Yanbu Steel Company

Quality Control Procedure

TITLE

Liquid Penetrant Testing Procedure

DOCUMENT NO

PT-2

ISSUE NO.

COPY NO.

YSC hereby certifies that the above named procedure complies with the requirements of the latest edition
of the respective Codes and Standards listed below when noted in the procedure.

CODES AND STANDARDS

ASME B&PV Code Section V (2007 edition with 2009 Addenda)
AWS D1.1/D1.1M:2008
ANSI/ASNT CP-189-2006

Rev. 0

Prepared By:

Accepted by:

Ishfaq Ur Rehman
ASNT NDT Level III
Certificate # 165135

Iain M. Lemond
QA/QC Manager
Yanbu Steel Company

Issued for Implementation

YSC NDT Level III

Mar. 22, 2010

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TABLE OF CONTENTS
1

Scope

Governing Documents

Personnel Qualification

Extent of Testing .

General requirments

Materials

Examination

Procedure for Non Standard Temperature. .

Acceptance Criteria

10

Weld Profiles

11

Engineers Approval for Alternate Acceptance Criteria

12

Repairs .

13

Post Examination Cleaning

14

Records and Reports

15

Procedure Qualification

10

11

12

13

Table
1

Visual Inspection Acceptance Criteria

Figure
1

Acceptable and Unacceptable Weld Profiles

Form
1

1795

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1.0

SCOPE

1.1

Procedures and Standards

This procedure specifies the technique, acceptance standards and documentation requirements for liquid
penetrant examination.
The liquid penetrant examination method is an effective means for detecting discontinuities which are open
to the surface of nonporous metal. Typical discontinuities detectable by this method are cracks, seams, laps,
cold shuts, laminations and porosity. A liquid penetrant is applied to the surface to be examined and
allowed to enter discontinuities. All excess penetrant is then removed, the part is dried, and a developer is
applied. The developer functions both as a blotter to absorb penetrant that has been trapped in
discontinuities and as a contrasting background to enhance the visibility of penetrant indications. The test
part is then examined visually to determine the presence or absence of indications.
This procedure covers liquid penetrant examination by the color contrast (visible) technique using a solvent
removable penetrant system. The materials to be examined may be aluminum, magnesium, steel, titanium
and high temperature alloys.
This procedure is written in accordance with ASME Section V and complies with the requirements of T-150.

1.2

Variations
Variations in testing procedure, equipment, and acceptance standards not included in this procedure may
be used with the approval of the NDT Engineer. Such approved variations shall be recorded in the contract
records.

1.3

Base Metal
The procedure is not intended to be employed for the procurement testing of base metals. However,
welding related discontinuities (cracking, lamellar tearing, delaminations, etc.) in the adjacent base metal
which would not be acceptable under the provisions of this procedure shall be reported to the Engineer for
disposition.

2.0

GOVERNING DOCUMENTS

2.1

Codes and Standards

Those referenced in the Contract Documents including ASME B&PV Code Section V, AWS D1.1/1.1M and
ANSI/ASNT CP-189.

2.2

YSC Documents
Drawings, procedures and specifications listed on the Contract Drawing Index.

3.0

PERSONNEL QUALIFICATION

3.1

ASNT Requirements
Personnel performing PT shall be qualified and certified in accordance with YSC Quality Control Procedure
"Certification Procedure for Qualification and Certification in Nondestructive Testing (CERT-189)", which
meets the requirements of ANSI/ASNT CP-189. Individuals who perform VT shall be qualified for:
(a) NDT Level II, or
(b) NDT Level I working under the NDT Level II

3.2

Certification
Certification of Level I and Level II individuals shall be performed by a Level III individual who has been
certified by:
(a) The American Society for Nondestructive Testing, or
(b) Has the education, training, experience, and has successfully passed the written examination described
in ANSI/ASNT CP-189.

