Visual Inspection Pipe Report Training

Name [Block Capitals] MR. JOHN BLUE Signature MR. JOHN BLUE Date 10 JULY 2012

Code/Specification Used TWI CODE 02 Welding Process MMA Joint Type SINGLE V BUTT

Welding Position PA Outside Ø & Thickness Ø 168mm, Thk 12mm Pipe Ident# 1

WELD FACE

TRAINING 1

A C

Incomplete Cap Undercut Porosity

Filled Groove 65 Sharp 40 L:12*W:11= 132mm2
L=16, D=1 L=50, D=2 L=ϭϮ, W=ϭϭ Ø=ϭ

L=10, D=1 L=25, D=0,5 L=3, D=0,5 L=58, D=0,5 L=4, D=0,5
Cap Undercut 55 Cap Undercut 127 Cap Undercut Cap Undercut 88 Cap Undercut
Sharp Smooth Sharp Sharp

Note :
Spatter throughout the pipe 47
Arc Strike
Grinding mark throughout the pipe

Notes :
Excess Weld Metal Height : 5 Misalignment : 3 Weld Width : 18 Toe Blend : Poor

C D A

Cap Undercut Intermittent Incomplete

102 Sharp & Smooth 100 Filled Groove
L=80, D=0,5 L=34, D=2,5

L=20, D=1,5 L=10, D=0,5 L=14, D=0,5 L=71, D=1

6 Incomplete Filled 28 Cap Undercut 92 Cap Undercut 63 Cap Undercut
Groove + Lack of
Smooth Sharp Sharp
sidewall fusion

83
Arc Strike

Notes :
Excess Weld Metal Height : 4,5 Misalignment : 3 Weld Width : 17,5 Toe Blend : Poor

Editied By : Sharul Rohaizad Mohamad Darus

 PIPE ROOT FACE

TRAINING 1

A C

Root Undercut
30 Sharp
L=74, D=1,5

L=70, D=1 L=5, D=0,5 L=7, D=0,5

Root Undercut 23 Root Undercut 77 Root Undercut
Intermittent
Sharp Sharp
Sharp&Smooth

Notes :
Excess Penetration Height : 3,5 Toe Blend : Poor

C D A

Root
23 Concavity
L=9, D=1,5

L=6, D=1
106 Root Undercut
Sharp

Notes :
Excess Penetration Height : 4 Toe Blend : Poor

Editied By : Sharul Rohaizad Mohamad Darus

 CSWIP 3.1 Training Question for Pipe Sample Training 1
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 Signature MR.JOHN BLUE Date : 09 JULY 2012

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) Flush
b) < 2,5 mm
c) 3,0 mm
d) > 4,5 mm
e) Accept
f) Reject

2. 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) Toe blend and surface profile generally good
c) Poor toe blend and with good surface profile
d) Poor toe blend in certain areas, profile generally good
e) Accept
f) Reject

3. With reference to incomplete filled groove which of the following best matches your
findings and Would you accept or reject your findings ?
a) No incomplete filled groove visually detected
b) Full weld length
c) 50 mm to 70 mm length
d) 10 mm to 20 mm in length
e) Accept
f) Reject

4. 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) 10 mm to 15 mm in length
b) 15 mm to 20 mm in length
c) < 5 mm
d) No slag inclusions visually detected
e) Accept
f) Reject

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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 to 60 mm
b) Accumulative length 10 mm to 40 mm
c) No cap undercut visually detected
d) Accumulative intermittent length > 300 mm
e) Accept
f) Reject

6. With reference to cap undercut, which of the following best matches your findings and
would you accept or reject your finding ?
a) Depth < 1,0 mm
b) Depth > 2,5 mm all sharp
c) Maximum depth approximately 2,0 mm, some areas sharp
d) No cap undercut visually detected
e) Accept
f) Reject

7. With reference to surface porosity, what is the maximum single pore size and would you
accept or reject your finding ?
a) Ø 0,5 mm
b) Ø 1,0 mm
c) Ø > 2,0 mm
d) No porosity visually detected
e) Accept
f) Reject

8. Regarding your samples parent material, which of the following best matches your
findings and would you accept or reject ?
a) One arc strike visible, no mechanical damage
b) Two arc strikes plus mechanical damage visible
c) One arc strikes plus mechanical damage visible
d) No arc strikes visible, mechanical damage visible
e) Accept
f) Reject

9. With reference to question number 3, which of the following best matches your findings
and would you accept or reject your findings ?
a) Incomplete filled groove associated with lack of sidewall fusion, approximately 25
mm in length
b) Incomplete filled groove only
c) Incomplete filled groove associated with lack of sidewall fusion, full weld length
d) None of the above
e) Accept
f) Reject
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10. With reference to the general weld/parent pipe condition which of the following best
matches your findings ?
a) Both weld and parent pipe clean and ready for coating
b) Spatter noted throughout parent pipe and weld area requires further cleaning
c) Spatter noted in one or two areas, acceptable for application of coating
d) Very heavy spatter noted, cap run requires grinding flush before the application of
the coating
e) Accept
f) Reject

