.)
Conduct all additional testing as required by fabrication standards.
S9074-AQ-GIB-010/248 4-7.2.a
Filler metal cleanliness not being properly maintained in storage or at work station
Ensure proper storage and cleanliness of filler metals.
S9074-AR-GIB-010/278 5.3
Filler metal being comingled with other grades or commercial grade filler metal
Ensure proper storage and cleanliness of filler metals.
S9074-AR-GIB-010/278 5.3
Implement procedures to return filler metals to control points after shifts.
Filler metal not being returned to control point at end of shift
S9074-AR-GIB-010/278 5.3
Welding Filler Metal:
Common Audit Finding
Requirement
Correction
Filler metal being exposed to atmospheric moisture longer than allowed
Limit exposure time of filler metals to atmospheric moisture.
S9074-AQ-GIB-010/248 4-7.2.a, 4-7.2.b
Filler metal rod ovens temperature device not calibrated or out of calibration
Regularly calibrate temperature devices in rod ovens.
S9074-AQ-GIB-010/248 4-7.2.c
Filler metal rod ovens being used to heat food or other possible contaminants
Implement detection methods for power or temperature loss in rod ovens.
S9074-AQ-GIB-010/248 4-7.2.c
Properly control and monitor holding and baking times in rod ovens.
Rod oven temperature ranges not compliant to specifications
S9074-AQ-GIB-010/248 4-7.2.c
Welding Filler Metal:
Common Audit Finding
Requirement
Correction
No method to prevent discarded filler metal from being used in product
Establish methods to prevent the use of discarded filler metal in products.
S9074-AR-GIB-010/278 5.3
Implement a controlled process for issuing and returning filler metals.
No method for controlled filler metal issue or return
S9074-AR-GIB-010/278 5.3
welding heat control
Common Audit Finding
Requirement
Correction
Welder not checking preheat and interpass min/max at appropriate times or locations
Ensure welders check preheat and interpass temperatures at specified times and locations.
S9074-AR-GIB-010/278 4.2.2
Calibrate devices used for checking temperatures and ensure their accuracy.
Device for checking minimum and maximum preheat and Interpass
S9074-AR-GIB-010/278 4.2.2, S9074-AQ-GIB-010/248 4-7.2.c
temperatures not accurate (infrared device not calibrated, canted contact pyrometer)
Post weld heat treatment (see Tech Pub 278 Section 8 if applicable or for guidance): Non- weld spec driven thermal processes (such as stress relief of formed of CuNi fittings or nitriding) effectively become PWHT that must be qualified
Qualify non-weld spec driven thermal processes as PWHT if applicable.
S9074-AQ-GIB-010/248 4-7.2.c
Oven temperature measurement devices not calibrated
Regularly calibrate oven temperature measurement devices.
S9074-AQ-GIB-010/248 4-7.2.c
welding heat control
Common Audit Finding
Requirement
Correction
Improper heat up or cool down rate or loading/unloading temperatures limits
Regularly calibrate oven temperature measurement devices.
S9074-AQ-GIB-010/248 4-7.2.c
Control heat up, cool down rates, and adhere to temperature limits for loading/unloading.
Improper heat up or cool down rate or loading/unloading temperatures limits
S9074-AR-GIB-010/278 4.8.1, 4.8.2
Not conducting final NDT after heat treatment
Conduct final NDT after heat treatment as required.
S9074-AR-GIB-010/278 4.8.3
Place and number thermocouples correctly according to specifications.
Placement and number of thermocouples not correct
S9074-AR-GIB-010/278 4.8.1, 4.8.4
Maintain objective quality evidence (OQE) for the heat treatment cycle.
No OQE of heat treatment cycle
S9074-AR-GIB-010/278 4.8.3
· Other Welder Workmanship Requirements:
Common Audit Finding
Requirement
Correction
Implement and follow strict cleaning procedures for the weld zone before welding, between intermediate passes, and for the final surface to remove all contaminants.
Proper weld zone cleaning prior to welding, intermediate passes, and final surface
S9074-AR-GIB-010/278 4.4.1, 4.4.2
Employ protective measures such as heat shields and barriers to prevent damage to surrounding components from heat and contaminants during welding. Perform Visual Inspection (VT) using lighting with at least 100 foot-candles of illumination and calibrated measurement tools as specified.