3.3

Exemption of QC1 Requirements

Personnel performing NDT under the provisions of paragraph 3 need not be qualified and certified under
the provisions of AWS QC1.

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3.4

Eye Examination
Inspectors and Assistant Inspector shall have passed an eye examination with or without corrective lenses
to prove near vision acuity of Jaeger J-2 at a distance of 12 in-17 in [300 mm-430 mm]. Eye examination of
all inspection personnel shall be required every three years or less if necessary to demonstrate adequacy.

4.0

EXTENT OF TESTING
Items to be examined in accordance with this procedure shall be as specified on the detail and erection
drawings.

4.1

Full Testing
Weld joints requiring testing by contract specification shall be tested for their full length, unless partial or
spot testing is specified.

4.2

Partial Testing
When partial testing is specified, the location and lengths of welds or categories of weld to be tested shall
be clearly designated in the contract documents.

4.3

Spot Testing
When spot testing is specified, the number of spots in each designated category of welded joint to be tested
in a stated length of weld or a designated segment of weld shall be included in the information furnished to
the bidders. Each spot test shall cover at least 4 in. [100 mm] of the weld length. When spot testing reveals
indications of unacceptable discontinuities that require repair, the extent of those discontinuities shall be
explored. Two additional spots in the same segment of weld joint shall be taken at locations away from the
original spot. The location of the additional spots shall be agreed upon between the Contractor and the
verification Inspector. When either of the two additional spots show defects that require repair, the entire
segment of weld represented by the original spot shall be completely tested. If the weld involves more than
one segment, two additional spots in each segment shall be tested at locations agreed upon by the
Contractor and the verification Inspector, subject to the foregoing interpretation.

4.4

Relevant Information
UT personnel shall, prior to testing, be furnished or have access to relevant information regarding weld joint
geometries, material thicknesses, and welding processes used in making the weldment. UT personnel shall
be apprised of any subsequent repairs to the weld.

5.0

GENERAL REQUIREMENTS

5.1

Extent of Examination
Items to be examined in accordance with this procedure shall be specified on the fabrication drawings,
applicable procedures and specifications for the contract.

5.2

Surface Preparation

5.2.1

General
Material surfaces qualified for testing with this procedure are in the as-welded, as-rolled, as cast or asforged conditions. When only loose surface residuals are present, these may be removed by wiping the
surface with lint-free cloths. However, precleaning of metals to remove processing residuals such as oil,
graphite, scale, insulating materials, coatings, and so forth, should be done using cleaning solvents, vapor
degreasing or chemical removing processes. Surface conditioning by grinding, machining, polishing or
etching shall follow shot, sand, grit and vapor blasting to remove the peened skin and when penetrant
entrapment in surface irregularities might mask the indications of unacceptable discontinuities or otherwise
interfere with the effectiveness of the examination.
All welds shall be visually examined prior to liquid penetrant examination.

5.2.2

Cleaning
Prior to each liquid penetrant examination, the surface to be examined and all adjacent areas within at least
1 inch (25mm) shall be dry and free of any coating, all dirt, grease, lint, scale, welding flux, weld spatter,

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paint, oil and other extraneous matter that could obscure surface openings or otherwise interfere with the
examination.
Typical cleaning agents which may be used are detergents, organic solvents, descaling solutions, and paint
removers. Cleaning agents shall meet the requirements of Paragraph 5.2 when applicable. The surface to be
examined shall not be cleaned by abrasive blasting prior to examination.

5.3

Drying After Cleaning

After cleaning, drying of the surfaces to be examined shall be accomplished by normal evaporation or with
forced hot or cold air. Al least five (5) minutes shall be allowed for drying to ensure that the cleaning
solution has evaporated prior to application of the penetrant.

5.4

Calibration
Light meters shall be calibrated at least once a year or whenever the meter has been repaired.

