J pun cngincering fibrctio nas ast vty the sexens ok aT sua out o dispatch, This aeiity canna Denti hme tbc of Aa sma oft ing ts product afl asus No + ic i atentiated by etn cmmpstnt person eer ie ah mer se hat ome mating = ps se ar ‘pcordonee th apis stadia ad und egineeing practCs, insiphyh Tomer ee ining te duets sul make eur wich san een he BAA NEL wile product was Being manufactured. Questions can be sfallowed at was the rept rate during production? 1D fetner any concessions or weaver were given, yes wy” 3) Hom were the weather conditions? 3 Herne tnere were any safety sus, Cites, major acide / ides ie? 3} Whether thre were any labour problems? ctments 5 mini, arrose an ia rvewing of coments dhe shuld make that ata lo sy quay cont plan ensue al tages ae complet an signed of 2 3 ggpcton check lites al tages ae complet and signed off 3 Very materia ctiiates sue asl test cetieas le 2 Ye et oingprocedares which are tobe atiched have all Ben pene Eee epae ) NDT) PWHT e) Hardness) PMI) Ho test 8) Coating sy vce te itn levels and vad ofthe welders and NOT pusomne] 2 Yet ton epors of sing diggs and csr at hey cover all apron and susie ay oY Visual B)NDT c) Dimensional conte 7) oe cdl cette equipments an sume su as presse gE WS nachinas et 6) Verity hardness test repos 5) Verify PMI copons LO) Verify PWIIT reports 11) Werf hyo test reports 12) Verity Asbult drawings are completed 13) verify weld maps are available for traceability 1 Yeti mameplt, rubbing dts re availabe when apiable 1) Veni the concession request, site query t., 1) Verify pent to work 19} erty paintings coating inspeetion reports Nii ewm spect ery be igo wines ina ty es il speci of completed pats, As a mater of quai assurance he may ase oe jowanhs ar randor and may even conduct radiographic wid P~ Gy Lamellar Tearing aime TE curing in the pret pee: 1A oft wh por though chs ett the fusion Boondary ofthe weld Wis eS Hs ually soctd with ested ot x coc, eo et eles ins thik plate, Causes : 8) Poor through thickness dusty 3) Non-metallic inclusion nthe destion of rating ©) Restrained joint 8) Though thicknes stresses f) High sulphur content 4) Presence of hydrogen ont i 2) Modify Joint design 1b) Coniol restraint 1) Use forged products for eriial work es ged etl an iwi ute weld sl bering yer of Wh liy wel meal may Ye deposited where the vertical member ito be welded ce) ses he trough thickness doit by short terse test $)frapeet the plate for non metalic wncinsions 3 Gabyout il cheat analysis io mae sue spr ss than 0.05% 2) Solidification Cracking ( Ferritie Steel) etditcaton cracking i ot rcking chan ht asd ing slieation of wei in re Se igh sulphur content. evng Satan te plate mayb ened nd se wth ton fm on ais FSP) Th iron-ulpides ar low melting point ae tacit arcund the grain boundries, which ae snd geal Sess oe of eontactional forces. The bonding betoeen the imate ens oman oesion an nek wil eal eming toh Ne ee ofthe weld ceareline. Causes 2) igh sulphur content B) High liltion process 1) High earhon content in weld metal ) High contraction stresses Controt 1) Control the sulphur content 1) Use ow dition process 1) Usbeonsumales with high manganese ‘Keep Manganese supe ; carbon ratios loans possibie fS) Mise restraints13) Weld Decay ~ Solidification cracking in austenitic staintess steel Seliiclion ering 2 Not racking means that ves turing solidification of weld stl i austria ses} Assen stonens tec, one Lager oe compared 1 aie st] ests Turn welding lw meng pot imposes elec round Hae ara slice ee rat inthe wed gen. Tes ag grate mil aia boundaries compas etic tel, Thi ack rn bandana aaa Ene lag isis wo consent in smal ack Def ih cotracioal oss thes grain boas ae mgs sess andthe bonne Pacers sexinenay he fue lo nna cohesion aud cracks oecur in the centeine of weld along its eh 4) Lowaieing pot isp 1) ighaintion process 8). Highsonactlon stress