Quality and Inspection

D.DHANASEKAR M.E.,Mem.A.S.M.E., Design Engineer - mechanical

Important definitions
Quality The totality of features and characteristics of a product or service that bear on its ability to satisfy a given need. Quality The system, including all activities, documentation and Assurance functions concerning the achievement of the required quality. Quality The operational techniques and activities that ensure Control the product or service quality complies with specified requirements. It is also the use of such techniques and activities. Specification The document that prescribes in detail, the requirements with which the product or service has to comply. Inspection The process of measuring, examining, testing, gauging, or otherwise comparing the item with the applicable requirements. Certification The authoritative act of documenting compliance with requirements.

Main Types of Inspection

Design Checking he dimensions so that these are consistent with satisfactory operations Checking the materials for their strength, toughness, stiffness etc. Check is often done by a third party. These checks involve examination of drawings, specifications, calculations and computer program listings. Manufacture The manufacture of basic components such as steel sections and plates, bolts and welding consumables requires the following checks : Identification of batch. Chemical analysis. Mechanical testing. Dimensional checks - external, internal.

Stages of Inspection

Completion of calculations. Completion of working drawings. Completion of shop drawings. Manufacture of basic products. Delivery to and removal from store. Procedure trials. Operator qualification tests (particularly welding). Completion of preparation of materials (cutting, drilling, etc.). Completion of jigging, and fitting up of components. Completion of shop assembly (welding, etc.). Completion of preparation for protective coating. Completion of protection coating. Completion of assembly on site. Completion of erection on site.

Methods of Inspection Identification Steel plates and sections are identified by the cast number. Individual pieces are marked permanently by hard stamping or indelible painting.

Welding rods usually have the standard or grade to which they are made embossed or marked on each item. The batch number is marked on the bag or container in which they are supplied. Structural components are given identification numbers by the fabricator. All materials and components should be traceable back to source at any stage of the project. Drawings and revisions to them should be clearly identified & superseded issues withdrawn from the shop. Test certificates should have an unique identification number.

Methods of Inspection

Material Test Certificate

Chemical analysis Analysis of steel is normally carried out for each cast. Levels of carbon and manganese have a direct bearing on strength.

Levels of Cr, Mo, V, Ni, Mn, Cu etc are into account in measuring weldability by the use of the Carbon Equivalent Formula.
Levels of S & P should also be controlled to ensure weldability. Most structural steel specifications have defined limits of carbon, manganese, sulphur and phosphorus. Mechanical tests Tensile test is carried out by the steel supplier on each batch of a particular cast, product form and grade. A typical batch may be 40 to 50 tonnes. Charpy V-notch test is to assess the notch-ductility of the steel at the relevant temperature. This test must be carried out at the prescribed temperature which may vary from Room Temperature (+20C) to -50C or 60C depending on the specified toughness grade. The requirement is that the energy absorption is not less than the specified minimum energy at the test temperature (usually 27 Joules)

Methods of Inspection

Material Test Certificate

Other Mechanical tests

These include the through-thickness ductility test, for determining the resistance to lamellar tearing, the bend test for butt welds, the nick break test for fillet welds and a bend test for shear connectors.
The quality of trial welds is usually assessed by taking a macro-section through the weld. This section is then polished and etched to reveal the fusion boundary and heat affected zone (HAZ). A hardness survey is then done to find the peak hardness.

Methods of Inspection

Dimensional Measurements

A range of simple tools is used to check dimensional accuracy

Thicknesses of plates may be checked with a micrometre gauge. Lengths and crosssections are checked with steel tapes. Straightness of beams and columns are checked with a line pulled taut between the ends. The departure from the straight is measured between the side of the member and the line at different positions along the member. Flatness of plate elements is checked with a steel or aluminium straight edge and a feeler or dial gauge. Angles are measured with a protractor or, in the case of shallow angles, they are measured as the slope (cotangent) of the angle, e.g. 1 in 20, 1 in 10, etc.

On site, levels are checked with a surveryor's automatic level and, for short lengths, by a spirit level. Columns are plumbed with a theodolite or a vertical plumb line. Fit up of machined parts is checked with a set of feeler gauges or a taper feeler gauge.