6.0

MATERIALS
The following penetrant type shall be used.
Magnaflux (Solvent Removable Type)
Dye
:
SKL-SP
Cleaner
:
SKC-S
Developer
:
SKD-S2
ELY (Solvent Removable Type)
Dye
:
Cleaner
:
Developer
:

Checkmor 222
S-72
LD-3S

Intermixing of penetrant materials from different families is not permitted.

Certification of contaminant content shall be obtained for all liquid penetrant materials used on nickel base
alloys, austenitic or duplex stainless steels, and titanium. These certifications shall include the penetrant
manufacturers batch numbers and the test results.
When examining nickel base alloys, all penetrant materials shall be analyzed individually for sulphur
contents. The sulphur content shall not exceed 1% by weight.
When examining austenitic or duplex stainless steel and titanium, all penetrant materials shall be analyzed
individually for halogens content. The halogens content shall not exceed 1% by weight.

7.0

EXAMINATION

7.1

Technique for Standard Temperature

As the standard technique for this procedure, the temperature of the penetrant and the surface of the part
0
0
0
0
to be processed shall not be below 50 F (10 C) nor above 125 F (52 C) through out the examination
0
period. Local heating or cooling is permitted provided the part temperature remains in the range of 50 F
0
0
0
(10 C) to 125 F (52 C) during the examination. Where it is not practical to comply with these temperature
limitations, other temperatures and time may be used, provided the procedures are qualified as specified in
Section 8.0.

7.1.1

Penetrant Application
The penetrant may be applied by dipping, brushing or spraying.
The minimum penetration time shall be ten (10) minutes when examining welds and twenty (20) minutes
when examining forgings and plate material.
The maximum penetration time shall be thirty (30) minutes, but in no case shall be penetrant material be
permitted to dry. If the penetrant material does dry, all dried material shall be removed and the area shall
be recleaned and reexamined.

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7.1.2

Excess Penetrant Removal

After the specified penetrant time has elapsed, any penetrant remaining on the surface shall be removed.
Excess penetrant shall be removed by wiping with a cloth or absorbent paper, repeating the operation until
most traces of penetrant have been removed. The remaining traces shall be removed by lightly wiping the
surface with a cloth or absorbent paper moistened with solvent. To minimize removal of penetrant from
discontinuities, care shall be taken to avoid the use of excess solvent. Flushing the surface with solvent,
following the application of the penetrant and prior to developing, is prohibited.

7.1.3

Drying after Excess Penetrant Removal.

The surface may be dried by normal evaporation, blotting, wiping or forced air

7.1.4

Developing
Nonaqueous developer shall be applied by spraying only to a dry surface. The time between removal of
excess penetrant and the application of the developer in no case shall exceed 10 minutes. The developer
should be agitated to ensure that particles are in suspension and well dispersed. The part shall be sprayed in
such a manner as to assure complete coverage of the part with a thin, even coat of developer. Insufficient
coating thickness may not draw the penetrant out of discontinuities; conversely, excessive coating thickness
may mask indications.
Developing time for final interpretation begins as soon as the developer coating is dry. The minimum
developing time shall be 10 minutes.

7.1.5

Interpretation
Final interpretation shall be made within Ten (10) to sixty (60) minutes after the developer coating is dry. If
bleed-out does not alter the examination results, longer periods are permitted. If the surface to be
examined is large enough to preclude complete examination within this prescribed time, the examination
shall be performed in increments.
Some types of discontinuities are difficult to evaluate if the penetrant diffuses excessively into the
developer. If this condition occurs, close observation of the formation of indications during application of
the developer may assist in characterizing and determining the extent of the indication (s).
With a color contrast penetrant, the developer forms a reasonably uniform coating. Surface discontinuities
are indicated by bleed-out of the penetrant which is normally a deep red color that stains the developer.
Indications with a light pink color may indicate excessive cleaning. Inadequate cleaning may leave an
excessive background making interpretation difficult. A minimum light intensity of 100 fc (1000 Lx) is
required to ensure adequate sensitivity during the examination and evaluation of indications.