The Weld Root

11. With reference to root undercut, which of the following best matches your assessment of
the total accumulative length and is it acceptable or rejectable ?
a) 5 mm
b) 40 mm to 60 mm
c) 18 mm to 20 mm
d) > 120 mm
e) Accept
f) Reject

12. With reference to pipe misalignment which of the following best matches your visual
assessment of the pipe sample and would you accept or reject your findings ?
a) > 2,0 mm
b) < 1,5 mm
c) 5 mm
d) None of the above
e) Accept
f) Reject

13. 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) < 3,0 mm
b) 7,0 mm
c) Flush
d) > 3,5 mm
e) Accept
f) Reject

14. 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) Heavy rusting throughout, requires cleaning
b) Material staŵpiŶg ŵark’s, requires blending
c) The parent material condition is generally clean throughout
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 d) Heavy mill scale noted requires further cleaning
e) Accept
f) Reject

15. 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) Three visible of various diameter
d) Two visible not exceeding 5 mm in diameter
e) Accept
f) Reject

16. With reference to root concavity which of the following best matches your findings and
would you accept or reject your findings ?
a) > 130 mm accumulative length
b) < 10 mm, < 1,5 mm depth
c) One area 23 mm in length, < 1 mm depth
d) No root concavity visible
e) Accept
f) Reject

17. 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) None of the above
e) Accept
f) Reject

18. With reference to lack of root penetration which of the following best matches your
findings and would you accept or reject your findings ?
a) 18 mm to 20 mm in total length
b) > 30 mm in length
c) 12 mm to 15 mm in length
d) None of the above
e) Accept
f) Reject

19. With reference to lack of root fusion which of the following best matches your findings
and would you accept or reject your findings ?
a) All sharp
b) Accumulative length 70 mm to 75 mm
c) > 130 mm accumulative length
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 d) None of the above
e) Accept
f) Reject

20. Your overall assessment of the weld sample is :

a) Accept
b) Reject

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

Acceptance Levels
Defect Type
Acceptance Levels Plate and Pipe Macro only

Remarks Maximum allowance Remarks

At no point shall the excess weld
Excess weld metal will not exceed H = 3mm
Excess weld metal fall below the outside
1 in any area on the parent material, showing As for plate and pipe
metal surface of the parent material. All
smooth transition at the weld toes.
weld runs shall blend smoothly
Slag inclusion are defined as non-
The length of the slag inclusion shall not
Slag/silica metallic inclusions trapped in the
2 exceed 20mm continuous or intermittent. Slag not permitted
inclusions weld metal or between the weld
Accumulative totals shall not exceed 50mm
metal and the parent material.
No sharp indications smooth blend
Undercut is defined as a groove required. The length of any undercut shall
melted into the parent metal,at not exceed 20mm continuous or
No sharp indications
3 Undercut the toes of the weld excess intermittent. Accumulative total shall not
smooth blend required
metal, root or adjacent weld exceed 50mm. Max D = 2mm for the cap of
metal. weld metal.
Root undercut not permitted
Trapped gas, in weld metal, Individual pores ≤ 1mm max. Cluster porosity not
Porosity or elongated, individual pores, Cluster porosity maximum 20mm total area. permitted. Individual
4
Gas Cavities cluster porosity, piping or Elongated, piping or wormholes 15mm max. pores acceptable, max
wormhole porosity. L continuous or intermittent. 3 indications
Cracks or Transvere, longitudinal, star or
5 Not permitted Not permitted
laminations crater cracks.
Surface breaking lack of side wall fusion,
Incomplete fusion between the
lack of inter-run fusion continuous or
weld metal and base material,
6 Lack of fusion intermittent not exceed 35mm. Not permitted
incomplete fusion between weld
Accumulative totals not exceed 35mm over
metal. (lack of inter-run fusion)
a 300mm length of weld
Damage to the parent material or
weld metal, from an
unintentional touch down of the
7 Arc strikes Only 1 permitted Not permitted
electrode or arcing from poor
connections in the welding
circuit.
Parent material must be smoothly blended
Damage to the parent material or
Mechanical Max. D = 2mm
8 weld metal, internal or external Not permitted
damage Only 1 location allowed
resulting from any activities
No stray tack welds permitted
Mismatch between the welded or
9 Misalignment Max H = 2mm As for plate and Pipe
unwelded joint.
Excess weld metal, above the
10 Penetration base material in the root of the Max H ≤ 2mm As for plate and Pipe
joint
Lack of root The absence of weld metal in the
11 Not permitted Not permitted
penetration root area
Lack of root Inadequate cross penetration of Lack of root fusion, not to exceed 30mm
12 Not permitted
fusion both root faces. total continuous or accumulative.
Excessive penetration, collapse of
13 Burn through Not permitted Not permitted
the weld root
Angular Distortion due to weld
14 3mm max. Plate only Accept
distortion contraction
Root Irregularities in the root profile
35mm maximum length
15 shrinkage or due to shrinkage and contraction Accept
2mm maximum depth
root concavity of the weld metal.
Training acceptance standard Rev 0 July 2009