CSWIP 3.

2 Senior Welding Inspection

ThicknessTransition
Thetransitionshouldbeaminimumof1in4

Transition Joints

TWI Training & Examination

Services
Course Reference WIS 10
Course notes section reference None

MaterialTransition
DissimilarweldingStainlesstoCarbonSteel

Cracking

Effectsofchromiumonsteel

Effectsofcarbononstainlesssteel
Thechromiumfromthestainlesssteelside
mixeswiththecarbonsteelandcanleadto
hardzonesbeingproducedresultingin
cracking

Effectsofcarbononstainlesssteel

Welddecay

Effectsofcarbononstainlesssteel
Thecarbonfromthecarbonsteelside
mixeswiththestainlessandcanleadto
welddecay

Appendix 1

CSWIP Senior Welding Inspector

Question:
You are required to visit a site on which your inspection team have been working. The fabrication is now
completed in accordance with a nominated specification and is awaiting your final inspection/approval.
Prior to signing the Certificate of Conformance;
1)
2)
3)

What questions do you ask?

What measurements would you take?
What documents would you review?

Typical answer:
Prior to the site visit it is vital to spend some time planning the visit in order that a logical approach be
made and that important details are not overlooked. Knowledge of the standard used and an idea of the
service conditions would be useful in assessing the fitness for purpose of the product. A list of all
personnel in the inspection team(s) and contact details of team leader(s) will ensure that relevant personnel
are available to answer questions as required. Types of questions may include any difficulties encountered
with the job, particularly attention being given to those concerning the contractor. Further information
regarding repair rates, safety standards on-site and the general moral and standard of work amongst the
inspection team(s) throughout production. Any unusual incidents may also need to be investigated. The
availability of quality plans will help greatly in the planning of the audit. The review/audit of all relevant
documentation is a major requirement prior to signing any Certificate of Conformance or compliance. In
some major standards/codes the list of documents to be included within the fabrication file are listed. In
the absence of such the following could be considered a basic guide to these documents for review/audit:
1) A review of the quality plan and inspection check list to ensure all stages are completed and signed off.
2) Material certificates, mill test reports, and material traceability records are documented and accepted.
(This may include welding consumables)
3) Process control procedures should be reviewed for adequacy, accuracy and approval. These should
include approved procedures for cutting, welding, repair, NDT, heat treatment, coating etc.
4) Review of qualifications should include welder approvals, NDT operator or technician approvals. All
inspection approvals should be in date at time of fabrication and as identified and described within the
contract documents.
5) Inspection reports should be reviewed and should include visual inspection, NDT, dimensional
control, painting/coating etc.
6) If the product is pressure containment i.e. pressure vessel or high pressure pipeline etc. then
hydrostatic testing procedures and a test report/acceptance reports should be reviewed, along with test
gauge calibration certificates and any associated documentation.
7) As built drawings showing materials and weld maps should be reviewed for completeness.
8) Finally, transit and tie down procedures should all have been approved by the relevant engineer prior to
the final acceptance of the product and issue of any signed certificate of conformance.
1

Reference to the specification

As Built Weld Maps Weld Traceability log
Weld Numbers
Welder Numbers
Material Classification & Certification
Welding Procedure Numbers (WPS PQRs) and Documentation
Material Traceability & Material Certificates
Consumable Control Procedures & Consumable Certificates
Welders register and all approval Certificates
Weld Visual Inspection
& Visual Inspection Reports
NDT Procedures
Procedures:
List of NDT Operators & Approval Certificates
NDT Procedures
NDT Reports
R/T Report Numbers
U/T Report Numbers
MPI Report Numbers
Dye/Pen Report Numbers
Dimensional Control Procedures & Dimensional Control Reports
PWHT Procedures & PWHT Reports + Calibration Cert.s
Hydro-test Procedures & Hydrotest Reports + Calibration Cert.s
Painting Procedures & Painting Conformance Reports
Non-Conformance Reports
Load Out Procedure
Engineering Queries
As Built Drawings

Appendix 2

Senior Welding Inspector

Technical Notes Rad. U/T. MPI & Penetrant
Radiography:
X ray:
KV as low as possible = Best definition. Generally 60kV lowest is OK for
lower density aluminium. Normally a minimum of 140 kV is required for steels
but must be increased as thickness increases
Focal Spot:

The larger the focal spot the longer must be the FFD

Gamma:

SFD typically 500mm but varies greatly, Double the distance

= 4 x original exposure
Typical source size of 1.5mm x 1.5mm

Ytterbium:
Iridium 192:
Cobalt 60:
Lead screens:
front/back

Used on thickness under 12 mm (Costly)

Used for applications thickness 12 to 60mm
Used on thickness over 40 to 200 mm
0.1mm front and 0.15 mm back but often 0.125
Used on all gamma and x-ray above 120 kV

Development:
Density:

Typically 4 mins at 20 C
Typically 2-3.5

Sensitivity:
Typically 2% or less. (IQI Diameter of smallest
wire/thickness x 100)
Viewing Light Conditions:

20 lux. Viewer able to view up to density of 4

Minimum screen luminance 100,000 cd/m2
1

Appendix 2

Senior Welding Inspector

Ultrasonic:
Probes:
Check for lamination

0 Compression Probe

Plate thickness <10 mm

70

Plate thickness 10 15 mm

60-70

Plate thickness 15 + mm

45- 60

Plate thickness >50 mm

45 only

Mhz:
Normal welds
4-5 MHz Larger grains lower value.
Higher value = less pen
Record crystal size (Usually 10mm) single or twin?
Sensitivity:
Which calibration block V1/V2? Hole diameter + depth
(side drilled hole)
Couplant:

Record of the type used

Appendix 2

Senior Welding Inspector

Magnetic Particle:
Through paint up to 50 microns
With DC Sub surface defects can be detected approximately 2mm deep
(depends on strength of current)
Above 50 C up to 3150C usually dry powder
Yokes:

No current recorded lift off of > 4.5kg

Normally AC but can be DC

Prods:

6 amp/mm of space i.e. 200mm = 1200 amps

Space and amperage must be recorded. 7.5 20 cm (75 200 mm)

All must record 2 directions at 90 Burmah Castrol Strip type 1 indications of 3

lines

Appendix 2

Senior Welding Inspector

Penetrant:
Temperature:

10C to 50 C

Dwell/Contact time 5 60 mins

Evaluation time 10 30 mins
Viewing Light Conditions for Penetrant and MPI:
Normal light:

500 lux minimum

Fluorescent: Use UVA lamp minimum power 1000 microwatt/cm2

Light levels: Below 20 lux ambient light

Appendix 2

Senior Welding Inspector

AUDIT of NDT Reports
Reports Check List
RT Radiographic Testing
1)

Material Type (All types)

2)

Time/Stage of inspection

3)

Place of inspection

4)

Procedure/Standard number given

5)

Radiographic Technique (e.g. DWDI)

6)

Screens (Type & thickness)

7)

Type of radiation (Gamma/x-ray)

8)

Type/Strength of source or Kva

9)

SFD

10) Type and range of IQI

11) Speed of film (Characteristic Curve)
12) Sensitivity as % (below 2%)
13) Density range (2-3.5)
14) Focal Spot Size
15) Geometric Un-sharpness (g)
16) Exposure Time
17) Development method and time
18) All Defects Identified, Sized and Located
19) NDT Technicians Qualifications & Name
20) Signed stamped and dated
21) BS Method BS 2910 (pipe) BS 2600 (Plate) Now replaced by BS EN 444

Appendix 2

Senior Welding Inspector

AUDIT of NDT Reports
Reports Check List
UT Ultrasonic Testing
1)

Material Type

(Large grain lower Hz)

2)

Time/Stage of inspection

3)

Place of inspection

4)

Procedure/Standard number given

5)

Shear/Compression Probe

6)

Probe Size (Usually 10 mm) & Type

7)

Probe Frequency (4-5 MHz < 3 for Cu/SS)

8)

Probe Angle <10 =70 /10-15 = 60-70 >15 = 45 -60

9)

Calibration Block (Type & Hole used)

10) Calibration Range

11) Scanning method
12) Surface finish
13) Type of Couplant
14) Type of equipment
15) Scanning Sensitivity
16) Recording Level
17) Joint configuration and area of weld tested
18) All Defects Identified, Sized and Located
19) NDT Technicians Qualifications & Name
20) Signed stamped and dated
21) BS Method BS 3923
22) Now replaced by BS EN 585 & BS N 1714

Appendix 2

Senior Welding Inspector

AUDIT of NDT Reports
Reports Check List
MT Magnetic Particle Testing
1)

Material Type (Ferritic Steels Only)

2)

Time/Stage of inspection

3)

Place of inspection

4)

Procedure/Standard number given

5)

Method (Wet/Dry Fluorescent/Contrast etc.)

6)

Method & standard of surface preparation

7)

Method of Magnetisation (Direct current etc)

8)

Equipment type (Prod/Yolk/Magnet/Bench)

9)

Prod spacing/amperage (7.5 amp/mm)

10) Contrast Paint (Type and application

11) Test sequence (2 x directions @ 90)
12) Poor surface finish may mask Indications
13) Sub Surface imperfections (2mm Max)
14) Black light 20 Lux or 1000W/cm2
15) Contrast Light Minimum 500 Lux
16) Flux measurement Strips/kg Force etc.
17) > 50C dry powder inks are sued
18) All Defects Identified, Sized and Located
19) NDT Technicians Qualifications & Name
20) Signed stamped and dated
21) BS Method BS 6072 & Inks BS 4049
22) Now replaced by BS EN 571

Appendix 2

Senior Welding Inspector

AUDIT of NDT Reports
Reports Check List
PT Penetrant Testing
1)

Material Type (Non Porous Only)

2)

Time/Stage of inspection

3)

Place of inspection

4)

Procedure/Standard number given

5)

Method (Colour Contrast/Fluorescent)

6)

Method & standard of surface preparation

7)

Surface finish is critical (EB as welded??)