8.0

PROCEDURE FOR NON-STANDARD TEMPERATURE

8.1

General
0

When it is practical to conduct a liquid penetrant examination within the temperature range of 50 F (10 C)
0
0
to 125 F (52 C), the examination procedure at the proposed lower or higher temperature range requires
qualification. This shall require the use of a quench cracked aluminum block, which is designated as a liquid
penetrant comparator block in this procedure.

8.2

Liquid Penetrant Comparator

The liquid penetrant comparator blocks shall be made of aluminum, ASTM B 209, Type 2024, 3/8 inch
(10mm) thick, and should have approximate face dimensions of 2 inch (50mm) x 3 inch (75mm). At the
0
0
centre of each face, an area approximately 1 inch (25.4mm) in diameter shall be marked with a 950 F (510
C) temperature indicating crayon or paint. The marked area shall be heated with a blowtorch, Bunsen
0
0
0
0
burner, or similar device to a temperature between 950 F (510 C) and 975 F (524 C). The specimen shall
then be immediately quenched in cold water, which produces a network of fine cracks on each face.
0

The block shall then be dried by heating to approximately 300 F (149 C). After cooling, the block shall be
cut in half. One-half of the specimens shall be designated block A and the other block B for
identification in subsequent processing. Appendix II illustrates the comparator blocks A and B. As an
alternative to cutting the block in half to make blocks A and B, a separate block 2 inch (50mm) x 3 inch
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(75mm) can be made using the heating and quenching technique as described above. Two comparator
blocks with closely matched crack patterns may be used. The blocks shall be marked A and B.

8.3

Comparator Application

8.3.1

If it is desired to qualify a liquid penetrant examination procedure at a temperature of less than 50 F (10
C), the proposed procedure shall be applied to block B after the block and all materials have been cooled
and held at the proposed examination temperature until the comparison is completed. A standard
procedure which has previously been demonstrated as suitable for use shall be applied to block A in the
0
0
0
0
50 F (10 C) to 125 F (52 C) temperature ranges. The indications of cracks shall be compared between
block A and B. If the indications obtained under the proposed conditions on block B are essentially the
0
0
0
0
same as obtained on block A during examination at 50 F (10 C) to 125 F (52 C), the proposed procedure
shall be considered qualified for use.

8.3.2

A procedure qualified at a temperature lower than 50 F (10 C) shall be qualified from that temperature to
0
0
50 F (10 C).

8.3.3

If the proposed temperature for the examination is above 125 F (52 C), block B shall be held at this
temperature throughout the examination. The indications of cracks shall be compared as described in
0
0
0
paragraph 7.3.1 while block "B" is at the proposed temperature and block "A" is at the 50 F (10 C) to 125 F
0
(52 C) temperature range.

8.3.4

To qualify a procedure for temperatures above 125 F (52 C), the upper and lower temperature limits shall
be established and the procedure qualified at these temperatures.

8.3.5

As an alternate to the requirements of paragraphs 8.3.1 and 8.3.2, it is permissible to use a single
comparator block for the standard and nonstandard temperatures and to make the comparison by
photography.

8.3.6

When the single comparator block and photographic technique is used, the processing details (as
applicable) describe in paragraphs 8.3.1 and 2.3.2 apply. The block shall be thoroughly cleaned between the
two processing steps. Photographs shall be taken after processing at the nonstandard temperature and then
after processing at the standard temperature. The indication of cracks shall be compared between the two
photographs. The same criteria for qualification as paragraph 8.3.1 shall apply.

8.3.7

Identical photographic techniques shall be used to make the comparison photographs.

9.0

ACCEPTANCE CRITERIA

All visually inspected welds shall be acceptable if the criteria of Table 1 are satisfied.