Contr 5) Slot ow dilution proesss, modi join design 1) Lnwt the eat input hance minimising expansion contraction 2) Increase ths gran boundary by ang deta erie Mininise estrint ©) Ennie plates are very lean. 4) Liquation Cracks Ligation eracks occur in sels, which have high slp, When welding ow qbaby high sulphur suse ses it pose ta areas cgominadnenvolp ice (Pe8) i the FLAZ wl liquefy These Tow ming point iton=slyhideuszally oecumute athe gain Bowndarcs.Tthis ‘Paling occu in Ue presone of a high costational sus, en ie baundaris wl be pulled apr and tquation cracks peu. Caves 8) Hg sulphur content 1) High esti 6) High contracting stresses Contes) 5) Use quay refined steel, 1) Conta hee mt 6} Mainiserestaiat 1) Use peect 5) Reheat Cracking Reteat etckng eka known a relaxation cracking mainly occurs ip HAZ of welds particularly in low ally stl dura pos well est ‘ueatment orseree at eleva temperatncs, Met aloy of sel subject oan incase of embrilement of vie coarse grained region oF the HAZ when rea eran COD Dew Che prion is wove with hicks teks containing Ce, Cu, Mla, V, Nb andi. Seip and Phosphor al area ius: ‘Tien iets susceptible would be the 2% CeMo.¥ po. Example Creepesixng see ‘acing pst eld stress rete wid at igh operating temmeratne the reid strsses would be reeves by creep deformation whic inva wan vpoundey aida and gaia deformation, Tf dus metallurgical exnitions ese rtions cannot eect, then gras boandaces may open wp ilo rks, Coyses 2) Areas of high sce coneeatration and existing wel defeats 1) The toes of bay sped fil elds, incomplete rot penetration welds ©) High rep resistence Coca 4) Toe pringng, elimination of pati penetration welds 1} Rejetin ofr weld prvi (Hest quickly through the susceptible temperature ie. 480 ~ $80 Des. C. 1) Osc hgh preheat temper and sage Wise PWHT during welding relieving ©) Use of Weld mata with igh uti 1 fahren reduce the sk of chet erecking in he ira ros 6) Phewomenon of HC or Underbead Cracking “These type of erseks often ovine from sub-stToe factions under or ear de weld in HAZ, Thi eracking i etsed by to a ets 2) Hligh Carbon a low alloy content of see that allowed te oo! too rapidly. 1) Presonoe e7hydrogen during welding ‘bo presches of stress eonesntatons in he peighbourhood of welt can promote undesbend cracking too great extent "The phanomenon fellows ering welding sll amount of fice hydogen is generated de to decempeitio of moiaure fon st, eestode coating, shielding gs oF onfamitapos on Ge sutfge fo be welded. This hyroges can dissolve in rolien sel a from thee dfs into eareaely ot bul soffit base me ite coltg suit dow, hs evel hycgen has nigh de ezape ito ac Us diffs, Hamer ie eoling i rapi some hoger ay [einaged se HAZ, This Ryden proces a cendigon called os” Hydrogen eninsiement nthe aca of serpent whith te dsiaatons aderly 2 thebeats sl Beata ele Bc ces ft mabe seh ttt te il eed shou be Slaed 1 sol way ive fil low the grad sit vite shoot he chen kg cone fratos a hikes thieker merce] ‘on sel te FLAY ofthe wold tend a be mare ile Le thus Tower note ougbnes kan the atl mal The HAZ we 5 thorafine nse prone to eicking especialy when hyatogcn nda. although iret Be ned thal the tensile strength of Che HAZ moral igh in comparison wah the weld and pact meal. Una’ i ftir welding proses Is being used thea the HAZ cannot be elated 16) CTOD (Crack Opening Dispincement Test) TOD is atest sto fr He detention ofa metals estan tae inition ofa eck resting rom notch dees, CTOD nies the ease pati etness of dhe metal inthe dail bile tansion, The propagation af a eack a welded true depends "upon Gets inline mera used The sae and sharpness of seth press uneriing tempera, de dpe of estat a yelling. procedere requires, ‘CTOD fest penis fl she specimens tobe used inespetie of itt thickness to ich a uote of gen wi an dep fs applied ‘he specimen i subjocte Wo» gh speed