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INSTITUT KEMAHIRAN MARA

BES
ERI PERLIS

DIPLOMA COMPETENCE IN WELDING

ASSINGMENT 1

SEMESTER 1 / JAN – JUN 2024

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WELDING DOCUMENT PREPERATION

PREPARE WELDING DOCUMENT, REPORT AND CHECK THE

COMPLETION OF WELDING DOCUMENTATION AND

REQUIREMENTS

LECTURER NAME : ADISHARMAN BIN RAHMAT

STUDENT NAME : MUHAMAD AQIL WAFIY BIN IMRAN

NO MATRIKS : 333501224072

NO IC : 020128-10-1379

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PENGAKUAN PELAJAR

Dengan ini saya akui bahawa tugasan ini adalah hasil kerja saya sendiri dan
dibuat berdasarkan undang-undang yang termaktub dibawah peraturan Institut
Kemahiran MARA Beseri, Perlis. Ia adalah asli daripada saya. Projek ini belum
dihasilkan oleh mana-mana pihak atau institut untuk mana-mana Diploma atau
sebarang kelayakan.

Saya dengan ini berjanji sekiranya projek yang dilaksanakan oleh saya melangar
mana-mana syarat yang tertera diatas, segala hasil kerja saya akan digagalkan
dan oleh sebab tidak melengkapkan Diploma saya bersetuju untuk dikenakan
tindakan undang-undang dibawah peraturan Institut Kemahiran MARA Beseri,
Perlis.

Nama Pelajar : MUHAMAD AQIL WAFIY BIN IMRAN

Kad Pengenalan : 051109-10-2079

Kursus : DIPLOMA KOMPETENSI KIMPALAN (1.5 TAHUN)

Institut : INSTITUT KEMAHIRAN MARA BESERI, PERLIS.

Tajuk Projek : PREPARE WELDING DOCUMENTS,REPORT,RECORD AND

CHECK THE COMPLETION OF WELDING
DOCUMENTATION
AND QUALITY REQUIREMENT.

Tandatangan :

Tarikh : 06/02/2024

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CONTENT

NO. PERKARA PAGE

1. PENGAKUAN PELAJAR i

2. PENGAKUAN PENGAJAR ii

3. ABSTRACT iii
4. OBJECTIVE iv

5. QUALITY MANUAL 1

6. WELDING PROCEDURE SPECIFICATION (WPS) 2

7. FIT-UP REPORT 4

8. VISUAL INSPECTION REPORT (VI) 5

9. WELD MAP 8

10. POSITIVE MATERIAL IDENTIFICATION REPORT (PMI) 10

11. PWHT CHART 12

12. HARDNESS TEST REPORT 14

13. NDT REQUEST FORM 17

14. MILL CERTIFICATE 19

15. CONCLUSION 21

16. REFERENCE 22

17. APEENDIX 23

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ABSTRACT

in this assignment I have learned and understood the important things in presenting
welding work. I gained knowledge from quality manual, welding procedure
specification (WPS), fit up report, visual inspection report (VI), welding map, positive
material identification (PMI), PWHT chart, hardness test report, NDT request form

and mill certificate. all these things are easy when I combine with all the general

knowledge I have learned and I studied. with this I feel very happy when I can learn
new knowledge from what the lecturer taught me I also like to learn many things and
it helps me improve the quality of welding work. Paperwork is a form of work that is
important in a project that carried out. It also organizes every task that occurs in the
project such as the welding procedure specification that tell the workers to use the
welding process and so on.

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OBJECTIVE

WELDING SPECIFICATION : Clearly defined requirements for the welding process,

including materials to be used, joint designs, and welding positions.

WELDING PROCEDUR SPECIFICATION : A formal document outlining the welding

parameters such as welding method, current, voltage, travel speed, preheat
temperature, and interpass temperature. The WPS serves as a guide for welders to
follow during fabrication.

QUALITY STANDARDS : Criteria for acceptable weld quality, including visual

inspection, non-destructive testing, and other quality control measures.

SAFETY GUIDELINES : Safety protocols and measures to be followed during the

welding process to prevent accidents and protect personel.

DOCUMENTATION : Detailed records of each welding procedure, including date,

time, welder's identity, and any deviations from the established procedure.