Non Destructive Testing

Visual Inspection Visual inspection will detect gross weld discontinuities like crater cracks, reinforcement, weld profile, arc strikes, spatter etc.

Marine growth

Visual inspection will detect external corrosion, most likely associated with damage to the riser's protective coatings. Rope access

Penetrant Testing

Scientific Principles Penetrant solution is applied to the surface of a precleaned component. The liquid is pulled into surface-breaking defects by capillary action. Excess penetrant material is carefully cleaned from the surface. A developer is applied to pull the trapped penetrant back to the surface where it is spread out and forms an indication. The indication is much easier to see than the actual defect.
Main Uses Used to locate cracks, porosity, and other defects that break the surface of a material and have enough volume to trap and hold the penetrant material. Liquid penetrant testing is used to inspect large areas very efficiently and will work on most nonporous materials.

Main advantages Large surface areas or large volumes of parts/materials can be inspected rapidly.
Indications are produced directly on surface of the part providing a visual image of the discontinuity. Equipment investment is minimal.

Penetrant Testing

Main disadvantages
Detects defects. only surface breaking

Surface preparation is critical as contaminants can mask defects. Requires a relatively smooth and nonporous surface. Post cleaning is remove chemicals. necessary to

Requires multiple operations under controlled conditions.

Chemical handling precautions are necessary (toxicity, fire, waste).

Magnetic Particle Testing

Scientific Principles Alternating electrical current is passed through a coil producing a magnetic field. When the coil is placed near a conductive material, the changing magnetic field induces current flow in the material. These currents travel in closed loops and are called eddy currents. Eddy currents produce their own magnetic field that can be measured and used to find flaws and characterize conductivity, permeability, and dimensional features.
Main Uses Used to detect surface and near-surface flaws in conductive materials, such as the metals. Eddy current inspection is also used to sort materials based on electrical conductivity and magnetic permeability, and measures the thickness of thin sheets of metal and nonconductive coatings such as paint.

Main advantages Detects surface and near surface defects. Test probe does not need to contact the part. Method can be used for more than flaw detection. Minimum required. . part preparation is

Magnetic Particle Testing Main disadvantages Only ferromagnetic materials can be inspected. Proper alignment of magnetic field and defect is critical.

Large currents are needed for very large parts.

Requires relatively smooth surface. Paint or other nonmagnetic coverings adversely affect sensitivity. Demagnetization and post cleaning is usually necessary.

Eddy current Testing

Scientific Principles A magnetic field is established in a component made from ferromagnetic material. The magnetic lines of force travel through the material, and exit and reenter the material at the poles. Defects such as crack or voids cannot support as much flux, and force some of the flux outside of the part. Magnetic particles distributed over the component will be attracted to areas of flux leakage and produce a visible indication.
Main Uses Used to inspect ferromagnetic materials (those that can be magnetized) for defects that result in a transition in the magnetic permeability of a material. Magnetic particle inspection can detect surface and near surface defects.

Main advantages Large surface areas of complex parts can be inspected rapidly. Can detect surface and subsurface flaws. Surface preparation is less critical Magnetic particle indications are produced directly on the surface of the part and form an image of the discontinuity.

Magnetic Particle Testing Main disadvantages Only conductive inspected. materials can be

Ferromagnetic materials require special treatment to address magnetic permeability. Depth of penetration is limited. Flaws that lie parallel to the inspection probe coil winding direction can go undetected. Skill and training required is more extensive than other techniques. Surface finish and roughness may interfere. Reference standards are needed for setup.

Ultrasonic Testing

Scientific Principles X-rays are used to produce images of objects using film or other detector that is sensitive to radiation. The test object is placed between the radiation source and detector. The thickness and the density of the material that X-rays must penetrate affects the amount of radiation reaching the detector. This variation in radiation produces an image on the detector that often shows Main advantages internal features of the test object. Can be used to inspect virtually all materials.
Main Uses Used to inspect almost any material for surface and subsurface defects. Xrays can also be used to locates and measures internal features, confirm the location of hidden parts in an assembly, and to measure thickness of materials. Detects surface and subsurface defects.

