Visual Inspection Plate Report Training Sample 5 Weld Face

Candidates Name : Candidates Signature : MR. JOHN BLUE MR. JOHN BLUE Specification : Welding Prcocess : Welding Position : TRAINING 5 MMA PA

Measure from this datum only

Incomplete filled 18 groove + Cap undercut L=28, D=1

Cap undercut 176 sharp L=22, D=1,5

190

Slag Inclusion L=7

Incomplete filled groove +Lack of 245 sidewall fusion L=13

L=50, D=0,5 Cap undercut Intermittent smooth

L:6*W:4= 24mm2 105 L=6, W=4 =1 Porosity

L=11, D=0,5 236 Cap Undercut sharp

Note : Intermittent spatter of the plate

100

L=43, W=10 Hard Stamping

Notes : Excess Weld Metal :

Linear Misalignment :

Toe Blend :

Poor

Weld Width :

19

Visual Inspection Plate Report Training Sample 5 Weld Root

A
And also have burn through that has been repaired (not Included) 112 Mechanical damage =1 Lack of root 193 fusion L=16, D=1,5

Edited By : Sharul Rohaizad Mohamad Darus

Measure from this datum only

Note : Light grinding mark throughout the plate

73

Root undercut =16

=1,5 213 Crater pipe

Notes : Penetration Height :

3,5

Toe Blend :

Poor

Weld Width :

15

CSWIP 3.1 Training Question for Plate Sample Training 5

Answer all 20 questions on the seperate candidate answer sheet provided. Your answers to be marked with an X in the appropriate box. Your acceptance criteria is to be based on the requirement of TWI Code 02 Name : MR.JOHN BLUE The Weld Face. 1. What is the maximum excess weld metal to be found on your sample and would you accept or reject your finding ? a) < 1,5 mm b) > 5,0 mm c) 4,0 mm to 5,0 mm d) 2,5 mm e) Accept f) Reject With regards to the surface profile, which of the following comments best matches your assessment and would you accept or reject your finding ? a) Toe blend generally good b) Good toe blend and surface profile c) Poor toe blend with good surface profile d) Poor toe blend and poor surface profile e) Accept f) Reject With reference to incomplete filled groove which of the following best matches your findings. Would you accept or reject your findings ? a) No incomplete filled groove visually detected b) Length 30,0 mm to 40 mm associated with lack of sidewall fusion c) Length < 15 mm associated with lack of sidewall fusion d) Length < 15 mm not associated with lack of sidewall fusion e) Accept f) Reject With reference to slag inclusions, which of the following best matches your assessment of the total accumulative length and would you accept or reject your finding ? a) 25 mm to 30 mm in length b) > 15 mm in length c) < 10 mm d) No slag inclusion visible e) Accept f) Reject
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MC Plate TR5. Rev 2. Date: 15-11-11

Signature MR.JOHN BLUE

Date : 09 JULY 2012

2.

3.

4.

5.

With reference to cap undercut, which of the following best matches your findings and would you aceept or reject your finding ? a) Accumulative length > 50 mm, all sharp b) Accumulative length > 50 mm both smooth and sharp c) Accumulative length < 50 mm all smooth d) No cap undercut visible e) Accept f) Reject With reference to cap undercut, which of the following best matches your findings and would you accept or reject your finding ? a) Maximum Depth < 0,5 mm b) Maximum depth > 2,0 mm c) Maximum depth 1,5 mm d) No cap undercut visually detected e) Accept f) Reject With reference to surface porosity, what is the maximum single pore size and would you accept or reject your finding ? a) > 3 mm one area b) < 2,0 mm numerous areas c) < 0,5 mm one area d) No porosity visually detected e) Accept f) Reject Regarding your samples parent material, which of the following best matches your findings and would you accept or reject ? a) One Arc strike visible b) Two arc strikes visible c) Three arc strikes visible d) No arc strikes visible e) Accept f) Reject With reference to cracking which of the following best matches your findings and would you accept or reject your findings ? a) Longitudinal crack 10 to 12 mm in length b) Longitudinal crack < 5 mm in length c) Transvere crack < 5 mm in length d) No crack visible e) Accept f) Reject
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6.

7.

8.

9.

MC Plate TR5. Rev 2. Date: 15-11-11

10.

With reference mechanical damage, which of the following best matches your assessment and would you accept and reject your findings ? a) No mechanical damage visible b) Hard stamping and light grinding visible c) Heavy grinding throughout d) Chipping marks and heavy grinding throughout e) Accept f) Reject

The Weld Root 11. With reference to lack of root fusion, which of the following best matches your assessment of the total accumulative length and is it acceptable or rejectable ? a) > 22 mm b) 15 mm to 19 mm c) < 5 mm d) None visually detected e) Accept f) Reject 12. With reference to plate misalignment which of the following best matches your visual assessment of the plate sample ? a) > 2,5 mm b) < 1,5 mm c) < 0,5 mm d) None of the above e) Accept f) Reject With reference to excessive root penetration which of the following best matches your assessment of the highest individual point measured and would you accept or reject your findings ? a) 5,0 mm b) Flush root c) < 4 mm d) < 2,5 mm e) Accept f) Reject With reference to parent material condition which of the following best matches your assessment and would you accept or reject the parent material condition ? a) Light grinding throughout b) Mechanical damage plus tack weld visible c) The parent material condition is generally clean throughout d) Heavy mechanical damage in excess of 2 mm in depth e) Accept
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MC Plate TR5. Rev 2. Date: 15-11-11

13.