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WELDING PROCEDURE SPECIFICATION (WPS)

A Welding Procedure Specification, or WPS, is a formal written document describing

standard welding procedures.
Like a recipe for welders, these procedures provide clear direction for your welders
to make quality products that are up to code and industry standards. They will
include any details and information that are required to make a desired weld.
These are proven and tested procedures that include but are not limited to,
information such as the materials needed, the tools required, the processes to follow,
the techniques to employ and finally confirmation of the desired outcome.
A WPS can go beyond just a great weld. Although a WPS will ensure the welded
component meets design requirements, a WPS can also help you make hiring
decisions.
You can employ welders and welding operators whose skills are in line with the WPS
and a WPS can also help you complete a fast inspection with quick testing times.
Since your employees will follow strict safety standards, you can also reduce the risk
of company liability.

Welding Procedure Specification (WPS) is a vital document in welding operations

that outlines the specific welding procedures to be followed for a particular welding
job. The WPS serves as a guide for welders, supervisors, inspectors, and quality
control personnel in ensuring that welding is performed consistently and to the
required standard.

Welding procedures involve many variables such as welding position, base metal
thickness, filler metal, welding parameters, preheating, and post-weld heat
treatment, among others. The WPS documents all these variables to ensure that
welding is carried out in a standardized manner. It also specifies the acceptance
criteria for the welds, which is usually determined by applicable codes and
standards.

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NON-DESTRUCTIVE TESTING (NDT)

NDT stands for Non-Destructive Testing. It refers to an array of inspection methods

that allow inspectors to evaluate and collect data about a material, system, or
component without permanently altering it.

In the field, NDT is often used as an umbrella term to refer to non-destructive

inspection methods, inspection tools, or even the entire field of non-destructive
inspections.

THE IMPORTANCE OF NDT:

When it comes to ensuring that assets are properly maintained, the importance of
non-destructive testing cannot be over emphasized.

"NDT is the life blood of a well-run facility, and the high importance of NDT is known
by any trained inspector. NDT techniques and repeatable results depend on highly
trained technicians with experience and integrity. Not only does the technician need
to be certified in a specific NDT method, but they also need to know how to operate
the equipment being used to gather data. Understanding equipment capailities and
limitations is the difference between making an accept or reject determination."

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Figure 1 MAGNETIC PARTICAL INSPECTION

 The figure above shows the method is used for the detection of surface and near-
surface flaws in ferromagnetic materials and is primarily used for crack detection.
The specimen is magnetised either locally or overall, and if the material is sound
the magnetic flux is predominantly inside the material.

Figure 2 PENETRANT SPRAY TEST

 The figure above shows a simple low-cost method of detecting surface-breaking

flaws such as cracks, laps, porosity, etc. To be detected, the flaw must reach the
surface to be tested.

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Figure 3 ULTRASONIC TEST

 The figure above shows a Ultrasonic non destructive testing, also known as
ultrasonic NDT or simply UT, is a method of characterizing the thickness or
internal structure of a test piece through the use of high frequency sound waves.
The frequencies, or pitch, used for ultrasonic testing are many times higher than
the limit of human hearing, most commonly in the range from 500 KHz to 20
MHz.

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POST WELD HEAT TREATMENT (PWHT)

Figure 4
 The figure above show work piece is heated slowly, kept at temperature and also
cooled slowly again. Among other things, this reduces the stresses in the material
that occur after welding. By reducing the stresses, you prevent cracks or
fractures from forming as soon as the work piece is to be worked on

Post weld heat treatment (PWHT) is a controlled process in which a material that has
been welded is reheated to a temperature below its lower critical transformation
temperature, and then it is held at that temperature for a specified amount of time. It
is often referred to as being any heat treatment performed after welding; however,
within the oil, gas, petrochemical and nuclear industries, it has a specific meaning.
Industry codes, such as the ASME Pressure Vessel and Piping Codes, often require
mandatory performance of PWHT on certain materials to ensure a safe design with
optimal mechanical and metallurgical properties.

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Figure 5
 Figure above show temperature showing temperature and time graft on hot and
cold pipes in degrees Celsius. The graft show heat ratio start 50 celcius/hour and
cold ratio start 37 celcius/hour.

The need for PWHT is mostly due to the residual stresses and micro-structural
changes that occur after welding has been completed. During the welding
process, a high temperature gradient is experienced between the weld metal and
the parent material. As the weld cools, residual stress is formed. For thicker
materials, these stresses can reach an unacceptable level and exceed design
stresses.

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FIT UP REPORT

Figure 6
 Figure above shows an example someone is inspecting the pipe incase there are
mistake on the pipe.

A fit-up report in welding is a document that provides information about the fit-up or
alignment of the components to be welded before the actual welding process takes
place. This report is typically prepared by the welding inspector or a qualified
personnel responsible for ensuring the quality of the welding work. The fit-up report
includes details about the alignment, dimensions, and overall condition of the joint or
weldment.