Ability to inspect complex shapes and multi-layered structures without disassembly.

Minimum required. part preparation is

Ultrasonic Testing Main disadvantages Only conductive inspected. materials can be

Ferromagnetic materials require special treatment to address magnetic permeability. Depth of penetration is limited. Flaws that lie parallel to the inspection probe coil winding direction can go undetected. Skill and training required is more extensive than other techniques. Surface finish and roughness may interfere. Reference standards are needed for setup.

Radiographic Testing Main disadvantages Extensive required. operator training and skill

Access to both sides of the structure is usually required.

Orientation of the radiation beam to nonvolumetric defects is critical.

Field inspection of thick section can be time consuming. Relatively expensive equipment investment is required. Possible radiation hazard for personnel.

Radiographic Testing

Scientific Principles High frequency sound waves are sent into a material by use of a transducer. The sound waves travel through the material and are received by the same transducer or a second transducer. The amount of energy transmitted or received and the time the energy is received are analyzed to determine the presence of flaws. Changes in material thickness, and changes in material properties can also be measured.
Main Uses Used to locate surface and subsurface defects in many materials including metals, plastics, and wood. Ultrasonic inspection is also used to measure the thickness of materials and otherwise characterize properties of material based on sound velocity and attenuation measurements.

Main advantages Depth of penetration for flaw detection or measurement is superior to other methods. Only single required. sided access is

Provides distance information. Minimum part preparation required.

is

Method can be used for much more than just flaw detection.

Destructive Testing

HYDROSTATIC TEST
This is a nondestructive test used to check the quality of welds on closed containers such as pressure vessels and tanks. The test usually consists of filling the vessel with water and applying a pressure greater than the working pressure of the vessel. Sometimes, large tanks are filled with water which is not under pressure to detect possible leakage through defective welds. Another method is to test with oil and then steam out the vessel. Back seepage of oil from behind the liner shows up visibly.

Welding Procedure Specification

Topics covered Welding Procedure Specification (WPS) is a Formatted Document that is mandatory for any Firm desirous of Designing and manufacturing Pressure vessels and structures as per Standard Codes. WPS is deemed to have been approved if certain tests are satisfactorily conducted on Weld Coupons prescribed in Procedure Qualification Tests Procedure Qualification Record (PQR) is a Formatted Document that is accompanied with WPS. PQR becomes a valid document only when the prescribed tests conducted on Weld Coupons pass the acceptance criteria stipulated by the Code. Every WPS must have at least one PQR. Welder Performance Qualification (WPQ) is a Document that is necessary to prove the ability of the welder to deliver sound and good quality welds. The codes generally permit the evaluation of the welder to be done by the use of non-destructive tests viz. Radiography. Only with this document, a welder is certified.

A WPS is a document that describes how welding is to be carried out in production. They are recommended for all welding operations and many application codes and standards make them mandatory.

What information should they include? Sufficient details to enable any competent person to apply the information and produce a weld of acceptable quality. The amount of detail and level of controls specified on a WPS is dependant on the application and criticality of the joint to be welded.

A WPS is a document that describes how welding is to be carried out in production. They are recommended for all welding operations and many application codes and standards make them mandatory.

What information should they include? Sufficient details to enable any competent person to apply the information and produce a weld of acceptable quality. The amount of detail and level of controls specified on a WPS is dependant on the application and criticality of the joint to be welded.

A WPS is a document that describes how welding is to be carried out in production. They are recommended for all welding operations and many application codes and standards make them mandatory.

What information should they include? Sufficient details to enable any competent person to apply the information and produce a weld of acceptable quality. The amount of detail and level of controls specified on a WPS is dependant on the application and criticality of the joint to be welded.

A WPS is a document that describes how welding is to be carried out in production. They are recommended for all welding operations and many application codes and standards make them mandatory.

What information should they include? Sufficient details to enable any competent person to apply the information and produce a weld of acceptable quality. The amount of detail and level of controls specified on a WPS is dependant on the application and criticality of the joint to be welded.

