DATE:

29/7/2017
DEFECTS OBSERVATION
REPORT

Observations Results And Its Causes

Purpose: To trace causes of leakages and Material Defects

Scope : Piping P-146 Dora Dora Project Al Kharj
Type of Test: Liquid Penetration test and Visual Inspection
Spool length: 34 meters, 12 sch 10
Material Grade: SS TP304L MTC is attached
Location: New Steep Tanks

Description
This report is made as per actual facts those were observed during visual and liquid
penetration tests. Material porous, pin holes, cracks, joints without purging, poor weld fit up,
mechanical damaged, undercut and porosity were identified through liquid penetration test
and visual inspection. These defects and its reasons are discussed as under.

1-Porous Material: In taken pictures it is clearly can be seen in mid of pipe or in some
other places of pipe away from welding joints or near to welding joints is a defect called
material porous defects. It is manufacturing defects of material when it is manufactured. In
piping spools holes where there material is porous were observed. It can be seen in
attached pictures with this report. This type of defects caused leakages in piping.

2-Pinhole: Pinholes/ crater pipe on welding joints were identified. These occur in TIG
welding mostly. This defect is called man made defect, mistake of welder or UN trained
welder did the job, and causing holes cross of piping. One of these reasons is cause of
leakages in piping.

3-Cracks: Cracks were observed in or near to weld joints or in heat effected zone of
weldment can be seen in attached pictures where pipe caused leakages. Poor joint fit up,
contaminated filler wire used or different grade filler (SS 304/308/316L) wire was used.

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 DATE:
29/7/2017
DEFECTS OBSERVATION
REPORT

4- Joint without back Purging: in taken pictures and visual inspected in three spools
joints were done without purging. Root side, inside of pipe there was oxide observed.SS
grade material needs back purging. However, pipe is of 10 schedule low thickness and only
one pass was done in each joint in some spools, were observed. Therefore, these caused
leakages.

5- Poor fit up: When installed piping spools were dismantled and replaced because of
leakages so spools were cut from weld joints, it was observed misalignments and poor weld
deposited metal with one pass this misalignment left cracks and non deposited metals
space from weld side. Because of this leakages occurred.

6-Mechanical Damage: near to weld joint there was cracks or damaged through
hammering were observed. When two pieces of pipe are fitted if both of pipes dia somehow
are different not circular so hammer was used to fix both side of pipe for fit up. Although
pipe scheudule is 10 low thicknesses dont need to hammer un cautiously with CS metal
this left cracks and mechanical damaged on surface of pipe which can be seen in pictures.

7-Under cut and Porosity: in some are of pipe under cut was identified it is because of
poor setting of amperage or high travel speed of welders. Because of this deposition of
material was less on weld joint and high current left burn through and low strength and
causes longitudinal cracks.
Porosity may happen environmental temperature, contamination of filler wire or base metal
or low quality of argon gas. Being a low thickness pipe, both defects under cut and porosity
caused leakages.

Prepared by:
Inspected by:
Abdul Hafeez Azhar Sahzad

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