2-CSWIP Practical Plate Examples

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
Page 2 of 3
EXAMPLE PLATE REPORT
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
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)
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
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
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
Plate Sample 6A Root

Excess Penetration Excess Penetration Gas Pore
? Surface Slag
Root Undercut Lack of Root Fusion
?
Linear Misalignment
Note: Spatter and surface slag require removal

Plate Sample 6B Cap

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
Plate Sample 6B Root

Slag Inclusion
? Crater Pipe
?
Lack of Root Fusion
?
Lack of Root Penetration
?
Lack of Root Fusion
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

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
Plate Sample 6D Cap

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.
Plate Sample 6D Root

?
Lack of Root Fusion Mechanical Damage
?
Lack of Root Fusion
Plate Sample 6E Cap

Lack of Sidewall Fusion Cap Undercut I t Intermittent itt t
? ?
Incomplete Filled Groove
?
Excess Cap Height
?
Incomplete Filled Groove
Plate Sample 6E Root

? 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
Plate Sample 6F Cap

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

Plate Sample 6F Root

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

Plate Sample 6G Cap

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
Plate Sample 6G Root

? 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
Plate Sample 6H Cap

Incomplete Filled Groove Arc Strikes Arc Strikes Slag Inclusion
Arc Strikes
?
Arc Strikes
?
?
Cap Undercut
?
A St Arc Strikes ik
Note: Parent plate damage throughout throughout, seek advice advice. Arc strikes require blending and crack detection.
Plate Sample 6H Root

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
Plate Sample 6I Cap

Cap undercut Spatter
Arc strikes
Poor toe blend full weld length
?
Note: Arc strikes require blending and crack detection detection. Spatter requires removal.
Plate Sample 6I Root

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
Plate Sample 6J Cap

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.
Plate Sample 6J Root

?
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.

Plate Sample T4 Cap

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

Root undercut intermittent
Arc strike Lack of penetration intermittent
? ?
Ground flush root
Plate Sample H8 Cap

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.
Plate Sample H8 Root

? 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
Any Questions

2-CSWIP Practical Plate Examples

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CSWIP 3.

Practical Plate Inspection

TWI Training & Examination Services

World Centre for Materials Joining Technology

EXAMPLE PLATE REPORT Signature: I C Plenty

Test piece ident:

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

Length & thickness of plate: 300mm x 10 mm

40 Arc Strike 241

Slag inclusion NOTES:

World Centre for Materials Joining Technology

EXAMPLE PLATE REPORT

Copyright 2006, TWI Ltd

MEASURE FROM THIS DATUM EDGE

Root concavity 2 deep 23 10

Incomplete root penetration

NOTES: Penetration height :

Linear Misalignment: Angular Distortion: Any scale on plate surface

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

World Centre for Materials Joining Technology

EXAMPLE WELD INSPECTION REPORT/SENTENCE SHEET

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

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

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

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

Reject Reject Reject Reject Accept Accept Accept Accept Accept

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

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

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

Cap Undercut Intermittent

Cap Undercut I Intermittent i

World Centre for Materials Joining Technology

Plate Sample 6A Root

Root Undercut Lack of Root Fusion

Note: Spatter and surface slag require removal

World Centre for Materials Joining Technology

Plate Sample 6B Cap

Lack of Sidewall Fusion

World Centre for Materials Joining Technology

Plate Sample 6B Root

Copyright 2006, TWI Ltd

World Centre for Materials Joining Technology

Plate Sample 6C Cap

Surface slag & Spatter

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

Note: Spatter and surface slag requires removal

World Centre for Materials Joining Technology

Plate Sample 6C Root

Poor Stop/Start + Lack of Root Penetration

Copyright 2006, TWI Ltd