PEW-209.02 (Inspect Production Welds)

Saudi Aramco
Inspection Department
INSPECT PRODUCTION
WELDS
PEW-209.02
The training materials contained in this module are the property of the Saudi Arabian Oil Company (Saudi Aramco) and
are intended for the exclusive use of Saudi Aramco employees enrolled in advanced inspection training courses. Any
material contained in this manual which is not already in the public domain, may not be copied, reproduced, sold, given or
disclosed to third parties or otherwise used, in whole or in part, for purposes other than for use in Saudi Aramcos
Professional Engineering Development Unit courses without the prior written permission of the Chief Engineer of Saudi
Aramco.
PEW-209.02 PARTICIPANT REVISIONS
DATE REVISION DESCRIPTION PAGE(S) AFFECTED
12/06/04 COMPLETE REVISION

S.U. BASHA, S. CAVE, M. AKKAD
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PEW-209.02 PARTICIPANT TABLE OF CONTENTS
MODULE COMPONENT PAGE
OBJECTIVES
Terminal Objective
Enabling Objectives
INTRODUCTION
VERIFY PROPER WELDING TECHNIQUES
Type of Bead
Stringer Bead
Weave Bead
Weld Sequence
Welding Positions
Gas Mixtures
Gas Flow Rate
Travel Speed
Interpass Temperature
Interpass Cleaning
Back Gouging
Air Carbon Arc Gauging
VISUALLY INSPECT COMPLETED PRODUCTION WELD
Groove Weld Measurements
Fillet Weld Measurements
Welding Defects
Fillet Weld Excess Convexity
Oversize Fillet Welds
Undersized Fillet Welds
High-Low
Undercut
Cracks
Craters
Surface Porosity
Underfill
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PEW-209.02 PARTICIPANT TABLE OF CONTENTS
Poor Workmanship
Excessive Spatter
Excessive Weld Reinforcement
Overlap
Arc strikes
IDENTIFY NON-DESTRUCTIVE TESTING
EXERCISE 1. WELDING TECHNIQUE
EXERCISE 2. WELDING DEFECTS
WORK AID 1. HOW TO PERFORM THE PRODUCTION WELD INSPECTION
WORK AID 2. HOW TO VISUALLY INSPECT COMPLETED PRODUCTION WELDS
GLOSSARY
iii
PEW-209.02 PARTICIPANT OBJECTIVES
OBJECTIVES
Terminal Objective
Upon completion of this module, the Participant will be able to inspect production welds
in accordance with applicable standards.
Enabling Objectives
In order to accomplish the Terminal Objective, the participant will be able to do the
following:
Verify proper welding techniques
Visually inspect completed production weld
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PEW-209.02 PARTICIPANT INFORMATION
INTRODUCTION
To ensure that the final weld will meet the welding procedure, codes, standards and
project specifications, the Inspector checks several inspection points prior and during the
actual welding process. Pre-welding Inspection lists the duties of a Welding Inspector
prior to actual welding. However, this module follows it with the duties during the welding
operation.
If the production weld conditions are not satisfactory, the final welds may also not be
satisfactory. The inspector must look for any problems that might take place before and
during the welding process. Corrections should be made at this time. Waiting until later
could be costly and time consuming.
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VERIFY PROPER WELDING TECHNIQUES
The inspector checks in-process welding to see if the welder is producing the type of
welding bead specified in the WPS. A good bead is strong, with required penetration and
an even appearance. A good weld depends on:
Correct electrode
Correct current
Correct polarity of the electrical current
Correct movement of the welder
Correct arc distance
Steady travel speed
The Inspector shall check the welding technique for the following:
Type of Bead
Weld sequence
Welding position
Gas mixture, if any
Travel speed
Interpass temperature
Interpass cleaning
Back gouging, if any
Air carbon arc gouging, if any
Type of Bead
Stringer Bead
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A stringer bead is a weld bead that is made without much side-to-side motion by the
welder (See Figure 1). To deposit filler metal, the welder primarily moves in one
direction. The welder also uses a stringer bead when minimum heat input is preferable.
He uses stringer beads to build up metal for weld surfacing and overlays. The root pass
is usually a stringer bead because the joint is narrow at the root of the weld.
Figure 1. Stringer bead
Weave Bead
Weave welding is a type of weld made with a transverse oscillation in which the
electrode sweeps back and forth across the joint in a semi circular motion.
Weave welding increases the width of the deposit, decreases overlap and assists in slag
formation. With a V-groove or build-up of a pad on flat material, weave welding is more
practical than a stringer bead deposit.
Figure 2 shows that a weave weld produces a weld bead that is wider than the electrode
itself. Weave welding increases the weld heat input and has a tendency to trap slag
within the weld.
The inspector must be certain that the type and size of the bead weld that is specified in
the WPS matches the bead in production. If the specifications require a weave weld, the
inspector must be certain the width conforms to the WPS. The inspector measures the
width of the weave bead and compares it to the specifications.
4
Figure 2. Weave beads
Weld Sequence
The inspector makes certain the welder follows the required weld sequence. Welding in
sequence helps avoid distortion, stress or cracking in the weld. Figure 3 shows specified
weld sequencing in the WPS. The inspector cannot verify the welding technique on final
inspection, except in single-pass welds.
Figure 3. Weld sequence in a WPS
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Welding Positions
Different welding techniques specify different welding positions. Specifications for each
particular weld determine the welding position. There are four common welding positions
(See also Figure 4):
Flat welding is the easiest and cheapest welding position. The welding benefits
from the force of gravity and maximum deposit rates can be obtained. Flat
welding can eliminate some of the distortion that slower welding processes
cause.
In overhead welding, the molten metal from the material and the electrode may
fall down from the bead position. Arc current or flame temperature must never
overheat the base metal so much that the base metal melts and falls down due to
gravity.