Performing Visual Inspection (VT) using appropriate lighting and measurement tools
S9074-AR-GIB-010/278 4.5.3
Protecting surrounding components from potential heat or contamination damage
S9074-AR-GIB-010/278 4.5.1
Welding Procedure Compliance:
Reference Document
Failure Type
Welding Procedure Compliance
Best Practices to Prevent Noncompliance
Implement a system for verifying and documenting the approval status of welding procedures before work begins. Conduct regular training sessions for welders on the importance of using approved procedures. Ensure supervisors review and approve welding procedures prior to starting any welding activities. Establish a review process to ensure welding procedures are specific to the materials and standards required for each job. Maintain a database of approved procedures linked to specific applications and standards. Conduct periodic audits to verify compliance with approved procedures. Provide comprehensive training for welders on the detailed requirements of each approved procedure. Implement a system of checks and balances, such as peer reviews or supervisor sign-offs, to ensure adherence to procedures. Use visual aids and checklists at workstations to remind welders of critical procedure steps.
Welding performed without an approved welding procedure
S9074-AR-GIB- 010/278 4.7.1
Type I
Welding performed with an approved procedure that does not exactly match the application(s) for which it is used (for example, a base metal spec that has not been grouped into the S-group covered by the procedure, or the procedure was approved for a different fabrication standard than required)
S9074-AR-GIB- 010/278 4.7.2
Type II
Welding performed with an approved procedure that was appropriate for the application, but the welder was not following all requirements of the procedure
S9074-AR-GIB- 010/278 4.7.3
Type III
Welder Qualifications (all required record attributes):
Required Atrribute
Failure
Reference Document
Name of welder
Missing welder's name in records
TP248 p. 5.2.3.1(e)
Fabrication/acceptance standards covered
Fabrication/acceptance standards not documented
TP248 p. 5.2.3.1(e)
Date of examination
Examination date not recorded
TP248 p. 5.2.3.1(e)
Examination results including passing grade (75% minimum)
Examination results missing or not meeting the minimum passing grade
TP248 p. 5.2.3.1(c)
Certifying signature of Level III Examiner
Certifying signature of Level III Examiner missing
TP248 p. 5.2.3.1(d) & (e)
vision test
Required Atrribute
Failure
Reference Document
Name of welder
Missing welder's name in vision test records
TP248 p. 5.2.12
Vision test date or expiration date not recorded
TP248 p. 5.2.12
Date of vision test (or expiration date)
Natural or corrected (if any glasses/corrective aids needed to pass equivalent aids must be used in production)
Corrective aids not documented if needed
TP248 p. 5.2.12
Near vision test type (Jaeger-type J-1 chart or equivalent required)
Near vision test type not specified
TP248 p. 5.2.3.1(c)
Color perception test not conducted for titanium welders
Color perception test for titanium welders
TP248 p. 5.2.12
Qualification of vision tester not documented
Qualification of vision tester
TP248 p. 5.2.12
Signature of vision tester
Vision tester's signature missing
TP248 p. 5.2.12
performance test
Required Atrribute
Failure
Reference Document
Welder's name or identification not recorded
Name or identification of welder
TP248 p. 5.5.1
TP248 p. 5.5.1
Date of test
Date of performance test not recorded
Qualification test number
Qualification test number missing
TP248 Table X
Welding process
Welding process not documented
TP248 p. 5.5.1
Position of welding
Welding position not specified
TP248 p. 5.5.1
Base material type
Base material type not documented
TP248 p. 5.5.1
Base material size (thickness, diameter, etc.)
Base material size not recorded
TP248 p. 5.5.1
Filler metal type
Filler metal type not documented
TP248 p. 5.5.1
performance test
Required Atrribute
Failure
Reference Document
Welder's name or identification not recorded
Name or identification of welder
TP248 p. 5.5.1
TP248 p. 5.5.1
Date of test
Date of performance test not recorded
Qualification test number
Qualification test number missing
TP248 Table X
Welding process
Welding process not documented
TP248 p. 5.5.1
Position of welding
Welding position not specified
TP248 p. 5.5.1
Base material type
Base material type not documented
TP248 p. 5.5.1
Base material size (thickness, diameter, etc.)
