the duties of an inspector

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Frosio course hand-out: Section 03 The duties of an inspector

Frosio 03 Inspector duties slide # 1

The duties of an inspector


What characterises a qualified inspector?

• Basic training / knowledge / experience

• Straight & Honest approach à Reliable

• Communication

• Strict, but à Friendly à Humble

• Makes the correct decisions

• Has tidy routines

• Is quality conscious

• Use common sense à Comfortable worksituation

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Inspection Work

• The duties/responsibilities of the inspector (ISO12944-7)

• The role(s) of the inspector

• The different parties in a project

• The inspectors attitude and behaviour

• Reporting, documentation

• Verification of specified quality (section 17)

• Inspection planning (section 17)

• Inspection (section 17)

• Use of instruments (section 17)

• Reference areas (section 17)


ISO 12944

Part 1 General introduction.

Part 2 Classification of environments.

Part 3 Design considerations.

Part 4 Types of surface and surfacepreparation.

Part 5 Protective paint systems.

Part 6 Laboratory performance test methods.

Part 7 EXECUTION AND SUPERVISION OFPAINT WORK.

Part 8 Development of specifications for newwork and maintenance.

Paints and varnishes - Corrosion protection

of steel structures by protective paints systems.

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Extracts from ISO 12944-7

6.1 General

• The execution of the work shall be supervised at allstages. Supervision shall be undertaken by suitablequalified and experienced people. The contractor shall beresponsible for carrying out this supervision himself, butadditional supervision by the client – even for corrosionprotection in the workshop – is advisable.

• When coating material with which the contractor isunfamiliar are to be applied, the manufacturer of thecoating material shall be consulted.

• The level of supervision will depend on the type andimportance of the project, the degree of difficulty of thework and local conditions, and on the type of coating andits intended service life. This supervision will requireappropriate technical knowledge and experience.



6.2 Measurement and test instruments

• The instrument manufacturer’s instructionfor the use of their equipment shall becomplied with. The instruments used shallbe checked, calibrated and maintained atregular intervals and the results shall berecorded.

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6.3 Checking the paint coating

• Coatings shall be checked for compliance withthe specification, for example:– By visual assessment, e.g. for uniformity, colour, hiding

power and defects such as holidays, wrinkling, cratering, airbubbles, flaking, cracks and curtains

– By means of instruments for compliance with the followingcharacteristics of the dry film, if required:

• DFT: generally by non-destructive methods

• Adhesion: by destructive methods

• Porosity: by low or high-voltage detectors



6.3 Checking the paint coating (cont’d)

• For DFT measurements, the parties concerned shall agreeon the following:– The method to be used (instrument, calibration, surface profile, etc.)

– The sampling plan (how and how many measurements)

– How the results are to be reported and how they are to be comparedwith acceptance criteria

• Dry film thicknesses (including the nominal and maximumthicknesses) shall be checked at each critical stage, andwhen the complete system has been applied. A criticalstage is, for example, when there is a change in theresponsibility for the paint work or when a long timeelapses between application of priming coats andsubsequent coats.

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An inspector deals withseveral parties

• The customer / owner’s rep.

• The yard

• The contractor / sub-contractor

• The paint supplier

• Suppliers of equipment

• The classification society (DnV,ABS etc)


The inspector’s role

At the yard the inspector may be seen as:

• Advisor or Consultant

• Mediator or Arbitrator

• ”Policeman”

• Paint seller

• *&$%*£” (too rude to print)

• Which role shall he take?

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The inspector’s role

• The paint inspector is a key person in the QAsystem.

• He performs the practical QC work at the yard.

• However, the inspector’s prime role is to protect hisemployer’s interests. The inspector must neverforget whom he works for (who pays his salary)

• Usually the inspector has no formal authority inrelation to the yard and contractor


What is QA - QC ?

QA = Quality Assurance

(A documented company managementsystem)

QC = Quality Control

(Inspection and testing routines)

QC is a part of the QA system

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Why QA and QC ?

• The purpose is to make sure that one getswhat one wants

• A good QA system makes the futureresults predictable:– The object / structure / ship is delivered on time

– It is made according to specification

– The quality of the work is satisfactory


Quality Assurance standards

• The ISO 9000 series ofstandards:

Requirements and guidelinesto establish a QA system in anorganization and keep iteffective

Deals with managementroutines, organisation, controlof activities, verification,reporting etc

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The challenge for the paint inspectorThe challenge for the paint inspector

• To ensure that the coatingspecification is met

• To verify the quality ofwork carried out by thecontractor/yard.

• To prepare written recordsfor the standard work– Approval (Good enough?)

– Not acceptable (non-conformance)


An inspector’s work includes:

• Be capable of interpreting

the specifications

• Understand the objective

of the inspection

• Inspect all structures to be painted

• Ensure that all specifiedrequirements are met

• Document the results from theinspections

• In case of non-conformance: Issuewritten reports

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• All paints that will be used

• All relevant inspection methods andinspection tools

• Relevant standards

• Relevant TDS and MSDS

• Methods used for pre-treatment andpaint application

• The equipment used for pre-treatment and application: Benefitsand limitations

An inspector needs to know


What needs to be inspected ?

• Shop-priming of the steel

• The steel work

(Pre-blasting preparation)

• Cleaning and surface preparationprior to paint application

• Application of paint

• The applied paint film and itscuring/drying conditions.

