211279153-2-CSWIP-Practical-Plate-Examples.pdf

CSWIP 3.1 Welding InspectionCSWIP 3.1 Welding Inspectiong pg p

Practical Plate InspectionPractical Plate Inspection

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Course Reference WIS 5

Copyright © 2006, TWI Ltd World Centre for Materials Joining TechnologyWorld Centre for Materials Joining Technology

Course Reference WIS 5

Page 1 of 3 EXAMPLE PLATE REPORTName: [Block capitals] Mr. I C Plenty Signature: I C Plenty Test piece ident: 001

Code/Specification used: TWI 09 09 03 Welding process: MMA/SMAW Joint type: Single V ButtCode/Specification used: TWI 09-09-03 Welding process: MMA/SMAW Joint type: Single V Butt

Welding position: Flat /PA Length & thickness of plate: 300mm x 10 mm Date 22/08/2003

M

Lack of sidewall C

M E A S U

R

WELD FACE

BAUndercut smooth

1.5 max

236

Gas pore1.5 Ø

230

ac o s de afusion

8730

22

E F R O

15351

30

408

M

T H I S

241Centreline crack

Slag inclusion

Cap height : 4mm

Arc Strike

S D A T NOTES:NOTES: Cap height : 4mm.

Weld width: 12-14mmToe blend: Poor Misalignment: 2mmAngular Distortion 3mm in 50mm

U M

E D

NOTES:NOTES:


Angular Distortion 3mm in 50mmSpatter along weld length or scale on the plate surface

G E

Page 2 of 3 EXAMPLE PLATE REPORTEXAMPLE PLATE REPORT

M

Root concavityC

M E A S U

R

WELD ROOT

BA

Lack of rootFusion

247

Root concavity 2 deep

232010

E F R O

128 50

M

T H I S

Incomplete root penetration

Penetration height : 4mm

S D A T

NOTES:NOTES: Penetration height : 4mm.Linear Misalignment: 2mmAngular Distortion: 3mm in 50mmAny scale on plate surface

U M

E D

NOTES:NOTES:


G E

EXAMPLE WELD INSPECTION REPORT/SENTENCE SHEETEXAMPLE WELD INSPECTION REPORT/SENTENCE SHEET

I C Plenty001SPECIMEN NUMBER

PRINT FULL NAME001SPECIMEN NUMBER

EXTERNAL DEFECTSEXTERNAL DEFECTS Defects NotedDefects Noted Code or Specification ReferenceCode or Specification Reference

Defect TypeDefect Type Pipe/Plate Pipe/Plate SectionSection

11

AccumulativeAccumulativeTotalTotal

22

MaximumMaximumAllowanceAllowance

33

Section/Section/Table NTable Noo

44

Accept/RejectAccept/Reject55

Excess weld metal heightExcess weld metal height 1515

Excess weld metal appearanceExcess weld metal appearance AA--CC Poor blendPoor blend SmoothSmooth 88 RejectReject

A-C 4mm 2mm Reject

pppp jj

Incomplete fillingIncomplete filling AA--CC 22mm22mm NoneNone 55 RejectReject

Inadequate weld width (PIPE)Inadequate weld width (PIPE) AA--CC N/AN/A ------------------------ -------------------- AcceptAccept

Slag InclusionsSlag Inclusions AA--CC 70mm long70mm long 50mm50mm 99 RejectReject

UndercutUndercut AA--CC 1 5mm depth1 5mm depth 1mm1mm 66 RejectRejectUndercutUndercut AA--CC 1.5mm depth1.5mm depth 1mm1mm 66 RejectReject

Surface PorositySurface Porosity AA--CC 1.5mm 1.5mm 1mm1mm 22 RejectReject

Cracks/CrackCracks/Crack--like defectslike defects AA--CC 40mm40mm NONENONE 11 Reject*Reject*

Lack of fusionLack of fusion AA--CC 22mm22mm NONENONE 33 RejectReject

Arc strikesArc strikes AA--CC 33 NONENONE 77 Reject***Reject***

Mechanical damageMechanical damage AA--CC NONENONE ------------------------ ---------------------- AcceptAccept

Laps/LaminationsLaps/Laminations AA--CC NONENONE ------------------------ ---------------------- AcceptAccept

Misalignment (Linear)Misalignment (Linear) AA--CC 2mm2mm 2mm2mm 1515 AcceptAccept


Longitudinal seams (PIPE)Longitudinal seams (PIPE) AA--CC N/AN/A ------------------------ -------------------- AcceptAccept