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QUALITY MANUAL

A quality manual in welding is a document that outlines the quality management

system (QMS) for welding processes within an organization. The purpose of the
quality manual is to establish and communicate the company's commitment to
producing high-quality welded products and services. It serves as a reference
document for employees, customers, and other stakeholders, providing a framework
for understanding how the organization manages and ensures the quality of its
welding activities.

 Welding Procedures: Detailed documentation of the welding procedures

employed by the organization, ensuring that welding processes are performed
consistently and in accordance with applicable standards.

 Quality Objectives: Specific and measurable objectives related to welding quality,

which help the organization continuously improve its processes and meet
customer requirements.

 Document Control: Procedures for creating, reviewing, approving, and updating

documents related to welding processes to ensure that the latest and most
accurate information is used.

1. AWS- American Welding Society

2. ASME-American Society of Mechanical Engineering
3. API-American Petroleum Institute
4. ISO-International Standards organization
5. NBBI-National Board of Boiler and Pressure Vessel Inspectors
6. NAVSEA-Naval Sea Systems Comand
7. Customer and project requirements

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HARDNESS TEST REPORT

ROCKWELL HARDNESS TEST

Figure 7

 Figure above shows a Rockwell hardness test general method for measuring the
bulk hardness of metallic and polymer materials. Although hardness testing does
not give a direct measurement of any performance properties, hardness of a
material correlates directly with its strength, wear resistance, and other
properties.

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HARDNESS TEST BRINELL

Figure 8

 Figure above shows the resistance to indentation, and it is determined by

measuring the permanent depth of the indentation. More simply put, when using
a fixed force (load) and a given indenter, the smaller the indentation, the harder

the material.

HARDNESS TEST VICKERS

Figure 9

 Figure above show a common method used to measure the hardness of a

material, including metals. In the context of welding, the Vickers hardness test
can be employed to assess the hardness of welded joints or heat-affected zones.

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OBJECTIVE

The hardness test is a mechanical test for material properties which are used in
engineering design, analysis of structures, and materials development. The principal
purpose of the hardness test is to determine the suitability of a material for a given
application, or the particular treatment to which the material has been subjected. The
ease with which the hardness test can be made has made it the most common
method of inspection for metals and alloys.

THEORY

Current practice divides hardness testing into two categories: macrohardness and
microhardness. Macrohardness refers to testing with applied loads on the indenter of
more than 1 kg and covers, for example, the testing of tools, dies, and sheet material
in the heavier gages. In microhardness testing, applied loads are 1 kg and below,
and material being tested is very thin (down to 0.0125 mm, or 0.0005 in.).
Applications include extremely small parts, thin superficially hardened parts, plated
surfaces, and individual constituents of materials.

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VISUAL INSPECTION REPORT(VI)

Figure 10

 Figure above show a Visual inspection is a common method of quality

control, data acquisition, and data analysis. Visual Inspection, used in
maintenance of facilities, mean inspection of equipment and structures using
either or all of raw human senses such as vision, hearing, touch and smell and/or
any non-specialized inspection equipment. Inspections requiring Ultrasonic, X-
Ray equipment, Infra-red, etc. are not typically regarded as visual inspection as
these Inspection methodologies require specialized equipment, training and
certification.

Visual inspection is a non-destructive testing technique that helps identify issues with
assets or manufactured goods. While modern inspection techniques like vibration
analysis continue to evolve, visual inspection remains one of the most cost-
effective quality control methods of condition-based maintenance.

Visual inspection can cause reduced uptime. The traditional way of inspecting
machines requires turning them off, which can impact production efficiency. It’s a
reactive maintenance technique. These days, maintenance professionals rely
on preventive maintenance techniques.

That said, VI is far from obsolete. Plus, technological improvements make visual
inspections easier. For example, maintenance professionals can now use remote
cameras, drones, and AI systems to inspect areas of equipment that are hard to
reach or housed in locations with hazardous materials.

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SLAG/SILICIA INCLUSION

Figure 11

Figure above show a slag inclusions are the nonmetallic particles (slag) that are
trapped in the weld or between layers. They are easy to detect (see below) since
they are needle-shaped or spherical. Sometimes they penetrate the entire thickness
of the weld.

