QD-QA-022

REVISION F
George C. Marshall Space Flight Center EFFECTIVE DATE: November 22, 2005
Marshall Space Flight Center, Alabama 35812

ORGANIZATIONAL ISSUANCE

VISUAL WELD
INSPECTION

OPR(s) OPR DESIGNEE

Bobby Rains
QD10, QD20, QD30,
and QD40

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 Organizational Issuance

Title: Visual Weld Inspection QD-QA-022 Revision: F

Date: November 22, 2005 Page: 2 of 8

DOCUMENT HISTORY LOG

Status
(Baseline/
Revision/ Document Effective
Canceled) Revision Date Description

Baseline 1/13/99
Changes made to reflect new organization code changes and/or Changes
Revision A 7/1/99 made to reflect new directives renumbering scheme and to incorporate the
corrective action for closure of NCR 266
Changes made to paragraph 10 to reflect new certification requirements and a
Revision B 6/9/00 general document format update to bring the document inline with the current
S&MA OI template.

Revision C 9/09/02 Format and numbering change to implement requirements of QS-A-001 rev F.
Changes made to reflect new organization and to reflect use of electronic forms.
Revision D 10/07/02 Reworded paragraphs 4.1.1 and 4.2.3 (no change to technical content).

Revision E 10/1/04 Revised to bring document in compliance with the HQ Rules Review Action
(CAITS: 04-DA01-0387). Changes were also made to reflect S&MA
organizational name changes (i.e., QS to QD).

F Administrative Revision changed OPR

Revision 11/22/05

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 Organizational Issuance

Title: Visual Weld Inspection QD-QA-022 Revision: F

Date: November 22, 2005 Page: 3 of 8

TITLE

1. PURPOSE, SCOPE, APPLICABILITY (As Required)

1.1. Purpose - This procedure is written to ensure the consistent performance of visual weld
inspections.

1.2. Scope – This procedure applies to structural and pressure welding associated with test
fixtures and facilities, in accordance with the codes listed in paragraph 2. Qualified quality
assurance personnel will perform this procedure.

1.3. Applicability – This instruction is applicable to quality assurance personnel that perform
inspection of structural and pressure welding.

2. DOCUMENTS (Applicable and/or Reference)

2.1. Applicable Documents

AWS D1.1 Structural Welding Code

ASME/ANSI B31.1 Code for Power Piping

ASME/ANSI B31.3 Code for Chemical Plant and Refinery Piping

TD70-007 Facility Nonconformance Reporting System For The Technology

Evaluation Department

2.2. Reference Documents - The following reference documents provide additional information
concerning the subject of Visual Weld Inspection:

(Not numbered) ASME Boiler and Pressure Vessel Code

TD70-9005 Welding Qualifications and Procedures

3. DEFINITIONS

3.1. Temporary Attachments. Attachments which are welded to a component during

construction that are not incorporated into the final welded joint, such as alignment lugs,
thermocouples, tie straps, braces, or other similar items.

3.2. Weld Area. The weld and heat affected area includes areas such as runoff tabs, alignment
lugs, thermocouple nuts, and other temporary fit-up welds.

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Title: Visual Weld Inspection QD-QA-022 Revision: F

Date: November 22, 2005 Page: 4 of 8

4. INSTRUCTIONS

4.1. Fit-up and Cleanliness.

4.1.1. The fit-up inspection shall be performed by qualified personnel (normally the performing
contractor) in accordance with the methods specified by the applicable process specification,
code, and work authorizing documentation. The inspection shall be performed by someone other
than the performing welder. The checklist in Appendix A may be used as a guide for the
performance of the fit-up examination. Quality assurance personnel may use the checklist when
auditing the fit-up process.

4.1.2. The item shall be inspected to ensure the absence of foreign material or debris. Notify
welder or welding supervisor if clean up is required.

4.1.3. Acceptance criteria shall be in accordance with applicable process specification, code and
work authorizing documentation.

4.2. Visual Inspection.

4.2.1. Visual inspection shall be performed in accordance with the methods specified by the
applicable process specification, code, and work authorizing documentation.

4.2.2. Verify personnel are certified for the process and the process is being followed.

4.2.3. Verify a weld map is available, if required.

4.2.4. The weld area where temporary attachments (to facilitate fit-up) are removed shall be
examined at the time of visual inspection. NDE may be required in accordance with the process
specification. Refer to the appropriate NDE procedure.