The welding position in which the weld axis, at the point of welding, is
approximately vertical and the weld face lies in an approximately vertical plane.
Horizontal welding creates the same problem as vertical and overhead welding.
Gravity may pull the molten metal down, causing overlap.
The inspector must be certain that the welder uses the welding direction and the welding
position that are specified in the WPS.
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Figure 4. Welding positions
Gas Mixtures
The welder uses various gases to create the gas shield. The welder can also use
mixtures of gases. All gases have different properties. The inspector must check the
WPS for the specified gas or mixture of gases.
Figure 5. Different shielding gases
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Gas Flow Rate
The gas flow rate is the amount of gas that flows from the gas cylinder during a given
period. Gas flow rate is measured in liters per minute or cubic feet per minute.
The flow rates of the various shielding gases depend upon the density or specific gravity
of the gases. The specific gravity of gas is a measure of its weight relative to the weight
of the air. For example, the density of the air is 1.0, and the specific gravity of helium is
0.137. Thus, helium is much lighter than air. Helium tends to rise quickly from the weld
area. If the welder uses helium, higher flow rates are needed to provide adequate
shielding. Helium is also affected by drafts more than other gases.
The inspector must look for job site conditions that may adversely affect the gas shield.
For example, a wind or a strong draft can contaminate the shield. It contaminates the
shield by removing the gas from its protective zone. The inspector must make certain
that the welder protects the gas shield from a wind or a draft. Another cause of loss of
shielding could be from damaged gas hoses and connections. Loss of shielding
atmosphere or improper shielding gas mixtures can create porosity.
Travel Speed
In manual arc welding, continuous small changes in the voltage and amperage occur.
This happens because the arc length changes as the welders hand moves. The arc
length partly determines the arc voltage. Increasing the arc length decreases the arc
voltage. Moving the electrode enables the welder to control the length of the arc.
If the welder moves the electrode too rapidly, the bead will be weak and porous. This
occurs because of poor penetration and fusion. This could also result from an electrical
current setting that is too low. If the welder moves the electrode too slowly, it creates
high, wide beads. These may overlap and possibly cause burn-through. Burn-through
results in excessive melting or a hole.
The inspector must check the WPS for the designated travel speed. He makes certain
the welder maintains the travel speed within the range that is specified in the WPS.
Travel speed is normally expressed in inches per minute. To check travel speed, the
inspector marks off 25 MM spaces on the base metal. He then records the time that it
takes a welder to complete a weld that is 25MM in length. This calculates the welder's
travel speed in inches per minute.
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Interpass Temperature
The inspector must make sure that the interpass temperature is maintained correctly
(See Figure 8). The minimum interpass temperature is usually the same as the pre-heat
temperature. The welder must maintain preheat and interpass temperatures throughout
the entire welding cycle. If the welder discontinues welding operations for a period of
time, he must re-establish the pre-heat temperature before he resumes welding.
The maximum interpass temperature is also specified. The temperature of a small weld
usually increases rapidly because of the heat that is produced during the welding
process. In certain cases, the welder cannot allow this heat to build up and exceed a
specific temperature.
If heat build-up becomes too great, the welder must allow the weld to cool. However, he
cannot allow it to cool below the minimum pre-heat. He must maintain the temperature
of the weld within the range of the minimum pre-heat and maximum interpass
temperatures. The maximum interpass temperature for welding stainless steels is much
less than on carbon steel. Usually, the maximum interpass temperature is specified in a
Welding Procedure Specification.
Figure 8. Digital Pyrometer to measure interpass temperature
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Interpass Cleaning
The slag covers the finished weld and keeps the weld cool. The welder must remove the
slag. The welder removes the slag with a chipping hammer, grinder or wire brush. The
welder must remove the slag when he deposits beads on top of beads (See Figure 6).
Slag that is left on the lower beads produces a weld of poor quality
In SAW, a granular flux blanket provides the flux. The work surfaces must be clean when
the submerged arc welding method is used.
In GTAW, the welder uses a filler rod. In this welding method, a gas mixture provides a
shield, which does not produce slag.
The inspector must inspect for correct interpass cleaning. The welder is responsible for
the interpass cleaning.
Figure 6. Interpass cleaning with a grinder
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Back Gouging
Back gouging occurs when weld metals and base metals are removed from the opposite
side of a partially welded joint (See Figure 7). Back gouging is done to assure that
complete penetration is achieved.
Light grinding followed by wire brushing is normally adequate cleaning for properly
gouged carbon steel. Pick-up of carbon from the carbon electrodes is usually minimal
with good cutting technique. For some welding processes, such as short-circuiting
GMAW or GTAW, grinding to bright metal after air arc gouging is required for proper
fusion. Grinding is required on corrosion resistant alloys to remove the thin layer of
material contaminated by oxidation and carbon, in order to prevent pick-up in the weld
deposit
Figure 7. Illustration of back gouging technique on welds
The gouging process has proved to be successful for a wide spectrum of applications in
engineering industries:
repair and maintenance of structures - bridges, earth-moving equipment, mining