estate lon! ecina an ahcee point bending ig. Alp pau Ie fxed (he muha the nora securely meastses the sos pening oF te eack and afoce sensing device enables te applic Toad to be plotted waist dsplacerent on 2 spi HAZ—eat Affected Zone? Dosing welding using a usin welding process there isa huge tempest diffrence betwen the Weld na paren matenal, Hecause of ths ltaperaturédilftence , the malta immediately adjacent fo Use weld undargoce mira seta hangs, ‘Tals are whic: es beteen he fasion boundary ad the wrlTets port mata called Ue AZ. Ths een of changes in measure wll depend othe following, 2} Material composition, especially carbon content 'b) Heat nat —The higher the heat input or are enc ibe wider AZ. Mouslurical properties wil alsa be affected 2) Therate of cooling = Higher the rate of cooling hecdes the HAZ eapecaly ithe CE. ofthese is high The TAZ ina weld zon on sect cousins ef up four separate gion, staring Iron the mes invrediately adjacent the wel 1) Coarse grained region et beter 130 Dee) and mei 2) Grain efined region 600 1 1360 Dey. C: 33) _ Region of paral iansformation (75019900 Dep, C} 42) Region ofsparoidization (jus Below 750 Deg. C) i) \& (fp sent tat an NOT radiograph team under the supervision of your inspect has aographed the same wed sear and uly chang the led NP Gets 2) What woul be your inital somse of action? 1) Trsour suspicion is proved fo Be comteet what would be your fuer eruse of tion? Conduct the ndiographie anit Matches aad if sini ooking rdingraghs ae found then they should be veifeé Job agains the wel. many such suspected ratiogrephs ace fourd then a ful audit of ll he radbogrups shout be perfoned, The outecae ofthis instigation could be of we Ws 1 Rare cas of duplication 2 Occurence of dopliestion in many eases Inthe former ease ts mst fkety a be ahammar eso, ence the mater can be esolved by aking NDT supervise swae of fats. However in he later eas ite a ineuons ction performed to help somebody's interest, whichis cbviuslyas21 back w the quality. Hence cepenaig. upon the extent of Raudhlence following pmposal ean be made 1 Ge higher authority as dssiptinary menses. 1) Waving ete 2) Cat payment order 3) ‘Termination of NDT service contact 4) Debaning the NDT contractors ‘Ameating fll inspectors. tobe conducted and they shoal be i:ued 9 rong wsering prve the evel af their etfrinee fo sold auch incidents fie. 2m) tehae come to your ation that dhe morale of your inspection tes ped oe ow wf ay Wha ould you fave observed to determine this? What sould ooear Hf his wes nat reatied quickly? ©) What eould you dato li low male? 2) Low morale can be Henttied by the flowing symone 1) High eof absenteism 2}. Shlugish expanse othe situation 3) Casual approscs tours week 4. Negligence Poor covord Keeping, mot inspecting welds eto) 3) Complaints fom client PA, by Low more may rsutin the following 1) Lack of contol aver production stiviies tee qu 2) Higher ejection rats by lien TPA. 3) Substandard work osipue, 42) Delay in work schedule 3) Lek of eredilty othe organisation iy pin of view 1 Observing all above it 1s imperative thet iting the fow mors 1: itl ting, hi be done we allows 1) Arrngs the meetng of af sour sub-oedinte aT fe fez ficussion om eset mater 2) Fuom thet responses yu ean for aealectve pia a for Fw maa 4) Fonlarw this yoo may have priate disetesion Wilh ac individ! dh can help you ta ete 8 hs poems te ple ssthen sed eas general pralen and anita pales‘erga to ger peobbars. yoo can at © Ge ca vt wll do eserthies poet \ouE caps Fa ARES + exampl ockof gd workin ppm. stay pons: se statutes ate We rgd te indnld problems Saad behest o . station ote empisges in gene haf aa that re lava pd ans ws 0st rove Neverhcless ecm ‘rounds you wily toseek companys help for fas pew probes asa. Racy this they shoul be tice thatthe elfen hgh one! ‘wil refietn eo salary rise, fier Cais