4.2.5. When Borescopes or mirrors are used, record in the comments section of the form
provided by Appendix B.

4.2.6. Acceptance criteria shall be in accordance with the applicable process specification. If
acceptable, stamp and date the work-authorizing document and complete the form provided as
Appendix B, MSFC Record of Visual Weld Inspection, if required, or MSFC form 4456,(if work
authorizing document is electronic, affix password protected initials/signature) . If the weld is
rejected, notify the welder or welding supervisor and engineer. If required, generate appropriate
nonconformance documentation per TD70-007.

5. NOTES

5.1. Preliminary Drawings - If the drawing is preliminary, withhold final acceptance stamp on
the work authorizing documentation until signed drawings are provided.

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Title: Visual Weld Inspection QD-QA-022 Revision: F

Date: November 22, 2005 Page: 5 of 8

5.2. Directive Replacement - This issuance replaces QS10-QA-022 Revision D, “Visual Weld
Inspection”, dated 6/9/00.

5.3. Records are maintained by the Quality Assurance Records Center for flight hardware and
by the using organization for test stand and test facility hardware.

6. SAFETY PRECAUTIONS AND WARNING NOTES

None

7. APPENDICES, DATA, REPORTS, AND FORMS

Appendix A Weld Fit-Up Examination Checklist

Appendix B MSFC Record of Visual Weld Inspection

MSFC Form 4456 “Visual Weld Inspection Report” may also be used to document performance
and results of visual weld inspection.

8. RECORDS

None

9. TOOLS, EQUIPMENT, AND MATERIALS

The following tools may be required to perform to this instruction:

a. Fillet gauges.

b. Fit-up gauges.

c. Mirrors.

d. Flashlights.

e. Oxygen sensor

10. PERSONNEL TRAINING AND CERTIFICATION

Personnel who perform visual weld inspection shall be American Welding Society (AWS)
Certified Weld Inspectors.

11. FLOW DIAGRAM

None

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Title: Visual Weld Inspection QD-QA-022 Revision: F

Date: November 22, 2005 Page: 6 of 8

Appendix A

WELD FIT-UP EXAMINATION CHECKLIST

TPS/WORK AUTH. # __________________ DATE____________

DWG. # __________________ WELD PROCEDURE # ___________________

MATERIAL TYPE_________________ WELD #___________________________

1. Pre-fit-up cleanliness inspection performed _______

2. Welder has proper welding procedure specification _______

(with reference to the procedure qualification record)

3. Welder has applied I. D. to joint ______

4. Welder has correct filler material _______

5. Oversized root openings corrected by welding _______

6. Welder is certified for the process _______

7. The correct weld number is applied to the joint _______

8. Material identification _______

9. Cleanliness of welding surfaces ________

10. Weld edge preparation, dimensions and finish _______

11. Clearance dimensions of backing strips, and rings or consumable inserts ________

12. Alignment, mismatch and fit-up _______

13. Tack welds removed or suitable to weld over _______

14. Temporary attachments handled per procedure _______

15. The proper preheat has been established and is maintained _______

16. Correct purge equipment is used ________

17. Socket welds properly marked to ensure socket withdrawal _______

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Title: Visual Weld Inspection QD-QA-022 Revision: F

Date: November 22, 2005 Page: 7 of 8

Appendix B

MSFC RECORD OF VISUAL WELD INSPECTION

TPS/WORK AUTH#_____________ PROG./PROJ._________________

INSP. DATE __________________ DWG. # ______________________

WELD PROCEDURE # ________________ WELD #________________

ACCEP. SPEC. # ___________________ NASA FIT-UP INSP yes/no

_____________________________________________________________

MATERIAL TYPE ________________________

WELD SIZE __________________________

DEFECTS NOTED:

DEFECT ACCEPT REJEC

T
CLEANLINESS & SPATTER
CONTOUR & REINFORCEMENT
POROSITY & CRATERS
WELD SIZE & TRANSITION
LOF
LOP
OVERLAP
UNDERCUT
OTHER (SPECIFY)

REPAIR: ACC_____________ REJ_______________

COMMENTS:__________________________________________________________________
_____________________________________________________
________________________________________________________________

INSPECTOR_____________________ STAMP__________ DATE___________

EMPLOYER__________________

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