machinery, railway rolling stock, ships, offshore rigs, piping and storage tanks
removal of cracks and imperfections - blow holes and sand traps in both ferrous
and non-ferrous forgings and castings
preparation of plate edges for welding
removal of surplus metal - riser pads and fins on castings, excess weld bead
profiles, temporary backing strips, rivet washing and shaping operations,
demolition of welded and unwelded structures - site work
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Air Carbon Arc Gauging
Air carbon arc cutting and gouging,(See figure 9.) also known as arc air gouging and
carbon arc gouging is an arc cutting process in which metals to be cut are melted by the
heat of a carbon arc and the molten metal is removed by a blast of air. Normally, it is a
manual operation used in all positions, but may also be operated automatically. The
process can be used on steels and some nonferrous metals. The process is commonly
used for back gouging welds, for gouging out defective welds and gouging castings. The
process requires a relatively high degree of cutting skills.
Figure 9. Air carbon arc gouging
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VISUALLY INSPECT COMPLETED PRODUCTION WELD
Visual examination before, during and after welding is the single most effective method
for finding and eliminating weld defects and repairs. Visual inspection before welding is
used to check fit-up, alignment, joint detail and cleanliness. Visual inspection during
welding is used to find production flaws, such as slag, undercut, cracks, etc., that could
lead to defects in the completed weld.
Visual inspection of completed welds is used to find surface defects such as undercut,
overlap, surface cracks, craters, porosity and poor workmanship as indicated by
excessive weld spatter, irregular beads, high weld crown, arc strikes and other self-
explanatory defects.
The welding inspector tries not to cause unnecessary delays in the construction or
fabrication when he performs his inspections.
A flashlight, a small extension mirror and a magnifying glass are recommended tools for
close work and for inspecting through small openings such as the interior diameter (ID)
of a pipe or boss.
Before conducting a visual examination, excess rust, scale, weld slag, oxides, oil,
grease, dirt, paint and coatings must be removed from the surface to be examined.
Light intensity for visual examination is usually specified in units of foot-candles. For a
general examination, a minimum of 32.5 foot-candles of light intensity is required, and
for detection of small anomalies (flaws), the minimum required intensity is 50 foot-
candles.
Groove Weld Measurements
The welding inspector examines a groove weld for its conformance to the weld size and
location that are specified on the drawing. If no weld size is specified for a groove weld,
it shall be a full penetration weld for the full thickness of the joint (See Figure 10).
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Arrow shows thickness of weld
Figure 10. Size of V-groove weld
Fillet Weld Measurements
The weld leg is measured with a weld gauge as shown. The fillet weld gauge is placed
flat on the base metal surface. Different size fillet weld gauges are used until the gauge
sits flat at both surfaces of the weld at (A and C). The retractable scale is placed at the
weld leg at (D). The size of the weld is read from the fillet gauge ruler.
The actual throat of a fillet weld is also measured with a weld gauge (See Figure 11).
The weld gauge is placed between the base metal surfaces at (A and C). The sliding
scale is placed at the weldment throat at (D). The measurement of the throat is read
from the weld gauge sliding ruler scale at (D). The dimension referred to as the actual
throat is the shortest distance from the root of the weld to its face. The theoretical throat
of an equal leg weld is approximately 0.7 times the leg size (B).
Figure 12 shows different fillet weld shapes with a as the throat of the weld.
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Figure 11. Measurement of a fillet weld
Figure 12. Fillet weld shapes
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Welding Defects
The welding inspector examines the weld reinforcement, concavity and surface profile
for conformance to procedure and specification. He also inspects for discontinuities. A
discontinuity is any irregularity in the normal pattern of a material, or any interruption of
the uniform nature of an item.
A defect is a discontinuity that exceeds the permissible limit of a code. In other words, a
defect is a rejectable discontinuity requiring repair or replacement. Following are
discontinuities that a Welding Inspector should be able to identify in the field.
Fillet Weld Excess Convexity
It may be described as weld metal lying outside the plane joining the weld toes (See
Figure 13). ASME and AWS D1.1 have limits relating width to acceptable excess (See
Figure 14).
Figure 13. Excess convexity
Width of weld face Maximum convexity
W 8mm 2mm
W <8 to W<25mm 3mm
W 25mm 5mm
Figure 14. AWS D1.1 limitation on convexity
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Causes
Poor technique
Deposition of large volumes of 'cold' weld metal.
Oversize Fillet Welds
Oversize fillet welds are welds with a throat larger than required by the design (See
Figure 15). Oversize fillet welds can represent a significant additional cost and loss of
productivity.
Figure 15. Oversized fillet weld
Causes
High welding current
Slow travel speeds
Undersized fillet welds (fillet welds smaller than those specified)
Undersized Fillet Welds
Undersized fillet welds are welds with a throat smaller than required by the design (See
Figure 16).
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Figure 16. Undersized fillet weld
Causes
High welding speeds
Low welding currents
High-Low
High-low, also called mismatch, is a sharp ledge where the two sides of a joint are
misaligned, or where the thicker of two pieces has not been tapered to match the thinner
member before welding (See Figure 17). High-low is particularly serious in vibration or
other cyclic loading conditions. It is limited by most codes.
Figure 17. Hi-low (mismatch)
Causes
Incorrect assembly
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Base material dimensional variation - particularly common on pipes where ovality

