CSWIP 3.

1 Welding Inspection

Practical Plate Inspection

TWI Training & Examination

Services

Course Reference WIS 5

 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

Welding position: Flat /PA Length & thickness of plate: 300mm x 10 mm Date 22/08/2003
MEASURE

WELD FACE

A B C
Lack of sidewall
fusion Gas pore Undercut smooth
1.5 Ø 1.5 max
FROM

87 236
22 230
30
THIS

51 8 153 40
Arc Strike
Slag
Centreline 241
inclusion
DATUM

crack
NOTES: Cap height : 4mm.
Weld width: 12-14mm
Toe blend: Poor
Misalignment: 2mm
EDGE

Angular Distortion 3mm in 50mm

Spatter along weld length or scale on the plate surface
Page 2 of 3
MEASURE EXAMPLE PLATE REPORT

WELD ROOT

A B C
Root concavity
2 deep Lack of root
Fusion
FROM

23 247
10 20
THIS

128 50

Incomplete root
penetration
DATUM

NOTES: Penetration height : 4mm.

Linear Misalignment: 2mm
Angular Distortion: 3mm in 50mm
Any scale on plate surface
EDGE
 Plate final Inspection Report
PRINT FULL NAME I C Plenty
SPECIMEN NUMBER 001
EXTERNAL DEFECTS Defects Noted Code or Specification Reference

Defect Type Accumulative Maximum Section/ Accept/Reject

Total Allowance Table No
2 3 4 5
Excess weld metal height 4mm 1.6mm 15 Reject

Excess weld metal appearance Poor blend Smooth 15 Reject

Incomplete filling 22mm None Accept
Inadequate weld width (PIPE) N/A 3mm Accept

Slag Inclusions 70mm long None Reject

Undercut 1.5mm depth 0.8mm Reject

Surface Porosity 1.5mm  2mm  Accept

Cracks/Crack-like defects 40mm NONE Reject*

Lack of fusion 22mm 25mm Accept

Arc strikes 30x25 ------------ Not specified Reject**

Mechanical damage NONE ------------ ----------- Accept

Laps/Laminations NONE ------------ ----------- Accept
Misalignment (Linear) 2mm 3mm Accept

Longitudinal seams (PIPE) N/A ------------ ---------- Accept

 Pipe final Inspection Report Root
EXTERNAL DEFECTS Defects Noted Code or Specification Reference

Defect Type Accumulative Maximum Section/ Accept/Reject

Total Allowance Table No
2 3 4 5

Misalignment 2mm 3mm Accept

Excessive Root Penetration 4mm ------------ Accept

Incomplete Root Penetration 50mm 25mm Accept

Lack of Root Fusion 20mm 25mm Accept

Root Concavity 2mm depth 1mm See Notes ***

Root Undercut 0.5mm 0.8mm Accept

Cracks/Crack-like defects NONE ------------ Accept

Slag inclusions 70mm long None Reject

Porosity 1.5mm  2mm  Reject

Laps/Laminations NONE ------------ ---------- Accept

This *pipe/plate has been examined to the requirements of code/specification TWI Code Provided
and is accepted/rejected accordingly.
Comments:
* Request MPI testing.
** Recommend arc strikes are ground flush prior to MPI testing for cracks.
*** Radiography Required

Signature I C Plenty Date 22nd August 2003

*Delete which is not applicable. Use the other side for any comments.
 Inspection Practice Specification
Number TWI 09-09-03
All dimensions are given in mm
No Imperfection Comments Allowance
1 Cracks All types of cracks Not permitted

