Egyptian Academy For Training & consultations ( EGAC )
Fundamentals of Visual Inspection
Dr. Eng, Ismail A. Abdallah
EGAC Chairman
General
Visual examination is a method for identifying
surface flaws and imperfections. Quality control
program consisting essentially of visual
inspection should include a continual sequence of
examinations performed during all phases of
welding. This will allow visual inspection of the
exposed surfaces as they occur in the welding
sequence.
Welding Inspection
Conditions for Visual Inspection (to BS EN
970)Illumination:
•350 lux minimum required
•(recommends 500 lux -normal shop or office
lighting)Vision Access:
•eye should be within 600mm of the surface
•viewing angle (line from eye to surface) to be not less
than 30°
Standard for Visual Inspection
Welding Inspection Personnel should:
•be familiar with relevant standards, rules and
specifications applicable to the fabrication work to be
undertaken
•be informed about the welding procedures to be used
•have good vision (which should be checked every 12
months)
Welding Inspectors Equipment
Measuring devices:
•flexible tape, steel rule
•Temperature indicating crayons
•Welding gauges
•Voltmeter
•Ammeter
•Magnifying glass
•Torch / flash light
•Gas flow-meter
Visual Inspection Kit
Welding Inspectors Gauges
Multipurpose welding gauge
Welding Inspectors Equipment
Stages of Visual Inspection
For high integrity fabrications inspection
required throughout the fabrication process:
•Before welding
(Before assemble & After assembly)
•During welding
•After welding
Before to Welding.
Prior to welding, some typical action items requiring
attention by the visual inspector include:
1. Review drawings and specifications.
2. Check qualification of personnel to be utilized.
3. Review materials to be utilized
4. Check fit-up and alignment of weld joints.
5. Check preheat, if required.
6. Welding process and consumables.
7. Welding procedures and machine setting.
8. Tacks weld quality
During Welding
During welding, visual inspection is the primary
method for controlling quality.
1. Treatment of tack welds.
2. Quality of the root pass and the succeeding weld
layers.
3. Proper preheat and inter pass temperature.
4. Sequence of weld passes.
5. Inter pass cleaning.
6. Root preparation prior to welding a second side.
7. Conformance with the applicable procedure.
After Welding.
Some of the various items which require attention after welding
has been completed are:
1. Final weld appearance
2. Final weld size
3. Weld length
4. Dimensional accuracy
5. Amount of distortion
6. Post Weld Heat Treatment
Discontinuities.
Typical discontinuities found in welds are:
1. Porosity 5. Overlap
2. Incomplete fusion 6. Cracks
3. Incomplete joint penetration 7. Slag inclusions
4. Undercut 8. Excessive reinforcement
While code requirements may permit limited amounts of some of
these discontinuities, cracks, and incomplete fusion defects are never
allowed.
Measurements of Welding -
Fillet welds:
Fillet Welds
Most used
Weld strength - ‘Effective Throat’
Weld cost - function of weld size
Measurements of Welding -
Fillet Gages
Convex Gage measures weld size from ‘leg’ length (2 measurements)
Measurements of Welding -
Fillet Gages
Concave Gage measures throat -- weld size read directly from gage but
derived from: S=T/0.707
Fillet Weld Gauges
10mm
5m
m
m
m
4mm
G.A.L.
12
3mm
L
9m
S.T.D.
m
16mm
6m
Leg Length Gauge
10mm
5m
m
m
m
12
G.A.L.
4mm
3mm
T
S.T.D.
9m
m
m
6m
16mm
Throat Thickness Gauge
TWI Multi-Purpose Welding Gauge
IN
1/4 1/2 3/4
0 1
0 MM
5 1/
10 2
IN 15
MM MM
20 15
50
60
40
Fillet weld leg length
The scale is used to read off these dimensions up to a
maximum of 25mm and 1 inch.
