CHAPTER 1

INTRODUCTION

1.0 Introduction
A boiler is a closed vessel in which water or other fluid is heated. The heated or
vaporized fluid that exits from the boiler is used for various processes or heating
applications.The demand for the higher power outputs from the boiler and associated
plant has increased in the last ten years. It is a common practice to use high pressure and
temperature steam in power plants to increase the efficiency of the plant and to decrease
the cost of electricity production. In the last ten years, the operating pressures and
temperatures of boilers have risen and this has been the possible because of the
development of materials. For the given steam conditions and boiler size, there is not
much variation in efficiency between different types and the widest scope left to the
designer only in increasing the plant economy by making use of the high temperature
flue gases.

The modern high pressure boilers used for power generation are for steam
capacities ranging from 30 to 650 tons/hr and above with a pressure up to 160 bar and
maximum steam temperature of about 540 deg celcius. One of the largest boiler plants in
the world is in U.K. used in Central Electricity Generation Board. This boiler was
designed for 1700 tons of steam generation per hour at a pressure of 160 bar and 560 deg
celcius with one reheat to 560 deg celcius burning 220 tons of coal/hr.

Welding Process holds a very important role in the manufacture of boilers. Butt
welding is the type of welding carried out in boilers. Generally two types of welding is
carried out. First one is the long seam and the other one is the circumferential seam.
Long seam is done to join the two longitudinal shells of the boiler. Cir seam is used to

1
join the two dish ends of the boiler. Welding defect causes lot of rework and increase in
cycle time and also amounts to increase in costs. Here the defect, refers to unacceptable
portion in the weld, which may be detrimental to the product performance. Apart from
the unacceptable part, undesired part is also there, which includes, cosmetic defects,
which are predominant in fillet welds. A holistic approach was undertaken to list out all
such impedences in productivity arising out of poor welding pertaining to drum and ring
headers. To address to these impedences, this study was conceived. Samples were tested
and results are presented to augment the quality of welding in drum shop.

The scope of the project work is to provide a broad perspective into the problems
encountered in Drum Shop due to welding and to suggest solutions that shall be
implemented along with quality control and surveillance activities

The main objectives of this study were:

• To enlist all the problems encountered in drum shop related to welding.

• To suggest the remedial measures for minimizing the problems and hence also to
avoid the rework, therby improving productivity.

The project study was executed in Drum shop which includes, bay193, 197, 164
and 160. The project was consummated with its implementation. But never the less,
learning is a continuous process and using this as a guidelines for future welding works in
shop, every effort shall be put to strive for improvement in welding.
.

2
1.1 ABOUT BHEL

Bharat Heavy Electrical Limited (BHEL) was established in 1963 and became
production in 1965. It is a leading public sector enterprise engaged in designing,
manufacturing and commissioning of power generating equipments, among others. From
an initial start of manufacturing 60MW and 120MW boilers in the sixties, the plant has
progressed to building equipments up to 500MW size for thermal stations. It has a
capacity to manufacture industrial boilers of any design and capacity features, fluidized
bed combustion boilers, waste heat recovery boilers, nuclear steam generators, valves for
power, industrial and oil sectors, industrial fans, air pre-heaters, pollution control
equipments, industrial piping and seamless steel tubes. In addition, the plant has build
modern laboratory facilities with an ability to conduct major coal based research as well
as welding research.

B.H.E.L., Trichy is perhaps the only manufacturer in the world to design,

engineer and supply the entire range of steam generators and its auxiliaries needed for
power stations and industries. Its manufacturing capacity has steadily grown from
750MW/annum to 4000MW/annum to meet the complete requirements of the national
power programs. The High Pressure Boiler Plant specializes in the manufacturer of steam
generators for thermal and nuclear stations of unit size up to 500MW and 235MW
respectively along with all related auxiliary equipments.

B.H.E.L. also manufactures industrial process stem boilers sizes to meet the
requirements of fertilizer, petrochemical, steel and paper industries. These boilers are
designed for a wide range of fuels such as coal, oil, gas, asphalt, black liquor and any
other combinations of this.

B.H.E.L., Trichy, has seen over the years growth in terms of capacity, turn over
and profitability, hand in hand with product diversity. Newer product technologies have

3
been developed, absorbed and adapted to Indian conditions. Modern facilities have been
continuously added to raise capability and improve quality and productivity. There has
also been a matching growth of ancillaries and sub contractors.

Quality is a commitment according to B.H.E.L.,Trichy. Over 400 qualified

scientists and engineers backup its quality assurance and quality control services. It
boasts of state of the art facilities like spectroscopes, high magnification electron
microscopes, real time imaging system, X-ray diffraction equipment, strain gauges, creep
testing facility and NDT facilities such as 4 million electron volts linear accelerator
which are among the most advance Quality Control facilities in its fields.
With these Quality Control facilities and systems, B.H.E.L., Trichy, manufacture the
equipments to meet ASME, B.S and ISO standards.

B.H.E.L., Trichy, holds the ASME “S” stamp for boiler and piping, U and
U2 stamps for pressure vessels and API monogram for valves and seamless steel tubes.
Lloyds register of shipping has accorded B.H.E.L., Trichy, as a class-I vessel
manufacturer. The in-house systems for quality assurance and control are supplemented
by periodic quality audits.

1.2 ABOUT BOILER DRUM

The boiler drum is the backbone of a boiler. Together with internal and external
attachments and other parts, the boiler drum constitutes a boiler. The boiler drum consists
of a shell closed with dished end covers of hemispherical shapes or semi ellipsoidal shape
The shell is generally made of two half shells by hot (or) cold pressing with two
longitudinal weld joints called long seams. The joint made by closing the dished end are
called cirseams or circumferential seams.
Similar to Drum, In the boiler circuit, there are nodes of such collection and
distribution, which are also pipe-fabricated-products, called headers. In a typical 500MW

4
boiler, these are arranged in the bottom to form the ring header, which is a rectangular
arrangement of four headers. The boiler drum has the following sub components:
i) Drum Internals:
Turbo separators, feed header, separating chamber, screen dryer and
chemical dosing.
ii) Drum Externals:
Feed nozzle, super heater tube, riser tube, down comer nozzle and
instrumentations.

1.3 MANUFACTURING PROCESS OF A BOLIER DRUM

Boiler drums are manufactured as per the” INDIAN BOILER REGULATIONS”
(IBR) codes. Also, guidelines are taken from international standards and codes like
ASME, BS, etc. the manufacture of drums involve a high caliber of welding in line with
section IX of ASME and chapter XIII of IBR.
The following are the major stages of manufacturing in a boiler drum, namely
• Shell formation
• End covers pressing
• Drum processing

1.3.1 Shell Formation:

The shell formation of a boiler drum is done by two methods:
• Shell formation by pressing
• Shell formation by rolling (Not in practice in BHEL)

Shell formation by pressing

Single thickness of diameter less than 1524mm and By thickness drums are generally
formed by hot pressing. The sequence of operations is as follows:

5
 • Heating the plate to 800ºC to 900ºC in the case of SA299 and 880ºC to
1010ºC in the case of SA515 Gr 70 with half a hour/ inch of thickness
soaking (max 4 hrs).
• Hot pressing to U-shape with approximate dimensions.
• Stress relieving at 600ºC to 620ºC with half an hour/ inch of thickness
soaking (max 4 hrs)
• Cold calibration to the required size and shot blasting.
• Checking the dimensions of both the half shells and end matching.
• Cutting the extra length available on either side of the half shells by gas
cutting followed by edge preparation..
• Long seam fit up and welding along with the test plate. The inside of the
groove is welded by Flux Cored Arc Welding (FCAW) and the outside by
Submerged Arc Welding (SAW).
• Grinding of seams.
• Non-Destructive Examinations (NDE), Magnetic Particle Inspection (MPI)
and Radiographic Testing (RT).

1.3.2 End Covers Pressing:

The end covers are formed as follows:
• Gas cutting to the required size from the raw plate.
• Drilling the guide hole at the center.
• Heating to 1050ºC with half an hour per inch of soaking.
• Mounting on the die and pressing.
• Normalising at 870ºC to 900ºC with half an hour per inch of thickness
soaking.
• Shot blasting.
• Checking the dimensions and thickness.

6
1.3.3 Drum Processing:
The drum processing is done in the following sequence of steps:

• Edge preparation of shells and end covers.

• Marking and inspection of all stub holes and nozzle locations.
• Gas cutting and grinding of nozzle openings.
• Drilling and debugging of stub holes.
• Fit up and welding of stubs and nozzle. Welding is done by SMAW or
FCAW.
• Grinding and magnetic particle inspection for welds.
• Marking and welding of all attachments outside and inside.
• Grinding and MPI on attachments holes.
• Fixing and welding of man hole doorplates to end covers and MPI on
• the welds.
• Fit up and welding of circumferential joints- inside by SMAW and
outside by SAW.
• Grinding of cirseams.
• Non Destructive Examination of the welds.
• Final stress relieving at 600± 20ºC with one inch per hour of thickness
• Soaking along with the test plate.
• NDE on all weldments- MPI.
• Mechanical testing of test plates, namely
o Transverse tensile test.
o All welds tensile test.
o Impact test.
o Bend test.

7
 o Macro and Micro examinations.

• Hydraulic test at 1.5 times the working pressure.

• Assembly of intervals- separating chamber assembly and piping
assembly.
• Kerosene leak test on separating chamber assembly.
• Dryer box and turbo separator assembly.
• Cleaning, painting and axes marking by water level. The axes of
suspensions are also marked.
• Dispatch to site.

1.4 PRODUCTION TEST PLATE

• Statutory (IBR) requirement

• Attached and welded with long seam (one TP per shell )
• Undergoes same heat treatment with the drum
• Tested for mechanical properties after final Heat Treatment (Tensile, bend,
impact, micro, macro test) before drum hydro test.

1.5 LIST OF MATERIALS

The specifications of various materials used in the manufacture of boiler drums

as per ASME section II. Drum Plate: SA299 & SA515 Gr 70

1.6 COMPOSITION

TABLE 1.1 Composition of Materials

8
 SA299 (%) SA515Gr70
C 0.28 0.22
Mn 1.5 1.1
Si 0.4 0.33
Ni 0.4 0.18
Cr 0.3 0.08
Mo 0.12 0.01
Cu 0.4 0.01
Si 0.04 0.01
P 0.04 0.02
Al 0.03 0.001
V 0.03
Nb 0.002
I 0.002

CHAPTER 2
LITERATURE SURVEY

2.1 Welding Process

2.1.1 Shielded Metal Arc Welding (SMAW)

SMAW is a manual arc welding process in which the heat for welding is
generated by an arc established between a flux-coated consumable electrode and the work
piece. The electrode tip, weld puddle, arc and adjacent areas of he work piece are
protected from atmospheric contaminations by a gaseous shield obtained from the
combustion and decomposition of flux covering. Additional shielding is provided for he

9
molten metal in the weld puddle by a covering of molten flux (slag). Filler metal is
supplied by the core of consumable electrode.

SMAW is mostly widely used welding process for joining the metal parts
mainly because of its versatility. SMAW is generally more useful than the other welding
processes in joining the components of complex structural assemblies because it I better
adopted to multi position welding and difficult locations. Limitations of SMAW mainly
relate to poor deposition rate and deposition efficiency. Electrodes used in SMAW have
fixed length (L<= 16 inch) and therefore welding must be stopped after each electrode is
consumed. Another limitation is that deslagging is required after each pass to remove he
slag coverings which forms on the weld.

2.1.2 Flux Cored Arc Welding (FCAW)

FCAW is a process in which the heat for welding is produced by an arc between
a tubular consumable electrode wire and the work metal with shielding provided by a gas
evolved during combustion and decomposition of flux contained within the tubular
electrode wire or he flux gas plus an auxiliary shielding gas. The metal transfers are
globular, spray and short-circuiting. The flux in the core forms the molten slag, the
moment that establishes an arc and subsequently welds pool.

This slag covers the weld metal. He arc is shielded a gas evolved during the
decomposition of the flux. In the Gas shielded flux cored process, a separate gas envelope
ensures positive shielding of the arc. In FCAW, the flux is inside a tubular electrode,
which can be coiled and supplied to the arc as a continuous wire and a separate shielding
gas Co2 is used. Thus, a continuous welding is possible. The welds are strong and tough.
He arc starts easily and cored wire produces high quality welds at faster speeds than stick
welding even when hand welded.

10
2.1.3 Submerged Arc Welding (SAW)
SAW, also known, as hidden arc welding is an automatic welding process
developed primarily for the production of high quality butt welds in thick steel plates.
The arc is formed between the electrode and the base metal surface under a layer of
protective mineral powder. This mineral powder is known as flux, which can also be used
to add alloying elements to the joint ahead of the welding wire. While the weld is being
made, the arc is submerged under the powder and is invisible, hence, the name SAW.

The coalescence is produced by heating with an arc between a base metal

electrode and he work piece. The end of the electrode and the weld zone are shielded by
an envelope of molten and unused flux. The electrode is in contact with the work piece
and the current is carried through the fluid flux. The fluxes are granular fusible mineral
materials containing oxides of Mn, Si, Ti, Al, Ca, Mg and other components. It shields
the metal from atmospheric contamination, enables the weld to be free from spatter,
smoke, lash, and facilitates a smooth bead. The molten flux floats to the top of the pool to
solidify finally as a slag while the rest of flux remains unaffected and can be reclaimed.

2.2 WELD DEFECTS

A defect is a reject able discontinuity or a flaw of rejectable nature. Acceptance
or rejection of flaw is dependent on different factors. Few critical factors include

• Stress to which the part will be subjected during the service.

• Type of material used.
• The temperature and pressure to which the parts will be subjected.
• It’s thickness.
• The environment (corrosive or non-corrosive).
• Safety.
• Consequence of failure.

11
 • Cost and accessibility for repair etc.

Weld defects can be classified into:

• Plan
ar defects: these include cracks, l/f, l/p, undercut etc.

• Volu
minar or three-dimensional defects: These include slag inclusion, cavity,
pores, etc.

• Geo
metric defects: These include excessive reinforcement, under fill or under
flush, root cavity. These are permitted to certain extent.

2.3 Causes of rework and quality related problems, in Butt welds.

2.3.1 Slag Inclusion
This occurs due to entrapment of oxides and non-metallic solid material in the
weld deposit or between the weld metal and base metal. Due to their low specific gravity,
the slag normally floats over the molten metal unless they are restrained. Because of the
stirring action of the arc, the slag may be forced down below the molten metal and the
high viscosity of the weld metal rapid solidification.
At a low temperature may prevent the release. Slag inclusions usually appear as
linear continuous or interrupted bands. Slag inclusion inside the weld would have rarely
resulted in service failures unless they occur along the surface or were of a significantly
large section to reduce sufficiently the strength across the wall thickness.

2.3.2 Porosity

12
 Porosity is the presence of gas pockets or voids caused by the entrapment of gas,
evolved during the weld metal solidification. Porosity is caused due to improper
shielding, rust on the weld surface, too much generation of gas in the weld pool; sudden
cooling of slag etc. sometimes elongated tubular gas pockets are called worm holes. It is
seen by testing those porosities reducing the cross sectional area of the weld up to 5% has
no significant effect on the strength, ductility or toughness. Porosity is considered the
least dangerous defect, but is often an indication of damp electrodes having been used.

2.3.3 Cracks

Cracks occur in the weld metal and base metal when localized stress exceeds the
ultimate strength of he metal. Cracks can be classified as either hot or cold types. Hot
cracks develop at elevated temperatures. They commonly form during solidification of
weld metal. Cold cracks develop after solidification of fusion weld because of stresses.
Hot cracks propagate between the grains while the cold cracks propagate both between
grains and through grains. Cracks may be longitudinal or transverse with respect to weld
axis. Longitudinal weld metal cracks and the heat affected zone cracks are parallel to the
axis of the weld, transverse cracks are perpendicular to the weld axis.

2.3.4 Incomplete Penetration

In butt-welding, a root opening is usually left at the bottom of the groove (in one
side welding) or at the center of the weld (in two side welding). If the opening between
the two plates is too narrow in relation to the diameter of the weld rod employed, and he
current used, it is difficult to attain the complete penetration and fusion at the root of the
weld.

2.3.5 Lack of Fusion

Because of insufficient heat or of the presence of scales on the face of a weld

level, the deposited metal may remain separated from the base metal by a very thin layer

13
of oxide. This involves the lack of complete melting and fusion of some portion of metal
in a weld joint.

2.3.6 Undercuts

Undercuts refers to the gouging off of parent metal at the ends of welds causing
notch effect, which may be hazardous in many cases. This is due to the use of excess
amperages and also due to combination of excess voltage and poor manipulation by the
welders.

2.3.7 Spatters
Because of highamperage. This is not detrimental to the product, but shall mask
the NDE defects on the surface, if any.

2.3.8 Coarse Ripples and surface Undulations

Coarse ripples are due to combination of improper parameter selection and skill
of the welders. Undulations include excess fillet, which does not add strength and ridges
of bead and valleys in between weld beads that may prevent magnetiv particle
intrepretations.

2.4 TESTING OF WELDS

There are several techniques used for testing the weld. The techniques are
broadly classified as:
2.4.1 Destructive Testing
• Tensile Test
o Transverse tensile weld
o All weld metal tensile test.

14
 • Impact Test
o Charpy impact test
o Izod impact test

2.4.2 Non-Destructive Testing:

• Radiographic Test
• Magnetic Particle Inspection
• Ultrasonic Testing
• Eddy Current Testing
• Visual Inspection

Out of these methods, three are widely used for the testing of defects in the butt welds of
the boiler drums.

They are as follows:

X-ray/ Radiographic
Uitrasonic
Magnetic Particle Test

2.4.2.1 X-ray/ Radiographic Testing

X-rays are produced in an X-ray tube where a (cathode) filament provides
electrons, which proceed towards the target (anode), strike and are suddenly stopped; a
part of their kinetic energy is converted to energy of radiation or x-rays. The portion of
the weldments where the defects are expected is exposed to X-rays emitted from X-rays
tube. A cassette containing the X-rays film is placed behind and in contact with
weldment, perpendicular to the X-rays. During exposure, X-rays penetrate the welded
15
object and thus affect the X-ray film. Since most of the defects posses lesser density than
the sound parent metal, they transmit X-rays better the parent metal. Hence, the film
appears to be darker where defects are in line of the X-ray beam. The exposed and
developed X-ray film showing the light and dark areas is termed as “Radiograph” or
“Exograph”. The wavelength of the X-ray ranges from .001exp(-8)cm to about 40exp(-
8)cm. Instead of X-rays, Gamma rays from cobalt-60 or iridium-192 can also be used for
radiography.

2.4.2.2 Ultrasonic Testing

When a high frequency alternating current (of about 1 million cycles per
second) is impressed across the faces of the quartz crystal, the crystal will expand during
the first half of the cycle and contract during the second half when the electric field is
reversed. In this matter, mechanical vibrations (sound wave) are produced in the crystal.
The frequency of the waves varies from 20kHz to 20MHz. The surface of the job to be
inspected for defects is made smooth by machining so that the probe of the apparatus
succeeds in detecting even the minor flaws efficiently.

This method employs two separate probes, one each for transmitting and
receiving the transmitted waves after their passage through the welded jobs. An oil film is
provided between

The probe and the job surface, which ensures proper contact between them
and better transmission of waves from the probe into the surface of the object to be
tested. Ultrasonic waves are introduced into the metal and the time interval between the
transmission of the outgoing and reception of the incoming pulse is measured with a
cathode ray of oscilloscope (CRO). The time base of the CRO is so adjusted that the full
width of the trace represents the section being examined. In case a defect will be reflected
16
from the defect, reach the receiver probe and indicate a pip (echo) on the CRO screen
before the pip given by the waves striking he far end of the job ad returning. The distance
of the defect from the surface where the transmitted probe is applied can be determined
with the help of a time distance scale in the form of a square wave constantly shown on
the oscilloscope. The distance scale may be changed as per convenience.

It is to be noted that while RT is used to detect the length and type of the
defect, UT is used to detect the depth of the defect from the surface also.
2.5 WELD SYMBOLSTABLE

17
2.1Elementary Symbols of Weld

18
19
20
21
TABLE 2.2 Shape of Weld Surface

TABLE 2.3

22
 CHAPTER 3
PROBLEM DESCRIPTION AND DATA COLLECTION

3.1 PROBLEM DESCRIPTION

With surge in load there is a focus on productivity improvement. This in turn is

reflected by the quantum of rework that is done in shops. The more the rework, the more
the cycle time and delivery schedule is affected. Hence a study was taken on weld
optimization, wherein the existing measures for preventing defects shall be revisited and
other delay causing activities shall be examined and solutions evolved, for the same .
The delay causing activities were noted based on the data we collected. The data is about
the various projects carried out in BHEL during the year 2009-2010

23
4.2 DATA COLLECTED

TABLE 4.1 Data Collected

cust_ pg_no ma_no rt_no seam_seam_mater weld_

thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0398 04 126 D3468 LS 1.2 SA299 FCAW 140 7690 31 3 06/09/ 193
6.89 02-03 Slag 280 90
0398 04 126 D3468 LS 1.2 SA299 FCAW 140 7690 31 3 06/09/ 193
6.89 00-01 Slag 170 90
0398 04 126 D3468 LS 1.2 SA299 FCAW 140 7690 31 3 06/09/ 193
6.89 01-02 Slag 80 90
0398 04 126 D3469 LS 2.1 SA299 FCAW 140 6414 23 2 06/11/ 193
6.86 18-19 Pores 240 10
0398 04 126 D3469 LS 2.1 SA299 FCAW 140 6414 23 2 06/11/ 193
6.86 19-20 Pores 200 10
0398 04 126 D3469 LS 2.1 SA299 FCAW 140 6414 23 2 06/11/ 193
6.86 18-19 Pores 240 10
0398 04 126 D3469 LS 2.1 SA299 FCAW 140 6414 23 2 06/11/ 193
6.86 19-20 Pores 200 10
0398 04 126 D3469 LS 2.1 SA299 FCAW 140 6414 23 2 06/11/ 193
6.86 18-19 Pores 240 10
0398 04 126 D3469 LS 2.1 SA299 FCAW 140 6414 23 2 06/11/ 193
6.86 19-20 Pores 200 10
0398 04 126 D3471 CS 1 SA299 SMAW 140 5495 22 1 09/02/ 193
1.09 04-05 Slag 60 15
0398 04 126 D3472 CS 2 SA299 SMAW 140 5495 22 1 07/13/ 193
1.09 15-16 Slag 60 15
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 14-15 Slag 45 15
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 09-10 Slag 50 25
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 15-16 Slag 25 15
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 09-10 Slag 50 25
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 15-16 Slag 25 15
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 00-01
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 14-15

24
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 15-16
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 16-17 Slag 20 10
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 17-18
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 18-19
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 19-20
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 20-21
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 21-22
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 13-14
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 00-01 Slag 35 20
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 06-07
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 12-13
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 11-12
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 10-11
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 09-10
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 09-10 Slag 50 25
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 07-08
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 21-00 Slag 20 25
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 05-06
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 04-05
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 03-04

25
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 02-03
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 01-02
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 00-01 Slag 35 20
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 14-15 Slag 45 15
0439 04 116 D3427 LS 1.1 SA299 FCAW 100 5625 21 1 04/29/ 193
0.36 08-09
0439 04 116 D3428 LS 2.1 SA299 FCAW 100 5625 21 2 04/30/ 193
6.04 15-16 Slag 60 15
0439 04 116 D3428 LS 2.1 SA299 FCAW 100 5625 21 2 04/30/ 193
6.04 00-01 L/F 280 10
0439 04 210 D3405 CS 1 SA299 SMAW 90 2871 11 1 04/22/ 193
1.39 04-05 Slag 40 10
0439 04 210 D3406 CS 2 SA299 SMAW 90 2871 11 5 04/22/ 193
13.58 10-00 Slag 250 10
0439 04 210 D3406 CS 2 SA299 SMAW 90 2871 11 5 04/22/ 193
13.58 02-03 Slag 30 10
0439 04 210 D3406 CS 2 SA299 SMAW 90 2871 11 5 04/22/ 193
13.58 03-04 Slag 40 10
0439 04 210 D3406 CS 2 SA299 SMAW 90 2871 11 5 04/22/ 193
13.58 08-09 Slag 40 10
0439 04 210 D3406 CS 2 SA299 SMAW 90 2871 11 5 04/22/ 193
13.58 06-07 Slag 30 10
0440 04 116 D3444 LS 2.1 SA299 FCAW 100 4375 16 4 05/05/ 193
13.03 14-15 Slag 150 15
0440 04 116 D3444 LS 2.1 SA299 FCAW 100 4375 16 4 05/05/ 193
13.03 01-02 Slag 50 15
0440 04 116 D3444 LS 2.1 SA299 FCAW 100 4375 16 4 05/05/ 193
13.03 00-01 Slag 220 15
0440 04 116 D3444 LS 2.1 SA299 FCAW 100 4375 16 4 05/05/ 193
13.03 15-16 Slag 150 15
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 12-13
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 03-04
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 05-06

Page 3 of 26

26
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 06-07 Slag 20 10
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 07-08
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 08-09 Slag 100 10
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 09-10
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 01-02
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 11-12
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 02-03
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 13-14
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 14-15
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 15-16
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 16-17
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 10-11
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 19-20 Slag 65 10
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 04-05
0440 04 116 D3445 LS 2.2 SA299 FCAW 100 4375 16 2 05/05/ 193
2.74 00-01
0440 04 116 D3446 CS 1 SA299 SMAW 100 5210 21 8 07/21/ 193
9.12 10-11 Slag 20 30
0440 04 116 D3446 CS 1 SA299 SMAW 100 5210 21 8 07/21/ 193
9.12 00-01 Slag 45 10
0440 04 116 D3446 CS 1 SA299 SMAW 100 5210 21 8 07/21/ 193
9.12 01-02 Slag 40 10
0440 04 116 D3446 CS 1 SA299 SMAW 100 5210 21 8 07/21/ 193
9.12 02-03 Slag 100 10
0440 04 116 D3446 CS 1 SA299 SMAW 100 5210 21 8 07/21/ 193
9.12 03-04 Slag 45 10

Page 4 of 26

27
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0440 04 116 D3446 CS 1 SA299 SMAW 100 5210 21 8 07/21/ 193
9.12 09-10 Slag 100 30
0440 04 116 D3446 CS 1 SA299 SMAW 100 5210 21 8 07/21/ 193
9.12 18-19 Slag 80 20
0440 04 116 D3446 CS 1 SA299 SMAW 100 5210 21 8 07/21/ 193
9.12 04-05 Slag 45 10
0440 04 116 D3448 CS 3 SA299 SMAW 100 5210 20 2 07/12/ 193
1.15 02-03 Slag 30 15
0440 04 116 D3448 CS 3 SA299 SMAW 100 5210 20 2 07/12/ 193
1.15 00-01 Slag 30 30
0440 04 210 D3414 LS 1.1 SA299 SMAW 85 8400 30 1 03/26/ 193
1.43 14-15 Pores 120 10
0440 04 210 D3416 CS 1 SA299 SMAW 85 2910 11 1 04/25/ 193
5.15 04-05 Slag 150 10
0492 04 114 D3457 CS 1 SA299 SMAW 70 4247 16 2 08/21/ 193
4.94 02-03 Slag 60 0
0492 04 114 D3457 CS 1 SA299 SMAW 70 4247 16 2 08/21/ 193
4.94 04-05 Slag 150 10
0492 04 114 D3457 CS 1 SA299 SMAW 70 4247 16 2 08/21/ 193
4.94 02-03 Slag 60 10
0492 04 114 D3457 CS 1 SA299 SMAW 70 4247 16 2 08/21/ 193
4.94 02-03 Slag 60 10
0492 04 114 D3458 CS 2 SA299 SMAW 55 5066 16 2 07/15/ 193
2.17 07-08 Slag 70 20
0492 04 114 D3458 CS 2 SA299 SMAW 55 5066 16 2 07/15/ 193
2.17 06-07 Slag 40 20
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 00-01
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 12-13
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 06-07 Slag 80 15
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 15-16 Slag 70 15
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 07-08 Slag 120 15
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 08-09 Slag 50 10
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 09-10

28
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 04-05 Slag 100 15
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 11-12
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 16-17
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 13-14
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 14-15
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 15-00
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 05-06 Slag 70 15
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 02-03
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 03-04
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 10-11
0492 04 114 D3459 CS 3 SA299 FCAW 70 4247 16 5 08/10/ 193
9.89 01-02
0495 04 124 D3451 CS 1 SA299 SMAW 85 5100 18 1 06/29/ 193
0.98 11-12 Slag 50 5
0495 04 126 D3449 LS 1 SA299 FCAW 85 102 33 6 05/11/ 193
9.75 17-18 ICP 35 10
0495 04 126 D3449 LS 1 SA299 FCAW 85 102 33 6 05/11/ 193
9.75 14-15 ICP 60 10
0495 04 126 D3449 LS 1 SA299 FCAW 85 102 33 6 05/11/ 193
9.75 12-13 ICP 280 10
0495 04 126 D3449 LS 1 SA299 FCAW 85 102 33 6 05/11/ 193
9.75 05-06 ICP 280 10
0495 04 126 D3449 LS 1 SA299 FCAW 85 102 33 6 05/11/ 193
9.75 03-04 ICP 60 10
0495 04 126 D3449 LS 1 SA299 FCAW 85 102 33 6 05/11/ 193
9.75 32-33 ICP 280 10
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 12-13
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 07-08 Slag 30 15

29
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 02-03
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 03-04
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 04-05
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 05-06
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 06-07 Slag 30 15
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 20-21 Slag 75 55
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 08-09
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 09-10
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 00-01
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 11-12
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 18-19 Slag 30 45
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 13-00
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 14-15
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 10-11
0497 04 114 D3387 CS 1 SA299 SMAW 55 4144 14 2 04/15/ 193
1.45 01-02
0497 04 114 D3388 CS 2 SA299 SMAW 55 4144 14 3 04/15/ 193
3.62 09-10 Slag 50 15
0497 04 114 D3388 CS 2 SA299 SMAW 55 4144 14 3 04/15/ 193
3.62 08-09 Slag 70 15
0497 04 114 D3388 CS 2 SA299 SMAW 55 4144 14 3 04/15/ 193
3.62 07-08 Slag 30 10
0497 04 210 D3400 LS 1.2 SA299 FCAW 35 8810 30 2 01/21/ 193
1.25 15-16 Slag 60 10
0497 04 210 D3400 LS 1.2 SA299 FCAW 35 8810 30 2 01/21/ 193
1.25 21-22 Slag 50 10

30
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0497 04 210 D3402 CS 2 SA299 SMAW 35 2653 9 2 04/29/ 193
5.65 08-00 Pores 60 20
0497 04 210 D3402 CS 2 SA299 SMAW 35 2653 9 2 04/29/ 193
5.65 00-01 Slag 90 20
0651 04 126 D3418 LS 1.1 SA299 FCAW 160 110 39 1 04/20/ 193
0.23 30-31 Slag 25 10
0651 04 126 D3419 LS 1.2 SA299 FCAW 160 110 39 2 04/20/ 193
0.45 02-03 Slag 20 15
0651 04 126 D3419 LS 1.2 SA299 FCAW 160 110 39 2 04/20/ 193
0.45 08-09 Slag 30 20
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 00-01
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 02-03
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 04-05
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 05-06
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 06-07
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 07-08
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 08-09
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 09-10
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 10-11
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 11-12
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 01-02
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 15-16
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 14-15
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 12-13
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 22-23

Page 8 of 26

31
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 21-00 Slag 50 10
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 20-21
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 19-20
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 18-19
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 17-18
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 16-17
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 13-14
0651 04 126 D3422 CS 1 SA299 SMAW 160 5586 22 1 06/26/ 193
0.9 03-04
0651 04 126 D3424 CS 3 SA299 SMAW 160 5576 22 2 06/29/ 193
1.17 07-08 Slag 25 0
0651 04 126 D3424 CS 3 SA299 SMAW 160 5576 22 2 06/29/ 193
1.17 14-15 Slag 40 0
0655 04 126 D3382 CS 2 SA299 SMAW 160 5586 22 1 04/08/ 193
0.45 20-21 Slag 25 75
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 09-10
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 10-11
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 11-12
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 12-13
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 14-15
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 16-17 Slag 30 25
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 08-09
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 14-15 Slag 45 15
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 13-14

Page 9 of 26

32
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 01-02 Slag 150 45
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 00-01 Slag 120 35
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 22-23
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 21-00
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 20-21 Slag 60 45
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 19-20 Slag 50 40
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 18-19 Slag 80 25
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 17-18 Slag 60 25
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 06-07
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 05-06
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 04-05
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 03-04
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 02-03
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 15-16 Slag 25 15
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 15-16
0655 04 126 D3383 CS 3 SA299 SMAW 160 5536 22 7 04/08/ 193
9.93 07-08
0657 04 126 D3390 LS 1.2 SA299 FCAW 160 7991 28 1 03/07/ 193
3.5 27-28 Slag 280 15
0657 04 126 D3391 LS 2.1 SA299 FCAW 160 7991 29 2 02/16/ 193
4.38 27-28 Slag 150 15
0657 04 126 D3391 LS 2.1 SA299 FCAW 160 7991 29 2 02/16/ 193
4.38 28-29 Slag 200 15
0657 04 126 D3392 LS 2.2 SA299 FCAW 160 7791 29 6 02/16/ 193
9.18 28-29 Slag 150 15

Page 10 of 26

33
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0657 04 126 D3392 LS 2.2 SA299 FCAW 160 7791 29 6 02/16/ 193
9.18 01-02 Slag 30 80
0657 04 126 D3392 LS 2.2 SA299 FCAW 160 7791 29 6 02/16/ 193
9.18 00-01 Slag 100 80
0657 04 126 D3392 LS 2.2 SA299 FCAW 160 7791 29 6 02/16/ 193
9.18 25-26 Slag 0 0
0657 04 126 D3392 LS 2.2 SA299 FCAW 160 7791 29 6 02/16/ 193
9.18 27-28 Slag 280 15
0657 04 126 D3392 LS 2.2 SA299 FCAW 160 7791 29 6 02/16/ 193
9.18 26-27 Slag 105 15
0657 04 126 D3392 LS 2.2 SA299 FCAW 160 7791 29 6 02/16/ 193
9.18 05-06 Slag 50 15
0657 04 126 D3394 LS 3.2 SA299 FCAW 160 7991 22 2 02/21/ 193
0.88 13-14 Slag 30 15
0657 04 126 D3394 LS 3.2 SA299 FCAW 160 7991 22 2 02/21/ 193
0.88 20-21 Slag 40 15
0657 04 126 D3396 CS 2 SA299 SMAW 160 5607 23 1 04/23/ 193
0.54 13-14 Slag 30 15
0657 04 126 D3397 LS 3 SA299 FCAW 160 7991 21 1 04/24/ 193
0.25 00-01 Slag 20 10
0658 04 126 D3432 LS 1.2 SA299 FCAW 160 7991 25 5 05/02/ 193
4.44 23-24 Slag 30 05
0658 04 126 D3432 LS 1.2 SA299 FCAW 160 7991 25 5 05/02/ 193
4.44 12-13 Slag 90 05
0658 04 126 D3432 LS 1.2 SA299 FCAW 160 7991 25 5 05/02/ 193
4.44 22-23 Slag 55 05
0658 04 126 D3432 LS 1.2 SA299 FCAW 160 7991 25 5 05/02/ 193
4.44 07-08 Slag 60 10
0658 04 126 D3432 LS 1.2 SA299 FCAW 160 7991 25 5 05/02/ 193
4.44 11-12 Slag 120 05
0658 04 126 D3434 LS 2.1 SA299 FCAW 160 6096 29 1 05/12/ 193
1.64 28-29 Others 100 10
0658 04 126 D3435 LS 2.2 SA299 FCAW 160 6096 29 2 05/12/ 193
9.19 22-23 ICP 280 10
0658 04 126 D3435 LS 2.2 SA299 FCAW 160 6096 29 2 05/12/ 193
9.19 23-24 ICP 280 10
0658 04 126 D3436 LS 3.1 SA299 FCAW 160 7991 22 1 05/04/ 193
0.88 21-22 Slag 70 120
0658 04 126 D3438 LS 3.2 SA299 FCAW 160 7991 22 2 05/04/ 193
2.88 01-02 Slag 40 15

34
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0658 04 126 D3438 LS 3.2 SA299 FCAW 160 7991 22 2 05/04/ 193
2.88 00-01 Slag 190 15
0658 04 126 D3438 LS 3.2 SA299 FCAW 160 7991 22 2 05/04/ 193
2.88 00-01 Slag 190 15
0658 04 126 D3440 CS 3 SA299 SMAW 160 5570 22 2 07/03/ 193
2.51 11-12 Slag 40 40
0658 04 126 D3440 CS 3 SA299 SMAW 160 5570 22 2 07/03/ 193
2.51 21-00 Slag 100 35
0659 04 126 D3460 LS 1.1 SA299 FCAW 160 110 40 3 06/02/ 193
0.63 11-12 Slag 30 95
0659 04 126 D3460 LS 1.1 SA299 FCAW 160 110 40 3 06/02/ 193
0.63 09-10 Slag 25 60
0659 04 126 D3460 LS 1.1 SA299 FCAW 160 110 40 3 06/02/ 193
0.63 00-01 Slag 15 125
0659 04 126 D3461 LS 1.2 SA299 FCAW 160 110 40 7 06/02/ 193
10.15 17-18 Slag 30 10
0659 04 126 D3461 LS 1.2 SA299 FCAW 160 110 40 7 06/02/ 193
10.15 38-39 Slag 200 20
0659 04 126 D3461 LS 1.2 SA299 FCAW 160 110 40 7 06/02/ 193
10.15 39-40 Slag 200 20
0659 04 126 D3461 LS 1.2 SA299 FCAW 160 110 40 7 06/02/ 193
10.15 15-16 Slag 40 85
0659 04 126 D3461 LS 1.2 SA299 FCAW 160 110 40 7 06/02/ 193
10.15 14-15 Slag 280 85
0659 04 126 D3461 LS 1.2 SA299 FCAW 160 110 40 7 06/02/ 193
10.15 13-14 Slag 220 85
0659 04 126 D3461 LS 1.2 SA299 FCAW 160 110 40 7 06/02/ 193
10.15 12-13 Slag 150 85
0659 04 126 D3465 CS 2 SA299 SMAW 160 5540 22 4 08/03/ 193
2.62 12-13 Slag 25 75
0659 04 126 D3465 CS 2 SA299 SMAW 160 5540 22 4 08/03/ 193
2.62 10-11 Slag 40 80
0659 04 126 D3465 CS 2 SA299 SMAW 160 5540 22 4 08/03/ 193
2.62 11-12 Slag 40 75
0659 04 126 D3465 CS 2 SA299 SMAW 160 5540 22 4 08/03/ 193
2.62 01-02 Slag 40 150
0661 04 126 D3563 LS 1.2 SA299 FCAW 160 7991 29 1 12/10/ 193
1.38 28-29 Slag 110 30
0661 04 126 D3565 LS 2.2 SA299 FCAW 160 6096 29 1 12/02/ 193
0.9 25-26 Slag 55 45

Page 12 of 26

35
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0661 04 126 D3567 LS 3.2 SA299 FCAW 160 7991 22 2 12/03/ 193
0.69 02-03 Slag 30 35
0661 04 126 D3567 LS 3.2 SA299 FCAW 160 7991 22 2 12/03/ 193
0.69 21-22 Slag 25 95
0664 04 126 D3514 LS 1.2 SA299 FCAW 160 7991 29 3 10/14/ 193
1.69 00-01 Slag 45 20
0664 04 126 D3514 LS 1.2 SA299 FCAW 160 7991 29 3 10/14/ 193
1.69 05-06 Slag 40 10
0664 04 126 D3514 LS 1.2 SA299 FCAW 160 7991 29 3 10/14/ 193
1.69 13-14 Slag 50 20
0664 04 126 D3515 LS 2.1 SA299 FCAW 160 6096 29 3 10/12/ 193
2.3 08-09 Slag 50 20
0664 04 126 D3515 LS 2.1 SA299 FCAW 160 6096 29 3 10/12/ 193
2.3 09-10 Slag 50 20
0664 04 126 D3515 LS 2.1 SA299 FCAW 160 6096 29 3 10/12/ 193
2.3 22-23 Slag 40 15
0664 04 126 D3516 LS 2.2 SA299 FCAW 160 6096 29 6 10/12/ 193
10.17 16-17 Slag 45 40
0664 04 126 D3516 LS 2.2 SA299 FCAW 160 6096 29 6 10/12/ 193
10.17 15-16 Slag 50 40
0664 04 126 D3516 LS 2.2 SA299 FCAW 160 6096 29 6 10/12/ 193
10.17 17-18 Slag 200 40
0664 04 126 D3516 LS 2.2 SA299 FCAW 160 6096 29 6 10/12/ 193
10.17 27-28 Slag 120 25
0664 04 126 D3516 LS 2.2 SA299 FCAW 160 6096 29 6 10/12/ 193
10.17 06-07 Slag 35 45
0664 04 126 D3516 LS 2.2 SA299 FCAW 160 6096 29 6 10/12/ 193
10.17 15-16 Slag 50 40
0664 04 126 D3516 LS 2.2 SA299 FCAW 160 6096 29 6 10/12/ 193
10.17 16-17 Slag 45 40
0664 04 126 D3516 LS 2.2 SA299 FCAW 160 6096 29 6 10/12/ 193
10.17 17-18 Slag 200 40
0664 04 126 D3516 LS 2.2 SA299 FCAW 160 6096 29 6 10/12/ 193
10.17 27-28 Slag 120 25
0664 04 126 D3516 LS 2.2 SA299 FCAW 160 6096 29 6 10/12/ 193
10.17 28-29 Slag 170 25
0664 04 126 D3516 LS 2.2 SA299 FCAW 160 6096 29 6 10/12/ 193
10.17 06-07 Slag 35 45
0664 04 126 D3517 LS 3.1 SA299 FCAW 160 7991 22 2 09/15/ 193
1.75 21-22 Slag 40 20