Root DefectsRoot Defects

MisalignmentMisalignment AA--CC 2mm2mm 2mm2mm 99 AcceptAccept

Excessive Root PenetrationExcessive Root Penetration AA--CC 4mm4mm 2mm2mm 1515 RejectReject

Incomplete Root PenetrationIncomplete Root Penetration AA--CC 50mm50mm NONENONE 1313 RejectReject

Lack of Root FusionLack of Root Fusion AA--CC 20mm20mm NONENONE 1111 RejectReject

Root ConcavityRoot Concavity AA--CC 2mm depth2mm depth 1mm1mm 1010 RejectReject

Root UndercutRoot Undercut AA--CC NONENONE ------------------------ -------------------- AcceptAccept

Cracks/CrackCracks/Crack--like defectslike defects AA--CC NONENONE ------------------------ -------------------- AcceptAccept

Slag inclusionsSlag inclusions AA--CC NONENONE ------------------------ 99 AcceptAccept

This *pipe/plate has been examined to the requirements of code/specification TWI-N/WIS-PI

PorosityPorosity AA--CC NONENONE ------------------------ 22 AcceptAccept

Laps/LaminationsLaps/Laminations AA--CC NONENONE ------------------------ -------------------- AcceptAccept

This *pipe/plate has been examined to the requirements of code/specification .........................................and is accepted/rejected accordingly.

/

Comments:* Request MPI testing to confirm crack and length.** Large amount of spatter on weld face Recommend this is removed and re inspected

22nd August 2003I C Plenty

** Large amount of spatter on weld face. Recommend this is removed and re inspected.*** Recommend arc strikes are ground flush prior to MPI testing for cracks.


Signature......................................................... Date.....................................................................................*Delete which is not applicable. Use the other side for any comments.

22nd August 2003I C Plenty

Inspection Practice Specification Inspection Practice Specification Number Number TWI 09TWI 09--0909--03 03

All dimensions are given in mmAll dimensions are given in mm

NoNo ImperfectionImperfection CommentsComments AllowanceAllowance

11 CracksCracks All types of cracksAll types of cracks Not permittedNot permitted

All dimensions are given in mmAll dimensions are given in mm

22 Porosity/Gas pores/elongatedPorosity/Gas pores/elongatedGas cavities (wormholes) pipesGas cavities (wormholes) pipes

ClusterCluster Max dimension of areaMax dimension of areaSingle poreSingle pore Max dimension Max dimension

L = 13mm MaxL = 13mm MaxL = 1mm MaxL = 1mm Max

33 Solid InclusionsSolid Inclusions Non metallic. Individual sizeNon metallic. Individual size Maximum 1mmMaximum 1mm

44 Solid InclusionsSolid Inclusions Metallic. Individual sizeMetallic. Individual size Not permittedNot permitted

55 Lack of FusionLack of Fusion Side wall/Root/InterSide wall/Root/Inter--runrun Not permittedNot permitted

66 Incomplete Root PenetrationIncomplete Root Penetration Not permittedNot permitted

77 Overlap/Cold lapOverlap/Cold lap Weld face/RootWeld face/Root Not permittedNot permitted

88 I l t l fill dI l t l fill d N t itt dN t itt d88 Incompletely filled grooveIncompletely filled groove Not permittedNot permitted

99 Linear MisalignmentLinear Misalignment 0.2t Maximum 4mm0.2t Maximum 4mm

1010 Angular MisalignmentAngular Misalignment Maximum 10ºMaximum 10º

1111 UndercutUndercut Smoothly blended Smoothly blended 10%t Maximum d 1mm 10%t Maximum d 1mm

1212 Arc StrikesArc Strikes Area to be tested by MPIArea to be tested by MPI Seek adviceSeek advice

1313 LaminationsLaminations Not permittedNot permitted

1414 Mechanical DamageMechanical Damage Not permittedNot permitted

1515 C H i htC H i ht Sh ll f ll b l l t fSh ll f ll b l l t f 00 3 h M i3 h M i1515 Cap HeightCap Height Shall fall below plate surfaceShall fall below plate surface 0 0 ––3mm h Maximum3mm h Maximum

1616 Penetration BeadPenetration Bead 0 0 ––2mm h Maximum2mm h Maximum

1717 Toe BlendToe Blend SmoothSmooth

1818 SpatterSpatter Clean & ReClean & Re--inspectinspect Refer to manufacturerRefer to manufacturer


1919 Weld AppearanceWeld Appearance All runs shall blend smoothlyAll runs shall blend smoothly RegularRegular

2020 Root concavityRoot concavity 10%t Maximum10%t Maximum

Plate Sample 6A CapPlate Sample 6A Cap

Incomplete Filled Groove

Welding Process MMA (SMAW)Welding Process MMA (SMAW)

Cap UndercutSlag

Porosity

Lack of f i Cap Undercut

Incomplete Filled Groove

?? ????