TWI Multi-Purpose Welding Gauge
40
60
50
MM
15 20
MM
15 IN
2 10
1/ 5
MM 0
1 0
3/4 1/2 1/4
IN
Fillet throat thickness
The sliding pointer reads up to 20mm and 3/4 inch. In
measuring throat thickness it is assumed that the fillet weld
has normal root penetration
Plate / Pipe Inspection
TWI Multi-Purpose Welding Gauge
IN
1/4 1/2 3/4
0 1
0 MM
5 1/
2
10
15
MM 15
20
IN
50
60
40
Angle of preparation
The scale reads from 0o to 60o in steps of 5o. The
angle is read against the chamfered edge of the
segment
TWI Multi-Purpose Welding Gauge
IN
1/4 1/2 3/4
0
1
0 MM
5 1/
2
10
IN MM 15
MM
20 15
50
40
60
Misalignment
The scale is used to measure misalignment of
components by placing the edge of the gauge on the
lower one and rotating the segment until the pointer
contacts the higher piece
TWI Multi-Purpose Welding Gauge
IN
1/4 1/2 3/4
0
1
0 MM
5 1/
2
10
IN MM 15
MM
20 15
50
60
Undercut40
The scale reads from 0 in the negative up to 5m. The
segment is rotated until the pointer reaches the full depth
of the undercut.
TWI Multi-Purpose Welding Gauge
IN
1/4 1/2 3/4
0 1
0 MM
5 1/
2
10
IN MM 15
MM
20 15
50
60
40
Excess weld metal
The scale is used to read off these dimensions up
to a maximum of 25mm and 1 inch
HI-LO Welding Gauge
6
Root gap
dimension
HI-LO Single Purpose Welding Gauge
Internal
alignment
Dimensional Conformance
Welds are commonly inspected for dimensional tolerance.
• There are several types of gages used to inspect welding fit up and
finished weldments.
• These gages are intended for general inspection where close
tolerances are not required.
• The gage used is determined by the application.
Fillet gage set
Palmgren gage
VWAC gage
Cambridge gage
Dimensional Conformance
Visual inspection is commonly used to determine weld size and tolerances
according to standards and engineering specifications.
Throat measurement Leg size determination Convexity measurement
using a Palmgren gage. with fillet gage. with VWAC gage.
Dimensional Conformance
Undercut in a weld is readily seen visually. In many cases its depth
must be measured to determine if it exceeds code requirements.
Measurement of undercut
depth with VWAC gage.
Weld Examination
Page 1 of 3 PLATE REPORT - EXAMPLE
Name: [Block capitals] xxxxxxxxxxxxSignature: ssssssss Test
: piece Identity: 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 02/04/2005
PLATE
MEASURE
WELD FACE mechanical
236
damage
A B C
lack of sidewall fusion undercut
gas pore
F R O M T H I S
(+ incomplete fill) 1.5 max
1.5 Ø
87 246
22 230
30
51 8 153 40
D A T U M - E D G E OF
arc strike
slag
centreline 261
inclusion
crack
Excess weld metal: 4 max
Weld appearance / toe blend: poor
Linear misalignment: 2 max
Angular distortion: present
Spatter: over full length of weld
Oxide scale: on both plates
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
F R O M
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
F R O M
23 247
10 20
THIS
128 50
Incomplete root
DATUM
penetration
NOTES: Penetration height : 4mm.
Linear Misalignment: 2mm
Angular Distortion: 3mm in 50mm
EDGE
Any scale on plate surface
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
Weld Examination
SENTENCING (Accept/Reject)
WELD INSPECTION REPORT/SENTENCING SHEET
PRINT FULL NAME
SPECIMEN NUMBER Example Only PLATE
THICKNESS = 11mm
EXTERNAL DEFECTS Defects Noted Code or Specification Reference
Defect Type Pipe/Plate Accumulative Maximum Section/ Accept/Reject
Section Total Allowance Table No.
1 2 3 4 5
Excess Weld Metal (Height) A-C 3 max 3 8 accept
Excess Weld Metal (Appearance) A-C smooth smooth 8 accept
Incomplete filling A-C 35 none 5 reject
Inadequate Weld Width A -C none - - accept
Slag Inclusions A-C none - - accept
Undercut A-C 1.5 max. 1 6 reject
Surface Porosity A-B cluster 8 13 2 accept
isolated 2 dia. 1 reject
Cracks/Crack-like Defects B-C none - - accept
Lack of Fusion B-C 67 15 3 reject
Arc Strikes B-C 1 none 7 reject
Mechanical Damage A-C 1 area not defined 14 reject *
Laps/Laminations A-C none - - accept
Misalignment A-C 1 max 10% t (= 1.1) 15 accept
Longitudinal Seams (pipe) N/A - - - accept
