Review of Day 1

A Brief synopsis of:

Terms & Definitions
Duties & Responsibilities
Welding Imperfections
Mechanical Testing
Welding Procedures & Approval
Welder Approval

Any Questions ?*
 Macro Inspection Part II
1) Use a pencil only for the arrow line, but make
all writing in ink
2) Report everything that you can observe

3) Do not forget to compare and sentence your

report to the code provided

4) Do not forget to date & sign your report

5) Make any observations, such as

recommendations for further investigation for
crack-like imperfections*
Macro Inspection Part II
Using the macro photographs and report sheets given
to you, prepare your reports using the sheets given
(20 min’s/macro)
Identify indications, then draw a line on the report
sheet smaller macro photograph and number it. Using
the boxes below, identify the number and indicate what
you have identified
Place the size of the indication in the next box on the
right, remembering to divide the dimension from
photograph by 10
Use the following slides as guidance!
Macro Inspection Part II
Macro Inspection Points
1) Use a pencil for the arrow lines, but make all
writing in ink only
2) Do not forget to print your name
3) Do not forget to put the date
4) Do not forget to SIGN the report
5) Make any comments such as
recommendations for further investigation for
crack-like imperfections*
Macro Inspection Part II 09.20

Example Macro Photo

Macro Photo x 10*

Macro Inspection Part II
NOTE: PHOTOGRAPH IS AT X10 MAGNIFICATION
MATERIAL: LOW CARBON STEEL
8 WELDING PROCESS: [MAG/GMAW]
9
7 1
11 All dimensions in mm
6 2 3
4
10 5 12
# DEFECT SIZE ACCEPT/REJECT
1 Overlap
  + 2 pores  
0.5 Ø max *  

2 Laminations/inclusions*
     

3 Lack
  of side wall fusion*    

4 Overlap*
      Assess
5 Linear
  misalignment   0.4*  

6 Lack
  of inter-run fusion + silica*    

7 Gas
  pore/pipe ? Check penetrant 2.2 Ø *   To
8 Lack
  of side wall fusion + silica*    

9 Poor
  toe blend Sharp
  75° *  

1  
Angular misalignment  
5°* Specification
 

0
1
1
1
EXCESS WELD METAL
EXCESS PENETRATION
 
4.7*
1.4 Sharp*
 
 

 
*
2
 Macro Inspection Part II

Continue with Practical Macro

Inspection.
(Or as directed by your lecturer/presenter)*
Coffee Break 10.45
Materials Inspection

Materials arriving at the site need to be inspected

for the following:

1) Size
2) Condition
3) Specification*
Materials Inspection
Rolling Imperfections
Direction of rolling

Cold Laps*

Laminations
Segregation
Materials Inspection
Plate Inspection
Condition
(Corrosion, Mechanical damage, Laps, Bands and Laminations)

Specification
5L
Size

Other checks may need to be made such as:

distortion tolerance, number of plates and
storage*
 Materials Inspection
Pipe Inspection
Condition
(Corrosion, Damage, Wall thickness Ovality, Laminations & Seam)

Specification LP 5

Size
Welded seam

Other checks such as:

distortion, tolerance, number and storage*
Codes & Standards

General discussion on areas of industry

employing codes or standards*
Discuss the 3 areas of responsibility:

Design
Manufacture
Testing*
 Codes & Standards

The 3 agencies generally identified in a code or standard:

*
1) The customer, or client*

2) The manufacturer, or contractor*

3) The 3rd party inspection, or clients representative*

Codes & standards often do not contain all relevant data,

but may refer to other standards*
Weld Symbols on Drawings
Interpretation of Drawings &
Weld Symbols
It could be strongly argued that without a
thorough knowledge of weld symbols, a
welding inspector is unable to fully carry out
his full scope of work*
Weld Symbols on Drawings
Welding Symbols
Most weld symbols contain 5 elements, which are:

1) The arrow line* a. 7 b. 10 5 x 100 (100)

111*
2) The reference line*
3) The symbol*

4) The dimensions*

5) The supplementary information*

 Weld Symbols on Drawings
1) Convention of the arrow line:
BS. BSEn & AWS
  a)   Shall touch the joint intersection
b) Shall not be parallel to the drawing
c) Shall point towards a single plate preparation*

*
Weld Symbols on Drawings

2) Convention of The reference line:

BS 499 (UK) & AWS A 2.4 (US)
a)        Shall touch the arrow line
b) Shall be parallel to the bottom of the
drawing*
*
Weld Symbols on Drawings
  Symbols: BS 499 (UK) & AWS A2.4 (US)
a) Welds this side of joint, go underneath the reference line
b) Welds the other side of the joint, go on top of the reference line
c) Symbols with a vertical line component must be drawn with
the vertical line to the left side of the symbol
d) All CSA dimensions are shown to the left of the symbol

e) All linear dimensions are shown on the right of the symbol

i.e. Number of welds, length of welds, length of any (spaces)*

10 4 x 50 (50)*
Weld Symbols on Drawings
Representation of welds done from both sides
of the joint intersection, touched by the arrow
head
Fillet weld Double Double
bevel J*