10.0

WELD PROFILES
All welds meet the visual acceptance criteria of Table 1 and shall be free from cracks, overlaps, and the
unacceptable profile discontinuities exhibited in Figure 1 except as otherwise allowed in 10.3.

10.1

Fillet Welds
The faces of fillet welds may be slightly convex, flat, or slightly concave as shown in Figure 1. Figure 1 (C)
shows typically unacceptable fillet weld profiles.

10.2

Intermittent Fillet Welds

Except for undercut, as allowed by the code, the profile requirements of Figure 5.4 shall not apply to the
ends of intermittent fillet welds outside their effective length.

10.3

Convexity
Except at outside welds in corner joints, the convexity C of a weld or individual surface bead shall not
exceed the values given in Figure 1.

10.4

Groove or Butt Welds

Groove welds shall be made with minimum face reinforcement unless otherwise specified. In the case of
butt and corner joints, face reinforcement shall not exceed 1/8 in. [3 mm] in height. All welds shall have a
gradual transition to the plane of the base-metal surfaces with transition areas free from undercut except as
allowed by this code. Figure 1 (D) shows typically acceptable groove weld profiles in butt joints. Figure 1 (E)
shows typically unacceptable weld profiles for groove weld butt joints.

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10.4.1

Flush Surfaces
Butt welds required to be flush shall be finished so as to not reduce the thicknesses of the thinner base
metal or weld metal by more than 1/32 in. [1 mm], or 5% of the material thickness, whichever is less.
Remaining reinforcement shall not exceed 1/32 in. [1 mm] in height. However, all reinforcement shall be
removed where the weld forms part of a faying or contact surface. All reinforcement shall blend smoothly
into the plate surfaces with transition areas free from undercut.

10.4.2

Finish Methods and Values

Chipping and gouging may be used provided these are followed by grinding. Where surface finishing is
required, roughness values (see ASME B46.1) shall not exceed 250 microinches [6.3 micrometers]. Surfaces
finished to values of over 125 microinches [3.2 micrometers] through 250 microinches [6.3 micrometers]
shall be finished parallel to the direction of primary stress. Surfaces finished to values of 125 microinches
[3.2 micrometers] or less may be finished in any direction.

11.0

ENGINEERS APPROVAL FOR ALTERNATE ACCEPTANCE CRITERIA

Acceptance criteria for production welds different from those described in this procedure may be used for a
particular application, provided they are suitably documented by the proposer and approved by the NDT
Engineer. These alternate acceptance criteria may be based upon evaluation of suitability for service using
past experience, experimental evidence or engineering analysis considering material type, service load
effects, and environmental factors.

12

REPAIRS
Welds found unacceptable by PT shall be repaired Re-paired areas shall be retested by Penetrant Testing
with results tabulated on the original form (if available) or additional report forms. The removal of weld
metal or portions of the base metal may be done by machining, grinding, chipping, or gouging. It shall be
done in such a manner that the adjacent weld metal or base metal is not nicked or gouged. Oxygen gouging
shall not be used in quenched and tempered steel. Unacceptable portions of the weld shall be removed
without substantial removal of the base metal. The surfaces shall be cleaned thoroughly before welding.
Weld metal shall be deposited to compensate for any deficiency in size.

12.1

Contractor Options
The Contractor (YSC) has the option of either repairing an unacceptable weld or removing and replacing the
entire weld, except as modified by 12.3. The repaired or replaced weld shall be retested by the method
originally used, and the same technique and quality acceptance criteria shall be applied. If the Contractor
(YSC) elects to repair the weld, it shall be corrected as follows:

12.1.1

Overlap, Excessive Convexity, or Excessive Reinforcement

Excessive weld metal shall be removed.

12.1.2

Excessive Concavity of Weld or Crater, Undersize Welds, Undercutting

The surfaces shall be prepared and additional weld metal deposited.

12.1.3

Incomplete Fusion, Excessive Weld Porosity, or Slag Inclusions

Unacceptable portions shall be removed and rewelded.

12.1.4

Cracks in Weld or Base Metal

The extent of the crack shall be ascertained by use of acid etching, MT, PT, or other equally positive means;
the crack and sound metal 2 in. [50 mm] beyond each end of the crack shall be removed, and rewelded.

12.2

Localized Heat Repair Temperature Limitations.

Members distorted by welding shall be straightened by mechanical means or by application of a limited
amount of localized heat. The temperature of heated areas as measured by approved methods shall not
exceed 1100F [600C] for quenched and tempered steel nor 1200F [650C] for other steels. The part to be
heated for straightening shall be substantially free of stress and from external forces, except those stresses
resulting from the mechanical straightening method used in conjunction with the application of heat.

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12.3

Engineers Approval
Prior approval of the Engineer shall be obtained for repairs to base metal, repair of major or delayed cracks,
repairs to ESW and EGW with internal defects, or for a revised design to compensate for deficiencies. The
Engineer shall be notified before welded members are cut apart.

12.4

Inaccessibility of Unacceptable Welds

If, after an unacceptable weld has been made, work is performed which has rendered that weld inaccessible
or has created new conditions that make correction of the unacceptable weld dangerous or ineffectual,
then the original conditions shall be restored by removing welds or members, or both, before the
corrections are made. If this is not done, the deficiency shall be compensated for by additional work
performed conforming to an approved revised design.

12.5

12.5.1

12.5.2

12.5.3

12.5.4

13.

Welded Restoration of Base Metal with Mislocated Holes

Except where restoration by welding is necessary for structural or other reasons, punched or drilled
mislocated holes may be left open or filled with bolts. When base metal with mislocated holes is restored by
welding, the following requirements apply:
Base metal not subjected to cyclic tensile stress may be restored by welding, provided the Contractor
prepares and follows a repair WPS. The repair weld soundness shall be verified by appropriate NDT, when
such tests are specified in the contract documents for groove welds subject to compression or tension
stress.
Base metal subject to cyclic tensile stress may be restored by welding provided:
(a)
The Engineer approves repair by welding and the repair WPS.
(b)
The repair WPS is followed in the work and the soundness of the restored base metal is verified by
the NDT method(s) specified in the contract documents for examination of tension groove welds or
as approved by the Engineer.
In addition to the requirements of 16.5.1 and 16.5.2, when holes in quenched and tempered base metals
are restored by welding:
(a)
Appropriate filler metal, heat input, and PWHT (when PWHT is required) shall be used.
(b)
Sample welds shall be made using the repair WPS.
(c)
RT of the sample welds shall verify that weld soundness conforms to the requirements of 14.2.1 of
YSC Radiographic Testing Procedure (RT-2).
(d)
One reduced section tension test (weld metal); two side bend tests (weld metal); and three CVN
tests of the HAZ (coarse grained area) removed from sample welds shall be used to demonstrate
that the mechanical properties of the repaired area conform to the specified requirements of the
base metal.
Butt Weld surfaces shall be finished so as to not reduce the thicknesses of the thinner base metal or weld
metal by more than 1/32 in. [1 mm], or 5% of the material thickness, whichever is less. Remaining
reinforcement shall not exceed 1/32 in. [1 mm] in height. However, all reinforcement shall be removed
where the weld forms part of a faying or contact surface. All reinforcement shall blend smoothly into the
plate surfaces with transition areas free from undercut.

POST EXAMINATION CLEANING

Surface shall be cleaned to remove residual penetrant and developer using the solvent cleaner described in
Paragraph 7.1.2

14

RECORDS AND REPORTS

14.1

Forms
When required by contract or the applicable Code or Standard, acceptable visual inspections shall be recorded
on the Process Control Plan or PT Inspection Report Form 17959, as they apply. The sign-off shall include any
special equipment used to complete the visual inspection.