If relevant, the following stages

of the production need to be inspected

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Inspection of steel work (Pre-blasting preparation)

• Rounding of sharp edges.

• Smoothing of rough welding

seams.

• Removal / grinding of weld spatter

and beads.

• Cracks and pittings.

• Surface faults like laminates etc.

• ISO 12944 - 3 , or ISO 8501 - 3

The following items need to

be inspected during construction


Inspection of cleaning and surface preparationprior to application

• Cleanliness (salt, oil, grease and dust/dirt)

• Evaluation of present condition (rust grade)

• Surface preparation (e.g. blast cleaning)

• Cleanliness of prepared surface

(salts, oil, grease, dust and dirt)

• Climatic conditions

(temperature, relative humidity etc.)

If relevant, the following conditions

must be inspected / verified

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Inspection during application

• Record name of coating and batch no.

• Ensure proper mixing of 2-pack paints

• Ensure use of the correct thinner

• Measuring the wet film thickness (WFT)

• Number of coats as given in the specification

• Cleanliness between coats (salts, dust, oil etc.)

• Drying time / recoating intervals

• Control of equipment: Pressure, nozzle etc.

• Climatic conditions (Ventilation, Air and steel temperatureand the relative humidity)

The following must be verified, inspected or tested:


Inspection after application

• Climatic conditions (Ventilation,

Temperature and humidity)

• Curing / drying of the film

• Dry film thickness (DFT)

• Adhesion

• Holiday detection (if required)

After application

the following must be checked

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Joining a new project

• First impression – Company Representative

• Correct presentation à Confidence

• Prepare yourself, read and understand applicablespecifications

• Obtain site work procedures

• Do a round trip on site / familiarisation / say hello

• Make a short list of personnel who are mostimportant in your job

• Get phone numbers and locations

• Establish a proper filing system


Proceedings on site

• Make use of your personal logbook and write theinformation in a report when required

• Make a priority list à Effectiveness

• Make up progress plan and monitor activities

• Establish weekly inspection plan with the contractor

• Formalise “Mutual agreements” and disagreements

• Beware of the responsibility, both towards theCompany and the Contractor

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Inspection planning

• Preparations

• Your daily work

• Meetings

• Reporting


Preparations

• Read and understand relevantspecifications

• Get hold of work procedures at site

• Make a round-trip on site – establishcontact with people who will be importantfor you

• Organize your office – make a suitablefiling system for documents

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Your daily work

• Establish a weekly inspection plan with thecontractor

• Use a daily log book and transferinformation into reports as required

• Formalize ”mutual agreements” anddisagreements (i.e. write down and sign)

• Maintain a close contact with youremployer


Meetings

• Always prepare yourself

• Bring up relevant issues– skip minor subjects

– don’ t bring up repeats

• Accept a decision – end of case. Makea report if required

• Follow up pending issues

• Write down important things yourself,and ask the chairman for Minutes ofMeeting

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Reporting

• The inspector shall be able to prepareinspection reports and ensure properdistribution of such reports

Different types of reports:

• Daily logs, Weekly report– (reporting progress)

• Inspection reports– (reporting findings during a visit)

• Consultant report– (3rd party report)


Routine Reports to be made by the paintinspector

• Daily reports, weeklyreports, final reports

(Do not camouflage yourfindings!)

• Non conformance reports:To be signed by theresponsible contractor, andbrought forward to youremployer

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Content of the daily reports

• Steel temperature

• Air temperature

• % Relative Humidity

• Dew point

• Object no. and name

• Exact specification

• Pre-treatment, specified andactually conducted

• Film thickness (to be measuredalso at spot repair)

• Area, m²

• Product name, place ofproduction and batch no.

• Name of relevant personnel

• What was discussed

• Non conformance report(remember signatures)

• Other comments


Inspection report (made during a visit)

Purpose:

• Establish condition of a ship / structurebefore preparation of a specification /quotation

• Routine follow-up of a guarantee

• Technical service in order to assist with aproblem

• Investigation in connection with a productcomplaint

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Inspection report

The report shall contain– General surface condition

– Specific areas deviating has to be evaluated and specified

• When evaluating the general surface conditionand/or a specific area – the stated conditionshould be further described with reference tothe coating being:– Intact

– Blistering

– Peeling off

– Spot rusting

– Etc.


Inspection report

Ballast tanks, etc.

• Blistered surfaces:– Fluid inside the blisters

– Inspection result should be reported

– Use photos for documentation

Complete surface condition report:

• Clearly state and define both location and size ofdamaged areas

• Severe corrosion / pitting and loss of materialmust be investigated and measured. Thecondition must be included in the report

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Consultant report (neutral / 3rd party)

• Title

• Summary

• Observations

• Investigations

• Discussion, assessment

• Proposal for repair procedure

• Conclusion, date and signature


A First Class Professional Inspector will:

• be one of the best assets a company can have in terms ofpromoting its products and services

• be polite and respectful, calm and firm, reliable andhonest, and represent his employer in a diplomatic way

• communicate extensively with all parties to a project

• perform his duties in such a way that he contributes toconstructive measures to be taken, instead of taking anindifferent (or negative) approach (i.e. seek a solution)

• whenever circumstances force compromises to be the onlysolution, he ensures that this is properly authorised,recorded and reported

the duties of an inspector

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