cannot be guaranteed
Distortion during welding
Prevention
Use of alignment jigs
Size pipes before machining the weld preparation
Use of strong backs and other clamping techniques
Undercut
Undercut is a groove melted into the base material (See Figure 18). Undercut is located
adjacent to the toe of the crown or root in completed welds. Undercut is left unfilled by
weld metal and, thus, reduces the cross-section thickness of members and can act as a
severe stress riser. External undercut is an especially serious defect in vibratory service
and is strictly limited by the ASME Process Piping Code B31.3.
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Figure 18. Illustrations of undercut
Causes
Base material is melted by the arc and undercut is formed when there is insufficient flow
of weld metal to replace the original material. Undercut is often present as a shape
discontinuity at the weld toe. Undercut constitutes a defect if it exceeds the specification
limits
Cracks
Surface cracks are the separation, rupturing or tearing of metal under stress, resulting in
a sharp notch (See Figure 19). Cracks can occur anywhere stresses exist in the weld
metal and/or the base metal (See Figure 20). A crack is the most serious weld defect
and is not tolerated by most codes.
Causes
Where a single weld pass is made between two base metals, the solidification will
progress from the base metal toward the center of the weld. Since shrinkage occurs
during cooling, cracking is most likely to occur in the center. The cracking tendency
increases with increasing heat, higher interpass temperatures, larger weld cross-
sections, greater restraint across the weld joint, etc.
Figure 19. Illustration of a crack
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Longitudinal Crack
Base Metal Crack
Transverse Crack
Star Crack in Root of Weld
Figure 20. Different types of cracks
Craters
Craters, also called concave caps or fisheyes, are depressions or craters formed at the
end of a weld bead when the weld is stopped and allowed to cool (See Figure 21). The
weld crater is usually filled with filler metal to complete the weld and reduce the risk of
crater cracks forming.
Figure 21. Illustration of a crater
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Causes
Crater pipes are caused by shrinkage of the weld pool on completion of a weld run, often
assisted by some gas evolution (porosity).
Surface Porosity
As molten weld metal temperature decreases, hydrogen tends to diffuse out the weld
deposit into the atmosphere and into the adjacent heat-affected zone of the base metal
(See Figure 22).
The heat-affected zone is the portion of the base metal that has not been melted but
where properties have been altered by the welding heat.
Being lighter than molten metal, gas bubbles tend to rise to the weld deposit's surface. If
the bubbles fail to reach the surface before solidification, they will be entrapped as
internal porosity. If they reach the surface, they may appear as external or surface
porosity.
Piping porosity, also known as wormholes or tunneling, which extends through layers of
weld passes, is caused primarily by turbulence in the weld pool This is usually a result of
excessively high welding currents. Since hydrogen generation tends to be the greatest
at the start of a weld run and weld metal solidification is most rapid, weld starts are
particularly susceptible to entrapped porosity.
In the SMAW process, the tendency towards porosity formation is greatest at slow
welding speeds and low currents. Rust on steel is another source of porosity. Low-
hydrogen, iron powder electrodes upon moisture pick-up may produce clusters of
porosity, as may excessive arc length when using them.
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Figure 22. Illustration of weld porosity
In GTAW and GMAW welding, insufficient gas protection or contaminated shielding