Slag and silica inclusions in welding refer to undesired discontinuities or defects that
can occur in a welded joint. Here's a breakdown:

1. Slag Inclusions:
 Definition: Slag is a byproduct formed during the welding process when flux, used
to protect the weld pool from atmospheric contamination, becomes molten. If the
slag is not effectively removed from the weld metal, it can be trapped within the
weld, resulting in slag inclusions.
 Appearance: Slag inclusions often appear as elongated or irregular dark lines
within the weld metal.
2. Silica Inclusions:
 Definition: Silica is a component of many welding fluxes, and silica
inclusions occur when particles of silica are trapped in the weld metal
during the welding process.
 Appearance: Silica inclusions may appear as small, shiny, or glass-like
particles within the weld metal.

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POROSITY OR GAS CAVITIES

Figure 12

 Figure above show the formation of rounded air pockets or voids on the surface
or within the casting. It is one of the most prevalent types of die-casting defects.
Porosity analysis has shown that a combination of both gas porosity and
shrinkage porosity forms together in a casting.

Porosity or gas cavities in welding refer to the presence of trapped gas pockets
within the weld metal. This can be a welding defect that negatively impacts the
quality and integrity of the welded joint. Here's more detail:

Porosity:
 Definition: Porosity is the term used to describe the presence of small cavities
or voids in the weld metal, which are filled with gas, typically hydrogen,
nitrogen, or a combination of gases.
 Causes: Porosity can result from various factors, including inadequate
shielding gas coverage, contamination of the base metal or filler material,
improper welding parameters, or the presence of moisture in the welding
environment.
 Appearance: Porosity appears as small, round or elongated cavities within the
weld metal. These cavities can be evenly distributed or clustered in specific
areas.
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LACK OF FUSION

Figure 13

 Figure above shows incompletely fused spots, called lack of fusion, persist. A
weld can lack union with the parent metal or with a previous weld bead. An
adhesion joint forms, which can be rather strong in certain cases. It is much like a
brazed joint or joint formed in metallisation.

Lack of fusion in welding refers to a welding defect where the molten weld metal fails
to fuse adequately with the base metal or previously deposited weld metal. This
incomplete fusion can lead to a weak and unreliable joint. Key points about lack of
fusion include:

1. Definition:
 Lack of fusion occurs when there is insufficient melting and bonding
between the deposited weld metal and the adjacent base metal or previously
laid weld passes.
2. Causes:
 Lack of fusion can result from factors such as inadequate heat input,
improper welding technique, fast travel speeds, incorrect electrode angles, or
poor joint preparation. It can also be influenced by the welding process used.

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MILL CERTIFICATE

A mill certificate is a quality assurance document used in the metals industry to

quantify the chemical and physical properties of a material. It states that a product
made of metal (titanium, steel, aluminum, brass, or other alloys) complies with the
specifications of the order. It provides test results to assure compliance with the
specified standards. The standards for biomaterials are specified by international
organizations including ASTM and ISO and may be referred to by national standards
bodies such as ANSI for trade and regulatory purposes. Typically, mill certificates
are formatted to conform with the EN 10204 standards as well.¹ Some of the other
names for mill certificates include :
 material test report (MTR)
 mill test report

 certified material test report

 mill test certificate (MTC)

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WELD MAP

Figure 14

 Figure above show an extension of a technical drawing that outlines the number
of welds, the types of weld joints, and their locations on a fabrication. The weld
mapping process also documents important information associated with the
project in the form of a weld log.

A weld map is an extension of a technical drawing that outlines the number of welds,
the types of weld joints, and their locations on a fabrication. The weld mapping
process also documents important information associated with the project in the form
of a weld log. This documentation is similar to a spread sheet and accompanies the
weld map to show who worked on the piece, what was done, and in what sequence,
along with other information.

A weld map drawing indicates more than just the number and location of welds. For
a welder to perform a repeatable process from one project to another requires
extensive documentation of the following data:

 Weld number/locations
 Type of joints (butt, bevel, corner, lap, tee, etc.)

 Size and thickness

 Welding procedure (GMAW/MIG vs. GTAW/TIG vs. CAW, etc.)

 Materials and filler materials

 Fit and fit checks

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 Welder name

POSITIVE MATERIAL IDENTIFICATION

Figure 15

 Figure above show Portable X-ray fluorescence (XRF) is a method of positive

material identification (PMI) which is a non destructive semi-quantitative method
that determines the chemical composition of a material. History shows numerous
industrial incidents have occurred as a result of inadvertent substitution of
materials in piping systems, fittings, flanges, gaskets, bolting materials and other
components.