Base material size not recorded
TP248 p. 5.5.1
Filler metal type
Filler metal type not documented
TP248 p. 5.5.1
performance test
Required Atrribute
Failure
Reference Document
Filler metal size
Filler metal size not recorded
TP248 p. 5.5.1
TP248 p. 5.5.1
Results of test – List
Results of test not listed
Types of tests, both NDT & destructive
Types of tests not specified
TP248 p. 5.5.1
Acceptance standard
Acceptance standard not documented
TP248 p. 5.5.1
Results
Test results not recorded
TP248 p. 5.5.1
Identification & qualification of tester not documented
Identification & qualification of tester
TP248 p. 5.5.1
Record of omission of space restriction
Omission of space restriction not recorded
TP248 p. 5.5.1
Certifying signature of fabricator
Certifying signature of fabricator missing
TP248 p. 5.5.1
maintenance
Required Atrribute
Failure
Reference Document
Lapse in three month period or calendar quarter
Three month period or calendar quarter
TP248 p. 5.2.11
TP248 p. 5.2.11
Welding process used
Welding process used not documented
Titanium use not documented lapsed for 6- month period
Titanium 6-month use
TP248 p. 5.2.11
Surveillance of Welders:
Common Audit Finding
Requirement Reference
Best Practices to Prevent Noncompliance
Implement a comprehensive written procedure for welder surveillance that includes all required attributes and guidelines.
Lack of a system including a written procedure covering
Tech Pub 1688, Paragraph 5.8.1, 6.3.1, 6.3.2, 4.9,
Surveillance form (attributes from Tech Pub 1688 paragraph 5.8)
Ensure surveillance forms include all required attributes as specified in the reference documents.
Tech Pub 1688, Paragraph 6.3.1, 6.3.2
Verify and document the qualifications of all observers conducting welder surveillance.
Frequency and coverage guidelines
Tech Pub 1688, Paragraph 6.3.1, 6.3.2
Record of immediate corrective action and long term preventive action
Establish and adhere to frequency and coverage guidelines for welder surveillance to ensure thorough monitoring.
Tech Pub 1688, Paragraphs 5.8.1(i), 6.3.1, 6.3.2
Periodic analysis of data, and action plan for continuous improvement
Maintain detailed records of corrective and preventive actions taken in response to surveillance findings.
Tech Pub 1688, Paragraphs 5.8.1(j), 6.3.1, 6.3.2
Lack of a system including a written procedure covering
Lack of a system including a written procedure covering
Conduct regular data analysis and develop action plans aimed at continuous improvement in welder performance.
Welding equpment
Common Audit Finding
Requirement Reference
Correction/Best Practice
T9074-AD-GIB-010/1688, Section 6.4.1, 6.4.2;
Establish and adhere to regular maintenance schedules for all welding equipment. Document and verify each maintenance activity to ensure compliance.
Maintenance interval and guidelines
S9074-AQ-GIB-010/248, Section 4.4.1
T9074-AD-GIB-010/1688, Section 6.2.7, 16.3.1;
Conduct regular calibration of welding equipment to verify setting and display accuracy. Maintain records of each verification and calibration activity.
Verification of setting or display accuracy
S9074-AQ-GIB-010/248, Section 6.2.7
Regularly inspect and calibrate shielding and purge gas flow meters. Ensure they match the types of gas mixtures required by welding procedures and can measure the specified flow ranges.
T9074-AD-GIB-010/1688, Section 10.4;
Shielding and purge gas flow meters
S9074-AQ-GIB-010/248, Section 6.2.7.1
Verify that the gas mixtures used match the specifications in the welding procedures. Conduct periodic checks and maintain records of gas types and mixtures.
T9074-AD-GIB-010/1688, Section 10.5.1, 16.6.4;
Matching the types of gas mixtures required by procedures
S9074-AQ-GIB-010/248, Section 6.2.7.1
Welding equpment
Common Audit Finding
Requirement Reference
Best Practices to Prevent Noncompliance
Ensure flow meters are capable of accurately measuring the flow ranges specified in the welding procedures. Perform regular calibrations and maintain records of compliance.
T9074-AD-GIB-010/1688, Section 16.6.3;
Measuring the flow ranges allowed by welding procedures
S9074-AQ-GIB-010/248, Section 6.2.7
Verify that the supply side pressure range is within the limits specified in the welding procedures. Regularly inspect pressure regulators and maintain records of pressure checks.
T9074-AD-GIB-010/1688, Section 16.6.4.1;
Proper supply side pressure range for manifold system
S9074-AQ-GIB-010/248, Section 6.2.7.1
Regularly verify the accuracy of welding equipment under actual service conditions. Conduct routine inspections and maintain detailed records of equipment condition and verification tests.
T9074-AD-GIB-010/1688, Section 10.3;
Service condition and verification of accuracy
S9074-AQ-GIB-010/248, Section 6.2.7
Flow down of welding requirements to subcontractors: Audit Failure Requirement Reference
Correction/Best Practice
Ensure all subcontractors receive and understand all relevant prime contract requirements. Conduct regular reviews and updates of subcontractor documentation to match prime contract revisions.