gases may also result in porosity. Sudden or severe drafts may interfere with proper
shielding and cause severe porosity. When welding in draft areas, the last weld deposits
tend to be the most susceptible since the weld bevel provides the least protection at that
point. This is also true when welding with low-hydrogen, iron-powder electrodes.
In the inert gas processes, helium tends to be more effective in reducing porosity than
argon or nitrogen.
Porosity, even under the most liberal of standards, is not likely to result in service
failures so long as it is removed from the surface. Far more critical are surface
conditions or notches, which can trigger mechanical or metallurgical failures. (Figure 23
shows elongated porosity.
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Figure 23. Elongated Porosity
Underfill
Underfill occurs when the weld groove has not been filled with filler weld metal (See
Figure 24). Underfill is a depression on the face of the weld that extends below the
surface of the base metal. In most cases, the edge of the weld bevel is visible.
Figure 24. Illustration of a weld underfill
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Poor Workmanship
Excessive Spatter
Spatter is unwanted globules of weld metal that are sprayed outside the bead on the
base metal surface (See Figure 25). In small amounts, it is normal and acceptable.
However, large-sized spatter may heat the base metal above its transformation
temperature. The surrounding mass will cool the hot spot quickly enough to quench it.
The result is a hard, brittle spot Inspection for minute cracks should be conducted when
spatter quality is questionable.
Figure 25. Illustration of a weld spatter
Excessive Weld Reinforcement
Excessive weld reinforcement is an excess of filler metal deposited in the final weld
bead. It is easily recognized by its crown feature (See Figure 26). The acceptance
criteria for excessive weld reinforcement are listed in SAES-W-011 for Process Piping.
Figure 26. Illustration of weld reinforcement
Overlap
Overlap (sometimes called cold lap) is an excess of filler metal piled up along the weld
bead (See Figure 27). Excess filler metal must flow somewhere so it usually extends
outward and laps over and along the top edges of the weld groove. The edge of the weld
bead does not fuse with the base metal or adjacent weld beads. Overlapping of fillet
welds may result in an apparent increase in weld size, which may lead to incorrect
estimates of fillet weld strength and size. Overlapping is usually caused by too slow
travel speed or incorrect electrode angle.
Figure 27. Illustration of a weld overlaps
Arc strikes
Arc strikes occur when there is melting or heating outside the weld deposit area (See
Figure 28). Arc strikes have an effect similar to spatter but are more serious. As in
spatter, an arc strike brings a spot on the surface to a high temperature. The strike is
then quickly cooled by the transfer of heat to the surrounding base metal. The result is a
hard and brittle structure that is a source of cracks. Arc strikes can be seen quite easily.
Figure 28. Illustration of an arc strike
IDENTIFY NON-DESTRUCTIVE TESTING
In case of a welding defect or discontinuity, the welding inspector reports the results of
his inspection to his supervisor and to the Saudi Aramco construction representative so
that repair can proceed immediately.
In addition, other tests on the weld or on the base metal are usually necessary to
uncover any hidden defects undetected by visual inspection. The preferred testing is
non-destructive testing (NDT) which does not affect or damage the equipment or the
material in question. Following are the NDT methods required by various codes:
magnetic particle
liquid penetrant
radiography
ultrasonic
Usually, the contractor's inspectors perform most non-destructive tests for Saudi
Aramco. Nevertheless, the welding inspector has to monitor the performance of these
nondestructive tests. He also reviews the results of these tests. Afterwards, he receives
the test results, which determine acceptability of the weld.
The welding inspector must check the job file to determine if NDT requirements, other
than visual inspection, exist. Individual job and code requirements determine which
inspection method should be used.
It is important to note that no individual NDT method can detect all types of defects.
Each method has its limitations. Each technique evaluates different characteristics of the
material or weldment. The inspector must understand the limitations of each method in
order to know what types of defects he is most likely to find.
PEW-209.02 PARTICIPANT EXERCISES
EXERCISE 1. WELDING TECHNIQUE
1. Give an example where a stinger bead would be used?
2. Explain what is meant by term Weld Sequence?
3. Which is the easiest welding position?
4. What is meant by the welding term 1F?
5. Why is it important that welder maintains welding direction?
6. Where would inspector find out information regarding the travel speed of the
welding?
7. What is the minimum interpass temperature usually the same as ?
8. How is the gas flow rate usually measured?
9. Explain how a weave bead is different from a stringer bead?
10. What effect does slag have on the weld?

