2-CSWIP Practical Plate Examples

CSWIP 3.1 Welding g Inspection p

Practical Plate Inspection

TWI Training & Examination Services Course Reference WIS 5 Copyright © 2006, TWI Ltd

World Centre for Materials Joining Technology

Page 1 of 3 Name: [Block capitals] Mr. I C Plenty

EXAMPLE PLATE REPORT Signature: I C Plenty

Code/Specification used: TWI 09-09-03 09 09 03 Welding position: Flat /PA

Welding process:

Test piece ident:

MMA/SMAW

Joint type: Single V Butt

Length & thickness of plate: 300mm x 10 mm

Date

22/08/2003

MEASURE

WELD FACE A

C

B Lack ac o of s sidewall de a fusion

FROM

87

THIS

51

DATUM

Slag inclusion NOTES:

230

236 30

153

8

Undercut smooth 1.5 max

Gas pore 1.5 Ø

22

40 Arc Strike

Centreline crack

241

EDGE

Cap height : 4mm 4mm. Weld width: 12-14mm Toe blend: Poor Misalignment: 2mm Angular Distortion 3mm in 50mm Spatter along weld length or scale on the plate surface

Copyright © 2006, TWI Ltd

001


EXAMPLE PLATE REPORT

Page 2 of 3

MEASURE

WELD ROOT

A

B

Root concavity 2 deep

FROM

23

C Lack of root Fusion 247

10

THIS

128

20

50

DATUM

Incomplete root penetration

NOTES: Penetration height :

EDGE

Linear Misalignment: Angular Distortion: Any scale on plate surface


4mm. 4mm 2mm 3mm in 50mm


EXAMPLE WELD INSPECTION REPORT/SENTENCE SHEET PRINT FULL NAME

I C Plenty 001

SPECIMEN NUMBER EXTERNAL DEFECTS

Defect Type

Defects Noted

Pipe/Plate Section 1

Accumulative Total 2

Code or Specification Reference

Maximum Allowance 3

Excess weld metal height

A-C

4mm

2mm

pp Excess weld metal appearance

A-C

Poor blend

Incomplete filling

A-C

Inadequate weld width (PIPE)

Section/ Table No 4

Accept/Reject 5

15

Reject

Smooth

8

Reject j

22mm

None

5

Reject

A-C

N/A

------------

----------

Accept

Slag Inclusions

A-C

70mm long

50mm

9

Reject

Undercut

A-C

1 5mm depth 1.5mm

1mm

6

Reject

Surface Porosity

A-C

1.5mm 

1mm

2

Reject

Cracks/Crack--like defects Cracks/Crack

A-C

40mm

NONE

1

Reject*

Lack of fusion

A-C

22mm

NONE

3

Reject

Arc strikes

A-C

3

NONE

7

Reject***

Mechanical damage

A-C

NONE

------------

-----------

Accept

Laps/Laminations

A-C

NONE

------------

-----------

Accept

Misalignment (Linear)

A-C

2mm

2mm

15

Accept

Longitudinal seams (PIPE)

A-C

N/A

------------

----------

Accept



Root Defects Misalignment

A-C

2mm

2mm

9

Accept

Excessive Root Penetration

A-C

4mm

2mm

15

Reject

Incomplete Root Penetration

A-C

50mm

NONE

13

Reject

Lack of Root Fusion

A-C

20mm

NONE

11

Reject

Root Concavity

A-C

2mm depth

1mm

10

Reject

Root Undercut

A-C

NONE

------------

----------

Accept

Cracks/Crack--like defects Cracks/Crack

A-C

NONE

------------

----------

Accept

Slag inclusions

A-C

NONE

------------

9

Accept

Porosity

A-C

NONE

------------

2

Accept

Laps/Laminations

A-C

NONE

------------

----------

Accept

/ This *pipe/plate has been examined to the requirements of code/specification TWI-N/WIS-PI ......................................... and is accepted/rejected accordingly. Comments: * Request MPI testing to confirm crack and length. ** Large amount of spatter on weld face. face Recommend this is removed and re inspected. inspected *** Recommend arc strikes are ground flush prior to MPI testing for cracks.

I C Plenty

Signature......................................................... *Delete which is not applicable.


22nd August 2003

Date..................................................................................... Use the other side for any comments.


