2-CSWIP Practical Plate Examples

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CSWIP 3.1 Welding Inspection

g

p

Practical Plate Inspection

TWI Training & Examination

Services

Course Reference WIS 5 Course Reference WIS 5

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Page 1 of 3 EXAMPLE PLATE REPORT

Name: [Block capitals] Mr. I C Plenty Signature: I C Plenty Test piece ident: 001 Code/Specification used: TWI 09 09 03 Welding process: MMA/SMAW Joint type: Single V Butt Code/Specification used: TWI 09-09-03 Welding process: MMA/SMAW Joint type: Single V Butt Welding position: Flat /PA Length & thickness of plate: 300mm x 10 mm Date 22/08/2003

M Lack of sidewall C M E A S U R WELD FACE B A Undercut smooth 1.5 max 236 Gas pore 1.5 Ø 230 ac o s de a fusion 87 30 22 E F R O 153 51 30 40 8 M T H I S 241 Centreline crack Slag inclusion Cap height : 4mm Arc Strike S D A T NOTES:

NOTES: Cap height : 4mm.

Weld width: 12-14mm Toe blend: Poor Misalignment: 2mm Angular Distortion 3mm in 50mm U M E D NOTES: NOTES: Angular Distortion 3mm in 50mm G E

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Page 2 of 3

EXAMPLE PLATE REPORT

M Root concavity C M E A S U R WELD ROOT B A Lack of root Fusion 247 Root concavity 2 deep 23 20 10 E F R O 128 ₅₀ M T H I S Incomplete root penetration Penetration height : 4mm S D A T NOTES:

NOTES: Penetration height : 4mm. Linear Misalignment: 2mm

Angular Distortion: 3mm in 50mm Any scale on plate surface

U M E D NOTES: NOTES: G E

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EXAMPLE WELD INSPECTION REPORT/SENTENCE SHEET

I C Plenty 001

SPECIMEN NUMBER PRINT FULL NAME

001 SPECIMEN NUMBER

EXTERNAL DEFECTS

EXTERNAL DEFECTS Defects NotedDefects Noted Code or Specification ReferenceCode or Specification Reference Defect Type

Defect Type Pipe/Plate Pipe/Plate Section Section 1 1 Accumulative Accumulative Total Total 2 2 Maximum Maximum Allowance Allowance 3 3 Section/ Section/ Table N Table Noo 4 4 Accept/Reject Accept/Reject 5 5 Excess weld metal height

Excess weld metal height 1515 Excess weld metal appearance

Excess weld metal appearance AA--CC Poor blendPoor blend SmoothSmooth 88 RejectReject A-C 4mm 2mm Reject pp

pp jj

Incomplete filling

Incomplete filling AA--CC 22mm22mm NoneNone 55 RejectReject Inadequate weld width (PIPE)

Inadequate weld width (PIPE) AA--CC N/AN/A ------ ------ AcceptAccept Slag Inclusions

Slag Inclusions AA--CC 70mm long70mm long 50mm50mm 99 RejectReject Undercut

Undercut AA--CC 1 5mm depth1 5mm depth 1mm1mm 66 RejectReject Undercut

Undercut AA--CC 1.5mm depth1.5mm depth 1mm1mm 66 RejectReject Surface Porosity

Surface Porosity AA--CC 1.5mm 1.5mm  1mm1mm 22 RejectReject Cracks/Crack

Cracks/Crack--like defectslike defects AA--CC 40mm40mm NONENONE 11 Reject*Reject* Lack of fusion

Lack of fusion AA--CC 22mm22mm NONENONE 33 RejectReject Arc strikes

Arc strikes AA--CC 33 NONENONE 77 Reject***Reject*** Mechanical damage

Mechanical damage AA--CC NONENONE ------ ------ AcceptAccept Laps/Laminations

Laps/Laminations AA--CC NONENONE ------ ------ AcceptAccept Misalignment (Linear)

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Root Defects

Misalignment

Misalignment AA--CC 2mm2mm 2mm2mm 99 AcceptAccept Excessive Root Penetration

Excessive Root Penetration AA--CC 4mm4mm 2mm2mm 1515 RejectReject Incomplete Root Penetration

Incomplete Root Penetration AA--CC 50mm50mm NONENONE 1313 RejectReject Lack of Root Fusion

Lack of Root Fusion AA--CC 20mm20mm NONENONE 1111 RejectReject Root Concavity

Root Concavity AA--CC 2mm depth2mm depth 1mm1mm 1010 RejectReject Root Undercut

Root Undercut AA--CC NONENONE ------ ------ AcceptAccept Cracks/Crack

Cracks/Crack--like defectslike defects AA--CC NONENONE ------ ------ AcceptAccept Slag inclusions

Slag inclusions AA--CC NONENONE ------ 99 AcceptAccept

This *pipe/plate has been examined to the requirements of code/specification TWI-N/WIS-PI

Porosity

Porosity AA--CC NONENONE ------ 22 AcceptAccept Laps/Laminations

Laps/Laminations AA--CC NONENONE ------ ------ AcceptAccept

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

/

Comments:

* Request MPI testing to confirm crack and length.