36
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0664 04 126 D3517 LS 3.1 SA299 FCAW 160 7991 22 2 09/15/ 193
1.75 00-01 Slag 100 75
0664 04 126 D3518 LS 3.2 SA299 FCAW 160 7991 22 1 09/15/ 193
3.13 00-01 Slag 250 15
0664 04 126 D3518 LS 3.2 SA299 FCAW 160 7991 22 1 09/15/ 193
3.13 00-01 Slag 250 15
0665 04 126 D3553 LS 1.2 SA299 FCAW 160 7991 29 1 11/20/ 193
0.44 28-29 Slag 35 65
0665 04 126 D3554 LS 2.1 SA299 FCAW 160 6096 29 2 11/16/ 193
5.74 27-28 Slag 150 35
0665 04 126 D3554 LS 2.1 SA299 FCAW 160 6096 29 2 11/16/ 193
5.74 26-27 Slag 200 35
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193

37
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0665 04 126 D3556 LS 3.1 SA299 FCAW 160 7991 22 0 11/23/ 193
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 31-32
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 24-25
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 25-26
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 26-27
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 27-28
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 04-05
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 28-29 Slag 60 65
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 03-04
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 39-40
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 30-31

Page 15 of 26

38
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 21-22
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 32-33
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 33-34
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 34-35
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 36-37
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 40-41
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 38-39
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 29-30
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 15-16
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 09-10
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 08-09
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 07-08
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 06-07
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 10-11
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 11-12
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 12-13
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 23-24
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 14-15
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 22-23
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 16-17

Page 16 of 26

39
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 17-18
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 05-06
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 18-19
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 19-20
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 20-21
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 37-38
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 13-14
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 00-01
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 01-02 Slag 100 15
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 01-02
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 02-03
0666 04 126 D3506 LS 1.1 SA299 FCAW 160 110 40 1 08/07/ 193
0.54 35-36
0666 04 126 D3507 LS 1.2 SA299 FCAW 160 110 40 3 08/07/ 193
1.13 00-01 Slag 25 25
0666 04 126 D3507 LS 1.2 SA299 FCAW 160 110 40 3 08/07/ 193
1.13 07-08 Slag 30 75
0666 04 126 D3507 LS 1.2 SA299 FCAW 160 110 40 3 08/07/ 193
1.13 22-23 Slag 70 65
0666 04 126 D3508 LS 2.1 SA299 FCAW 160 110 40 4 08/17/ 193
2.08 32-33 Slag 60 55
0666 04 126 D3508 LS 2.1 SA299 FCAW 160 110 40 4 08/17/ 193
2.08 09-10 Slag 25 30
0666 04 126 D3508 LS 2.1 SA299 FCAW 160 110 40 4 08/17/ 193
2.08 26-27 Slag 40 65
0666 04 126 D3508 LS 2.1 SA299 FCAW 160 110 40 4 08/17/ 193
2.08 25-26 Slag 105 65
0666 04 126 D3509 LS 2.2 SA299 FCAW 160 110 40 3 08/17/ 193
1.59 01-02 Slag 50 15

40
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
0666 04 126 D3509 LS 2.2 SA299 FCAW 160 110 40 3 08/17/ 193
1.59 24-25 Slag 55 65
0666 04 126 D3509 LS 2.2 SA299 FCAW 160 110 40 3 08/17/ 193
1.59 25-26 Slag 70 65
0666 04 126 D3509 LS 2.2 SA299 FCAW 160 110 40 3 08/17/ 193
1.59 25-26 Slag 70 65
0666 04 126 D3509 LS 2.2 SA299 FCAW 160 110 40 3 08/17/ 193
1.59 24-25 Slag 55 65
0666 04 126 D3509 LS 2.2 SA299 FCAW 160 110 40 3 08/17/ 193
1.59 01-02 Slag 50 15
0666 04 126 D3510 CS 1 SA299 SMAW 160 6086 22 3 12/04/ 193
3.04 13-14 Slag 110 15
0666 04 126 D3510 CS 1 SA299 SMAW 160 6086 22 3 12/04/ 193
3.04 13-14 Slag 110 15
0666 04 126 D3510 CS 1 SA299 SMAW 160 6086 22 3 12/04/ 193
3.04 20-21 Slag 55 15
0666 04 126 D3510 CS 1 SA299 SMAW 160 6086 22 3 12/04/ 193
3.04 20-21 Slag 55 15
0666 04 126 D3510 CS 1 SA299 SMAW 160 6086 22 3 12/04/ 193
3.04 21-00 Slag 20 15
0666 04 126 D3511 CS 2 SA299 SMAW 160 5567 22 1 11/12/ 193
0.54 20-21 Slag 30 25
0666 04 126 D3512 CS 3 SA299 SMAW 160 6086 22 3 12/05/ 193
6.16 13-14 Slag 40 65
0666 04 126 D3512 CS 3 SA299 SMAW 160 6086 22 3 12/05/ 193
6.16 05-06 Slag 75 15
0666 04 126 D3512 CS 3 SA299 SMAW 160 6086 22 3 12/05/ 193
6.16 04-05 Slag 260 15
0666 04 126 D3512 CS 3 SA299 SMAW 160 6086 22 3 12/05/ 193
6.16 13-14 Slag 40 65
0666 04 126 D3512 CS 3 SA299 SMAW 160 6086 22 3 12/05/ 193
6.16 04-05 Slag 260 15
0666 04 126 D3512 CS 3 SA299 SMAW 160 6086 22 3 12/05/ 193
6.16 05-06 Slag 75 15
1210 04 126 D3523 LS 1.1 SA299 FCAW 140 7690 28 2 09/29/ 193
1.17 27-28 Slag 60 30
1210 04 126 D3523 LS 1.1 SA299 FCAW 140 7690 28 2 09/29/ 193
1.17 11-12 Slag 30 20
1210 04 126 D3524 LS 1.2 SA299 FCAW 140 7690 28 1 09/29/ 193
0.78 19-20 Slag 60 10

