Checking fabricated components and structures

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This standard identifies the competences you need to carry out the dimensional and visual checks of fabricated components and structures, in accordance with approved procedures.

You will be required to obtain the necessary job instructions and all relevant documentation, and to obtain the tools and equipment required. This will involve selecting the appropriate equipment, based on the features to be checked and the accuracy to be measured. You must also ensure that the equipment to be used is within current test/calibration dates.

In carrying out the inspection activities, you will be expected to check the components for visual defects, and dimensional and geometrical accuracy, and this may be required to be undertaken at various stages of manufacture, such as random sampling of fabricated components during production, final inspection of completed components and checking assemblies and sub-assemblies. Components to be inspected will include items such as flat sheet components, pressings, fabricated frames, tanks, pipe sections, modular components, fabricated tubular components and fabricated structures.

Your responsibilities will require you to comply with organisational policy and procedures for checking the fabricated components or structures, and to report any problems with these activities that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to ensure that all tools and equipment used to check the fabrications are returned to the correct location on completion of the activities. You will be expected to work to instructions, either alone or in conjunction with others, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.

Your underpinning knowledge will be sufficient to provide a sound basis for your work, and will provide an informed approach to applying appropriate inspection techniques and procedures to fabricated components and structures. You will understand how to use the tools and equipment required for checking the fabrications, in adequate depth to provide a sound basis for carrying out the inspection activities and for identifying where features of the fabrications do not meet the required specification tolerances.

You will understand the safety precautions required when working with fabricated components, and the safeguards necessary for undertaking the checking activities safely and correctly. You will be required to demonstrate safe working practices and procedures throughout, and will understand the responsibilities you owe to yourself and others in the workplace.

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1. work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
2. follow the correct specification for the product or equipment being inspected
3. use the correct equipment to carry out the inspection
4. identify and confirm the inspection checks to be made and acceptance criteria to be used
5. carry out all required inspections as specified
6. identify any defects or variations from the specification
7. record the results of the inspection in the appropriate format
8. deal promptly and effectively with problems within your control and report those that cannot be solved

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1. the specific safety precautions to be taken when checking fabricated components (specific legislation or regulations governing the activities or work area, safe working practices and procedures to be adopted, general workshop safety practice)
2. the health and safety requirements of the work area in which you are carrying out the checking activities, and the responsibility these requirements place on you
3. the personal protective clothing and equipment (PPE) that should be worn (such as leather gloves, eye protection, ear protection)
4. the hazards associated with checking fabricated products (such as working at height, handling fabricated structures, slips, trips and falls), and how they can be minimised
5. how and where to obtain the required job instructions, drawings and quality control/inspection documentation
6. how to extract information from fabrication drawings and related specifications (to include symbols and conventions to appropriate BS or ISO standards) in relation to work undertaken
7. how to interpret first and third angle drawings, imperial and metric systems of measurement, workpiece reference points and system of tolerancing
8. the general principles of quality assurance systems and procedures
9. the preparations to be undertaken on the fabrication before it is inspected
10. the visual and dimensional inspection methods and techniques that are used for fabricated components/structures
11. the need to select and use set datum faces, and the effects of taking readings from different datums (such as accumulation of limits leading to errors)
12. the equipment that is used to carry out the various inspection checks (such as rules and tapes, precision Vernier instruments, levels and plumb lines, laser equipment and theodolite)
13. the importance of ensuring that tools and equipment are set up correctly, and are in a safe and useable condition
14. the need to check that the equipment is approved for the inspection activities undertaken (including calibration checks and current certification dates)
15. the techniques used to check for alignments, verticality and roundness/ovality
16. the need to take account of allowances for weld gaps and weld shrinkage, in order to attain overall global tolerances
17. the need to carry out the checks and to record the results in the appropriate documentation
18. the typical defects and variations that can be found on the fabrications, and how to identify them
19. the procedure to be followed when inspected products are out of specification
20. the importance of completing inspection documentation; what needs to be recorded, and where records are kept

the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve

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1. Carry out all of the following during the checking process:

   1. obtain all the necessary information to carry out the checking activities (such as job instructions and quality control/inspection documentation)
   2. obtain and check the condition and calibration dates of tools, measuring instruments and equipment to be used
   3. observe all the required safety procedures for the work area/activity
   4. carry out the checking activities, using the specified techniques and procedures
   5. use the correct and appropriate tools and equipment at all times
   6. identify and record out-of-specification features, in the appropriate format
   7. ensure that any out-of-specification products are clearly labelled/identified
   8. resolve any problems as they occur, within your level of responsibility
   9. leave the work area in a safe and tidy condition on completion of the activities

2. Carry out one of the following inspection procedures:

   1. in-process sample/patrol inspection                    
   2. one-hundred-percent final inspection of fabricated components
   3. random/selective sampling of finished fabrications           
   4. statistical quality control

3. Carry out the inspection of one of the following types of fabrication:

   1. fabricated frames             
   2. pipe sections           
   3. transformers
   4. structures                                
   5. cylindrical components      
   6. reduction pieces
   7. square/rectangular tanks          
   8. conical components              
   9. segmented bends
   10. curved/profiled structures        
   11. tubular structures            
   12. modular components
   13. trunking/ducting systems         
   14. panels                                
   15. other specific fabrication

4. Carry out six of the following checks:

   1. dimensional accuracy    
   2. visual appearance            
   3. orientation
   4. squareness                
   5. straightness        
   6. security of joints
   7. angle                
   8. position/location    
   9. weld size and profile
   10. alignment                 
   11. freedom from distortion/damage  
   12. computation of best fit centres
   13. circularity or ovality     
   14. completeness      
   15. prediction of erection positions
   16. flatness                  
   17. development of cut lines
   18. practical allowances for expansion and contraction
   19. computation of allowances for weld gap tolerances and weld shrinkage for attainment of global tolerances

5. Use four of the following types of inspection equipment:

   1. rules and tapes                   
   2. protractors             
   3. rafter squares
   4. squares                                
   5. plumb lines              
   6. templates and jigs
   7. spirit levels                          
   8. callipers                      
   9. theodolites
   10. dividers                                 
   11. Vernier instruments              
   12. laser equipment
   13. gauges                                 
   14. torque instruments

6. Complete the inspection documentation, to include one from the following, and pass it to the appropriate people:

   1. inspection report                   
   2. job card        
   3. customer specific documentation

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2

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30 Mar 2018

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Current

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Original

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Semta

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SEMTS2-12

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Engineering, Engineering and Manufacturing Technologies

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3113

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Engineering; technical support; checking fabricated components; checking structures; flat sheet components; pressings; fabricated frames; tanks; pipe sections; modular components

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