Cap Undercut Intermittent

Slag Inclusion fusion Cap Undercut

Intermittent

?? ????

??

Cap Undercut I i A St ik Arc Strike???? ??Intermittent Arc Strike Arc Strike

Note: spatter and surface slag requires removal arc strikes

?? ??


Note: spatter and surface slag requires removal, arc strikes require blending and crack detection

Plate Sample 6A RootPlate Sample 6A Root


Excess Penetration

Excess Penetration

Gas Pore?? ??????

??

??Lack of Root Fusion

Root UndercutLinear Misalignment

Surface Slag?? ?? ??

??

Surface Slag

Note: Spatter and surface slag require removal


Note: Spatter and surface slag require removal

Plate Sample 6B CapPlate Sample 6B Cap

I l t Fill d G??Welding Process MMA (SMAW)Welding Process MMA (SMAW)

Lack of Sidewall Fusion

Incomplete Filled Groove Porosity Lack of Sidewall Fusion

????

???? ????

??Overlap and Excess Cap Height Full Weld Length

Surface Slag??

??

Note: Surface slag requires removal and poor toe blending


Note: Surface slag requires removal and poor toe blending full weld length

Plate Sample 6B RootPlate Sample 6B Root


??Slag Inclusion

??Crater Pipe

?? ??

?? ????Lack of Root Fusion

Lack of Root Fusion

?? ??Lack of Root Penetration

??


Plate Sample 6C CapPlate Sample 6C Cap

IncompleteWelding Process FCAWWelding Process FCAW

Longitudinal Surface slag & Spatter

Cap UndercutIncomplete Filled Groove + Lack of Sidewall F i

??CrackSurface slag & Spatter Fusion

???? ??

??Slag Inclusion

Incomplete Filled Groove + Lack of

????Slag Inclusion Sidewall Fusion + Cap

Undercut Intermittent

Note: Spatter and surface slag requires removal


Note: Spatter and surface slag requires removal

Plate Sample 6C RootPlate Sample 6C Root

Welding Process FCAWWelding Process FCAW

B Th h

Poor Stop/Start + Lack of Root Penetration

Mechanical Damage??Burn Through

Excess Penetration?? ?? ??

????Lack of Root Fusion

Lack of Root Fusion

??


Plate Sample 6D CapPlate Sample 6D CapWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Excess Cap

Porosity Incomplete Filled Groove?? ??Cap

UndercutCap Undercut

Excess Cap Height

Lack of Sidewall Fusion

?? ????

?? ????

??Overlap between Capping Passes

Note: Excess cap height and poor cap profile throughout


Note: Excess cap height and poor cap profile throughout.

Plate Sample 6D RootPlate Sample 6D Root


Lack of Root Fusion??

Mechanical DamageLack of Root Fusion

??

Lack of Root Fusion??

Lack of Root Fusion


Plate Sample 6E CapPlate Sample 6E Cap

Welding Process MMA (SMAW)Welding Process MMA (SMAW)Lack of Sidewall Fusion

Cap Undercut

I t itt t Cap Undercut Intermittent?? Intermittent Cap Undercut Intermittent

????

??

??Excess Cap Height

Incomplete Filled Groove ?? ????

Excess Cap HeightIncomplete Filled Groove

??


Plate Sample 6E RootPlate Sample 6E RootWelding Process MMA (SMAW)Welding Process MMA (SMAW)

?? ??Lack of Root Fusion

Poor Stop/Start + Crater Pipe Lack of Root Fusion

Root Undercut??

?? ????

Excess Root Penetration Excess Root????Excess Root Penetration Excess Root Penetration

Crater Pipe Lack of Root fusion

????

????

??


Plate Sample 6F CapPlate Sample 6F CapWelding Process MMA (SMAW)Welding Process MMA (SMAW)

Mechanical Damage ??

Lack of Sidewall fusion?? ??Crater pipeLack of Sidewall fusion

Poor Toe Blend Lack of Sidewall Fusion + Incomplete Filled Groove

Arc?? ??

?? Arc StrikesTack Weld

Note: Arc strikes require blending and crack detection?? ??


Note: Arc strikes require blending and crack detection

Plate Sample 6F RootPlate Sample 6F Root


Arc Strikes Poor Stop/Start + Lack of Root Penetration + Crater Pipe

Mechanical Damage +Lack of Root

Blow Hole Lack of Root Fusion?? ??