8)

Shelf Life of Chemicals (Normally 1 Year)

9)

Penetrant Application Method (Spray/Tank)

10) Penetrant Dwell time (5 60 minutes)

11) Method of Penetrant Removal
12) Type and application of developer
13) Evaluation time (10- 30 minutes)
14) Black Light (20 Lux or 1000W/cm2)
15) Contrast Light (Minimum 500 Lux)
16) Operating Temperature range (5-50C)
17) Surface breaking only imperfections
18) All Defects Identified, Sized and Located
19) NDT Technicians Qualifications & Name
20) Signed stamped and dated
21) Method BS 6443 22) Now replaced by BS EN 9934 Parts 1-3

Ultrasonic Inspection Report

Ultrasonic Inspection Report
Reference Number:
Weld Reference:
Weld Preparation
40
2

Points to be Identified

Sheet 1 of 1
Welder No:

Material Type:
Surface Condition:
Welding Process:
Ultrasonic Unit:
Couplant:

Carbon Mn Steel (plate)

As Welded
SMAW
USM 3

Welders Number not stated

Root gap not stated
Manufacturers name not stated

Probe and frequency

Size

Sensitivity Setting

70 4 MHZ

MAP

F.S.H From 1.5 Hole

60 !0 MHZ

MAP

F.S.H From 1.5 Hole

Couplant not stated

Crystal diameter not stated
No technique stated Full/half skip

Longitudinal and Transverse carried out from surface side only. Lack of side wall fusion
located using 60 probe.

No procedure stated
No actions stated

Action:

No qualifications stated
No company stamp or name
Name: Tom Farthing

Qualification Details:

Signature: T.Farthing

Copyright TWI Ltd 2009

No dimensions given for defect

Report:

Date: 19/06/08
Place
stamp
here

No Reference to drawing Number

No Reference to Shear probe

Magnetic Particle Report

Points to be Identified

Magnetic Particle Report

Reference Number: MT 101

Sheet 1 of 1

No Welder Number Stated

Weld Reference: wn78

Welder No:

240v to high/ unsafe

Weld Preparation

Material Type: Carbon Mn Steel (Plate)

20

Surface Condition: As Welded

Should be Two Directions

Welding Process: GTAW

Black Ink to BS EN 9934

Dye Penetrant Method

Method of Magnetisation

Spacing to far apart (110mm)

Reference to Contrast Paint Not Stated

Reference to Ink Application not Stated

A.C Yoke 240v Spacing 150mm

One Direction used only
tU
No

Black Ink to BS4067

d
se

Lift of Force to low should be 4.5 Kg

A.C Will Not Find Sub-surface Defects

Lift of Force 2.5 Kg

Slight Sub-Surface indication 157mm from datum

Further Investigation would be Required

Wrong Name on Signature

Action:

No Action Required

Qualification Details not Stated

No Company Stamp

Name: Robert Staines

Qualification Details:

Signature: S. Staines
Place
Stamp
Here

Date: 30/04/08

No Procedure Stated
No Reference to Drawing Number

Copyright TWI Ltd 2009

Length of Defect not Stated

Report:

Radiographic Report
Radiographic Report
Reference Number: IR 12

Points to be Identified

Sheet 1 of 1

Weld Reference: wn 10

Welder Number should be stated

Welder No: NA

Co 60 wrong Source
Material Type:

Carbon Mn Steel (plate)

KV stated along with Gamma Stated

Surface Condition: As Welded

35

Source Strength to High

5.0

Welding Process:

Sub-arc

2nd

side Back Gouged

Radiographic Equipment/Gamma: Co 60

KV: 150

MA:

10cm

Exposure time:

Film Type & Size:

AGFA D4

Focal Spot/Source Dimensions: 3x3mm

Development time & Temp:

8mm@16c

Screens:

0.125 lead rear only

Radiographic Technique:

DWDI

IQI Type:

13 Cu EN 462

FFD/SFD:

Source Strength: 100C

Sensitivity

Density

Comments

A-B

1.9

2.5

150mm from,A, lack of penetration

B-C

1.9

2.2

3mm from B Transverse Crack, or Film Mark

C-D

1.9

Exposure time to long

Development to short/Temp to High 4min/20c

1Hr

Film Identification

SFD is Wrong, to Small

Action

Source Dimensions to large

Screens should be Front and Back
Technique Wrong, should be SWSI
Wrong IQI Type

2.2

Lengths of Defects not stated

No Action Stated

No Defects observed

Levels of Qualifications should be on

Name: Tom Farthing

Qualification Details: PCN

Signature: T.Farthing

Date: 19/06/08
Place
stamp
here

No Company Stamp

Copyright TWI Ltd 2009

Weld Preparation