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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 Code/Specification used: TWI 09-09-03 09 09 03 Welding position: Flat /PA MEASURE FROM Copyright 2006, TWI Ltd THIS DATUM EDGE

EXAMPLE PLATE REPORT Signature: I C Plenty


Welding process: MMA/SMAW

Test piece ident:

001

Joint type: Single V Butt Date 22/08/2003

Length & thickness of plate: 300mm x 10 mm

WELD FACE A Lack ac o of s sidewall de a fusion 87 22 B Gas pore 1.5 230 C Undercut smooth 1.5 max 236 30

51

153

40 Arc Strike 241

Slag inclusion NOTES:

Centreline crack

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

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Page 2 of 3

EXAMPLE PLATE REPORT

Copyright 2006, TWI Ltd

MEASURE FROM THIS DATUM EDGE

WELD ROOT

Root concavity 2 deep 23 10

B
Lack of root Fusion 247 20

128

50

Incomplete root penetration

NOTES: Penetration height :

Linear Misalignment: Angular Distortion: Any scale on plate surface

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

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EXAMPLE WELD INSPECTION REPORT/SENTENCE SHEET


PRINT FULL NAME SPECIMEN NUMBER
EXTERNAL DEFECTS

I C Plenty 001
Defects Noted Code or Specification Reference

Defect Type

Pipe/Plate Section 1 A-C A-C A-C A-C A-C A-C A-C A-C A-C A-C A-C A-C A-C A-C

Accumulative Total 2 4mm Poor blend 22mm N/A 70mm long 1 5mm depth 1.5mm 1.5mm 40mm 22mm 3 NONE NONE 2mm N/A

Maximum Allowance 3 2mm Smooth None -----------50mm 1mm 1mm NONE NONE NONE ----------------------2mm ------------

Section/ Table No 4 15 8 5 ---------9 6 2 1 3 7 --------------------15 ----------

Accept/Reject 5 Reject Reject j Reject Accept Reject Reject Reject Reject* Reject Reject*** Accept Accept Accept Accept

Excess weld metal height pp Excess weld metal appearance Incomplete filling Inadequate weld width (PIPE) Slag Inclusions Undercut Surface Porosity Cracks/CrackCracks/Crack -like defects Lack of fusion Arc strikes Mechanical damage Laps/Laminations Misalignment (Linear) Longitudinal seams (PIPE)

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Root Defects
Misalignment A-C 2mm 2mm 9 Accept

Excessive Root Penetration Incomplete Root Penetration Lack of Root Fusion Root Concavity Root Undercut Cracks/CrackCracks/Crack -like defects Slag inclusions Porosity Laps/Laminations

A-C A-C A-C A-C A-C A-C A-C A-C A-C

4mm 50mm 20mm 2mm depth NONE NONE NONE NONE NONE

2mm NONE NONE 1mm --------------------------------------------------------

15 13 11 10 ------------------9 2 ----------

Reject Reject Reject Reject Accept Accept Accept Accept 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.

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

I C Plenty

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

22nd August 2003

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Inspection Practice Specification Number TWI 0909-09 09-03


All dimensions are given in mm
Comments
All types of cracks Cluster Max dimension of area Single pore Max dimension Non metallic. Individual size Metallic. Individual size Side wall/Root/Interwall/Root/Inter-run

No
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Imperfection
Cracks Porosity/Gas pores/elongated Gas cavities (wormholes) pipes Solid Inclusions Solid Inclusions Lack of Fusion Incomplete Root Penetration Overlap/Cold lap I Incompletely l t l filled fill d groove Linear Misalignment Angular Misalignment Undercut Arc Strikes Laminations Mechanical Damage Cap C H Height i ht Penetration Bead Toe Blend Spatter Weld Appearance Root concavity

Allowance
Not permitted L = 13mm Max L = 1mm Max Maximum 1mm Not permitted Not permitted Not permitted

Weld face/Root

Not permitted N t permitted Not itt d 0.2t Maximum 4mm Maximum 10

Smoothly blended Area to be tested by MPI

10%t Maximum d 1mm Seek advice Not permitted Not permitted

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

0 3mm 3 h Maximum M i 0 2mm h Maximum Smooth

Clean & ReRe-inspect All runs shall blend smoothly

Refer to manufacturer Regular 10%t Maximum

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Plate Sample 6A Cap


Welding Process MMA (SMAW)
Incomplete Filled Groove Porosity Slag Inclusion Cap Undercut Intermittent