For most applications the information required is generally similar to that recorded on a Procedure Qualification Record (PQR) or Welding Procedure Approval Record (WPAR), except that ranges are usually permitted on thicknesses, diameters, welding current, materials, joint types etc. If a WPS is used in conjunction with approved welding procedures then the ranges stated should be in accordance with the approval ranges permitted by the welding procedure.

However careful consideration should be given to the ranges specified to ensure they are achievable, as the ranges given by welding procedure standards do not always represent good welding practice. For example welding positions permitted by the welding procedure standard may not be achievable or practical for certain welding processes or consumables.

EN 288 Part 2 European Standard For Welding Procedure Specifications This part of EN 288 defines the contents of a Welding Procedure Specification in the form of a list of information that should be recorded. For some applications it may be necessary to supplement or reduce the list. For example only in the case of a procedure requiring heat input control would there be a necessity to quote travel speed or run-out length for manual processes. ASME IX American Boiler and Pressure Vessel Code QW 250 Lists the variables for each welding process, all the variables stated should be addressed. The range permitted by the WPS is dictated by the PQR or PQRs used to qualify it.

Typical Items That Should Be Recorded in W.P.S:Common to all Processes .

Procedure number Process type Consumable Size, Type and full Codification. Consumable Baking Requirement if applicable Parent material grade and spec. Thickness range. Plate or Pipe, Diameter range Welding Position Joint Fit Up, Preparation, Cleaning, Dimensions etc. Backing Strip, Back Gouging information. Pre-Heat (Min Temp and Method) Interpass if Required (Maximum Temperature recorded ) Post Weld Heat Treatment. If Required (Time and Temp) Welding Technique (weaving, max run width etc.) Arc Energy Limits should be stated if impact tests are required

Specific To Welding Processes Welding current Type of Welding current Polarity Arc voltage

MMA

TIG

MIG / FCAW

SAW

yes yes

yes yes

yes yes yes

yes yes yes

Pulse parameters (Pulse time current)

Welding Speed Wire configuration Shielding gas (comp,flow rate) Purge gas (comp & flow rate) Tungsten electode Diameter and type. Nozzle diameter Type of Flux Nozzle Stand Off Distance

If auto is Used yes

If auto is Used yes yes yes

yes

yes

If auto is Used
yes yes

If auto is Used

yes yes yes

Sketches A sketch of the joint configuration is required which should include the basic dimensions of the weld preparation. Some indication of the run sequence is also beneficial, particularly if the correct sequence is essential to ensure the properties of the weld are maintained. Production Sequence Whilst this is good practice it is not a requirement of either ASME 9 or EN288 Part 2; it could be issued as a separate QA procedure if preferred. Non Destructive Testing A WPS is primarily concerned with welding not N D T, this activity should be covered by separate N D T procedures.

Welding Procedure Specification Weld Procedure No. Procedure Qualification Record No. Manufacturer : 30P1TIG1 Issue 1 : WP T17/A : Raichur TPS

Location
Welding Process Joint type Method of preparation & cleaning Parent metal specification Parent Metal thickness Wall pipe O.D

: Pent House
: Manual TIG : Single sided Butt weld : Machine & degrease : Grade 304L : 3 to 8 mm : 25 to 100 mm

Weld position
Weld progression

: All position
: Upwards

Joint design

Welding sequence

Run 1 2 & sub Polarity DC DC

Process TIG TIG

Size of Filler 1.2 mm 1.6 mm

Current 70 80 A 80 100 A

Voltage N/A N/A

Wire speed N/A N/A

Travel speed N/A N/A

Heat Input N/A N/A

Welding consumable
(type, designation & trade name)

BS 2901 Part 2
308S92

Shielding Gas Flow rate Electrode (type & Dia) Details of back gouging Pre-heat temperature

Argon 99.99 % Purity 8 12 LPM 2% thoriated W; 2.4 mm Gas backing 5C

Inter-pass temperature
Post Weld Heat Treatment (Time, temp, method,CR)

200 C
N/A N/A

Production sequence