Double V Double U
Weld Symbols on Drawings
Supplementary Weld Symbols
Toes to be ground
smoothly. (BSEn only))
Site
Weld
Ground flush

Concave or Convex
111
Weld all round Welding process.
Numerical BS En & BS
Further supplementary information, such as WPS
number, or NDT may be placed in the fish tail*
Weld Symbols on Drawings
3) Convention of The reference line:
BS En 22553 or ISO 2553
a)    Shall touch the arrow line
b) Shall be parallel to the bottom of the drawing
c) There shall be a further broken line above or beneath the
reference line (Except where the weld is symmetrical)*

or *
 Weld Symbols on Drawings
  Symbols: BSEn 22553. (ISO 2553)
a) Welds this side of joint, go on the unbroken reference line
b) Welds the other side of the joint, go on the broken reference line
c) Symbols with a vertical line component must be drawn with
the vertical line to the left side of the symbol
d) All CSA dimensions are shown to the left of the symbol
e) All linear dimensions are shown on the right of the symbol
i.e. Number of welds, length of welds, length of any spaces
f) All leg lengths shall be preceded by z and throat by a or s*

z 10 4 x 50 (50)*
Weld Symbols on Drawings
Weld Symbols on Drawings
BS 499 & AWS A 2.4

8
8

a5 b8 *

5
8
Weld Symbols on Drawings
Weld Symbols on Drawings
BS En 22553 (ISO 2553)

z8 or

8
z8

a5 z8
or
a5 z8 *
5
8
Weld Symbols on Drawings
Example:
Produce a drawing giving symbols for the welds
given as shown below to the specification given
Weld Drawing BS
499 MMA

Example:
Symbol Drawing

111*
Weld Symbols on Drawings
Student Symbols Exercise
Complete a symbols drawing for the
welded joint given below to BS 499 &
BSEn 22553
7
10
35 20

15 30

All Fillet weld leg lengths are 10 mm *

All butt welds are MIG welded and all fillet welds with MMA
 Weld Symbols on Drawings
Solution BS 499 10
a. 30 111
131
a. 20
10

*
a. 7 b
10
a. 35
111
131 a. 15
10
 Weld Symbols on Drawings
Solution BSEn z. 10
22553 s. 30 111
131
s. 20
z. 10

*
a. 7 z.
10
s. 35
111
131 s. 15
z. 10
 Welding Processes
A welding process:
*Special equipment used with method, for producing
welds
Heating Protection

Requirements:

To make a sound
weld we need to

Properties
Cleaning
 Welding Processes Safety
Before continuing with the welding processes section,
there are 2 safety related terms that should first be
understood*
“Duty Cycle” relates to the current carrying capacity of all
conductors, based on a 10 minute cycle i.e. 60% duty
cycle means it can carry the specified current for 6
minutes in 10 then must rest for 4. A 100% duty cycle has
no rest period requirement. (Explained fully in the WIS 5
course notes)*
 Welding Processes Safety
OEL/MEL (Occupational or Maximum Exposure Limit)
which is used in reference to fume exposure such as that
caused in arc welding. The value may be in PPM or mg/m3
depending on a particulate fume, or a gas. Typical values
in EH/40 are*
Fume or gas Exposure Limit Effect on Health

Cadmium 0.025Mg/m3 Extremely toxic

General Welding Fume 5Mg/m3 Low toxicity
Iron 5Mg/m3 Low toxicity
Aluminium 5Mg/m3 Low toxicity
Ozone 0.20 PPM Extremely toxic
Phosgene 0.02 PPM Extremely toxic
No OEL Value
Argon Very low toxicity
O2 air content to be
controlled
Arc Characteristics for MMA & TIG

Constant Current/Amperage Volt Amp Characteristic*

OCV Large change in voltage
=
Volts Smaller change in amperage*
Large
arc gap*
Welding
Voltage*
Small
arc gap

Amps
 Manual Metal Arc Welding
Power Power
control panel source.
Transformer/
Electrode
Rectifier
oven (Up to Holding Oven
350 °C) (Up to 200 °C)
Electrode
s Inverter
Power return power source
cable
Electrode
holder
Safety visor Power cable
(With dark lens)
*
 Requirements of MMA

1) A Transformer/Rectifier (Constant current type)

2) A power and power return cable

3) Electrode holder

4) Electrode (To correct specification)

5) Correct visor & glass, all safety clothing and

extraction
 Parameters & Inspection Points

1) Amperage 2) Arc Voltage

3) Polarity 4) Speed of Travel

5) Electrode type & Ø 6) Duty Cycles

7) Electrode condition 8) Connections

9) Insulation / extraction 10) Electrode treatments*

 Typical Imperfections

1) Slag inclusions

2) Arc strikes

3) Porosity

4) Undercut

Most welding imperfections in MMA are caused by a

lack of welder skill, the incorrect settings of the
equipment, or the incorrect use, and treatment of
electrodes*
 Advantages & Disadvantages
Advantages: Disadvantages:

1) Field or shop (Portable) 1) High skill factor

2) Range of consumables 2) Short electrode length

3) All positional 3) **Low productivity (OF)

4) *Quick electrode 4) High level of fume

change
5) Simple equipment 5) Hydrogen control

* Enabling fast changes in material types to be

welded
** Comparatively uneconomic with other processes*
 Tungsten Inert Gas Welding
Power Transformer
control / Rectifier
panel
Power Inverter
return power
cable source
Torch Power
assemblies control
panel
Power cable
Tungsten
electrodes*
Flow-meter
 TIG Torch Head Assembly
Tungste Tungsten
n electrode
housing s
Fitted Ceramic
ceramic shield
shielding cup cup
On/Off
switch Gas lens
Split collet
Gas diffuser
Spare Torch
ceramic body
shielding cup
*
 Grinding the Tungsten

The tungsten must

have the correct vertex
angle*

Grinding is done on a
special jig, and on a
dedicated wheel*
 Gas Flow Rates

Correctly adjusted
shielding with a gas lens
will give good cover
without turbulence*

Adjustments to the flow

rate need to made
according to joint design
and gas type*
 Fusible Inserts

Before welding

After welding*

A fusible insert is pre-formed and placed filler material

that is mainly used in the root of TIG welded pipes*

It is often termed an “EB insert” after*

The Electric Boat Company of America, who developed

it*
 Requirements of TIG
1) A Transformer/Rectifier (Constant current type)
2) A power and power return cable
3) An Inert shielding gas. (Argon or Helium)

4) Gas hose, flow-meter, & gas regulator

5) TIG torch head with ground tungsten, collets,

ceramics
6) Method of arc ignition (High frequency or lift arc)

7) Correct visor, all safety clothing and good extraction

8) Optional filler rod, to correct specification*
 Parameters & Inspection Points

1) Amperage 2) Arc Voltage

3) AC or DC + Polarity 4) Speed of Travel

5) Tungsten type & Ø 6) Duty Cycles

7) Tungsten vertex angle 8) Connections

9) Gas type & flow rate 10) Insulation / extraction

11) Ceramic condition 12) Gas lens fitted*
 Typical Imperfections

1) Tungsten inclusions (Low skill, or wrong vertex angle)

2) Surface porosity (Loss of gas shield mainly on site)

3) Crater pipes (Bad weld finish technique i.e. Slope out)

4) Oxidation of S/S weld bead, or root by poor gas cover

Most welding imperfections with TIG are caused by a

lack of welder skill, or incorrect setting of the equipment.
i.e. Current, torch manipulation, welding speed, gas flow
rate, etc*
 Advantages & Disadvantages

Advantages: Disadvantages:

1) High quality 1) Very high skill factor

2) High control of weld pool 2) Range of consumable

3) All positional 3) Loss of gas shield/site

4) Lowest H2 arc process 4) Low productivity (O/F)

5) Low inter-run cleaning 5) High ozone levels*

MMA & TIG Welding
Videos
TWI
“Welding with covered electrodes”
ESAB
“TIG Welding Steels & Stainless
Steels”
Or equivalent (1 hour)*
 Plate Inspection Points
1) Use a pencil for the arrow lines, but make all
written comments and measurements in ink
only everything that you can observe
2) Report
3) Do not forget to compare and sentence your
report
5) Do not forget to date & sign your report
6) Make any observations, such as
recommendations for further investigation for
crack-like imperfections i.e. penetrant testing*
Slides 52 - 60
WIS 5 Text Ref Section 23
WTC 7 Text Ref Section 17
 Visual Inspection Practice
The purpose of this session is to practice the reporting
format required by CSWIP in the practical plate
examination part of the CSWIP 3.1 Welding Inspectors
exam

Remember, the responsibilities of a welding inspector are:

Observe
Report
Compare*.
 Observe

To observe welding imperfections you are required to have

good close vision acuity
A close vision acuity test will be given to you before your
exam to establish if your vision meets the minimum
standard required

Its not just the project that must meet the standard!!
You will also require a thorough knowledge of welding
imperfections and their likely location, causes and
implications*
 Report
After you have observed an imperfection and determined
its type, you must be able to take measurements and
complete a report *

The first report should be in the form of a repair map of

the weld. (i.e. All observations are Identified Sized and
Located)
Should the imperfection be a defect and require repair, it
will need to be accurately found and re-identified*
The report map form used in CSWIP will look like the
following:*
 Report
Page 1 of 3 VISUAL INSPECTION PLATE REPORT
 
Name [Block capitals]__________________________ Signature ___________________________ Test piece identification
 
Code/Specification used ________________________ Welding process _____________________ Joint type__________________
 
Welding position ______________________________________ Length & thickness of plate____________________ Date___________________________

Weld Face
M
E
A
S A
U
R
E
 
F
R
O
M
 
T
H
I
S

D
A
T
U
M

E
D
G
E
 
 Compare
All CSWIP 3.1 candidates should use there
nominated pipe code for all your visual inspection
practice, as this will help them become conversant
with the specification
Practice this up and till the end of the day, or as
directed by your course lecturer*