?
Lack of f i fusion

Cap Undercut Intermittent

Cap Undercut I Intermittent i

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

World Centre for Materials Joining Technology

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

World Centre for Materials Joining Technology

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

World Centre for Materials Joining Technology

Plate Sample 6B Root


Welding Process MMA (SMAW)
Slag Inclusion

? Crater Pipe

?
Lack of Root Fusion

?
Lack of Root Penetration

?
Lack of Root Fusion

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Plate Sample 6C Cap


Welding Process FCAW
Cap Undercut Incomplete Filled Groove + Lack of Sidewall Longitudinal F i Fusion Crack

Surface slag & Spatter

? ?

?
Slag Inclusion

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

Note: Spatter and surface slag requires removal


Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Plate Sample 6C Root


Welding Process FCAW
Mechanical Damage B Burn Th Through h

Poor Stop/Start + Lack of Root Penetration

? Excess Penetration ?
Lack of Root Fusion

?
Lack of Root Fusion

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Plate Sample 6D Cap


Welding Process MMA (SMAW)

Porosity Excess Cap Height Cap Undercut

Incomplete Filled Groove Cap Undercut

Lack of Sidewall Fusion

? ?

?
Overlap between Capping Passes

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

World Centre for Materials Joining Technology

Plate Sample 6D Root


Welding Process MMA (SMAW)

?
Lack of Root Fusion Mechanical Damage

?
Lack of Root Fusion

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Plate Sample 6E Cap


Welding Process MMA (SMAW)
Lack of Sidewall Fusion Cap Undercut I t Intermittent itt t

Cap Undercut Intermittent

? ?
Incomplete Filled Groove

?
Excess Cap Height

?
Incomplete Filled Groove

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Plate Sample 6E Root


Welding Process MMA (SMAW)

? Lack of Root Fusion ?

Poor Stop/Start + Crater Pipe

Lack of Root Fusion Root Undercut

Excess Root Penetration

Excess Root Penetration Crater Pipe

?Lack of Root
fusion

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World Centre for Materials Joining Technology

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

World Centre for Materials Joining Technology

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

?
Lack of Root Fusion

?
Arc Strikes

?
Arc Strikes

Note: Arc strikes require blending and crack detection


Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

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

World Centre for Materials Joining Technology

Plate Sample 6G Root


Welding Process MMA (SMAW)

? Plate corrosion
Lack of Root Fusion

?
Poor Stop/Start

Parent material gas cavities

? ?
Surface slag

Crater pipe

?
Surface Slag

?
Li Linear Misalignment Mi li t

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

World Centre for Materials Joining Technology

Plate Sample 6H Cap


Welding Process MMA (SMAW)
Incomplete Filled Groove Arc Strikes Arc Strikes Slag Inclusion

Arc Strikes

?
Arc Strikes

?
Cap Undercut Intermittent

?
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

World Centre for Materials Joining Technology

Plate Sample 6H Root


Welding Process MMA (SMAW)
Crater pipe Excessive root penetration Linear misalignment + lack of root fusion

?
Arc strikes

Arc strikes

?
Poor stop/start p Lack of root fusion

?
Lack of root fusion

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

World Centre for Materials Joining Technology

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

World Centre for Materials Joining Technology

Plate Sample 6I Root


Welding Process MMA (SMAW)
Lack of root penetration Burn through Arc strike Poor stop/start

? ?
Linear misalignment

? ?
Lack of root fusion

Lack of root penetration Mechanical damage

?
Lack of root fusion + poor stop/start

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

World Centre for Materials Joining Technology

Plate Sample 6J Cap


Welding Process MMA (SMAW)

Suspect crater cracking Cap undercut Arc strikes

Porosity Cap undercut

? Cap undercut

?
Cap undercut intermittent

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

World Centre for Materials Joining Technology

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

World Centre for Materials Joining Technology

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 Centre for Materials Joining Technology cap World height 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

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Plate Sample H8 Cap


Welding Process MMA (SMAW)
Arc strikes Mechanical damage Cap undercut intermittent Surface slag

?
Mechanical g damage

Cap p undercut intermittent

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

World Centre for Materials Joining Technology

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

? ?
Spatter

? ?
Root undercut intermittent

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

World Centre for Materials Joining Technology

Any Questions

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology