Yanbu Steel Company Quality Control Procedure TITLE : Standard Visual & Dimensional Testing Procedure DOCUMENT NO : VT-1 ISSUE NO. : 1 COPY NO. : 0 YSC hereby certifies that the above named procedure complies with the requirements of the latest edition of the respective Codes and Standards listed below when noted in the procedure. CODES AND STANDARDS ASME B&PV Code Section V (2007 edition with 2008 & 2009 Addenda) ASME B&PV Code Section VIII Divisions 1 &2 (2007 edition with 2008 & 2009 Addenda) API 620 (11 th Edition, Feb. 2008 with Addendum 1, Mar. 2009) API 650 (11 th Edition, June 2007 with Addendum 1, Nov. 2008) ASME B31.1-2007 ASME B31.3-2008 ANSI/AWWA D100-05 ANSI/ASNT CP-189-2006 Prepared By: Reviewed By: Accepted by: Malik Sajjad Akhtar Ishfaq Ur Rehman Iain M. Lemond ASNT NDT Level III ASNT NDT Level III QA/QC Manager Certificate # 153071 Certificate # 165135 Yanbu Steel Company Rev. 2 Issued for implementation YSC Level III Date Mar. 23, 2010
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Yanbu Steel Company
Quality Control Procedure
TITLE : Standard Visual & Dimensional Testing
Procedure
DOCUMENT NO : VT-1
ISSUE NO. : 1
COPY NO. : 0
YSC hereby certifies that the above named procedure complies with the requirements of the latest edition
of the respective Codes and Standards listed below when noted in the procedure.
CODES AND STANDARDS
ASME B&PV Code Section V (2007 edition with 2008 & 2009 Addenda)
ASME B&PV Code Section VIII Divisions 1 &2 (2007 edition with 2008 & 2009 Addenda)
API 620 (11th Edition, Feb. 2008 with Addendum 1, Mar. 2009)
API 650 (11th Edition, June 2007 with Addendum 1, Nov. 2008)
ASME B31.1-2007
ASME B31.3-2008
ANSI/AWWA D100-05
ANSI/ASNT CP-189-2006
Prepared By: Reviewed By: Accepted by:
Malik Sajjad Akhtar Ishfaq Ur Rehman Iain M. Lemond
ASNT NDT Level III ASNT NDT Level III QA/QC Manager
Certificate # 153071 Certificate # 165135 Yanbu Steel Company
Rev.
2 Issued for implementation
YSC
Level III
Date
Mar. 23, 2010
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 2 of 29
Record of Change
Revision 2 March 23, 2010
Location Action Description
Page 1 Modification Added latest addenda and deleted ASNT SNT-TC-1A
Page 4 Modification Deleted ASNT SNT-TC-1A and added ANSI/ASNT CP-189-2006
Revision 1 August 17, 2009
Location Action Description
Page 2 Addition Record of Change
Page 3 Addition Table of Contents
Section 1.4 Modification Appendices numerical order modified
Section 3 Addition Added Definitions of direct and remote visual testing
Section 4.3 Addition Added requirements for visual examination personnel and addresses welding
inspection, tanks, piping and tanks certification exemption
Section 10 Modification Numerical Order modified as per section 1.4
Section 10.1
To
Section 10.8
Addition
Incorporated dimensional requirements along with visual inspection criteria in
accordance with the latest revisions of applicable codes and standards as
1.1 This procedure specifies the technique, acceptance standards and documentation requirements for all visual
examinations.
1.2 Visual examination is generally used to determine the acceptability of such things as the surface condition of the
part, alignment of mating surfaces as well as size, shape and condition of welds.
1.3 There may specific contract requirements which are more stringent than or in addition to the requirements of this
procedure. These requirements shall be specified on the detail or erection drawings.
1.4 Section 10 contains appendices, as listed below, covering the detail of acceptance standards, repairs and retests for
the applicable CODE or STANDARD. Appendices 1 through 8 are at the end of the procedure. When this procedure
is distributed to the field and customer for a contract, the main document and only the applicable Appendix (ces)
needed are to be issued.
Section 10.1 Appendix 1 – ASME Section VIII Division 1
Section 10.2 Appendix 2 – ASME Section VIII Division 2
Section 10.3 Appendix 3 – API 620
Section 10.4 Appendix 4 – API 650
Section 10.5 Appendix 5 – AWS D1.1
Section 10.6 Appendix 6 – ASME B31.1
Section 10.7 Appendix 7 – ASME B31.3
Section 10.8 Appendix 8 – ANSI/AWWA D100
2.0 GOVERNING DOCUMENTS
2.1 Codes and Standards
Those referenced in the Contract Documents
2.2 YSC Documents
Drawings and Procedures as listed on the Contract Drawing Index.
3.0 DEFINITIONS
3.1 Direct Visual Testing
Visual testing where there is an uninterrupted optical path from the observer’s eye to the test area. This is either unaided or aided via e.g. mirror, lens, endoscope or fibre optic.
3.2 Remote Visual Testing
Visual testing where is an interrupted optical path from the observer’s eye to the test area. Remote visual testing
may cover the use of photography, video systems and robots.
4.0 PERSONNEL
4.1 Visual examination personnel shall have vision, with correction if necessary, to enable them to read a Jaeger Type
No.1 standard chart at a distance of not less than 12 inches (305 mm). This requirement shall be checked annually.
4.2 Visual examination personnel shall be qualified and certified in accordance with YSC Quality Control Procedure
“Certification Procedure for Qualification and Certification of Nondestructive Testing Personnel” in accordance with either ASNT Standard for Certification and Qualification of Nondestructive Testing Personnel (ANSI/ASNT
CP-189) or as per client requirements.
4.3 Personnel shall be competent in the techniques of visual examination, including the examination, evaluation and
interpretation of the results, except that where the examination method consists of more than one operation,
personnel may be certified as being competent only for one or more of these operation. Those who possess
certification on weld inspection, tanks, piping or pressure vessels inspection (CWI, CSWIP, API 510, API 570
and/or API 653) shall be exempted from above requirement.
4.3 For ASME B31.1 work, visual examination personnel shall be qualified and certified in accordance with the
requirements of paragraph 136.1 of ASME B31.1.
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 5 of 29
5.0 GENERAL REQUIREMENTS
5.1 Extent of Examination
5.1.1 Items to be examined in accordance with this procedure shall be as specified on the detail fabrication and erection
drawings and applicable procedures and specifications for the contract.
5.1.2 This includes: assuring proper materials are used; inspecting joint fit-up, alignment and tack welds; assuring that
welding procedures, which are specified on the drawings are used; assuring that no unspecified welds are added
without approval; inspecting final weld shape, size and condition; inspecting welds after PWHT; inspection during
NDT (PT, MT) and inspection during hydrotest / pressure test.
5.2 Surface Preparation
5.2.1 Slag, oil, dirt, moisture, grease, and other foreign matter that would interfere with the examination shall be removed
from the area of interest and for a distance of at least one (1) inch (25.4 mm) from the area of interest prior to any
visual examination.
5.2.2 In general, welds shall be visually inspected after the completed welds have cooled to ambient temperature.
6.0 EQUIPMENT
Artificial Light Source
Mirrors
Magnifiers
Straight Edges or Rules
Weld Gauges
7.0 EXAMINATION TECHNIQUE
7.1 Direct Visual Examination
Direct visual examination may usually be made when access is sufficient to place the eye within 24 in. (600 mm) of
the surface to be examined and at an angle not less than 30 deg to the surface to be examined. Mirrors may be used
to improve the angle of vision, and aids such as a magnifying lens may be used to assist examinations. Illumination
(natural or supplemental white light) for the specific part, component, vessel, or section thereof being examined is
required. The minimum light intensity at the examination surface/site shall be 100 footcandles (1000 lux). The light
source, technique used, and light level verification is required to be demonstrated one time, documented, and
maintained on file.
7.2 Remote Visual Examination
In some cases, remote visual examination may have to be substituted for direct examination. Remote visual
examination may use visual aids such as mirrors, telescopes, borescopes, fiber optics, cameras, or other suitable
instruments. Such systems shall have a resolution capability at least equivalent to that obtainable by direct visual
observation.
8.0 RECORDS
When required by contract or the applicable Code or Standard, acceptable visual inspections shall be recorded on the
Process Control Plan or VT Inspection Report Form 18077, as they apply. The sign-off shall include any special
equipment used to complete the visual inspection.
9.0 ACCEPTANCE STANDARDS, REPAIRS AND RETESTS
9.1 All materials, joint preparation, assembly and welding shall be in accordance with the applicable contract drawings,
procedures and specifications.
9.2 Repairs and Retests
Unacceptable conditions found during inspections shall be marked on the item, corrected using qualified welding
procedures, welders and welding operators, and re-inspected using the original inspection procedure for acceptance.
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 6 of 29
10.0 Appendices
10.1 Appendix 1 – ASME Section VIII Division 1 Rules for Construction of Pressure Vessels
10.1.1 Weld which contain cracks and unacceptable.
10.1.2 Welded joints shall have complete penetration and full fusion. As-welded surfaces are permitted; however, the
surface of welds shall be sufficiently free from coarse ripples, grooves, overlaps, and abrupt ridges and valleys to
permit proper interpretation of radiographic and other required nondestructive examinations. If there is a question
regarding the surface condition of the weld when interpreting a radiographic film, the film shall be compared to the
actual weld surface for determination of acceptability.
10.1.3 A reduction in thickness due to the welding process is acceptable provided all of the following conditions are met:
a. The reduction in thickness shall not reduce the material of the adjoining surfaces below the minimum
required thickness at any point.
b. The reduction in thickness shall not exceed 1⁄32 in. (1 mm) or 10% of the nominal thickness of the adjoining surface, whichever is less.
Note: It is not the intent of this paragraph to require measurement of reductions in thickness due to the welding
process. If a disagreement between the Manufacturer and the Inspector exists as to the acceptability of any
reduction in thickness, the depth shall be verified by actual measurement.
10.1.4 If 100% radiography does not apply, rounded indications on the surface of welds shall not be cause for rejection;
however, for guidance purposes only, an acceptable surface condition of a weld may be judged on the basis of
founded indications as contained in Section VIII, Division 1 (Appendix 4)
10.1.5 Weld Reinforcement
When a single-welded butt joint is made by using a backing strip which is left in place, the requirement for
reinforcement applies only to the side opposite the backing strip. To assure that the weld grooves are completely
filled so that the surface of the weld metal at any point does not fall below the surface of the adjoining base
materials, weld metal may be added as reinforcement on each face of the weld. The thickness of the weld
reinforcement on each face shall not exceed the following:
Customary Units
Maximum Reinforcement, in.
Material Nominal Thickness, in. Category B & C Butt Welds Other Welds
Less than 3⁄32
3⁄32 1⁄32
3⁄32 to 3⁄16, incl.
1⁄8 1⁄16
Over 3⁄16 to
1⁄2, incl. 5⁄32
3⁄32
Over 1⁄2 to 1, incl.
3⁄16 3⁄32
Over 1 to 2, incl. 1⁄4
1⁄8 Over 2 to 3, incl.
1⁄4 5⁄32
Over 3 to 4, incl. 1⁄4
7⁄32
Over 4 to 5, incl. 1⁄4
1⁄4 Over 5
5⁄16 5⁄16
SI Units
Maximum Reinforcement, mm.
Material Nominal Thickness, mm Category B & C Butt Welds Other Welds
Less than 2.4 2.4 0.8
2.4 to 4.8, incl. 3.2 1.6
Over 4.8 to 13, incl. 4.0 2.4
Over 13 to 25, incl. 4.8 2.4
Over 25 to 51, incl. 5 3.2
Over 51 to 76, incl. 6 4
Over 76 to 102, incl. 6 6
Over 102 to 127, incl. 6 6
Over 127 8 8
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 7 of 29
10.1.6 Concavity
Concavity due to the welding process on the root side of a single welded circumferential butt weld is permitted when
the resulting thickness of the weld is at least equal to the thickness of the thinner member of the two sections being
joined and the contour of the concavity is smooth.
10.1.7 Alignment Tolerance
a. Alignment of sections at edges to be butt welded shall be such that the maximum offset is not greater than
the applicable amount for the welded joint category under consideration, as listed in Table UW-33. The
section thickness t is the nominal thickness of the thinner section at the joint.
b. Any offset within the allowable tolerance provided above shall be faired at a three to one taper over the
width of the finished weld, or if necessary, by adding additional weld metal beyond what would otherwise
be the edge of the weld.
TABLE UW - 33
Customary Units
Section Thickness, in. Joint Categories
A B, C, & D
Up to 1⁄2, incl.
1⁄4 t 1⁄4 t
Over 1⁄2 to
3⁄4, incl. 1⁄8 in.
1⁄4 t
Over 3⁄4 to 1
1⁄2, incl. 1⁄8 in.
3⁄16 in.
Over 11⁄2 to 2, incl.
1⁄8 in. 1⁄8 t
Over 2 Lesser of 1⁄16 t or
3⁄8 in. Lesser of 1⁄8 t or
3⁄4 in.
SI Units
Section Thickness, mm Joint Categories
A B, C, & D
Up to 13, incl. 1⁄4 t
1⁄4 t
Over 13 to 19, incl. 3 mm 1⁄4 t
Over 19 to 38, incl. 3 mm 5 mm
Over 38 to 51, incl. 3 mm 1⁄8 t
Over 51 Lesser of 1⁄16 t or 10 mm Lesser of
1⁄8 t or 19 mm
FIG. UW-3 ILLUSTRATION OF WELDED JOINT LOCATIONS TYPICAL OF CATEGORIES A, B, C, AND D
10.1.8 Out – of – Roundness of Cylindrical, Conical, and Spherical Shells subjected to Internal Pressure
The shell of a completed vessel shall be substantially round and shall meet the following requirements:
a. The difference between the maximum and minimum inside diameters at any cross section shall not exceed
1% of the nominal diameter at the cross section under consideration. The diameters may be measured on
the inside or outside of the vessel. If measured on the outside, the diameters shall be corrected for the plate
thickness at the cross section under consideration (see Fig. UG-80.2).
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 8 of 29
b. When the cross section passes through an opening or within 1 I.D. of the opening measured from the center
of the opening, the permissible difference in inside diameters given above may be increased by 2% of the
inside diameter of the opening. When the cross section passes through any other location normal to the axis
of the vessel, including head-to-shell junctions, the difference in diameters shall not exceed 1%.
For vessels with longitudinal lap joints, the permissible difference in inside diameters may be increased by the
nominal plate thickness.
FIGURE UG-80.2
Examples of Differences between Maximum and Minimum Inside Diameters in Cylindrical, Conical, and Spherical Shells
10.1.9 Tolerance for Formed Heads
A The inner surface of a torispherical, toriconical, hemispherical, or ellipsoidal head shall not deviate outside
of the specified shape by more than 11⁄4% of D nor inside the specified shape by more than
5⁄8% of D, where
D is the nominal inside diameter of the vessel shell at point of attachment. Such deviations shall be
measured perpendicular to the specified shape and shall not be abrupt. The knuckle radius shall not be less
than that specified.
B Hemispherical heads or any spherical portion of a torispherical or ellipsoidal head designed for external
pressure shall, in addition to satisfying (a) above, meet the tolerances specified for spheres in UG-80(b)
using a value of 0.5 for L/Do.
C Measurements for determining the deviations shall be taken from the surface of the base metal and not from
welds.
D The skirts of heads shall be sufficiently true to round so that the difference between the maximum and
minimum inside diameters shall not exceed 1% of the nominal diameter.
E When the skirt of any unstayed formed head is machined to make a driving fit into or over a shell, the
thickness shall not be reduced to less than 90% of that required for a blank head or the thickness of the shell
at the point of attachment. When so machined, the transition from the machined thickness to the original
thickness of the head shall not be abrupt but shall be tapered for a distance of at least three times the
difference between the thicknesses.
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 9 of 29
10.0 Appendices
10.2 Appendix 2 – ASME Section VIII Division 2 Alternative Rules – Rules for Construction of
Pressure Vessels
All welds for pressure retaining parts shall be visually examined. Welds that are observed to have indications
exceeding the criteria given in Table 7.6 are unacceptable. Unacceptable indications shall be removed or reduced to
an indication of acceptable size. Whenever an indication is removed by chipping or grinding and subsequent repair
by welding is not required, the area shall be blended into the surrounding surface so as to avoid notches, crevices, or
a Convexity, C, of a weld or individual surface bead with dimension W shall not exceed the value of the following table
WIDTH OF WELD FACE OR
INDIVIDUAL SURFACE BEAD, W
MAX. CONVEXITY, C
W< 5/16 in. [8 mm] W > 5/16 in. [8 mm] TO W< 1 in. [25 mm] W > 1 in. [25 mm]
1/16 in. [2 mm] 1/8 in. [3 mm]
3/16 in. [5 mm]
UNDERSIZE WELD
EXCESSIVE CONVEXITY
EXCESSIVE UNDERCUT
OVERLAP UNDERSIZE
WELD INCOMPLETE
FUSION
(C) UNACCEPTABLE FILLET WELD PROFILES
BUTT PLATE – EQUAL THICKNESS PLATE
BUTT JOINT (TRANSITION) – UNEQUAL THICKNESS PLATE
b Reinforcement R shall not exceed 1/8 in. [3 mm] (see 10.5.3)
(D) ACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINT
EXCESSIVE WELD REINFORCEMENT
UNDERFILL EXCESSIVE UNDERCUT
OVERLAP
(E) UNACCEPTABLE GROOVE WELD PROFILES IN BUTT JOINTS
Note: All welds shall meet the visual acceptance criteria of Table 6.1
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 19 of 29
10.5.3 Weld Profiles
All welds meet the visual acceptance criteria of Table in 10.5.2 and shall be free from cracks, overlaps, and the
unacceptable profile discontinuities exhibited in Figure 5.4 except as otherwise allowed in 10.5.3.
10.5.3.1 Fillet Welds
The faces of fillet welds may be slightly convex, flat, or slightly concave as shown in Figure 5.4.
Figure 5.4(C) shows typically unacceptable fillet weld profiles.
10.5.3.2 Intermittent Fillet Welds
Except for undercut, as allowed by the code, the profile requirements of Figure 5.4 shall not apply to
the ends of intermittent fillet welds outside their effective length.
10.5.3.3 Convexity
Except at outside welds in corner joints, the convexity C of a weld or individual surface bead shall not
exceed the values given in Figure 5.4.
10.5.3.4 Groove or Butt Welds
Groove welds shall be made with minimum face reinforcement unless otherwise specified. In the case
of butt and corner joints, face reinforcement shall not exceed 1/8 in. [3 mm] in height. All welds shall
have a gradual transition to the plane of the base-metal surfaces with transition areas free from
undercut except as allowed by this code. Figure 5.4(D) shows typically acceptable groove weld
profiles in butt joints. Figure 5.4(E) shows typically unacceptable weld profiles for groove weld butt
joints.
10.5.3.4.1 Flush Surfaces
Butt welds required to be flush shall be finished so as to not reduce the thicknesses of the
thinner base metal or weld metal by more than 1/32 in. [1 mm], or 5% of the material
thickness, whichever is less. Remaining reinforcement shall not exceed 1/32 in. [1 mm] in
height. However, all reinforcement shall be removed where the weld forms part of a faying
or contact surface. All reinforcement shall blend smoothly into the plate surfaces with
transition areas free from undercut.
10.5.3.4.2 Finish Methods and Values
Chipping and gouging may be used provided these are followed by grinding. Where surface
finishing is required, roughness values (see ASME B46.1) shall not exceed 250
microinches [6.3 micrometers]. Surfaces finished to values of over 125 microinches [3.2
micrometers] through 250 microinches [6.3 micrometers] shall be finished parallel to the
direction of primary stress. Surfaces finished to values of 125 microinches [3.2
micrometers] or less may be finished in any direction.
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 20 of 29
10.0 Appendices
10.6 Appendix 6 – ASME B31.1 Pressure Piping
10.6.1 Internal misalignment of the ends to be joined shall not exceed 1⁄16 in. (2.0 mm) unless the piping design specifically
states a different allowable misalignment. When the internal misalignment exceeds the allowable, it is preferred that
the component with the wall extending internally be internally trimmed to a 1:3 maximum slope. However,
trimming shall result in a piping component thickness not less than the minimum design thickness and the change in
contour shall not exceed 30 deg.
10.6.2 Socket Weld Assembly
The depth of insertion of a pipe or tube into a socket weld fitting shall be at least 1/4 in. (6.0 mm). Before welding,
there should be at least 1/16 in. (2.0 mm) clearance between the end of pipe and internal shoulder of the socket weld
fitting. The inside diameter of the socket or sleeve exceed the outside diameter of the pipe or tube by more than
0.080 in. (2.0 mm).
10.6.3 Components with different outside diameter or wall thicknesses are welded together, welding end transmission shall
provide for a maximum 30 degree angle across the weld with respect to the base metal (diameters) on each side of
the weld. Additionally when both components to be welded (other than pipe to pipe) have a transition from a thicker
section to the weld end preparation from a thicker section to the weld end preparation, the included angle between
the surface of the weld and the surface of either of the components shall not be less than 150 deg.
10.6.4 As-welded surfaces are permitted; however, the surface of welds shall be sufficiently free from coarse ripples,
grooves, overlaps, abrupt ridges, and valleys to meet the following:
a. The surface condition of the finished welds shall be suitable for the proper interpretation of radiographic
and other nondestructive examinations when nondestructive examinations are required.
b. If the surface of the weld requires grinding to meet the above criteria, care shall be taken to avoid reducing
the weld or base material below the minimum required thickness.
c. Concavity on the root side of a single welded circumferential butt weld is permitted when the resulting
thickness of the weld is at least equal to the thickness of the thinner member of the two sections being
joined and the contour of the concavity is smooth without sharp edges. The internal condition of the root
surface of a girth weld, which has been examined by radiography, is acceptable only when there is a
gradual change in the density, as indicated in the radiograph. If a girth weld is not designated to be
examined by radiography, a visual examination may be performed at welds which are readily accessible.
10.6.5 Fillet Welds
In making fillet welds, the weld metal shall be deposited in such a way as to secure adequate penetration into the
base metal at the root of the weld. Fillet welds may vary from convex to concave. The size of a fillet weld shall be as
shown on the Detail or Erection Drawing
a. Slip-On and Socket Welding Flanges
Weld Leg Length for socket and slip-on flanges shall be 1.4 times the nominal pipe wall thickness or
thickness of hub, whichever is smaller.
b. Socket Welding Components Other than Flanges
Weld Leg Length for socket welding components other than flanges shall be 1.09 nominal pipe wall
thickness or the thickness of the socket wall, whichever is smaller.
10.6.6 Seal Welds
Where seal welding of threaded joints is performed, threads shall be entirely covered by the seal weld. Seal welding
shall be done by qualified welders.
10.6.7 All completed welds in pipe and piping components shall be capable of complying with the acceptance standards
specified below or with the limitations on imperfections specified in the material specification under which the pipe
or component was furnished. The following indications are unacceptable:
a. Cracks — external surface.
b. Undercut on surface which is greater than 1⁄32 inch (1.0 mm) deep.
c. Weld reinforcement greater than specified in Table 127.4.2.
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 21 of 29
Table 127.4.2 Reinforcement of Girth and Longitudinal Butt Welds
Thickness of Base Metal,
Maximum Thickness of Reinforcement
for Design Temperature
> 750°F
(400°C)
350°F–750°F
(175°C–400°C)
< 350°F
(175°C)
in. (mm) in. mm in. mm in. mm
Up to 1⁄8 (3.0), incl.
1/16 2.0
3/32 2.5
3/16 5.0
Over 1⁄8 to
3⁄16 (3.0 to 5.0), incl. 1/16
2.0
1/8
3.0
3/16
5.0
Over 3⁄16 to
1⁄2 (5.0 to 13.0), incl. 1/16
2.0
5/32
4.0
3/16
5.0
Over 1⁄2 to 1 (13.0 to 25.0), incl.
3/32 2.5
3/16 5.0
3/16 5.0
Over 1 to 2 (25.0 to 50.0), incl. 1/8
3.0
1/4
6.0
1/4
6.0
Over 2 (50.0) 5/32 4.0 The greater of
1⁄4 in. (6 mm) or 1⁄8 times
the width of the weld in inches (millimeters).
GENERAL NOTES:
(a) For double welded butt joints, this limitation on reinforcement given above shall apply separately to both inside and outside surfaces of the joint.
(b) For single welded butt joints, the reinforcement limits given above shall apply to the outside surface of the joint only.
(c) The thickness of weld reinforcement shall be based on the thickness of the thinner of the materials being joined.
(d) The weld reinforcement thicknesses shall be determined from the higher of the abutting surfaces involved.
(e) Weld reinforcement may be removed if so desired.
d. Lack of fusion on surface.
e. Incomplete penetration (applies only when inside surface is readily accessible).
f. Any other linear indications greater than 3⁄16 in. (5.0 mm) long.
g. Surface porosity with rounded indications having dimensions greater than 3⁄16 in. (5.0 mm) or four or more
rounded indications separated by 1⁄16 in. (2.0 mm) or less edge to edge in any direction. Rounded
indications are indications which are circular or elliptical with their length less than three times their width.
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 22 of 29
10.0 Appendices
10.7 Appendix 7 – ASME B31.3 Process Piping (Except High Pressure Piping)
10.7.1 Fit-up, including misalignment of butt-welds, shall be in accordance with the WPS. Any misalignment of butt-welds,
exceeding the WPS shall be tapered to a 30-degree maximum angle. The resulting weld joint and tapered areas shall
not be thinner than the non-tapered base material.
Figure 328.4.3 Trimming and Permitted Misalignment
(a) Thicker Pipe Taper-Bored to Align
(b) Thicker Pipe Bored for Alignment
10.7.2 Opening through the pipe for branch on pipe connections shall align with the bore of the branch within 3.2 mm (1/8 in.)
or one-half the branch wall thickness, whichever is less.
10.7.3 The depth of insertion of a pipe or tube into a socket weld fitting shall be at least 1/4 in. (6.0 mm). Before welding,
there should be at least 1/16 in. (1.5 mm) approximate gap between the end of pipe and internal shoulder of the socket
weld fitting.
10.7.4 Fillet Welds
In making fillet welds, the weld metal shall be deposited in such a way as to secure adequate penetration into the
base metal at the root of the weld. Fillet welds may vary from convex to concave. The size of a fillet weld shall be as
shown on the Detail or Erection Drawing
a. Double-Welded Slip-On and Socket Welding Flange Attachment Welds
Weld Leg Length for socket and slip-on flanges shall be 1.4 times the nominal pipe wall thickness or
thickness of hub, whichever is smaller.
b. Socket Welding Components Other than Flanges
Weld Leg Length for socket welding components other than flanges shall be 11/4 t (t = pressure design
thickness) but not less than 3 mm (1/8 in.)
10.7.5 Seal Welds
Where seal welding of threaded joints is performed, threads shall be entirely covered by the seal weld. Seal welding
shall be done by qualified welders.
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 23 of 29
10.7.6 The acceptance criteria for welds are given in Table 341.3.2. Typical weld imperfections are shown in Figure 341.3.2. T
A Extent of imperfection Zero (no evident imperfection)
B Depth of incomplete penetration Cumulative length of incomplete penetration
≤ 1 mm (1 ⁄ 32 in.) and ≤ 0.2Tw ≤ 38 mm (1.5 in.) in any 150 mm (6 in.) weld length
C Depth of lack of fusion and incomplete penetration Cumulative length of lack of fusion and incomplete penetration [Note (7)]
≤ 0.2 Tw ≤ 38 mm (1.5 in.) in any 150 mm (6 in.) weld length
D Size and distribution of internal porosity See BPV Code, Section VIII, Division 1, Appendix 4
E Size and distribution of internal porosity For Tw ≤ 6 mm (1 ⁄ 4 in.), limit is same as D For Tw > 6 mm (1 ⁄ 4 in.), limit is 1.5 x D
F Slag inclusion, tungsten inclusion, or elongated indication Individual length Individual width Cumulative length
≤ Tw /3 ≤ 2.5 mm (3⁄32 in.) and ≤ Tw /3 ≤ Tw in any 12 Tw weld length
G Slag inclusion, tungsten inclusion, or elongated indication Individual length Individual width Cumulative length
≤ 2 Tw ≤ 3 mm (1 ⁄ 8 in.) and ≤ Tw /2 ≤ 4 Tw in any 150 mm (6 in.) weld length
H Depth of undercut ≤ 1 mm (1 ⁄ 32 in.) and ≤ Tw /4
I Depth of undercut ≤ 1.5 mm (1 ⁄ 16 in.) and ≤ [Tw /4 or 1 mm (1 ⁄ 32 in.)]
J Surface roughness ≤ 500 min. Ra per ASME B46.1
K Depth of root surface concavity Total joint thickness, incl. weld reinf., ≥ Tw
L Height of reinforcement or internal protrusion [Note (8)] in any plane through the weld shall be within limits of the applicable height value in the tabulation at right, except as provided in Note (9). Weld metal shall merge
M Height of reinforcement or internal protrusion [Note (8)] as described in L. Note (9) does not apply.
Limit is twice the value applicable for L above
NOTES:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Criteria given are for required examination. More stringent criteria may be specified in the engineering design. See also paras. 341.5 and 341.5.3.
Branch connection weld includes pressure containing welds in branches and fabricated laps.
Longitudinal groove weld includes straight and spiral seam. Criteria are not intended to apply to welds made in accordance with a standard listed in Table A-1 or Table 326.1. Alternative Leak Test requires examination of these welds; see para. 345.9.
Fillet weld includes socket and seal welds, and attachment welds for slip-on flanges, branch reinforcement, and supports.
These imperfections are evaluated only for welds ≤ 5 mm (3 ⁄ 16 in.) in nominal thickness.
Where two limiting values are separated by “and,” the lesser of the values determines acceptance. Where two sets of values are separated by “or,” the larger value is acceptable. Tw is the nominal wall thickness of the thinner of two components joined by a butt weld.
Tightly butted unfused root faces are unacceptable.
For groove welds, height is the lesser of the measurements made from the surfaces of the adjacent components; both reinforcement and internal protrusion are permitted in a weld. For fillet welds, height is measured from the theoretical throat, Fig. 328.5.2A; internal protrusion does not apply.
For welds in aluminum alloy only, internal protrusion shall not exceed the following values:
(a) 1.5 mm (1 ⁄ 16 in.) for thickness ≤ 2 mm (5 ⁄ 64 in.)
(b) 2.5 mm (3 ⁄ 32 in.) for thickness > 2 mm and ≤ 6 mm (1 ⁄ 4 in.)
For external reinforcement and for greater thicknesses, see the tabulation for symbol L.
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 25 of 29
Fig. 341.3.2 Typical Weld Imperfections
Lack of fusion between weld bead and base metal
(b) Lack of Fusion Between Adjacent Passes (a) Side Wall Lack of Fusion
Incomplete filling at root on one side only
Incomplete filling at root
(c) Incomplete Penetration due to Internal Misalignment
(d) Incomplete Penetration Of Weld Groove
Root bead fused to both inside surfaces but
center of root slightly below inside surface of pipe (not incomplete penetration)
(e) Concave Root Surface (Suck-Up)
(f) Undercut
(g) Excess External Reinforcement
External Undercut
Internal Undercut
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 26 of 29
10.0 Appendices
10.8 Appendix 8 - ANSI/AWWA D100-05 Welded Carbon Steel Tanks for Water Storage
Any of the following weld defects identified by visual inspection shall be cause for rejection, and the deficient weld
shall be repaired or replaced:
10.8.1 Any crack, regardless of size or location
10.8.2 Lack of fusion between adjacent layers of weld metal or between weld metal and base metal, except for tubular
support columns for multiple column tanks, large diameter dry risers, and single pedestal columns with either a
smooth cylindrical, conical, or bent plate surface as noted:
a. Circumferential Butt Joints
One sided welds, some nonfusion more than ten (10) times the column wall thickness in length shall be
rejected, provided that the governing stress is compression
b. Longitudinal Butt
Areas more than ten (10) times the column wall thickness in length shall be rejected.
10.8.3 Unfilled craters
10.8.4 Overlap resulting from the protrusion of weld metal beyond the weld toe or weld root
10.8.5 Weld size less than specified (insufficient throat or leg)
10.8.6 The thickness of the reinforcement of the welds on all butt joints shall not exceed the thicknesses given in Table 20.
The reinforcement need not be removed except to the extent that it exceeds the maximum acceptable thickness or
when required for radiographic inspections. In no case shall the face of the weld lie below the surface of the plates
being joined
Table 20 Maximum thickness of reinforcement for butt joints
Maximum Thickness of Reinforcement
Plate Thickness Vertical Joints Horizontal Joints
in. (mm) in. (mm) in. (mm)
< 1/2 (13)
3/32 (2.4)
1/8 (3.2)
> 1/2 (13) and < 1(25)
1/8 (3.2)
3/16 (4.8)
> 1 (25) 3/16 (4.8)
1/4 (6.4)
10.8.7 Fillet weld convexity in excess of
a. 1/16 in. (1.6 mm) for width of individual bead or weld face not over
5/16 in. (7.9 mm)
b. 1/8 in. (3.2 mm) for width of individual bead or weld face over
5/16 in. (7.9 mm), but less than 1 in. (25.4
mm)
c. 3/16 in. (4.8 mm) for width of individual bead or weld face 1 in. (25.4 mm) or over
10.8.8 Undercut in excess of the limits given as under:
a. For butt joints subject to primary stress due to weight or pressure of tank contents, maximum permissible
undercut shall be 1/64 in. (0.4 mm).
b. For butt joints subject to secondary stress, a maximum undercut of 1/32 in. (0.8 mm) is permitted, provided
that the unwelded portion plus the undercut shall not reduce the thickness of the joint by more than one
third of the thickness of the thinner plate joined.
c. For lap joints subject to primary stress due to weight or pressure of tank contents, the maximum
permissible undercut shall be 1/64 in. (0.4 mm).
d. For lap joints subject to secondary stress, the maximum undercut permitted shall be 1/32 in. (0.8 mm).
e. For butt joints in tension bracing, the finished surface of the splice weld shall be ground to eliminate sharp
notches and all undercut shall be repaired to provide a smooth transition from the splice weld to the brace
material (i.e., no undercut).
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 27 of 29
f. The maximum undercut permitted for all other joints shall be 1/32 in. (0.8 mm).
10.8.9 Porosity:
a. Any visible porosity in butt joints subject to primary stress
b. In all other joints, the sum of visible porosity greater than 1/32 in. (0.8 mm) in diameter shall not exceed
3/8
in. (9.5 mm) in any linear inch of weld and shall not exceed 3/4 in. (19.0 mm) in any 12 in. (305 mm) length
of weld
10.8.10 Plumbness
The maximum out-of-plumbness of the top of the shell relative to the bottom of the shell shall not exceed 1/200 of
the total shell height. The out-of-plumbness in one shell plate shall not exceed the permissible variations for
flatness and waviness as specified in ASTM A6 or in ASTM A20, whichever is applicable.
10.8.11 Roundness
Radii measured at 1 ft (0.3 m) above the bottom corner weld shall not exceed the tolerances as given in Table 21.
Table 21 Roundness—cylindrical shells
Diameter Max Radius Tolerance
ft (m) in. (mm)
40 (12.2) ±11/2 (13)
150 (45.7) ±13/4 (19)
< 250 < (76.2) ±1 (25)
≥ 250 ≥ (76.2) ±11/4 (32)
10.8.12 Peaking and banding at weld joints
Peaking is the out-of-plane distortion across a vertical weld seam. Banding is the out-of-plane distortion across a
circumferential weld seam.
1. Using a horizontal sweep board 36 in. (0.91 m) long, peaking shall not exceed 1/2 in. (13 mm).
2. Using a vertical sweep board 36 in. (0.91 m) long, banding shall not exceed 1/2 in. (13 mm).
10.8.13 Localized flat spots.
Flat spots (that deviate from the theoretical shape) measured in the vertical plane shall not exceed the appropriate
plate flatness and waviness requirements in ASTM A6 and A20, whichever is applicable.
10.8.14 Plate Misalignment:
The adjoining edges of butt joints shall be aligned accurately and retained in position during welding, so that the
offset tolerances of Table 22 are not exceeded in the welded joint.
Table 22 Maximum allowable offset of aligned butt joints
Thickness Subject to Primary Stress Subject to Secondary Stress
in. (mm) in. (mm) in. (mm)
5/8 1
/16 1.6 1/8 3.2
t > 5/8 t > 16 Lesser of 0.10t
or 1/4
Lesser of 0.10t or 6
Lesser of 0.20t
or 3/8
Lesser of 0.20t or 9.5
*t = nominal thickness of the thinner plate at the joint
10.8.15 Minimum Size of Fillet and Seal Welds
a. Fillet Welds
Plates 3/16 in. (4.76 mm) and less in thickness shall have fillet welds equal to the base metal thickness.
Plates more than 3/16 in. (4.76 mm) thick shall have welds of a size not less than one-third the thickness of
the thinner plate at the joint, with a minimum of 3/16 in. (4.76 mm).
b. Adjustment for root opening
Except for seal welds, the size of fillet welds shall be increased by the amount of root opening in excess
of 1/16 in. (1.6 mm) and the root opening shall not exceed
3/16 in. (4.8 mm).
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 28 of 29
c. Seal welds
Seal welding, when specified or required by this standard, shall be accomplished by a continuous weld
combining the functions of sealing and strength with weld sections changed only as required strength
may necessitate. Seal welds shall be of minimum size, but sufficient to prevent cracking from thermal
shrinkage. Seal weld acceptance shall be the same as for visual inspection of structural welds.
10.8.16 Minimum Length of Welds
The minimum length of any weld shall be four times the weld size, but not less than 11/2 in. (38 mm).
a. Fillet welds
The effective length of a fillet weld shall not include the length of tapered ends. A deduction of at least 1/4 in. (6.4 mm) shall be made from the overall length as an allowance for tapered ends.
10.8.17 Intermittent Welding
Intermittent welding shall not be used on tank-shell or riser surfaces in contact with tank contents or on plate
surfaces exposed to external weathering
a. Length
The length of any segment of intermittent welds shall not be less than four times the weld size but never
less than 11/2 in. (38 mm).
b. Seams
Seams that are to have intermittent welds shall have continuous lengths of welds at each end for a
distance of at least 6 in. (152 mm).
YSC STANDARD VISUAL AND DIMENSIONAL
TESTING PROCEDURE
Doc Ref: VT-1 – Rev. 2 Page 29 of 29
FORM 18077 Rev.01
Yanbu Steel Company
P.O.Box 30075
Madinat Yanbu Al Sinaiyah
Saudi Arabia
VISUAL INSPECTION
REPORT
Report No.:
Sheet: Date:
Description/ Contract No.:
Drawing No.:
Part No./Weld No. Procedure & Rev. No.: VT-1 Rev. 01