Inspection Practice Specification Number TWI 0909-09 09--03 All dimensions are given in mm

No

Imperfection

Comments

Allowance

1

Cracks

All types of cracks

Not permitted

2

Porosity/Gas pores/elongated Gas cavities (wormholes) pipes

Cluster Max dimension of area Single pore Max dimension

L = 13mm Max L = 1mm Max

3

Solid Inclusions

Non metallic. Individual size

Maximum 1mm

4

Solid Inclusions

Metallic. Individual size

Not permitted

5

Lack of Fusion

Side wall/Root/Interwall/Root/Inter-run

Not permitted

6

Incomplete Root Penetration

7

Overlap/Cold lap

8

I Incompletely l t l filled fill d groove

N t permitted Not itt d

9

Linear Misalignment

0.2t Maximum 4mm

10

Angular Misalignment

Maximum 10º

11

Undercut

Smoothly blended

10%t Maximum d 1mm

12

Arc Strikes

Area to be tested by MPI

Seek advice

13

Laminations

Not permitted

14

Mechanical Damage

Not permitted

15

Cap C H Height i ht

16

Penetration Bead

0 –2mm h Maximum

17

Toe Blend

Smooth

18

Spatter

Clean & ReRe-inspect

Refer to manufacturer

19

Weld Appearance

All runs shall blend smoothly

Regular

20

Root concavity


Not permitted Weld face/Root

Sh ll fall Shall f ll below b l plate l t surface f

Not permitted

0 –3mm 3 h Maximum M i

10%t Maximum


Plate Sample 6A Cap Welding Process MMA (SMAW) Incomplete Filled Groove Porosity Slag Inclusion

Cap Undercut Intermittent

?

Cap Undercut I Intermittent i

?

? Lack of f i fusion

?


?

?

?

?

A St Arc Strike ik

Arc Strike

?

Note: spatter and surface slag requires removal removal, arc strikes require blending and crack detection Copyright © 2006, TWI Ltd


Plate Sample 6A Root Welding Process MMA (SMAW) Excess Penetration

?

Excess Penetration Gas Pore

?

?

?

? Surface Slag

Root Undercut Lack of Root Fusion

?

? Linear Misalignment

Note: Spatter and surface slag require removal Copyright © 2006, TWI Ltd


Plate Sample 6B Cap Welding Process MMA (SMAW) I l t Filled Fill d Groove G ? Incomplete Lack of Sidewall Fusion

?

Porosity

?

Lack of Sidewall Fusion

?

?

Surface Slag Overlap and Excess Cap Height Full Weld Length

?

Note: Surface slag requires removal and poor toe blending full weld length Copyright © 2006, TWI Ltd


Plate Sample 6B Root Welding Process MMA (SMAW) Slag Inclusion

?

? Crater Pipe

? Lack of Root Fusion


? Lack of Root Penetration



Plate Sample 6C Cap Welding Process FCAW Cap Undercut

?

Surface slag & Spatter

?

Incomplete Filled Groove + Lack of Sidewall Longitudinal F i Fusion Crack

?

? Slag Inclusion

? ?

Incomplete Filled Groove + Lack of Sidewall Fusion + Cap Undercut Intermittent

Note: Spatter and surface slag requires removal Copyright © 2006, TWI Ltd


Plate Sample 6C Root Welding Process FCAW Mechanical Damage

?

Poor Stop/Start + Lack of Root Penetration

B Burn Th Through h

?


? Excess Penetration

?




Plate Sample 6D Cap Welding Process MMA (SMAW)

Incomplete Filled Groove

Porosity Excess Cap Height

?

Cap Undercut

?

?


?

Cap Undercut

? ?

? Overlap between Capping Passes

Note: Excess cap height and poor cap profile throughout throughout. Copyright © 2006, TWI Ltd


Plate Sample 6D Root Welding Process MMA (SMAW)

? Lack of Root Fusion Mechanical Damage

?




Plate Sample 6E Cap Welding Process MMA (SMAW)

?


Cap Undercut I t Intermittent itt t


?

?

? Incomplete Filled Groove

? Excess Cap Height

? Incomplete Filled Groove



Plate Sample 6E Root Welding Process MMA (SMAW)

?

Poor Stop/Start + Crater Pipe

? Lack of Root Fusion ?

?

Lack of Root Fusion

?

Root Undercut

Excess Root Penetration

?

Excess Root Penetration Crater Pipe

?


?Lack of Root fusion


Plate Sample 6F Cap Welding Process MMA (SMAW) Mechanical Damage

? ?

?

Crater pipe

Lack of Sidewall fusion

Poor Toe Blend

?

Lack of Sidewall Fusion + Incomplete Filled Groove

? ?