1. Give three examples of the cause of miss-match?
2. Explain underfill?
3. In which Saudi Aramco standard would we find the criteria for excessive weld
reinforcement?
4. Give examples of three non-destructive tests?

5. That is a common cause of excess convexity?
6. Give two examples of where we would measure a fillet weld for correct
dimensions?
7. Where in the weld could we find porosity?
8. What is the most effective method of finding welding defects?
9. What could excessive spatter cause?
10. Give one example where undercut may be found in a weld?

PEW-209.02 PARTICIPANT WORKAIDS
WORK AID 1. HOW TO PERFORM THE PRODUCTION WELD

INSPECTION
This Work Aid will assist you in verifying that the production weld procedure is performed
correctly. This checklist is an aid, not the standard. Standards will be referred to in all
cases.
Are safety rules being followed? (Check these items:)
o Does the work area have the proper airflow?
Are fire prevention precautions taken? (Check these items:)
o Have combustible materials been removed or covered?
o Is there a post observer watching for fires?
o Are fire extinguishers readily available?
o Is the welding equipment properly installed? Is the welding equipment

properly grounded?
o Is welding equipment a safe distance from the welding process?
Is proper protective gear being worn? (Check these items:)
o Safety shoes
o Safety (hard) hat
o Welding hood with filter lens (when welding with an electric arc).
o Safety glasses with side shields (during interpass cleaning)
Are special precautions practiced in a damp work area?
Does the on-site electrical current meet WPS specifications?
Does the on-site voltage meet WPS specifications?
Is the joint geometry satisfactory? (Check these items:)
o Is the bevel angle correct?

o Are root face dimensions correct?
o Are the root opening dimensions correct?
o Is the high-low measurement within limits? (if required)
o Is the depth of the counterbore correct?
o Do transition pieces match inside and outside diameter?
o Is the minimum wall thickness at the weld as specified?
Is weld joint preparation satisfactory? (Check these items:)
o Is the base metal(s) clean prior to welding?
o Have ragged or irregular edges been ground or machined smooth?
Are tack welds acceptable, if required? (Check these items:)
o Are tack welds long enough to hold material for welding?
o Have cracked tack welds been removed prior to welding?
o If tack weld process is different from root pass process, has it been
qualified and documents placed in the fob file?
o Is the specified pre-heat temperature obtained prior to welding?
o Is the correct electrode being used?
Is the correct welding technique being used for the specified welding pass?
Is the correct welding position being followed?
Is the correct welding direction being followed?
Are stringer beads being produced correctly?
Is the width of the weave pass within limitations?
Is the thickness of each weld pass within limitations?
Is the welding sequence being applied correctly?
Is the shielding gas mixture correct?

Is the shielding gas flow rate correct?
Is the shielding gas coverage range correct?
Is the correct amperage range being maintained?
Is the correct voltage range being maintained?
Is the correct travel speed being maintained?
Are the pre-heat and interpass temperatures maintained within the minimum and
maximum range specified throughout the weld cycle?
Is the pre-heat temperature reestablished before welding is resumed? (If welding

operation was discontinued)
Is the interpass cleaning performed correctly?
Has the first pass been back gouged to sound metal? (If required)
Have all entries been made in your personal notebook?
Has the Site Representative been notified of all discrepancies?
Have all entries been made in the site logbook as required?
Has Site Representative responded with appropriate actions to all discrepancies?
Have you signed the log entries after satisfactory corrections have been made?
WORK AID 2. HOW TO VISUALLY INSPECT COMPLETED

PRODUCTION WELDS
This Work Aid will assist you in visually inspecting a completed production weld. This
checklist is an aid, not the standard. Standards will be referred to in all cases.
Does the weld conform to specifications? (Check these items:)
o For groove welds, check these items:
o Is weld reinforcement size acceptable?
o Is weld in specified location?
o For fillet welds, check these items:
o Is the length of each leg acceptable?
o Is the actual throat size acceptable?
o For intermittent fillet welds, check these items:
o Is the length of the each leg acceptable?
o Is the actual throat size acceptable?
o Is the pitch distance between welds acceptable?
o Is weld concavity acceptable?
o Is weld surface finish acceptable?
Are there discontinuities in the base or weld metal?(Check these items)
o Is there arc strikes?
o Is there surface porosity?
o Is there root concavity?
o Is there incomplete penetration?
o Is there excess penetration?

o Is there irregular root penetration?
o Is there weld spatter?
o Is there undercut?
o Is there excess cap (overlap)?
o Is there concave cap?
o Is there uneven leg length?
o Is there lack of fusion in weld?
o Is there a cracked weld?
o Is there inclusion?
o Is there distortion?
Have entries been made in Inspector's personal logbook?
Have entries been made in the site logbook?
Has Site Representative taken appropriate repair action to correct all

discrepancies?
Have log entries been signed off by inspector after satisfactory corrections have
been completed?
PEW-209.02 PARTICIPANT GLOSSARY
GLOSSARY
alternating current An electrical current in which the flow of electrons reverses

direction at regular intervals
amperage The amount of electrical current that flows through a wire
ampere The unit by which an electrical current is measured
burnoff rate The rate of electrode consumption
buttering building up the weld area with additional metal before

welding begins
crater crack A crack in the crater of a weld
crater in arc welding, a depression at the termination of a weld

bead or in the weld pool beneath the electrode
direct current An electrical current in which the electrons flow

continuously in one direction
FCAW Flux-Cored Arc Welding
fillet weld size For equal leg fillet welds, the leg length of the largest
isosceles right-triangle which can be inscribed within the
fillet-weld cross-section
fillet weld, leg of a The distance from the root of the joint to the toe of the fillet
weld
For unequal let fillet welds, the leg length of the largest
right-triangle which can be inscribed within the fillet-weld
cross-section
gas flow rate The amount of gas that is provided within a given period of
time. Gas flow rate is usually measured in liters per minute
or cubic feet per minute
GMAW Gas Metal Arc Welding
groove weld A weld made in the groove between two members to be

