Practical Plate Answers

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

CSWIP 3.1 Welding InspectionCSWIP 3.1 Welding Inspection

TWI Training & Examination TWI Training & Examination ServicesServices

Practical Plate InspectionPractical Plate Inspection

Course Reference WIS 5


Un

der

cut

smo

oth

1.5

max

236

Gas

po

re 1

.5 Ø

230

Lac

k o

f si

dew

all

fusi

on

87

241

153

Cen

trel

ine

crac

k

51

Sla

g

incl

usi

on

Cap

hei

gh

t :

4m

m.

Wel

d w

idth

:

12-1

4mm

To

e b

len

d:

P

oo

r M

isal

ign

me

nt:

2m

mA

ng

ula

r D

isto

rtio

n

3m

m i

n 5

0mm

Sp

atte

r al

on

g w

eld

len

gth

or

scal

e o

n t

he

pla

te s

urf

ace

C

30

Arc

Str

ike

40

22

8

P

ag

e 1

of

3

E

XA

MP

LE

P

LA

TE

RE

PO

RT

N

am

e:

[Blo

ck

ca

pit

als

] M

r.

I C

Ple

nty

S

ign

atu

re:

I C

Ple

nty

T

es

t p

iec

e i

de

nt:

00

1

Co

de

/Sp

ec

ific

ati

on

us

ed

: T

WI

09

-09

-03

W

eld

ing

pro

ce

ss

:

MM

A/S

MA

W

J

oin

t ty

pe

:

Sin

gle

V B

utt

We

ldin

g p

os

itio

n:

F

lat

/PA

Le

ng

th &

th

ick

ne

ss

of

pla

te:

3

00

mm

x

10

mm

Da

te

2

2/0

8/2

00

3

M E

A S

U R

E F

R O

M T

H I S

D A

T U

M E

D G

E

WELD FACE

B

A

NO

TE

S:

NO

TE

S:

NDT


Lack o

f ro

ot

Fu

sio

n

247

R

oot

con

cavit

y 2

d

eep

23

128

Incom

ple

te

root

pen

etr

ati

on

Pen

etr

ati

on

heig

ht

:4m

m.

Lin

ear

Mis

alig

nm

en

t:2m

mA

ng

ula

r D

isto

rtio

n:

3m

m

in 5

0m

mA

ny s

cale

on

pla

te s

urf

ace

C

20

50

10

Pa

ge

2 o

f 3

EX

AM

PL

E P

LA

TE

RE

PO

RT

EX

AM

PL

E P

LA

TE

RE

PO

RT

M E

A S

U R

E F

R O

M T

H I S

D A

T U

M E

D G

E

WELD ROOT

B

A

NO

TES

:N

OTES

:


I C Plenty001

EXAMPLE WELD INSPECTION REPORT/SENTENCE EXAMPLE WELD INSPECTION REPORT/SENTENCE SHEETSHEET

SPECIMEN NUMBER

EXTERNAL DEFECTSEXTERNAL DEFECTS Defects Defects NotedNoted

Code or Specification ReferenceCode or Specification Reference

Defect TypeDefect Type Pipe/Plate Pipe/Plate SectionSection

11

AccumulativeAccumulativeTotalTotal

22

MaximuMaximumm

AllowancAllowancee33

Section/Section/Table NTable Noo

44

Accept/RejectAccept/Reject55

Excess weld metal heightExcess weld metal height 1515

Excess weld metal appearanceExcess weld metal appearance A-CA-C Poor blendPoor blend SmoothSmooth 88 RejectReject

Incomplete fillingIncomplete filling A-CA-C 22mm22mm NoneNone 55 RejectReject

Inadequate weld width (PIPE)Inadequate weld width (PIPE) A-CA-C N/AN/A ------------------------ -------------------- AcceptAccept

Slag InclusionsSlag Inclusions A-CA-C 70mm long70mm long 50mm50mm 99 RejectReject

UndercutUndercut A-CA-C 1.5mm depth1.5mm depth 1mm1mm 66 RejectReject

Surface PorositySurface Porosity A-CA-C 1.5mm 1.5mm 1mm1mm 22 RejectReject

Cracks/Crack-like defectsCracks/Crack-like defects A-CA-C 40mm40mm NONENONE 11 Reject*Reject*

Lack of fusionLack of fusion A-CA-C 22mm22mm NONENONE 33 RejectReject

Arc strikesArc strikes A-CA-C 33 NONENONE 77 Reject***Reject***

Mechanical damageMechanical damage A-CA-C NONENONE ------------------------ ---------------------- AcceptAccept