emer ss morale oatiaaes he is wamgsaten wil Re obliged wars Beller motions anda worst esos termination sa 21) Inter granutar eorrasion ovcuts in unstcbsed susie stuinles sel with 60-880 Deg. C. range ofthe HAZ. At tie tempera ri bon is sorbed the renin ad coms carbide pref atthe gin boundaries an mst cooly dowar This ean feel eve. ‘hu content, whieh has te effect of omerng the evistnee ta corosive attack allowing o vests Use stabilised lant secs withthe addition of Ni oT {se Love carbon saints sidl (below 0.04942) ‘Heating ot about {109 Dog.C hore comin sbi wit be dissolved. Then steel is normaly quent fom Hs trypeenore 2 stop e-ss0ciaton. Location: Weld HAZ (Longiutial) Susceplible misrostictre: Seni gra Boundaries ‘With col this ch of intl intxmtfon oe can conte thet the fice must be catastrophe, which nasi 1iketiness mods of Flue bas tobe brits, However there would be moc tha one wade Of Failure, the inition cou in tig ode flowed by bel. Becase of his reson i's aisable to personality visit the vee of fre and ta da some visual inspection af exposed sutures ihe fallare tapers tobe of purely ri nature ent folowing wl be te symptoys 8) Rough sd erste surface 2) Chern mans having “V" shane pointing lows pot fi 3) Smocth surface having dal textore 4} Hitfroand "Crescent or Beat marks "eis alo important to note eter the biiation Of ypu isin weld HAZ in ba mal Ihe Sine hay ny ftir investiga in foRwing evens, 1D Chemieal composition a physical propane erties supplied by manufacturer 2) Heat westmen esocds and lab test eports any 3) Hardness Phase metal and thickness int pare zane Suitably of material fr given service condone ‘Gore other hind if he Tue isn weld HAZ. then ellowing sons eae traced 1) WPS usec for welding 2). Visual inspection epee weld Begs 3) Radiographic records 9) Heattotment ecerds ikon oxherwise flue in nite in igus che it wil be manifested by lo be in bare ee then one ‘Based on he outcome of above investigations the suc rason of ine ca be fued 23) You hae overand « conversation snagting that thd party inspector who i under your charge hse besa allowing reps of eae to be Inde seithout reporting them tothe Qa / QC department 2) Whi wold be yor course oF action? 1) this is ound w be oarreat ha nul be your couse of sion Sings ia gzave consequence senior woking inspoir shoud go personally t he fob sity to etal fal in anionic ‘way. Once the fet are cstablished nd itis ean proved beyond any resonable doubt, ten the preventive action shouldbe ase i oh way he till ‘fiminae arte oeamencs of auch evens ba will not make any station sour For the sake of dseiplinary measires fie, the TPIA sald be suhanoned fora private dscusion and maybe questioned about his ation and tsi imperative Gat Weel be made aware of the fast fal ou ave awa {is omision. uber otis meeting ofall i inspectors should be concucked ad they should be made alert ag sch instances, azo ey shoul be insted fo rept such oecurrence if fous nen to QAVQC depusimant. fn ordee 0 rank higher management arn ofthe omissions of hid pty Inspector, strona llr may be deaied end cette (or hee iferaom ad ation 24) In service failure of a weld at 40 Deg.C Service temperature of ie oder of 40Dep.C tls athe Flue mort probably bes ogcured du 10 Itk of strength er toughnsss. athe ‘sempre, Compared to base nical, a weld is aways of iregular shape ad henoe is considered a regularity oF dsoowmuyi surface jes AN iscontnuly serves asa stress riser when itcomes eros lines of Rretes Te strength of material / meal dcops ate locations a igh ses8 concenizetion escvaly when temperate drops sighificuiy. 