** Large amount of spatter on weld face Recommend this is removed and re inspected

22nd August 2003 I C Plenty

** 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.

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

22nd August 2003 I C Plenty

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Inspection Practice Specification

Number

Number TWI 09

TWI 09--09

09--03

03

All dimensions are given in mm All dimensions are given in mm

No

No ImperfectionImperfection CommentsComments AllowanceAllowance

1

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

All dimensions are given in mm All dimensions are given in mm

2

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

Gas cavities (wormholes) pipes ClusterCluster Max dimension of areaSingle poreSingle pore Max dimension Max dimension of areaMax dimension L = 13mm MaxL = 13mm MaxL = 1mm MaxL = 1mm Max 3

3 Solid InclusionsSolid Inclusions Non metallic. Individual sizeNon metallic. Individual size Maximum 1mmMaximum 1mm 4

4 Solid InclusionsSolid Inclusions Metallic. Individual sizeMetallic. Individual size Not permittedNot permitted 5

5 Lack of FusionLack of Fusion Side wall/Root/InterSide wall/Root/Inter--runrun Not permittedNot permitted 6

6 Incomplete Root PenetrationIncomplete Root Penetration Not permittedNot permitted 7

7 Overlap/Cold lapOverlap/Cold lap Weld face/RootWeld face/Root Not permittedNot permitted 8

8 II l t l fill dl t l fill d N tN t itt ditt d

8

8 Incompletely filled grooveIncompletely filled groove Not permittedNot permitted 9

9 Linear MisalignmentLinear Misalignment 0.2t Maximum 4mm0.2t Maximum 4mm 10

10 Angular MisalignmentAngular Misalignment Maximum 10ºMaximum 10º 11

11 UndercutUndercut Smoothly blended Smoothly blended 10%t Maximum d 1mm 10%t Maximum d 1mm 12

12 Arc StrikesArc Strikes Area to be tested by MPIArea to be tested by MPI Seek adviceSeek advice 13

13 LaminationsLaminations Not permittedNot permitted

14

14 Mechanical DamageMechanical Damage Not permittedNot permitted 15

15 CC H i htH i ht Sh ll f ll b lSh ll f ll b l l tl t ff 00 33 h M ih M i 15

15 Cap HeightCap Height Shall fall below plate surfaceShall fall below plate surface 0 0 ––3mm h Maximum3mm h Maximum 16

16 Penetration BeadPenetration Bead 0 0 ––2mm h Maximum2mm h Maximum 17

17 Toe BlendToe Blend SmoothSmooth

18

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Plate Sample 6A Cap

Incomplete Filled Groove

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

Cap Undercut Slag

Porosity

Lack of

f i Cap Undercut

?

Cap Undercut Intermittent Slag Inclusion fusion Cap Undercut Intermittent

?

Cap Undercut I i

?

A St ik Arc Strike

?

Intermittent Arc Strike Arc Strike

Note: spatter and surface slag requires removal arc strikes

?

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

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Plate Sample 6A Root

Excess

Penetration Excess _Penetration Gas Pore

?

_?

?

Lack of Root Fusion Root Undercut Linear Misalignment Surface Slag

?

_?

?

Surface Slag

Note: Spatter and surface slag require removal Note: Spatter and surface slag require removal

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Plate Sample 6B Cap

I l t Fill d G

?

Lack of Sidewall Fusion Incomplete Filled Groove

Porosity _{Lack of Sidewall} Fusion

?

Overlap and Excess Cap Height Full Weld Length Surface Slag

?

Note: Surface slag requires removal and poor toe blending Note: Surface slag requires removal and poor toe blending

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Plate Sample 6B Root

?

Slag Inclusion

?

Crater Pipe

?

_?

Lack of Root Fusion Lack of Root Fusion

?

_?

Lack of Root Penetration

?

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Plate Sample 6C Cap

Incomplete

Welding Process FCAW Welding Process FCAW

Longitudinal Surface slag & Spatter

Cap Undercut Incomplete Filled Groove + Lack of Sidewall F i

?

Crack Surface slag & Spatter _Fusion

?

_?

?

Slag Inclusion Incomplete Filled Groove + Lack of

?

Slag Inclusion

Sidewall Fusion + Cap Undercut Intermittent

Note: Spatter and surface slag requires removal Note: Spatter and surface slag requires removal

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Plate Sample 6C Root

Welding Process FCAW Welding Process FCAW

B Th h

Poor Stop/Start + Lack of Root Penetration Mechanical Damage

?

Burn Through Excess Penetration

?