Laps/LaminationsLaps/Laminations A-CA-C NONENONE ------------------------ ---------------------- AcceptAccept

Misalignment (Linear)Misalignment (Linear) A-CA-C 2mm2mm 2mm2mm 1515 AcceptAccept

Longitudinal seams (PIPE)Longitudinal seams (PIPE) A-CA-C N/AN/A ------------------------ -------------------- AcceptAccept

PRINT FULL NAME

A-C 4mm 2mm Reject


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

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

TWI-N/WIS-PI

22nd August 2003I C Plenty

MisalignmentMisalignment A-CA-C 2mm2mm 2mm2mm 99 AcceptAccept

Excessive Root PenetrationExcessive Root Penetration A-CA-C 4mm4mm 2mm2mm 1515 RejectReject

Incomplete Root PenetrationIncomplete Root Penetration A-CA-C 50mm50mm NONENONE 1313 RejectReject

Lack of Root FusionLack of Root Fusion A-CA-C 20mm20mm NONENONE 1111 RejectReject

Root ConcavityRoot Concavity A-CA-C 2mm depth2mm depth 1mm1mm 1010 RejectReject

Root UndercutRoot Undercut A-CA-C NONENONE ------------------------ -------------------- AcceptAccept

Cracks/Crack-like defectsCracks/Crack-like defects A-CA-C NONENONE ------------------------ -------------------- AcceptAccept

Slag inclusionsSlag inclusions A-CA-C NONENONE ------------------------ 99 AcceptAccept

PorosityPorosity A-CA-C NONENONE ------------------------ 22 AcceptAccept

Laps/LaminationsLaps/Laminations A-CA-C NONENONE ------------------------ -------------------- AcceptAccept

Root DefectsRoot Defects

Comments:* Request MPI testing to confirm crack and length.** 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.


NoNo ImperfectionImperfection CommentsComments AllowanceAllowance

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

22 Porosity/Gas Porosity/Gas pores/elongatedpores/elongated

Gas cavities (wormholes) Gas cavities (wormholes) pipespipes

ClusterCluster Max dimension of Max dimension of areaarea

Single 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/Inter-runSide wall/Root/Inter-run Not permittedNot permitted

66 Incomplete Root Incomplete Root PenetrationPenetration

Not permittedNot permitted

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

88 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 Cap HeightCap Height Shall fall below plate surfaceShall fall below plate surface 0 –3mm h Maximum0 –3mm h Maximum

1616 Penetration BeadPenetration Bead 0 –2mm h Maximum0 –2mm h Maximum

1717 Toe BlendToe Blend SmoothSmooth

1818 SpatterSpatter Clean & Re-inspectClean & Re-inspect 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

Inspection Practice Specification Inspection Practice Specification Number Number TWI 09-09-03 TWI 09-09-03 All dimensions are given in mmAll dimensions are given in mm


Plate Sample 6A CapPlate Sample 6A Cap

Cap Undercut Intermittent


Slag Inclusion

Arc Strike

Porosity Lack of fusion


Arc Strike

Incomplete Filled Groove

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

??

????

??

?? ??

??

??

??

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


Plate Sample 6A RootPlate Sample 6A Root

Excess Penetration

Lack of Root Fusion

Excess Penetration

Gas Pore

Root Undercut

Linear Misalignment

Surface Slag

Note: Spatter and surface slag require removal

??

?? ??

??

??

??

??



Plate Sample 6B CapPlate Sample 6B Cap

Lack of Sidewall Fusion


Overlap and Excess Cap Height Full Weld Length

Surface Slag

Porosity Lack of Sidewall Fusion

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

??

??

??

??

????



Lack of Root Fusion

Plate Sample 6B RootPlate Sample 6B Root

Lack of Root Fusion

Crater Pipe

??

??

??Lack of Root Penetration

??

Slag Inclusion??



Longitudinal Crack

Surface slag & Spatter

Plate Sample 6C CapPlate Sample 6C Cap

Cap Undercut

Incomplete Filled Groove + Lack of Sidewall Fusion

Slag InclusionIncomplete Filled Groove + Lack of

Sidewall Fusion + Cap Undercut Intermittent

Note: Spatter and surface slag requires removal

??

??

??

??

??

??

Welding Process FCAWWelding Process FCAW


Plate Sample 6C RootPlate Sample 6C Root

Lack of Root Fusion

Burn Through

Excess Penetration

Lack of Root Fusion

Poor Stop/Start + Lack of Root Penetration

Mechanical Damage

??