1 Blt tl ted 1 lose its “notch fOuahaes", ence oar apa of iwestipatien shuld be oth toughness of given weld at Tow temperature This ean B: approached in elowing Wa>s, 1) eritying tha WPS hes recommsrde proper eonsurm-bles tobe used 46 al the essential variables vere adore to 2) Verify han esniet vecords (any) 3) Review and sertnize lab test eports including tha of charpy atch ests for alt well specimens 4) Revi batch ceticnes for consumables used $8) Location of failure shouldbe inspected aad peat of station: sul be etaished fF the location of failure ntaton happens 1 be wits. any defet siz, undoret or kot then fas ea be abe ta ae Ls of fo temperature strength and consumable giving hier low teneperare strength may be recoumcnded wad uatprsesneck weld pros ‘nay als be avin. even the poi of inlatos epee to bee dest suchas porosity oF ay subsueicedefet ten eure adograpl for that seston of weld may be cose ena and ipetod hee eases mocestremgent acceptance chon ines be ‘contended imauion to recommiendaens mento: 236.63 Soe of atti 3) Lengrodinal sirmhage ib) Transverse shrihage ©) Aguiar disgrtion 8 Bowing ‘Bactrs hie alec startin ; 2} Matera properties mn endiion b) Hes input 2) Lek of restraint ‘Method of reducing distortion 2) Prsseating 'a)Fovoed cestaint 2) Usingabaiaacing, welding techniquees. Back sip welding back step welding 8) Using aiffret joing design to reduce he amount of weld deposited 2) Redocing the hea input istortion & ‘The action of the residual stresses in welded joints is lo cause distortinn. Consider a simple weld with a single “vec” preparation, ‘es filo movement one acted 21 Contacto inthe wid nnd HAZ along we ent 3) Bowing de tote ger vole of metal ie op of he wel Peskin the"ye" aogle 4) Rppletinahe) si rom he weld ©) Canton nthe ned metal and A rns oe wel ‘Contra af distortion i achieved in one ot mir’ ofthe lowing thee ways: 2) Prssttng—So tat the metal distorts to the vegited postion 1) Clamping To prevent sstoion, bu this increases the level oF residual sieses ©) Welding sequence i, balaneed| 13) Mechanical Testing 2) Transverse tensile fest: To measure the wansverse teste strength under state iting) A reduced specimen access the cil strengih ofthe int 2). ral eedused spesien assesses the tensile srensth of te eld wea 'b} Cracforn tre: To measure te relative ent strength of joins wh fe elds unde static toading. NB: Load wnough wees ©) All wold ease stength To messere the tensile stength ofl) Electrodes of ier wie / Tex combinations 2) Quality of Wie weld meal ws deposited. STRA. Shon Tranaverse Reduction Ateas to access lnmelareaing ©) Bend tts (Transverse and longitu) ~ To determine the 1) Soundaess ofthe weld metal 2} Weld jntions 3) Heat acted zone. ‘Note: All specimens tobe removed and prepared witht causing signitian distortion or heating (@) Side bend test "To determine the soundness ofa jin in cas section 1) Charpy "V" nate to determine he energy sorbed at a specitied compere to acre the specimen, 2) Nick est: To fracture te joint throagh ce weld meta to permit examuaton ofthe ractoe sures fi) Fille weld facture test :To facture the join tugh the weld meal o pert examination of the fracture surfaces. Note: Sam natch i compression {Macro expmination: To exantne te whole joint for soundness 14) Lamination an Laps Basi difference between laination and tp is hat mination is su-uricedsaatinuly and apis susfoce dsseatinuty Lamination: {nthe te! mils aon stel i poured inte moulds to form ingots. While te solidification i faking ple hogs amouits of gases may rewain trapped inside te sofdfed sce. This ingot wen rolled the was pockeis inside ges Nand in the form of lamination. This decetinity adversely Tees ueoaps thickness strength ofthe tel and sno raseuble by MPL oe RT. The ory Way to Ute lowinaton is By LT. This discon nay esc ontibute to ane leering fu thik secon Lays: Laps ae basicaly chunks of rea tha has ls foo the sie providing operations suck as ht forming. This chunk of eae is ‘sect fo ts base racial some fection and overhanging portion oft atk simply His on the mca with being he homoganeous Fa oF i As itis ‘rice defet i van