joined
groove weld size The joint penetration (depth of chamfering plus the root
penetration when specified)
GTAW Gas Tungsten Arc Welding
high-low The misalignment in the joint of metals
inert gas A gas that does not normally combine chemically with the
base metal or filler metal
Interpass cleaning The removal of the slag that is formed between weld
beads or welding passes
Interpass temperature The temperature of deposited metal and base metal that is
maintained between welding passes
joint geometry The shape and dimensions of a joint in cross-section prior

to welding
polarity (reverse) The arrangement of direct current arc welding leads

wherein the work is the negative pole and the electrode is
the positive pole of the welding arc
polarity The positive and negative poles of a DC circuit
pre-qualified A procedure that has already been tested by the industry

such as the American Welding Society (AWS)
procedure qualification A document that contains conditions, test and test results
on a welding procedure qualification test that meets
standard requirements
production welding inspection

A series of checks on welding procedures, conditions,
materials, and equipment This inspection is done while
welding is being conducted
qualified Capable and certified to perform a specific type of welding.

It can also mean successful testing of a welding procedure
SAW Submerged Arc Welding
SMAW Shielded Metal Arc Welding
specific gravity of gas A measure of the density of specific gas relative to the
density of air
stringer bead welding The process of making a weld bead without much weaving
motion of the electrode. For example, the root weld is
usually a stringer bead
tack weld A weld made to hold parts of a weldment in proper

alignment until the final welds are made
thermal conduction The process by which heat is transferred away from the
weld
toe of weld The junction between the face of a weld and the base
metal
travel speed The amount of welding that a welder should complete

within a given period of time. It is usually measured in
inches per minute
volt A unit of electrical pressure. In an electrical circuit, the unit

of force that is exerted on electrons by the source. Volts
cause electrons to flow in a current
weave welding A process in which a welder travels the bead along a given
line with a side-to-side motion
welding procedure A document that provides all of the information about

methods and practices that is necessary to weld two
pieces of metal
welding technique The details of a welding operation which, within the

limitations of the prescribed joint welding procedure, are
controlled by the welder or welding operator
welding variables Conditions that have an effect on the weld.

PEW-209.02 (Inspect Production Welds)

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DATE REVISION DESCRIPTION PAGE(S) AFFECTED

12/06/04 COMPLETE REVISION

MODULE COMPONENT PAGE

Verify proper welding techniques

Visually inspect completed production weld

VERIFY PROPER WELDING TECHNIQUES

Correct polarity of the electrical current

Correct movement of the welder

Correct arc distance

Steady travel speed

Gas mixture, if any

Back gouging, if any

Air carbon arc gouging, if any

Figure 1. Stringer bead

Figure 2. Weave beads

Figure 3. Weld sequence in a WPS

Figure 4. Welding positions

Figure 5. Different shielding gases

Gas Flow Rate

Figure 8. Digital Pyrometer to measure interpass temperature

Figure 6. Interpass cleaning with a grinder

Figure 7. Illustration of back gouging technique on welds

repair and maintenance of structures - bridges, earth-moving equipment, mining

preparation of plate edges for welding

Air Carbon Arc Gauging

Figure 9. Air carbon arc gouging

VISUALLY INSPECT COMPLETED PRODUCTION WELD

Groove Weld Measurements

Arrow shows thickness of weld

Figure 10. Size of V-groove weld

Fillet Weld Measurements

Figure 11. Measurement of a fillet weld

Figure 12. Fillet weld shapes

Fillet Weld Excess Convexity

Figure 13. Excess convexity

Width of weld face Maximum convexity

W <8 to W<25mm 3mm

Figure 14. AWS D1.1 limitation on convexity

Deposition of large volumes of 'cold' weld metal.

Oversize Fillet Welds

Figure 15. Oversized fillet weld

High welding current

Slow travel speeds

Undersized fillet welds (fillet welds smaller than those specified)

Undersized Fillet Welds

Figure 16. Undersized fillet weld

High welding speeds

Low welding currents

Figure 17. Hi-low (mismatch)

Base material dimensional variation - particularly common on pipes where ovality

Distortion during welding

Use of alignment jigs

Size pipes before machining the weld preparation

Use of strong backs and other clamping techniques

Figure 18. Illustrations of undercut

Figure 19. Illustration of a crack

Base Metal Crack

Star Crack in Root of Weld

Figure 20. Different types of cracks

Figure 21. Illustration of a crater

Figure 22. Illustration of weld porosity

In GTAW and GMAW welding, insufficient gas protection or contaminated shielding