Inspection Trends

The first thing to recognize is the code is not read like a novel or epic poem, where you read from the front to the back. Don’t try to memorize the code. Rather, all codes and standards follow the same basic rules. The hard part for someone new using a standard is figuring out the rules. 

Rule 1. The number one rule is this: The numbering system used follows a certain hierarchy. See below: 

• 1. Header
• 1.1. Subclause is subordinate to 1 1.2.
• Subclause is subordinate to 1 1.2.1.
• Subclause is subordinate to 1.2 1.2.2.
• Subclause is subordinate to 1.2 1.2.2.1. Subclause is subordinate to 1.2.2 1.2.2.2.
• Subclause is subordinate to 1.2.2

Each subclause, subordinate to those before it, provides more-detailed information — either additional details, exceptions, or exemptions to the information contained in the clause higher in the hierarchy. Often, the subclause (lower in the hierarchy) will direct the user to a clause in a different section of the standard. The reference may be an additional test, table, or figure. 

Rule 2. Another rule is that you use the code in a fashion similar to how you would use a map. With a map, you look for the final destination and follow from point to point until you get to where you want to go. Using the standard is more like the map function on your cellphone. To find your final destination, you input the address and the map leads you by providing the route from one point to another in sequence. If you stray from the directions provided, the program recalculates and redirects you back on the correct path. But that isn’t going to happen when you don’t follow the map provided by the standard. 

Rule 3. The code is used to find answers to specific questions. Learn how the code or standard is organized. 

Let’s use a real-world example with AWS D1.1/D1.1M:2020, Structural Welding Code — Steel. We need to know which welder performance test should be administered to the welder, and we need to know some basic information to find a meaningful answer. First, the welder will be depositing groove welds and fillet welds in a high-strength, low alloy using the gas-shielded flux cored arc welding (FCAW-G) process. The thickness is unlimited, and the work will be in all positions. The application is nontubular structural shapes, e.g., not pipe (tubular). 

In the D1.1 standard, there are two starting points for the novice user: the table of contents (TOC) and index. The TOC, located in the front, lists the main subjects along with the main subclauses. The index is located in the back of the code. In this case, start with the TOC. There are 11 main clauses. Look at the question, and look for a clause that might include the information you are searching for. Our question is about welder performance qualification. There is a clause listed in the TOC titled Qualification. It is Clause 6. That’s where you begin your search to find an answer to the question.

Start with Clause 6 and continue on to subclause 6.1. The subclause shows Clause 6 is divided into four parts: Part A — General Requirements, Part B — Welding Procedure Specification (WPS) Qualification, Part C — Performance Qualification, and Part D — Requirements for CVN Toughness Testing. 

Back to the map analogy. You’re in your driveway, and before you back into the street, you need to determine whether to turn left or right or proceed straight back. You decide to turn right. In our case, you are directed by Subclause 6.1 to go to Part C — Performance Qualification. Parts A, B, and D don’t address welder performance testing, so you don’t have to read them. 

Once you get to Part C, the first subclause you will encounter is Clause 6.16 — General. Next we see Clause 6.16.1 Production Welding Positions Qualified; our question has included the requirement that the welder will be welding in all positions. Then you’ll see Clause 6.16.1.1. We know that the subclause is subordinate to 6.16.1, and it is providing more-detailed information on welding positions. Clause 6.16.1.1 will direct you to Table 6.10 — Fig. 1. 

The table is divided into four main columns; the far left is the weld type and test positions. The three columns to the right list the product form and the positions in which the production welds will be made. The product forms listed are structural shapes (other than tubular, pipe), and moving farther to the right, the table addresses pipe and box tubes. Pipe and box tubing are often referred to as hollow structural shapes (HSS). 

It is easy to overlook the footnotes, so I highlight them or rewrite them in large text. 

The question stated groove welds and fillets are to be welded in all positions on nontubular connections, e.g., structural shapes other than hollow structural shapes (pipes and tubulars).

The far-left column in the table lists “plate.” This means the welder is tested using a plate assembly rather than an assembly consisting of pipe or tube. The table indicates that if a grooved plate is used, the welder is qualified for both grooves and fillets (see footnote g). If the welder takes a fillet weld test, the welder is limited to fillet welds. We conclude that the welder should be tested using a grooved plate assembly. 

The next column to the right lists the test positions. 1G is flat, 2G is horizontal, 3G is vertical, and 4G is the overhead position. The alphanumeric designations — 1G, 2G, 3G, and 4G — are test positions. Production positions are flat, horizontal, vertical, or overhead. The welder can be tested in the 3G and 4G positions to qualify the welder for all positions on structural shapes other than HSS. 

