A CWI is tasked with inspecting welds on a large pipeline project governed by API 1104. During an in-process inspection, the CWI observes that the welder is using a different brand of filler metal than explicitly listed on the approved Welding Procedure Specification (WPS). The welder claims it is an 'equivalent' material. What is the CWI's immediate action?
- AReview the filler metal specifications to determine if it truly meets the requirements for essential variables.
- BDocument the deviation and obtain a written approval from the client's engineering department to use the alternative.
- CAllow welding to continue, but take a sample of the filler metal for later lab analysis to confirm equivalence.
- DStop welding immediately and require the use of the specified filler metal or a revised/re-qualified WPS.
Show answer & explanationAnswer & explanation
Correct answer: D. Stop welding immediately and require the use of the specified filler metal or a revised/re-qualified WPS.
Filler metal is typically an essential variable in many welding codes, including API 1104. Any change, even to an 'equivalent' brand, usually requires re-qualification of the WPS or specific approval from the engineering authority after verification. The CWI's immediate action is to stop the non-compliant welding.
Why the other options are wrong
- A. While reviewing specifications is part of the process, it's not the immediate action. Welding must stop first, then the review can happen to determine if a WPS revision is possible.
- B. Obtaining approval is a subsequent step. The immediate action is to stop the non-compliant activity.
- C. Allowing welding to continue with an unapproved filler metal constitutes a significant non-conformance and potential quality issue.
Essential Variable Deviation
A change in an essential variable (e.g., filler metal, base metal, welding process, preheat) from the approved Welding Procedure Specification (WPS) typically requires re-qualification of the WPS or specific engineering approval before welding can proceed or continue.
- Essential variables impact weld mechanical properties.
- Changes necessitate WPS re-qualification or formal approval.
- CWI must stop work immediately when deviations occur.
Memory trick: Filler's new? Stop and review, or quality's askew.