Welding Standard for Telcon

Sl.No. Weld Inspection Items Tolerance Limitation Sketch

Date:

01.09.2010 Rev - 1

Counter Action Against Defect

Missing weld

NOT ACCEPTED

Complete the weld.

Leg Length( L )

L - 1.2 L

INCASE OF DEFECT: Repair by grinding. (Without affecting weld toe) .

Weld under-fill

NOT ACCEPTABLE

Fill it by weld bead.

4(a) Under Cutting 4(b)

Under cut tolerance is 0.4mm (For less than 6 mm plate thickness) Under cut tolerance is 0.5mm For more than 6 mm plate thickness) (

INCASE OF DEFECT: Weld the groove and smooth grinding.

Overlap

The overlap tolerance is 0.3 mm .

IF OVERLAP EXCEED 0.3MM: Excess weld metal must be removed by grinding

6(a)

Bead Surface Blow Holes

Size of blow holes: even one blow hole more than 2mm -- NOT ACCEPTED

Redone by gauging and bead replacement

6(b)

Bead Surface Blow Holes

Number of blow holes: 4 nos/

500 length

IF IT IS MORE THAN 4 NOS / 500 LENGTH: Redone by gauging and bead replacement

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Welding Standard for Telcon

Date:

01.09.2010 Rev - 1

6(c)

Bead Surface Blow Holes

Density: 2 NOS within area of

500 mm 2

ACCEPTED.

6(d)

Bead Surface Blow Holes

Density: 3 nos or more within 2 area of 500 mm -- NOT ACCEPTED

Redone by gauging and bead replacement

Crater

Crater depth exceeding 1mm --

REJECTED

a) If no cracks exist, simply fill the crater. b) In case of crater crack, remove and reweld

Grinding mark(W eld finish)

0.1 mm deep within 10mm length -- ACCEPTABLE

If exceeds, weld it followed by smooth grinding.

9(a)

Reinforcement Height

Less than 1.5mm(for less than 12 mm thickness of plate)

IF HEIGHT > 1.5MM: Remove by grinding.

9(b)

Reinforcement Height

Less than 2.5mm(for 12 to 25 mm thickness of plate)

IF HEIGHT > 2.5MM: Remove by dressing.

9(c)

Reinforcement Height

Less than 3mm(for more than 25 mm)

IF HEIGHT > 3 MM: Remove by grinding.

10

Dent / Scratch marks

NO DENT marks are accepted.

Repair by welding and smooth grinding.

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Welding Standard for Telcon

Bead width varies, weld bead not straight, ripples are not consistent and spatter --NOT ACCEPTABLE

Date:

01.09.2010 Rev - 1

11

Weld appearance

Remove the bead by gauging and reweld it.

12

Spatter removal

Spatter more than 0.5 mm dia in the area of 300 mm sqr. -- NOT

Remove by grinding/chiseling.

ACCEPTABLE

13

Weld Cracks

Not accepted ( All items with a welding Cracks are rej ected).

Remove the crack completely and Reweld.

14

Bead Shape

Reinforcement angle less than 60 degree)

IF ANGLE EXCEEDS 60 : Remove by dressing.

15

Uneven Bead Width

Bead Width difference Less than 4 mm acceptable in a length of 50mm

IF BEAD WIDTH DIFFERENCE EXCEEDS 4MM: Remove by

grinding.

16

Bead Extension Edge

The bead extension edge shall be smooth.( It is desirable that finger nail is not caught in the extension direction.

Smooth grinding at weld toe region.

17

Bead joint

Bead joint section shall smoothly connected with less bead pile. Bead pile more than 2mm ----

REJECTED Repair the bead with grinder.

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Welding Standard for Telcon

Date:

01.09.2010 Rev - 1

18

Lack of fusion

NOT ACCEPTABLE

Remove the bead by gauging and weld caref ully

19

Lack of fusion

NOT ACCEPTABLE

Remove the bead by gauging and weld caref ully

20

Plate 1.6~4.5 mm: Both side

weld (No back-up bar used) 45 + /- 2.5 Within 1 mm (Plate thickness 4.5 Gap between 28 mm, Groove angle 45 +/ Backup bar and 2.5 ) Plate joint IF EXCEED 1 MM: Maintain 1mm by hammering to back up bar.

21

22

Plate beyond 28 mm : Both side welding (No back-up bar

used) -- Double V joint.

23

Corner welding

Weld start and stop should be 50mm away from corner j oint.

Acceptable

24

Welding at bead No weld joint is allowed within 50 intersection mm area from bead intersection.

Stress Concentration occurs where weld beads intersect. Accordingly, starting and ending of weld beads (craters) shall not be positioned in this area.

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