T9074-AD-GIB-010/1688, Section 4.2;
Flow down of welding requirements to subcontractors
S9074-AQ-GIB-010/248, Section 4.2.4
Clearly identify and communicate all pertinent prime contract requirements to subcontractors. Maintain an updated list of requirements and ensure subcontractors acknowledge receipt and understanding.
T9074-AD-GIB-010/1688, Section 4.2.1;
Identification of all pertinent prime contract requirements
S9074-AQ-GIB-010/248, Section 4.2.4
Provide subcontractors with all applicable documents, ensuring they have the latest revisions. Implement a document control system to track distribution and receipt of documents by subcontractors
T9074-AD-GIB-010/1688, Section 4.2.3;
Provision of all applicable documents with correct revisions
S9074-AQ-GIB-010/248, Section 4.2.3
Ensure all required qualifications and approvals are obtained before subcontractors begin work. Establish a verification process to confirm qualifications and approvals are in place.
T9074-AD-GIB-010/1688, Section 4.2.4;
Obtaining all required qualifications and approvals before the start of work
S9074-AQ-GIB-010/248, Section 4.2.2
T9074-AD-GIB-010/1688, Section 4.2.5;
Develop and implement a surveillance program to monitor subcontractor compliance. Conduct regular audits and inspections to verify adherence to all welding requirements.
Surveillance program to verify compliance
S9074-AQ-GIB-010/248, Section 4.2.5
base metal repair control
Audit Failure
Requirement Reference
Correction/Best Practice
Ensure all repairs are authorized and documented. Conduct NDT inspections as required and maintain thorough records. Establish a verification process for repair authorizations and inspections.
Repairs made without proper authorization, NDT inspection, or documentation records
T9074-AD-GIB-010/1688, Section 13.8.3.2, 13.8.3.3
Develop and implement written procedures for controlling base metal repairs. Ensure procedures are followed and reviewed regularly for effectiveness and compliance.
T9074-AD-GIB-010/1688, Section 4.2.1;
Identification of all pertinent prime contract requirements
S9074-AQ-GIB-010/248, Section 4.2.4
additional common audit failures
Common Audit Finding
Requirement Reference
Best Practices to Prevent Noncompliance
Ensure welding procedures are only transferred as permitted by the specification. Maintain detailed records and verification of transfers. Implement a verification process to ensure compliance with transfer requirements. Implement and follow a controlled procedure for flame straightening that meets the applicable fabrication specifications. Conduct regular reviews to ensure compliance. Provide training to personnel on proper flame straightening techniques. Ensure all tack welding and capture welding meets the specified welding procedure requirements. Perform inspections and maintain records of compliance. Provide continuous training and assessments for welders to ensure adherence to procedures. Avoid using prequalified welding procedures unless AWS D1.1 specifically applies. Verify and document any exceptions. Train personnel on the limitations and proper use of prequalified procedures.
Transfer of Welding Procedures
S9074-AQ-GIB-010/248D, Section 4.2.10.1
T9074-AD-GIB-010/1688, Section 13.5.2;
Flame Straightening
S9074-AQ-GIB-010/248D, Section 4.2.3.4
T9074-AD-GIB-010/1688, Section 13.4.3;
Tack welding/capture welding
S9074-AQ-GIB-010/248D, Section 4.2.3.1
Prequalified Welding Procedures
S9074-AQ-GIB-010/248D, Section 4.2.2
Common NDT Qualification Problems
NDT Certification and Recertification Requirements
INTRODUCTION
Brief overview of the importance of NDT (Non-Destructive Testing) in industry standards and compliance
OVERVIEW OF TP-271 AND SNT-TC-1A NAVSEA Technical Publication T9074-AS- GIB-010/271 (TP-271) SNT-TC-1A by ASNT (American Society for Nondestructive Testing
NDT Certification and Recertification Requirements CERTIFICATION AND RECERTIFICATION GUIDELINES TP-271 and SNT-TC-1A require NDT Level IIIs and Level IIs to be certified and recertified by taking examinations instead of using point systems, experience, and/or certificates for initial certification or recertification
MANDATORY REQUIREMENTS UNDER TP-271 SECTION 1.6 TP-271, section 1.6, makes the guidelines in SNT-TC-1A for NDT personnel qualifications and certifications minimum (mandatory) requirements and modifies others.