be Found viusly and cen be confined by MPL ‘Transition joi could be of wo categories 2) Different base meas 1B) Ditixen hicks Assuming tol he test ott in his ciscesion complied with both of the above two categories. Following care shoud be taken during, ‘veling Different hase meta) 1 Proper sslection of ekctoeto avoid ation ofthe weld metal 2} Proper seletion ofcarent range and polarity ype of curem 3) Bock pgm reuired 3 any 4) Cieanlness 5} Prodveat Pw Welding processbeara MS, Als el 3 7) Underbead Cracking in Quenched / Tempered Stee}, QF Toises ae nacelly Fl fy io igh war oquivalent Such sols ubesen ing ames ‘is cao dawn rpily rede frie werstreture an HAZ, Itch ele sanees ith hy ogo ele veyed se puocess sod Saped ile omicresteiore stilted above in phenomenon of Ungerer’ wrantgs! urs ease Undead each i Quench ad Temper ss Prevention: 9) Giving sffeoet new npn by teane oF pre-beaing 8) Reduce rt of cooling and azguote PWET ©) Use ul tow hydrogen processes for welding, )Pecrming welding a sts foe exons 8) Underbead eracking in HSLA steels Unlike in Q/T tees ISLA steels are vite iw mature The prupenies ofthese secs ae aeien ed ty seal moans ofallaying elemans Aissoled ia thee fone suctre For this vey ress ty ae sof abo. delle as compared fo CFT ses. Sucks sabsuypent to eltmg Hf eoned on apy. ay undergo changs of riiostrctare fom fete to macenste nately in HAZ. Onse maven is formed i ished ond Wile a sich drcamstances any Hydrogen pick takes pace may very well ead wo phenome of TIC. ot Underbené Cracking Eeevention 1) Ensue Mat base metas hare snugh doc . ‘b) Esse shat Base metas ave suticintiy los: $5 of Carbon, manganese and eter alloying element which use appresiabhe ancunt of mates: {eration : Reducing the ate of coating af weldment ©) Pesforming the welding in srs: ze conditions 2} Use ey hydeonen processes 9) Fracture Mechanism Fructus ean be divided ina thas asic ps8 a) Fatigue ») Ductile 9 Brie 4 farpue facture isthe outcome of eel leading and unloading which indus tuigue in the meta. Fonwing appsorenes of exposed sfaces manifests these kinds of facts 8) Sure is smooth b)Wiseneompessed by crescent marks oF besth mati ‘A docile faeure isan oxteome of plastic deformation of mee 8) Surfs isfom and rough 2) Shearhpsat 45 Deg. C. applied sess A brite rate i res of compasiton of hae, rile waist ane an impulsive stappy lad, I 8 a) Beg costalline bat cagh surtace. 0)"V" shaped eheszons onthe surface, poins twas the port nation, Ou of above types fine satay the fist meds offre, [flues fn Second mode, dette brit, then ese ares will rays be Tolling atigue und not vice-versa, Other there coud be purely dtl ox purely brite furs also which ae maf by the sppeariness m2 ‘mentioned abo, 10) Residual Stresses ‘Mola contrat during soliton and subsequent eo ag, Buti conredon is prevented or inhibited teidual tess wil velop ‘Most nl prodacts contain residual stresses, ten up tothe yelé unt, Pipe products for exarnple a ustaly very hight stressed. Th ender to ‘evelop rest streses increases when te Keating and eoling we lnafeed. So welding nth very locliod eating wl the presence of slid malin contac ean be expected to induce vee high levels of cidual esses. Resi streates con be dificult meus with are accuracy ‘buts rough pute echo wher the weld metal exsseds 2 tet (14 ra" ths te oa esidual ses isabel Yield pon in magnitude, Norms! wekis develop resid sess: ) Along he weld Longitutivel resi esses Across the weld = Transverse residalsresses ©) Through the wold» Shor: transverse esl stresses At} Distortion Disetion is cased by stess stron een nee to teeing ad spe of & compensa, which els fm weld Ths change i shape ‘abe tenporary (esto) oe peace (psi) I te pies of metvas op, Pst which are te be joined ares to move dring welling dst ilk ‘sev fhe two paves of material are no i no res (esac he free wl ronan ss seid toss.