_?

?

Lack of Root Fusion

?

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Plate Sample 6D Cap

Excess Cap Porosity Incomplete Filled Groove

?

_?

Cap Undercut Cap Undercut Excess Cap

Height Lack of Sidewall _Fusion

?

_?

?

Overlap between Capping Passes

Note: Excess cap height and poor cap profile throughout Note: Excess cap height and poor cap profile throughout.

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Plate Sample 6D Root

?

Mechanical Damage

?

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Plate Sample 6E Cap

Lack of Sidewall

Fusion _UndercutCap

I t itt t Cap Undercut Intermittent

?

Intermittent Cap Undercut Intermittent

?

Excess Cap Height

?

Excess Cap Height

?

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Plate Sample 6E Root

?

_?

Poor Stop/Start + Crater Pipe

Root Undercut

?

_?

Excess Root Penetration

?

Excess Root

_?

Excess Root Penetration Excess Root

Penetration

Crater Pipe Lack of Root fusion

?

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Plate Sample 6F Cap

Mechanical

Damage

?

Lack of Sidewall fusion

?

Crater pipe

?

Lack of Sidewall fusion

Poor Toe Blend _{Lack of Sidewall Fusion + Incomplete Filled Groove}

Arc

?

_?

?

Arc Strikes Tack Weld

Note: Arc strikes require blending and crack detection

?

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Plate Sample 6F Root

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

Mechanical Damage +

Lack of Root

Blow Hole Lack of Root Fusion

?

_?

Mechanical Damage +

?

Lack of Root Fusion Fusion

Fusion

?

_?

?

_?

?

Lack of Root Fusion Arc Strikes Arc Strikes

?

_?

?

Note: Arc strikes require blending and crack detection Note: Arc strikes require blending and crack detection

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Plate Sample 6G Cap

Arc Strikes Parent Material Damage

?

Arc Strikes

Lack of Sidewall Fusion + Incomplete Filled Groove

?

Poor Toe Blend + Excess Cap Height _Porosity

?

_?

p g _y

Note: Arc strikes require blending and crack detection Seek Note: Arc strikes require blending and crack detection, Seek

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Plate Sample 6G Root

Plate corrosion

Poor Stop/Start

?

Parent material gas cavities Lack of Root Fusion

Poor Stop/Start

?

Surface Slag

?

Crater pipe

?

Surface slag

?

Li Mi li t Surface Slag

?

Surface slag Linear Misalignment

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

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Plate Sample 6H Cap

Incomplete Filled Groove _{Arc Strikes} _{Arc Strikes Slag Inclusion Arc Strikes}

?

_?

?

Cap Undercut Intermittent Arc Strikes Cap Undercut A St ik

?

Arc Strikes

Note: Parent plate damage throughout seek advice Arc Note: Parent plate damage throughout, seek advice. Arc

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Plate Sample 6H Root

Crater pipe

?

Excessive root penetration

?

Linear misalignment + lack of root fusion

?

_?

?

Arc strikes Poor stop/start

?

_?

p

Lack of root fusion

Arc strikes Lack of root fusion

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Plate Sample 6I Cap

Cap undercut _Spatter

Arc strikes

?

_{Arc strikes}

?

Poor toe blend full weld length

?

Note: Arc strikes require blending and crack detection Note: Arc strikes require blending and crack detection.

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Plate Sample 6I Root

?

Lack of root penetration

?

Burn through

?

Poor stop/start

?

Arc strike

?

_?

?

Linear misalignment

?

Lack of root penetration _{Lack of root fusion}

?

Mechanical damage

?

Lack of root fusion + poor stop/start + poor stop/start

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Plate Sample 6J Cap

Suspect crater cracking Porosity

Suspect crater cracking

?

Cap undercut

?

Arc strikes

?

Cap undercut Porosity

?

Cap undercut

?

Cap undercut intermittent

?

Note: Material damage throughout seek advice Arc strikes Note: Material damage throughout, seek advice. Arc strikes

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Plate Sample 6J Root

Linear misalignment +

?

Lack of root fusion Linear misalignment + lack of root fusion

?

_?

Lack of root penetration

?

_?

Linear misalignment + lack of root fusion

?

Note: Material damage seek advice on course of action Note: Material damage seek advice on course of action.

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Plate Sample T4 Cap

Cap undercut Cap undercut

?

Spatter/irregular cap profile

?

Note: Grinding marks throughout seek advice on course of Note: Grinding marks throughout seek advice on course of action.

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Plate Sample T4 Root

Root undercut

intermittent _{Arc strike}

?

Lack of penetration intermittent

?

Ground flush root

?

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Plate Sample H8 Cap

Arc strikes Mechanical

damage _{Cap undercut intermittent Surface slag}

?

_?

?

_?

Cap undercut intermittent

?

Mechanical damage p

?

g

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