VISUAL INSPECTION REPORT (VI)

Visual inspection in welding is a critical aspect of quality control and assurance,

involving a thorough examination of welds and the surrounding areas using the
naked eye or aided by simple tools. This inspection is generally the first level of
assessment and is crucial for detecting visible defects, discontinuities, or deviations
from specified requirements. Visual inspection is often carried out by qualified
welding inspectors or other personnel with the necessary training and expertise.

1)Weld Profile: Inspectors examine the overall appearance of the weld, including its
size, shape, and alignment. They ensure that the weld conforms to the specified
dimensions and that there are no issues such as undercutting, overlap, or insufficient
penetration.

2) Weld Surface Condition: The surface of the weld is checked for cleanliness,
smoothness, and the absence of any undesirable features like spatter, slag, or other
contaminants.

3) Weld Reinforcement: Inspectors assess the amount of weld metal deposited

above the base material surface. Excessive or insufficient reinforcement can affect
the mechanical properties of the weld.
 ARC STRIKE

Figure 12

An "arc strike" in welding refers to the unintentional contact of an electric welding arc
with a surface other than the intended work piece. This can occur when the welding
electrode or arc momentarily touches a surface other than the base metal being
welded. Arc strikes can happen on nearby metal structures, clamps, or even the
welding equipment itself.

Arc strikes are generally considered undesirable for several reasons:

1. Surface Damage: Arc strikes can cause damage to the surface they touch, leading
to localized heating, melting, or even gouging. This can result in surface irregularities
and compromise the integrity of the material.
2. Hardening: In some cases, an arc strike can cause localized heat and rapid cooling,
leading to hardening of the affected area. This can result in increased susceptibility
to cracking or other metallurgical issues.
 MILL CERTIFICATE

A mill certificate, also known as a mill test certificate or material test report (MTR), is
a document that certifies a material's compliance with specific standards and
specifications. In the context of welding, mill certificates are often associated with the
base metals or filler metals used in the welding process.

Here are key points regarding mill certificates in welding:

1. Content: A mill certificate typically includes information about the chemical

composition, mechanical properties, heat treatment, and other relevant
characteristics of the material. It may also provide information about the
manufacturing process and any testing conducted on the material.
2. Material Traceability: Mill certificates are essential for ensuring traceability of
materials. They provide details about the source of the material, allowing users to
track its origin, production, and testing history.
3. Quality Assurance: Welding procedures and specifications often require the use
of materials that meet specific standards. The mill certificate serves as evidence
that the supplied material conforms to these standards, providing assurance of its
quality and suitability for the intended application.
4. Regulatory Compliance: Many industries, especially those involving critical
applications such as pressure vessels, pipelines, and structural components,
require compliance with specific material standards. Mill certificates help
demonstrate compliance with these standards and regulatory requirements.
 QUALITY MANUAL

Genaral welding & fabricating,inc.’s written quality manual contains documentation

outlining the requirements of the quality management system.such documentation
includes,but not limited to,aquality policy with stated goals and objectives,written
procedures and corresponding quality records,and any other documents needed to
ensure the effective operation of the quality management system.the quality manual
also describes the communication processes that exist to effectively disseminate
information between departments in order to ensure that all personnel proses the
most current product requiment information.such effective transfer of information is
necessary to reduce the occurrence of nonconformities due to audited information
being used within a department.

 ASME – American society of mechanical engineers

 API – American petroleum institute
 NBBI – National board of boiler and pressure vessel inspectrors
 ISO – International standards organization
 WELD MAP

Figure 14

A weld map in welding is a graphical or tabular representation that provides a

systematic and organized overview of the welding information for a particular project
or structure. It is a document that helps communicate and manage essential details
about the welding joints and welds in a construction or fabrication project. The
purpose of a weld map is to facilitate effective communication among various
stakeholders involved in the welding process, including welders, inspectors,
engineers, and project managers.

1. Welding Joint Details:

 Joint design (e.g., butt joint, fillet joint).
 Joint dimensions and configurations.
2. Welding Procedure Specification (WPS) Information:
 WPS number.
 Welding process and technique
 PWHT CHART

FIGURE 4
 The figure above show workpiece is heated slowly,kept at temperature and
also cooled slowly again.among other things,this reduces the stresses in the
material that occur after welding.by reducing the stresses,you prevent cracks
or fracture from forming as soon as the workpiece is to be worked on

Post weld heat trearment (PWHT) is a controlled process in which a material that
has been welded is reheated to a temperature below its lower critical transformation
temperature,and then it is held at that temperature for a specified amount of time.it is
often referred to as being any heat treatment performed after welding;however,within
the oil,gas,petrochemical and nuclear industries,it has a specific meaning.industry
codes,such as the ASME pressure vessel and piping code,often require mandatory
performance of PWHT on certain materials to ensure a safe design with optimal
mechanical and metallurgical properties
 FIGURE 5

 The figure above shows about effect of post weld weld heat treatment PWHT
on the microstructure,mechanical properties and corrosion resistance of
dissimilar stainless steels.610Cx10h 9 (heating up with coil) .
 WELDING PROCEDURE SPECIFICATION (WPS)

A Welding Procedure Specification (WPS) is a document that provides detailed

information and instructions for carrying out a specific welding operation. It is a
set of guidelines that ensure consistency and quality in the welding process.
WPS is typically developed by a qualified welding engineer or a welding specialist
and is used in various industries such as construction, manufacturing, and
fabrication.

Key components of a Welding Procedure Specification include:

Welding Process: Specifies the welding process to be used, such as shielded

metal arc welding (SMAW), gas tungsten arc welding (GTAW), or gas metal arc
welding (GMAW).
Base Metal: Describes the type and grade of the base metal or metals being
joined.
Joint Configuration: Defines the type of joint, such as butt joint, fillet joint, or lap
joint, and provides details on the joint preparation and dimensions.
Welding Positions: Indicates the welding positions (e.g., flat, horizontal, vertical,
overhead) in which the procedure is applicable.
Welding Consumables: Specifies the type and classification of welding
electrodes, filler wires, or other consumables to be used.

WPS serves as a guide for welders, ensuring that they follow a standardized and
approved procedure to achieve consistent and high-quality welds. It is a crucial
part of quality assurance and is often required in industries where welding plays a
significant role in the fabrication of structures, pipelines, and other component

NON-DESTRUCTIVE TESTING (NDT)

NDT stands for Non-Destructive testing.it refers to an array of inspection methods
that allow inspectors to evaluate and collet data about a material,system,or
component without permanently altering it.

FIGURE 1 MAGNETIC PARTICAL INSPECTION

 The figure above shows the method is used for the detection of surface and
near-surface flaws ferromagnetic materials and is primarily used for crack
detection.
 FIGURE 2 PENENTRANT SPRAY TEST

 The figure above shows a simple low-cost method of detecting surface-

breaking flaws such as cracks,laps,porosity,etc.To be detected,the flaw must
reach the surface to be tested
 FIGURE 3 ULTRASONIC TEST

 The figure above shows a ultrasonic non-destructive testing,also known as

ultrasonic NDT or simply UT , is a method of characterizing the thickness or
internal structure of a test piece through the use of high frequency sound
waves

THE IMPORTANCE OF NDT

When it comes to ensuring that assets are properly maintained.the importance of

non-destructive testing cannot be over emphasized.

‘NDT is the life blood of a well-run facility,and the high importance of NDT is known
by any trained inspector.NDT techniques and repeatable results depend on high
trained technicians with experience and integrity.Not only does the technician need
to be certified in a specific NDT method,but they also need to know how to operate
the equipment being used to gather data.