2 Porosity/Gas pores/elongated Cluster Max dimension of area L = 13mm Max

Gas cavities (wormholes) pipes Single pore Max dimension L = 1mm Max
3 Solid Inclusions Non metallic. Individual size Maximum 1mm
4 Solid Inclusions Metallic. Individual size Not permitted
5 Lack of Fusion Side wall/Root/Inter-run Not permitted
6 Incomplete Root Penetration Not permitted
7 Overlap/Cold lap Weld face/Root Not permitted
8 Incompletely filled groove Not permitted
9 Linear Misalignment 0.2t Maximum 4mm
10 Angular Misalignment Maximum 10º
11 Undercut Smoothly blended 10%t Maximum d 1mm
12 Arc Strikes Area to be tested by MPI Seek advice
13 Laminations Not permitted
14 Mechanical Damage Not permitted
15 Cap Height Shall fall below plate surface 0 –3mm h Maximum
16 Penetration Bead 0 –2mm h Maximum
17 Toe Blend Smooth
18 Spatter Clean & Re-inspect Refer to manufacturer
19 Weld Appearance All runs shall blend smoothly Regular
20 Root concavity 10%t Maximum
 Plate Sample 6A Cap
Welding Process MMA (SMAW)

?
Incomplete Filled Groove
?
Porosity Lack of
?
fusion
Slag Cap Undercut Cap Undercut
?
Inclusion ?
Intermittent ?
Intermittent

Cap Undercut
?
Intermittent ?
Arc Strike
?
Arc Strike

Note: spatter and surface slag requires removal, arc strikes

require blending and crack detection
 Plate Sample 6A Root
Welding Process MMA (SMAW)

?
Excess ?
Penetration ? Excess
Penetration
Gas Pore

Linear Misalignment
Root Undercut
Surface Slag Lack of Root
Fusion ? ?
? ?
Note: Spatter and surface slag require removal
 Plate Sample 6B Cap
Welding Process MMA (SMAW)
?
Incomplete Filled Groove

? ?
Porosity
Lack of Sidewall
Lack of Sidewall Fusion 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
Welding Process MMA (SMAW)

?
Crater Pipe
? Slag Inclusion

Lack of Root Fusion Lack of Root Fusion

Lack of Root
? Penetration
?
?
 Plate Sample 6C Cap
Welding Process FCAW

?
? Incomplete
Filled Groove +
Cap Undercut
? Lack of ?
Sidewall
Surface slag & Spatter Fusion Longitudinal
Crack

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 Poor Stop/Start + Lack of

Burn Through
Root Penetration
? ?
Excess Penetration
?
Lack of Root Fusion

? Lack of Root Fusion

?
 Plate Sample 6D Cap
Welding Process MMA (SMAW)

?
Porosity

? ? ?
Incomplete
Filled Groove
Excess Cap Cap ? Lack of Sidewall Cap
Height Undercut Fusion Undercut ?

Overlap between Capping Passes

Note: Excess cap height and poor cap profile throughout.

 Plate Sample 6D Root
Welding Process MMA (SMAW)

Mechanical Damage
?
? Lack of Root Fusion

Lack of Root Fusion

?
 Plate Sample 6E Cap
Welding Process MMA (SMAW)

?
Lack of
Sidewall
?
Fusion
?
Cap Undercut Intermittent Cap Undercut Intermittent

Incomplete Filled Groove

Excess Cap Height
? Incomplete Filled Groove
?
?
 Plate Sample 6E Root
Welding Process MMA (SMAW)

? ?
? Poor Stop/Start + Crater Pipe
Lack of Root Fusion ?
Lack of Root Fusion
Root Undercut

Excess Root Penetration Excess Root

Penetration
? ? Crater Pipe Lack of Root
fusion
?
?
 Plate Sample 6F Cap
Welding Process MMA (SMAW)

Mechanical
Damage

? ?
Lack of Sidewall fusion
? Crater pipe

Poor Toe Blend Lack of Sidewall Fusion + Incomplete Filled Groove

? ? ? Arc
Tack Weld Strikes
?
Note: Arc strikes require blending and crack detection
 Plate Sample 6F Root
Welding Process MMA (SMAW)

Poor Stop/Start + Lack of Root ?