14.2

Incomplete Inspection
Areas for which complete inspection was not practicable shall also be noted, along with the reason why the
inspection was incomplete.

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14.3

Reference Marks
Unless otherwise specified, the reference position and the location and extent of unacceptable
discontinuities shall also be marked physically on the workpiece.

14.4

Retest Reports
Evaluation of retested repaired weld areas shall be tabulated on a new line on the report form. If the
original report form is used, an R1, R2, Rn shall prefix the indication number. If additional report forms are
used, the R number shall prefix the report number.

14.5

Completed Reports
A full set of completed report forms of welds subject to PT by the Contractor for the Owner, including any
that show unacceptable quality prior to repair, shall be delivered to the Owner upon completion of the
work.
The Contractors obligation to retain VT Reports shall cease:

15.

(a)

Upon delivery of this full set to the Owner, or

(b)

One full year after the completion of the Contractors work, provided the Owner is given prior
written notice.

PROCEDURE QUALIFICATION
Any change of a requirement in Table T-621, Article 6 of ASME Sec V, identified as an essential variable shall
require requalification of this procedure by demonstration. A change of a requirement identified as a non
essential variable does not require requalification of this procedure. All changes of essential or non essential
variables from those specified in this procedure shall require revision of this procedure.

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Table 1
Visual Inspection Acceptance Criteria
Statically
Loaded
Nontubular
Connections

Cyclically
Loaded
Nontubular
Connections

Tubular
Connections
(All Loads)

(1) Crack Prohibition

Any crack shall be unacceptable, regardless of size or location.

(2) Weld/Base-Metal Fusion

Thorough fusion shall exist between adjacent layers of weld metal and between weld
metal and base metal.

(3) Crater Cross Section

All craters shall be filled to provide the specified weld size, except for the ends of
intermittent fillet welds outside of their effective length.

(4) Weld Profiles

Weld profiles shall be in conformance with 10

(5) Time of inspection

Visual inspection of welds in all steels may begin immediately after the completed welds
have cooled to ambient temperature. Acceptance criteria for ASTM A514, A517, and
A709 Grade 100 and 100 W steels shall be based on visual inspection performed not less
than 48 hours after completion of the weld.

(B) The frequency of piping porosity in fillet welds shall not exceed one in each 4 in. [100
mm] of weld length and the maximum diameter shall not exceed 3/32 in. [2.5 mm].
Exception: for fillet welds connecting stiffeners to web, the sum of the diameters of
piping porosity shall not exceed 3/8 in. [10 mm] in any linear inch of weld and shall not
exceed 3/4 in. [20 mm] in any 12 in. [300 mm] length of weld.

(C) CJP groove welds in butt joints transverse to the direction of computed tensile stress
shall have no piping porosity. For all other groove welds, the frequency of piping
porosity shall not exceed one in 4 in. [100 mm] of length and the maximum diameter
shall not exceed 3/32 in. [2.5 mm].

Discontinuity Category and Inspection Criteria

(6) Undersized Welds

The size of a fillet weld in any continuous weld may be less than the specified nominal
size (L) without correction by the following amounts (U):
L
specified nominal weld size, in. [mm]
<3/16 [5]
1/4 [6]
>5/16 [8]

U
allowable decrease from L, in. [mm]
<1/16 [2].
<3/32 [2.5]
<1/8 [3].

In all cases, the undersize portion of the weld shall not exceed 10% of the weld length.
On web-to-flange welds on girders, underrun shall be prohibited at the ends for a length
equal to twice the width of the flange.
(7) Undercut
(A) For material less than 1 in. [25 mm] thick, undercut shall not exceed 1/32 in. [1 mm],
with the following exception: undercut shall not exceed 1/16 in. [2 mm] for any
accumulated length up to 2 in. [50 mm] in any 12 in. [300 mm]. For material equal to or
greater than 1 in. thick, undercut shall not exceed 1/16 in. [2 mm] for any length of weld.

