WELDING QUALITY CONTROL

QC & INSPECTION MANUAL

Before
Preparation

During Welding
NDT

After Fillet fracture Fillet fracture Sample for DT

DT
Macro

Doc.
 BEFORE WELDING
• Specify the code of practice
• Inspection appointment
– Date
– Site location and route map
– Contractor, Owner, Consultant
– Project
• Product information
– Material, system,
• Manpower required
– Number of inspection personnel
– Support service requirement
• Inspection tools
– Welding gauge, mirror, e-camera, measuring instrument,
– lighting, thermometer, chalk, marker
• Related NDT DPI, MPI, U-Sonic
• Other requirement
– Pre-heat, inter-pass heating,
PWHT
• Forms and document
– Record, VI, PWPS, code book
 DURING WELDING
• Welding in progress
– Monitoring of welding parameter
• Support technician checked current, voltage, speed
• Observe wire extension, angle of torch etc
• Observe gas flow-rate,
• Inter-pass temperature checked
– Measurement of welding parameter
• Welding current, voltage, speed, flow-rate, temperature
– Inspection and NDT
• Visual, Hot MPI, U-sonic
• VI - Root pass quality, Inter-pass quality, cap pass quality
– Repairing
• Minor repair during welding- inter-pass bead, tungsten inclusion
• Finishing repair touch-up
– Recording
• Filling record sheet, ready for VI to endorse
 AFTER WELDING
• VISUAL INSPECTION – mandatory in most code of practice
– Visual inspection and evaluation by code
• Cap pass quality
– Undercut, over-lap, high bead, bead width, uneven height, under-fill, tool-
mark, bead profile, inter-bead continuation, crater-filling, crack
• Root pass
– Over-penetration, LOP, LOF, root profile, burnt thru, oxidation, etc
– Measurement
• High-low, distortion, dimension variation
– Recording in document
• Fill up VI document and endorsement/signing
• Signing of Record document
– Marking / stamping
• Sticker no, position for DT
• Write on test-piece – name, date, process, position, test no. etc
 Visual
inspection

• Root pass
• Cap pass
 Visual inspection

• Fillet weld
• Root pass of a pipe
 AFTER WELDING
• NDT - conduct the test if required – by authorized personnel,
witnessed by VI if required
– Dye Penetrant Testing
– Magnetic Particle Testing
– Radiography
– Ultra-sonic Testing
 LPT on fillet weld
- Indication of weld crack
MAGNETIC PARTICLE TESTING
 AFTER WELDING
• DT - conduct the test if required – at authorized test house, witnessed
by VI if required
– Bending Test – correct preparation, former diameter
– Nick Break Test – by tensile machine allowed
– Fillet Fracture test
– Tensile Test – prepare according the code, display the chart
Applied force

Weld

Base Support
 AFTER WELDING
• DT - conduct the test if required – at authorized test house, witnessed
by VI if required
– Macro-structure Test – produce the macrograph
– Hardness Test – Hardness Vickers
– Charpy Impact test – at required temperature
 AFTER WELDING
• DT – conduct the test if required – at authorized test house, witnessed
by VI if required
– Corrosion Test
– Ferrite count – for stainless steel
– Fatigue Test
– CTOD test
 AFTER WELDING
• DOCUMENTATION – fill the form, ready for endorsement by VI
– Welding Record
– Visual Inspection
– Radiography
– Bend Test
– Nick Break Test
– Fillet Fracture Test
 AFTER WELDING
• DOCUMENTATION – Fill the form, ready for
endorsement by VI
– Tensile Test
– Macro-structure Test
– Hardness Test
– Charpy Impact Test
– Corrosion Test
– Ferrite count
– Fatigue Test
 AFTER WELDING
• DOCUMENTATION – fill the form, ready for endorsement by VI
– WPQR
– WQTR
– WPS