14.

f) 15.

Reject

With reference to the collapse of the root resulting in a burn through, which of the following best matches your findings and would you accept or reject your findings ? a) One visible < 7 mm in diameter b) No burn through visible c) One visible > 12 in diameter d) Two visible not exceeding 12 mm in diamteter e) Accept f) Reject With reference to root concavity which of the following best matches your findings and would you accept or reject your findings ? a) 48 mm to 51 mm accumulative length, < 1 mm depth b) < 10 mm, 2 mm depth c) One area 65 mm to 69 mm in length, < 1 mm depth d) No root concavity visible e) Accept f) Reject With reference to root cracking which of the following best matches your findings and would you accept or reject the observed defect ? a) No crack visible b) One crater crack visible c) One longitudinal crack visible < 5 mm in length d) Crater pipe/shrinkage visible, recommend MT/PT inspection e) Accept f) Reject With reference to lack of root penetration which of the following best matches your findings and would you accept or reject your findings ? a) 17 mm to 21 mm in total length b) No lack of root penetration visually detected c) 11 mm to 13 mm in length d) None of the above e) Accept f) Reject With reference to root undercut which of the following best matches your findings and would you accept or reject your findings ? a) Accumulative length 6 mm to 10 mm b) Accumulative length 15 mm to 20 mm c) No root undercut visible d) None of the above e) Accept
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16.

17.

18.

19.

MC Plate TR5. Rev 2. Date: 15-11-11

f) 20.

Reject

Your overall assessment of the weld sample is : a) Accept b) Reject

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MC Plate TR5. Rev 2. Date: 15-11-11

Training Acceptance Levels for Plate, Pipe and Macro D = depth L = length H = height t = thickness
Table Number Defect Type

Acceptance Levels Plate and Pipe

Remarks
At no point shall the excess weld metal fall below the outside surface of the parent material. All weld runs shall blend smoothly Slag inclusion are defined as nonmetallic inclusions trapped in the weld metal or between the weld metal and the parent material. Undercut is defined as a groove melted into the parent metal,at the toes of the weld excess metal, root or adjacent weld metal. Trapped gas, in weld metal, elongated, individual pores, cluster porosity, piping or wormhole porosity. Transvere, longitudinal, star or crater cracks. Incomplete fusion between the weld metal and base material, incomplete fusion between weld metal. (lack of inter-run fusion) Damage to the parent material or weld metal, from an unintentional touch down of the electrode or arcing from poor connections in the welding circuit. Damage to the parent material or weld metal, internal or external resulting from any activities Mismatch between the welded or unwelded joint. Excess weld metal, above the base material in the root of the joint The absence of weld metal in the root area Inadequate cross penetration of both root faces. Excessive penetration, collapse of the weld root Distortion due to weld contraction Irregularities in the root profile due to shrinkage and contraction of the weld metal.

Acceptance Levels Macro only Remarks

As for plate and pipe

Maximum allowance
Excess weld metal will not exceed H = 3mm in any area on the parent material, showing smooth transition at the weld toes. The length of the slag inclusion shall not exceed 20mm continuous or intermittent. Accumulative totals shall not exceed 50mm No sharp indications smooth blend required. The length of any undercut shall not exceed 20mm continuous or intermittent. Accumulative total shall not exceed 50mm. Max D = 2mm for the cap of weld metal. Root undercut not permitted Individual pores 1mm max. Cluster porosity maximum 20mm total area. Elongated, piping or wormholes 15mm max. L continuous or intermittent. Not permitted Surface breaking lack of side wall fusion, lack of inter-run fusion continuous or intermittent not exceed 35mm. Accumulative totals not exceed 35mm over a 300mm length of weld

Excess weld metal

Slag/silica inclusions

Slag not permitted

Undercut

No sharp indications smooth blend required

Porosity or Gas Cavities Cracks or laminations

Cluster porosity not permitted. Individual pores acceptable, max 3 indications Not permitted

Lack of fusion

Not permitted

Arc strikes

Only 1 permitted

Not permitted

Mechanical damage Misalignment Penetration Lack of root penetration Lack of root fusion Burn through Angular distortion Root shrinkage or root concavity

Parent material must be smoothly blended Max. D = 2mm Only 1 location allowed No stray tack welds permitted Max H = 2mm Max H 2mm Not permitted Lack of root fusion, not to exceed 30mm total continuous or accumulative. Not permitted 3mm max. Plate only 35mm maximum length 2mm maximum depth

Not permitted

9 10 11 12 13 14 15

As for plate and Pipe As for plate and Pipe Not permitted Not permitted Not permitted Accept Accept

Training acceptance standard Rev 0 July 2009