? Penetration + Crater Pipe
? Blow Hole
Arc Strikes
? Damage + ?
? Mechanical Lack of
Root
Lack of
Root
Lack of Root Fusion Fusion Fusion

Lack of Root Fusion

Arc Strikes
?
? Arc Strikes

?
Note: Arc strikes require blending and crack detection
 Plate Sample 6G Cap
Welding Process MMA (SMAW)

Parent Material Damage ?

? ? ?
Arc Strikes
Arc Strikes
Lack of Sidewall Fusion +
Incomplete Filled Groove

Poor Toe Blend + Excess Cap Height

? Porosity

?
Note: Arc strikes require blending and crack detection, Seek advise on
parent material damage
 Plate Sample 6G Root
Welding Process MMA (SMAW)

Parent material
gas cavities
Plate corrosion
? Poor Stop/Start ?
?
Lack of Root Fusion ?
? ? Surface Slag
Crater pipe
Surface slag
?
Linear Misalignment
?
Note: Surface slag requires removal, plate corrosion requires wire
brushing
 Plate Sample 6H Cap
Welding Process MMA (SMAW)

? ? ?
Incomplete Filled Groove ? Inclusion
Arc Strikes Slag Arc Strikes
Arc Strikes
?

Cap Undercut
Arc Strikes Cap Undercut Intermittent
? ?
? ?
Arc Strikes

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

require blending and crack detection.
 Plate Sample 6H Root
Welding Process MMA (SMAW)

?
Crater pipe ? ?
Excessive root penetration
Linear misalignment +
lack of root fusion

Lack of root fusion

? Poor stop/start ? ?
Lack of root fusion Arc strikes
?
Arc strikes

Note: Arc strikes require blending and crack detection, Seek advise on
parent material damage
 Plate Sample 6I Cap
Welding Process MMA (SMAW)

?
?
Cap undercut
Spatter
Arc strikes
?

Poor toe blend full weld length

?
Note: Arc strikes require blending and crack detection. Spatter requires
removal.
 Plate Sample 6I Root
Welding Process MMA (SMAW)

Arc strike
? ?
Lack of root penetration Burn through ?
Poor stop/start
?
Linear misalignment
Lack of root fusion
? Lack of root penetration
?
? ?
Mechanical damage Lack of root fusion ?
+ poor stop/start

Note: Arc strikes require blending and crack detection, Seek advise
on parent material damage
 Plate Sample 6J Cap
Welding Process MMA (SMAW)

Suspect crater cracking

? ? ?
?
Cap undercut Arc strikes Porosity
Cap undercut

Cap undercut intermittent

Cap undercut ?
?
Note: Material damage throughout, seek advice. Arc strikes require
blending and crack detection.
 Plate Sample 6J Root
Welding Process MMA (SMAW)

?
? Mechanical damage
?
Linear misalignment +
Lack of root fusion lack of root fusion

Lack of root penetration

Linear misalignment +
lack of root fusion
?
?

Note: Material damage seek advice on course of action.

 Plate Sample T4 Cap
Welding Process MMA (SMAW)

Mechanical damage
? ?
? Cap undercut
Cap undercut

Spatter/irregular cap profile

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

cap height and poor cap profile throughout.
 Plate Sample T4 Root
Welding Process MMA (SMAW)

? Arc strike
Root undercut
intermittent ?
?
Lack of penetration intermittent

Ground flush root

?
 Plate Sample H8 Cap
Welding Process MMA (SMAW)

? ?
? Mechanical ? Surface slag
Arc strikes damage
Cap undercut intermittent

Cap undercut intermittent

?
Mechanical
?
damage

Note: Mechanical damage seek advice on course of action.

Excess cap height and poor cap profile throughout. Arc
strikes require blending and crack detection.
 Plate Sample H8 Root
Welding Process MMA (SMAW)

?
Arc strike
Lack of root
fusion
? ? ? ? ?
Lack of root Spatter
Lack of root Lack of root fusion
fusion fusion

Root undercut intermittent

Spatter

? ?

Note: Arc strikes require blending and crack detection.

Spatter requires removal
Any Questions