????

??

??

??

Welding Process FCAWWelding Process FCAW


Cap Undercut

Cap Undercut

Excess Cap Height

Plate Sample 6D CapPlate Sample 6D Cap

Porosity



Overlap between Capping Passes

?? ??

??

??

??

????


Note: Excess cap height and poor cap profile throughout.


Plate Sample 6D RootPlate Sample 6D Root


Lack of Root Fusion

Mechanical Damage

Lack of Root Fusion

??

??

??


Plate Sample 6E CapPlate Sample 6E Cap



Excess Cap Height




????

??

??

????



Plate Sample 6E RootPlate Sample 6E Root

Lack of Root Fusion

Excess Root Penetration

Poor Stop/Start + Crater Pipe

Excess Root Penetration

Lack of Root Fusion

Crater Pipe Lack of Root fusion

Root Undercut

????

????

??

??

??

??



Plate Sample 6F CapPlate Sample 6F Cap

Poor Toe Blend

Lack of Sidewall fusion

Mechanical Damage

Lack of Sidewall Fusion + Incomplete Filled Groove

Arc StrikesTack Weld

Note: Arc strikes require blending and crack detection

??

??

?? ??

?? ??


??Crater pipe


Plate Sample 6F RootPlate Sample 6F Root

Lack of Root Fusion

Arc Strikes

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

Mechanical Damage + Lack of Root Fusion

Arc Strikes

Arc Strikes

Lack of Root Fusion

Blow Hole

Lack of Root Fusion

????

??

????

?? ??

??

??

Note: Arc strikes require blending and crack detection



Plate Sample 6G CapPlate Sample 6G Cap

Poor Toe Blend + Excess Cap Height

Arc Strikes

Porosity

Lack of Sidewall Fusion + Incomplete Filled Groove

Arc StrikesParent Material Damage

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

??

??

??

??

????



Linear Misalignment

Plate Sample 6G RootPlate Sample 6G Root


Plate corrosion

Lack of Root Fusion

Poor Stop/Start

Surface Slag

???? ??

??

??

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

Parent material gas cavities??

Crater pipe?? Surface slag??


Plate Sample 6H CapPlate Sample 6H Cap




Arc Strikes

Arc StrikesArc Strikes Slag Inclusion

Cap Undercut

Arc Strikes

Arc Strikes

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

????

?? ??

?? ??

??

??

??


Plate Sample 6H RootPlate Sample 6H Root


Crater pipe??

Poor stop/startLack of root fusion

Arc strikes

??Lack of root fusion

Excessive root penetration

Arc strikes????

??

??


Linear misalignment + lack of root fusion??


Plate Sample 6I CapPlate Sample 6I Cap


Cap undercut

Poor toe blend full weld length

SpatterArc strikes?? ??

??

??

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


Plate Sample 6I RootPlate Sample 6I Root


Linear misalignment??

??Lack of root penetration

??Mechanical damage

??Lack of root penetration

??Burn through

??Lack of root fusion

??Poor stop/start ??Arc strike

??Lack of root fusion + poor stop/start



Plate Sample 6J CapPlate Sample 6J Cap


Suspect crater cracking

??Cap undercut

Cap undercut??

??Arc strikes ??Cap undercut

Cap undercut intermittent??

Porosity??

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


Plate Sample 6J RootPlate Sample 6J Root


Mechanical damage

Linear misalignment + lack of root fusion

Lack of root fusion

Lack of root penetration

Linear misalignment + lack of root fusion

??

??

??

??

??

Note: Material damage seek advice on course of action.


Plate Sample T4 CapPlate Sample T4 Cap


Mechanical damage

Cap undercut Cap undercut

Spatter/irregular cap profile

??

??

?? ??

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

Ground flush root

Lack of penetration intermittent

Arc strike

??

??

??

??


Plate Sample H8 CapPlate Sample H8 Cap


Arc strikesMechanical

damage

Mechanical damage

Cap undercut intermittent

Cap undercut intermittent

Surface slag

?? ??

??

??

????

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

strikes require blending and crack detection.


Plate Sample H8 RootPlate Sample H8 Root


Arc strike

Spatter

Lack of root fusion

Lack of root fusion

Root undercut intermittent

Lack of root fusion

Lack of root fusion

Spatter

??

??

?? ??

??

????

??

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


Any QuestionsAny Questions

??

Documents

Practical Plate Answers