NDT Certification and Recertification Requirements
MODIFICATIONS TO SNT-TC-1A GUIDELINES
DOCUMENTATION COMPLIANCE
Highlights specific modifications made by TP-271 to the SNT-TC-1A guidelines
Certification documentation shall meet the requirements of SNT-TC-1A Section 9
CERTIFICATION DOCUMENTATION REQUIREMENTS
Certification documentation shall meet the requirements of SNT-TC-1A Section 9. Additionally, to meet TP-271 and SNT-TC-1A Section 8 certification examination requirements, the following steps should be taken by an NNS contracted supplier to ensure their NDT sub-contracted supplier and their own in-house NDT program meet TP-271 NDT personnel qualification and certification requirements
Steps to Meet Certification Requirements
NDT Level III
NDT Level II
BOTH
1. Initial Certification Requirements 2. Recertification Requirements 3. Specific Examination Documentation 4. Composite Grade Sheet Maintenance
1. Initial Qualification and Recertification Requirements for Level II Inspectors
1. Vision Test Requirements for NDT Personnel
LEVEL II
For initial qualification and certification, Level II inspectors are required to take General, Specific and Practical exams for each NDT method and recertify by examination every 3 years; the exams required for 3 year recertification are to be as comprehensive as that employed in the initial certification. The NNS contracted supplier needs to ensure their NDT sub-contracted supplier develops a composite grade sheet for each NDT method and each sheet is required to show the individual grades for the General, Specific and Practical exams; an average grade for the 3 exams is also required to be on each sheet. Each composite grade sheet shall be provided to the NNS contracted supplier (and NNS upon request). Initial Qualification and Recertification Requirements for Level II Inspectors
LEVEL II & III
All NDT personnel are required to be administered vision tests in accordance with TP 271, paragraph 1.6.5.1 which modifies the SNT-TC-1A requirements by invoking the more stringent J- 1 letters on the Standard Jaeger’s Test chart, or equivalent type test for near vision. Color blind testing is also required. Vision test records for each certified Level II and III personnel shall be provided to the NNS contracted supplier (and NNS upon request). Vision Test Requirements for NDT Personnel
LEVEL III Initial Certification Requirements For initial certification, the NNS contracted supplier needs to ensure their NDT sub contracted supplier and their own in- house NDT Level III possess a pass/fail letter for the Basic and Method exams (for each NDT method). ASNT provides a pass/fail letter to the Level III only; ASNT will only accept a letter request from the Level III. If another certifying agency conducts the examinations a pass/fail letter or a grade sheet for each exam needs to be provided to the NDT Level III. The pass/fail letter from ASNT or a qualified NDT test facility shall be provided to the NNS contracted supplier (and NNS upon request).
1
LEVEL III
Recertification Requirements
For recertification required every 5 years, the NNS contracted supplier needs to ensure their NDT sub-contracted supplier and their own in-house NDT Level IIIs possess a pass/fail letter for the Method exam (for each NDT method). The Basic exam does not have to be taken again provided the Level III continuously maintains a certification in at least one NDT method; if the Level IIIs do not continuously maintain a certification in one NDT method then they would be required to take and pass the Basic exam again. The pass/fail letter from ASNT or a qualified NDT test facility shall be provided to the NNS contracted supplier (and NNS upon request).
2
LEVEL III
The NNS contracted supplier and their NDT sub-contracted supplier is required to maintain on file documentation that shows Level IIIs were initially administered and passed Specific examinations in each NDT method and that they recertified by examination every 5 years. The results of the Specific examination shall be recorded and provided on the composite grade sheet described in 4) below. Specific Examination Documentation
3
LEVEL III
Composite Grade Sheet Maintenance
The NNS contracted supplier and their NDT sub-contracted supplier needs to maintain on file a composite grade sheet for each NDT method and each sheet is required to show the individual grades for the Basic, Method, and Specific exams; an average grade for the 3 exams is also required to be on each sheet. A Practical exam grade, if administered, shall not be included in the average grade. Grades of 80% are required for passed Basic and Method exams if no grades are provided by the test facility. Each composite grade sheet shall be provided to the NNS contracted supplier (and NNS upon request).
4
THANK YOU
www. Rigfab.com Visit Our Website
Page 1 Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 Page 17 Page 18 Page 19 Page 20 Page 21 Page 22 Page 23 Page 24 Page 25 Page 26 Page 27 Page 28 Page 29 Page 30 Page 31 Page 32 Page 33 Page 34 Page 35 Page 36Made with FlippingBook - Share PDF online