(B) In primary members, undercut shall be no more than 0.01 in. [0.25 mm] deep when
the weld is transverse to tensile stress under any design loading condition. Undercut
shall be no more than 1/32 in. [1 mm] deep for all other cases.
(8) Porosity
(A) CJP groove welds in butt joints transverse to the direction of computed tensile stress
shall have no visible piping porosity. For all other groove welds and for fillet welds, the
sum of the visible piping porosity 1/32 in. [1 mm] or greater in diameter shall not exceed
3/8 in. [10 mm] in any linear inch of weld and shall not exceed 3/4 in. [20 mm] in any 12
in. [300 mm] length of weld.

Note: An X indicates applicability for the connection type; a shaded area indicates non-applicability.
Doc Ref: PT-2 (AWS D1.1/D1.1M)

Page 11 of 13

YSC PENETRANT TESTING PROCEDURE

PT-2
FIGURE 1 ------ ACCEPTABLE AND UNACCEPTABLE WELD PROFILES

(A) Desirable Fillet Weld Profiles

a

(B) Acceptable Fillet Weld Profiles

Convexity, C, of a weld or individual surface bead with dimension W shall not exceed the value of the following table
WIDTH OF WELD FACE OR
INDIVIDUAL SURFACE BEAD, W

MAX. CONVEXITY, C

W< 5/16 in. [8 mm]

W > 5/16 in. [8 mm] TO W< 1 in. [25 mm]
W > 1 in. [25 mm]

UNDERSIZE
WELD

EXCESSIVE CONVEXITY EXCESSIVE UNDERCUT

1/16 in. [2 mm]

1/8 in. [3 mm]
3/16 in. [5 mm]

UNDERSIZE
WELD

OVERLAP

INCOMPLETE
FUSION

(C) UNACCEPTABLE FILLET WELD PROFILES

BUTT PLATE
EQUAL THICKNESS PLATE
b

BUTT JOINT (TRANSITION)

UNEQUAL THICKNESS PLATE

Reinforcement R shall not exceed 1/8 in. [3 mm]

(D) ACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINT

EXCESSIVE WELD
REINFORCEMENT

UNDERFILL

EXCESSIVE
UNDERCUT

OVERLAP

(E) UNACCEPTABLE GROOVE WELD PROFILES IN BUTT JOINTS

Note: All welds shall meet the visual acceptance criteria of Table 1

Doc Ref: PT-2 (AWS D1.1/D1.1M)

Page 12 of 13

YSC PENETRANT TESTING PROCEDURE

PT-2
Form 17959 Rev. 0

Yanbu Steel Company

LIQUID PENETRANT
EXAMINATION REPORT

P.O.Box: 30075
Madinat Yanbu, Al Sinaiyah
Saudi Arabia
Client

Contract No:

Report No:

Date

Location

Code / Acceptance Criteria:

Procedure

Technique

Drawing No:

Assembly / Sub-Assembly

Mark No

Viewing Conditions

Material

Material Thickness

Welding Process

Surface Condition

Penetrant

Developer

Cleaner

Before PWHT

Penetration (Dwell) Time

Development Time

Penetrant Remover

After PWHT

Seam Weld
Number

Welder ID

Assembly

Mark Number

Location

Accept

Reject

Remarks

Remarks
We, the undersigned, certify that the statements in this record are correct and that the welds were prepared and tested
according to YSC Visual Inspection Procedure ( PT-2 ) which is in conformance with the requirements of Section 6.10,
Part C of AWS D1.1/D1.1M, (
2008
) Structural Welding CodeSteel.

PERFORMED / EVALUATED BY:

CLIENT REPRESENTATIVE

SIGNED

SIGNED

NAME

NAME

LEVEL

Doc Ref: PT-2 (AWS D1.1/D1.1M)

DATE

LEVEL

DATE

Page 13 of 13