Figure 16
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 Figure above Highlights on Positive Material Identification (PMI) Positive Material

Identification (PMI) is a fast and non-destructive testing (NDT) method for
verifying the chemical composition of metals and alloys. PMI can be used to
verify that supplied materials conform to the proper standards and
specifications.Positive Material Identification (PMI) is one of the non-destructive
testing (NDT) methods used to verify the material supplied is in compliance to the
standards and specifications code. Most of our PMI customers are involved in
Petrochemical, Oil & Gas Industries, Automotive and Power Generation. PMI is
particularly used for high-quality metals like stainless steel and high alloy metals.

Positive Material Identification (PMI) is a crucial aspect of quality control in

welding and other industrial processes. PMI involves the identification and
verification of the material composition of a metal or alloy to ensure that it meets
the required specifications. In the context of welding, PMI is often performed to
confirm that the materials used in the weld joint are consistent with the specified
material requirements.

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CONCLUSION

In conclusion I was learned about welding procedure specification (WPS), quality

manual, fit-up report, visual inspection report (VI), weld map, positive material
identification report (PMI), PWHT chart, hardness test report, NDT request form
and mill certificate. In the context of welding, a "conclusion" typically refers to the
final part of a written document or report summarizing key findings, results, or
insights related to a specific welding project, procedure, or research study. The
conclusion is an essential component as it provides a concise summary of the
important aspects discussed in the document and often offers recommendations
or implications for future work. Summary of finding is a brief recapitulation of the
main results and findings obtained through the welding process, experimentation,
or analysis. Implications is a significance of the results, this could include how the
findings contribute to industry practices, safety improvements, or technological
advancements in welding. Recommendation is a suggestion for improvements,
modifications, or changes based on the observed outcomes. This could involve
adjustments to welding procedures, materials, or equipment. Lesson learned is a
Reflection on any challenges faced during the welding project and the lessons
learned from those experiences. This section may provide insights for future
projects or research endeavours. Closing statements is a final thought or
concluding remark that reinforces the overall message of the document and
summarizes the importance of the work conducted.

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REFERENCE

INTERNET :

1. https://www.twi-global.com/technical-knowledge/faqs/ultrasonic-testing
2. https://www.ndeed.org/NDETechniques/Ultrasonics/Introduction/
description.xhtml

3. https://www.azom.com/article.aspx?ArticleID=21939

4. https://aimcontrolgroup.com/en/fit-up-inspection.html

5. https://www.iso9001help.co.uk/quality-manual.html

6. https://www.studocu.com/my/document/universiti-sains-malaysia/makmal-
sifat-sifat-bahan/lab-report-hardness-properties-of-materials/15751660

7. https://www.iiests.ac.in/assets/images/news/Merged_compressed.pdf

8. https://www.flyability.com/visual-inspection
9. https://www.hqts.com/material-test-certificate/

10. https://www.weldtrace.com/blogs/post/weld-mapping

11. https://www.nusatek.com/on-site-material-inspection/positive-material-
identification-pmi.html

BOOK :

Book Title : Fundam Welding entals

Published By : Goodheart-Willcox
Edited By : William A. Bowditch, Kevin E. Bowditch . Mark A. Bowditch
Book Title : How To Weld
Published By : Motorbooks
Edited By : Todd Bridigum
Book Title : Welding: Principles and Applications
Published By : Thomson/Delmar Learning

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Edited By : Larry F. Jeffus

APENDIX

VISUAL WELD EQUIPMENT :

Figure 17 : Fillet Weld Gage

 Figure above show a fillet weld gauge is a tool used in welding to measure and
inspect the size and dimensions of fillet welds. Fillet welds are commonly used in
various welding applications, joining two pieces of material at an angle, typically
forming a triangular cross-section.

1. The flatness of the weld

2. Convexity (how the weld is welded outward)
3. Concavity (how the weld is rounded inward)

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Figure 18
 Figure above shows a different between In the convex weld it is in effect the
same, i.e. the distance along the line through the root normal to the line joining
the toes. In the concave weld it is the distance from the root to the tangent to the
weld face at the centre of the face.

In the context of welding, an "appendix" typically refers to a section or supplementary

material within a welding code, standard, or specification. Welding codes and
standards are documents that provide guidelines, requirements, and procedures for
various aspects of welding to ensure the quality and safety of welded structures.

The appendix in a welding code may contain additional information, examples, or

supplementary details that support the main content of the document. This additional
information can include:

 Welding Procedure Qualification

 Welding Procudere Specification

 Non-Destructive Testing (NDT) Procedure

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 Welding Symbols and Terminology

 Additional Technical Information

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