Tack Weld

Arc ? Strikes

Note: Arc strikes require blending and crack detection Copyright © 2006, TWI Ltd


Plate Sample 6F Root Welding Process MMA (SMAW) Arc Strikes Poor Stop/Start + Lack of Root Penetration + Crater Pipe Mechanical Damage + Lack of Root Fusion

?

?

?


Blow Hole

?

Lack of Root Fusion

Lack of Root Fusion

?

?

?

?

Arc Strikes

Arc Strikes

Note: Arc strikes require blending and crack detection Copyright © 2006, TWI Ltd


Plate Sample 6G Cap Welding Process MMA (SMAW)

?

Parent Material Damage

?

Arc Strikes

Arc Strikes

Lack of Sidewall Fusion + Incomplete Filled Groove

? Poor Toe Blend + Excess Cap p Height g

?

?

? Porosity y

Note: Arc strikes require blending and crack detection detection, Seek advise on parent material damage Copyright © 2006, TWI Ltd


Plate Sample 6G Root Welding Process MMA (SMAW)

?

? Plate corrosion

Parent material gas cavities

Poor Stop/Start

?

?

Lack of Root Fusion

Crater pipe

?

?

?

Surface slag

Surface Slag

? Li Linear Misalignment Mi li t

Note: Surface slag requires removal removal, plate corrosion requires wire brushing Copyright © 2006, TWI Ltd


Plate Sample 6H Cap Welding Process MMA (SMAW) Incomplete Filled Groove

Arc Strikes

?

Arc Strikes Slag Inclusion

?

?

?

Arc Strikes


?

Arc Strikes

?

?

? Cap Undercut

? A St Arc Strikes ik

Note: Parent plate damage throughout throughout, seek advice advice. Arc strikes require blending and crack detection. Copyright © 2006, TWI Ltd


Plate Sample 6H Root Welding Process MMA (SMAW) Crater pipe

Excessive root penetration

?

?

Arc strikes

? Arc strikes

?

Linear misalignment + lack of root fusion

?

?

Poor stop/start p Lack of root fusion

?

Lack of root fusion



Plate Sample 6I Cap Welding Process MMA (SMAW) Cap undercut

Spatter

?

?

Arc strikes

?

Poor toe blend full weld length

? Note: Arc strikes require blending and crack detection detection. Spatter requires removal. Copyright © 2006, TWI Ltd


Plate Sample 6I Root Welding Process MMA (SMAW) Lack of root penetration

Burn through

?

?

? Linear misalignment

Lack of root penetration

?

?

Arc strike Poor stop/start

?

? ? Lack of root fusion

?

Mechanical damage

Lack of root fusion + poor stop/start



Plate Sample 6J Cap Welding Process MMA (SMAW)

Suspect crater cracking Cap undercut Arc strikes

?

?

? Cap undercut

Porosity Cap undercut

?

? Cap undercut intermittent

Note: Material damage throughout throughout, seek advice advice. Arc strikes require blending and crack detection. Copyright © 2006, TWI Ltd


?

Plate Sample 6J Root Welding Process MMA (SMAW)

? Lack of root fusion

? ? Linear misalignment + lack of root fusion

Mechanical damage

Linear misalignment + lack of root fusion

? Lack of root penetration

?

Note: Material damage seek advice on course of action action. Copyright © 2006, TWI Ltd


Plate Sample T4 Cap Welding Process MMA (SMAW) Mechanical damage

?

Cap undercut

?

Cap undercut

?

? Spatter/irregular cap profile

Note: Grinding marks throughout seek advice on course of action. Copyright © 2006,Excess TWI Ltd for Materials Joining Technology cap World heightCentre and poor cap profile throughout.

Plate Sample T4 Root Welding Process MMA (SMAW) Root undercut intermittent

?

?

Arc strike Lack of penetration intermittent

? ? Ground flush root



Plate Sample H8 Cap Welding Process MMA (SMAW) Arc strikes

?

Mechanical damage

Cap undercut intermittent Surface slag

?

?

?

?

?

Cap p undercut intermittent

Mechanical g damage

Note: Mechanical damage seek advice on course of action. Excess cap height and poor cap profile throughout. throughout Arc strikes require blending and crack detection. Copyright © 2006, TWI Ltd


Plate Sample H8 Root Welding Process MMA (SMAW)

? Arc strike Lack of root fusion

? ?

Lack of root fusion

?

Lack of root f i fusion

Lack of root f i fusion

?

?

Spatter

? Root undercut intermittent

Spatter

Note: Arc strikes require q blending g and crack detection. Spatter requires removal Copyright © 2006, TWI Ltd


?

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