??Mechanical Damage + Lack of Root Fusion Fusion

Fusion?? ???? ??

??

Lack of Root Fusion Arc Strikes Arc Strikes

?? ????




Plate Sample 6G CapPlate Sample 6G Cap


Arc StrikesParent Material Damage ????

Arc StrikesLack of Sidewall Fusion + Incomplete Filled Groove

????

Poor Toe Blend + Excess Cap Height Porosity

?? ??p g y

Note: Arc strikes require blending and crack detection Seek


Note: Arc strikes require blending and crack detection, Seek advise on parent material damage

Plate Sample 6G RootPlate Sample 6G Root


Plate corrosion

Poor Stop/Start

?? Parent material gas cavities??

Lack of Root Fusion

Poor Stop/Start

?? ??

Surface Slag??Crater pipe??

Surface slag??

Li Mi li t

Surface Slag

??Surface slag

Linear Misalignment

Note: Surface slag requires removal plate corrosion requires


Note: Surface slag requires removal, plate corrosion requires wire brushing

Plate Sample 6H CapPlate Sample 6H Cap


Incomplete Filled Groove Arc Strikes Arc Strikes Slag Inclusion Arc Strikes

?? ?? ?? ?? ??

?? ?? ??Cap Undercut IntermittentArc Strikes

Cap Undercut

A St ik

?? ?? ????

Arc Strikes

Note: Parent plate damage throughout seek advice Arc


Note: Parent plate damage throughout, seek advice. Arc strikes require blending and crack detection.

Plate Sample 6H RootPlate Sample 6H Root


Crater pipe

??Excessive root penetration

??Linear misalignment +

lack of root fusion

???? ??

??Arc strikes

Poor stop/start

?? ?? ?? ??p

Lack of root fusionArc strikes Lack of root fusion




Plate Sample 6I CapPlate Sample 6I Cap


Cap undercut Spatter

Arc strikes?? ??Arc strikes??

??

Poor toe blend full weld length

????



Note: Arc strikes require blending and crack detection. Spatter requires removal.

Plate Sample 6I RootPlate Sample 6I Root


??Lack of root penetration

??Burn through

??Poor stop/start ??

Arc strike

?? ?? ??

Linear misalignment??

?? ??Lack of root penetration

??Lack of root fusion

??Mechanical damage

????

Lack of root fusion + poor stop/start+ poor stop/start




Plate Sample 6J CapPlate Sample 6J Cap


Suspect crater cracking PorositySuspect crater cracking

??Cap undercut ??Arc strikes

??Cap undercut

Porosity

??

Cap undercut?? Cap undercut intermittent??

Note: Material damage throughout seek advice Arc strikes


Note: Material damage throughout, seek advice. Arc strikes require blending and crack detection.

Plate Sample 6J RootPlate Sample 6J Root


Linear misalignment +??

Mechanical damageLack of root fusion Linear misalignment + lack of root fusion?? ??

Lack of root penetration?? ??Linear misalignment + lack of root fusion

??

Note: Material damage seek advice on course of action


Note: Material damage seek advice on course of action.

Plate Sample T4 CapPlate Sample T4 Cap


Mechanical damageCap undercut Cap undercut ???? ???? ??

Spatter/irregular cap profile

??

Note: Grinding marks throughout seek advice on course of


Note: Grinding marks throughout seek advice on course of action.

Excess cap height and poor cap profile throughout.

Plate Sample T4 RootPlate Sample T4 Root


Root undercut intermittent Arc strike

????

Lack of penetration intermittent??

??

Ground flush root

??


Plate Sample H8 CapPlate Sample H8 Cap


Arc strikesMechanical

damage Cap undercut intermittent Surface slag?? ?? ?? ???? ?? ?? ??

Cap undercut intermittent??Mechanical

damage

p?? ??

g

Note: Mechanical damage seek advice on course of action.Excess cap height and poor cap profile throughout Arc


Excess cap height and poor cap profile throughout. Arc strikes require blending and crack detection.

Plate Sample H8 RootPlate Sample H8 Root


Arc strikeLack of root Lack of root

f iLack of root

f iSpatter??

Lack of root fusion

Lack of root fusion fusion fusion

?? ?? ?? ?? ??

??Spatter

Root undercut intermittent?? ??

Note: Arc strikes require blending and crack detection.


q gSpatter requires removal

Any QuestionsAny QuestionsAny QuestionsAny Questions


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211279153-2-CSWIP-Practical-Plate-Examples.pdf