This is probably a good time to mention forwarding and return addresses. If a clause includes a reference to another clause, table, or figure, it is good practice to write the page where the reference is found. The page number is written in the margin next to the clause containing the reference. I call these notations in the margin forwarding addresses. The table or the figure also includes a reference back to the clause that sent you to that table or figure. The page number where the clause is located is written in the margin adjacent to the table or the figure. I call this the return address — Fig. 2. Navigating the code is easier and quicker when the user adds the forwarding and return address. 

You are not done yet. You now know you can test the welder using a grooved plate assembly. But what are the details of the test assembly? You need to go back to Clause 6.16.1.1 to resume your reading. 

You will stumble upon Clause 6.16.2, where the subject of the thickness of the production weld is discussed. Clause 6.16.2.1 addresses the qualified thickness range of the welder performance qualification. Clause 6.16.2.1 directs the reader to Table 6.11. Write the forwarding address for Table 6.11 (page 156) in the margin adjacent to Clause 6.16.2.1. When you find Table 6.11, you will note the table header lists Clause 6.16.2.1. That notation tells the reader where Table 6.11 was referenced. You can write a return address for Clause 6.16.2.1 (page 132) in the margin adjacent to the table. 

From Table 6.11, if the thickness of the test plate is 1 in. or thicker, the qualified thickness range is 1/8 in. to unlimited thickness. One must read all relevant footnotes listed by the table or figure. The only relevant footnote in Table 6.11 appears to be footnote d. The footnote states the 1 in. or thicker test assembly qualifies the welder to weld fillets and partial joint penetration (PJP) groove welds of any size. What about footnotes a, b, and c? They are applicable when evaluating the test assembly (i.e., visual examination, using radiographic testing [RT] as an alternate to bend testing, and when side bends are substituted for face and root bends). They are applicable to our question. From Table 6.11, Figs. 6.16, 6.17, or 6.19 may be applicable. You must now follow the map and see if one of the figures is germane to the question. Figure 6.16 is used for manual and semiautomatic welding processes (welder qualification), Fig. 6.17 is for mechanized or automatic welding (welding operator), and Fig. 6.19 is used for welder qualification in the horizontal (2G) test position. We now know that only Figs. 6.16 and 6.19 are applicable to our question. 

We also see from the figures that Clause 6.21.1 may be applicable. A quick look tells us that Clause 6.21.1 simply reiterates which figures apply to the welder performance qualification. 

Using the return address listed by Table 6.11, go back to Clause 6.16.2.1. You did write the return address in the margin adjacent to Table 6.11, right? 

Continue reading the clauses and you will see that Clause 6.16.3 states a welder or welding operator may be qualified by welding a successful WPS qualification test assembly within the constraints of Table 6.10, thereby, meeting the conditions of Clauses 6.16.1 and 6.16.2. There’s nothing in the question alluding to welding up a coupon to qualify the WPS, so this clause doesn’t apply. 

Continuing to read, you will come across Clause 6.17, a clause that is addressing something not germane to the question. 

I believe you have all the information you need to test the welder. You will administer two plate tests that utilize groove welds. One test is in the horizontal position having the geometry depicted in Fig. 6.19, and the second test is a groove weld in the overhead position with the geometry depicted in Fig. 6.16. 

To recap, you start with Clause 6, Part C; go to Clause 6.16; then Clause 6.16.1; then on to Clause 6.16.1.1; then proceed to Table 6.10; then Figs. 6.16 and 6.19; back to 6.16.1.1; then to Clause 6.16.2.1. The next couple of clauses, 6.16.3 and 6.17, have nothing to do with our question. 

The point-to-point map you followed looks like the following: 

Clause 6, Part C → 6.16 → 6.16.1 → 6.16.1.1 → Table 6.10 → Fig. 6.16 and 6.19 → 6.16.1.1 → 6.16.2.1 

You have all the information needed to answer the original question. 

Your description that it feels like you are chasing a football bouncing on the ground isn’t too far off. One must learn to follow the map provided by the code. Even when you get comfortable using the code, don’t try to skip a step. That clause you skip may contain some important information. I hope this exercise clears up some of the mystery of using the code to answer a question. No magic decoder ring is required. 

The Society is not responsible for any statements made or opinions expressed herein. Data and information developed by the authors are for specific informational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users. 

ALBERT J. MOORE JR. (amoore999 @comcast.net) is president and owner of NAVSEA Solutions/Marion Testing & Inspection, Burlington, Conn. He is an AWS Senior Certified Welding Inspector, an NDT Examiner per NAVSEA TP271, and an ASNT SNT-TC-1 Level III. He is also a member of the AWS Qualification & Certification Committee and the B1 Committee on Methods of Inspection.