41
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 12-13
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 04-05
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 15-16
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 11-12
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 09-10
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 10-11
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 08-09
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 07-08
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 06-07
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 14-15
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 05-06
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 13-14
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 16-17
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 18-19
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 20-21
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 21-22
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 22-23
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 23-24
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 27-28 Slag 20 15
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 17-18 Slag 20 20

Page 19 of 26

42
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 03-04 Slag 55 10
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 00-01
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 27-28 Slag 150 15
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 19-20
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 10-11 Slag 0 0
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 01-02
1210 04 126 D3526 LS 2.2 SA299 FCAW 140 6414 23 2 10/05/ 193
1.17 02-03
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193

Page 20 of 26

43
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1210 04 126 D3528 CS 2 SA299 SMAW 140 5567 21 0 11/11/ 193
1211 04 126 D3550 CS 2 SA299 SMAW 140 5578 22 2 11/21/ 193
3.5 18-19 Gas 95 15
1211 04 126 D3550 CS 2 SA299 SMAW 140 5578 22 2 11/21/ 193
3.5 15-16 Slag 100 20
1213 04 126 D3496 LS 1.1 SA299 FCAW 140 7690 28 2 07/31/ 193
3.25 25-26 Slag 200 60
1213 04 126 D3496 LS 1.1 SA299 FCAW 140 7690 28 2 07/31/ 193
3.25 27-28 Slag 50 60
1213 04 126 D3497 LS 1.2 SA299 FCAW 140 7690 28 4 07/31/ 193
3.77 14-15 Slag 50 65
1213 04 126 D3497 LS 1.2 SA299 FCAW 140 7690 28 4 07/31/ 193
3.77 23-24 Slag 70 65
1213 04 126 D3497 LS 1.2 SA299 FCAW 140 7690 28 4 07/31/ 193
3.77 19-20 Slag 50 65
1213 04 126 D3497 LS 1.2 SA299 FCAW 140 7690 28 4 07/31/ 193
3.77 14-15 Slag 50 65
1213 04 126 D3497 LS 1.2 SA299 FCAW 140 7690 28 4 07/31/ 193
3.77 19-20 Slag 50 65
1213 04 126 D3497 LS 1.2 SA299 FCAW 140 7690 28 4 07/31/ 193
3.77 13-14 Slag 120 10

Page 21 of 26

44
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
1213 04 126 D3497 LS 1.2 SA299 FCAW 140 7690 28 4 07/31/ 193
3.77 13-14 Slag 120 10
1213 04 126 D3498 LS 2.1 SA299 FCAW 140 6414 23 3 07/28/ 193
1.87 13-14 Slag 50 15
1213 04 126 D3498 LS 2.1 SA299 FCAW 140 6414 23 3 07/28/ 193
1.87 07-08 Slag 30 15
1213 04 126 D3498 LS 2.1 SA299 FCAW 140 6414 23 3 07/28/ 193
1.87 08-09 Slag 40 15
1213 04 126 D3500 CS 1 SA299 SMAW 140 5533 22 2 11/02/ 193
3.07 12-13 Slag 30 60
1213 04 126 D3500 CS 1 SA299 SMAW 140 5533 22 2 11/02/ 193
3.07 03-04 Slag 140 20
1213 04 126 D3501 CS 2 SA299 SMAW 140 5573 22 2 10/05/ 193
4.04 21-00 Slag 200 30
1213 04 126 D3501 CS 2 SA299 SMAW 140 5573 22 2 10/05/ 193
4.04 11-12 Slag 25 20
1213 04 126 D3544 CS 3 SA299 SMAW 140 5533 22 5 11/02/ 193
3.71 15-16 Slag 60 15
1213 04 126 D3544 CS 3 SA299 SMAW 140 5533 22 5 11/02/ 193
3.71 11-12 Slag 35 15
1213 04 126 D3544 CS 3 SA299 SMAW 140 5533 22 5 11/02/ 193
3.71 05-06 Slag 30 45
1213 04 126 D3544 CS 3 SA299 SMAW 140 5533 22 5 11/02/ 193
3.71 02-03 Slag 50 70
1213 04 126 D3544 CS 3 SA299 SMAW 140 5533 22 5 11/02/ 193
3.71 01-02 Slag 30 60
1601 04 126 D3483 LS 1.1 SA299 FCAW 160 7748 28 1 07/27/ 193
1.94 00-01 Slag 150 30
1601 04 126 D3487 LS 3.1 SA299 FCAW 160 5182 19 2 08/01/ 193
1.93 15-16 Slag 50 60
1601 04 126 D3487 LS 3.1 SA299 FCAW 160 5182 19 2 08/01/ 193
1.93 16-17 Slag 50 60
1601 04 126 D3488 LS 3.2 SA299 FCAW 160 5182 19 1 08/01/ 193
1.35 16-17 Slag 70 35
1601 04 126 D3488 LS 3.2 SA299 FCAW 160 5182 19 1 08/01/ 193
1.35 16-17 Slag 70 35
1601 04 126 D3492 CS 2 SA299 SMAW 160 5531 22 2 10/26/ 193
1.9 05-06 Slag 25 10
1601 04 126 D3492 CS 2 SA299 SMAW 160 5531 22 2 10/26/ 193
1.9 01-02 Slag 80 10

Page 22 of 26

45
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
1601 04 126 D3493 CS 3 SA299 SMAW 160 5567 22 3 10/13/ 193
3.41 06-07 Slag 40 15
1601 04 126 D3493 CS 3 SA299 SMAW 160 5567 22 3 10/13/ 193
3.41 07-08 Slag 120 15
1601 04 126 D3493 CS 3 SA299 SMAW 160 5567 22 3 10/13/ 193
3.41 12-13 Slag 30 15
1601 04 126 D3494 CS 4 SA299 SMAW 160 5570 22 1 10/19/ 193
0.63 13-14 Slag 35 15
1604 04 126 D3574 LS 2.1 SA299 FCAW 160 5182 19 1 12/17/ 193
1.06 18-19 Slag 55 20
5720 04 118 D3477 LS 1.2 SA299 FCAW 140 8250 30 2 07/07/ 193
3.76 00-01 L/F 80 15
5720 04 118 D3477 LS 1.2 SA299 FCAW 140 8250 30 2 07/07/ 193
3.76 27-28 Slag 100 65
5720 04 118 D3477 LS 1.2 SA299 FCAW 140 8250 30 2 07/07/ 193
3.76 06-07 Slag 20 65
5720 04 118 D3477 LS 1.2 SA299 FCAW 140 8250 30 2 07/07/ 193
3.76 05-06 Slag 55 65
5720 04 118 D3477 LS 1.2 SA299 FCAW 140 8250 30 2 07/07/ 193
3.76 27-28 Slag 100 65
5720 04 118 D3477 LS 1.2 SA299 FCAW 140 8250 30 2 07/07/ 193
3.76 04-05 Slag 55 85
5720 04 118 D3477 LS 1.2 SA299 FCAW 140 8250 30 2 07/07/ 193
3.76 00-01 L/F 80 15
5720 04 118 D3477 LS 1.2 SA299 FCAW 140 8250 30 2 07/07/ 193
3.76 04-05 Slag 55 85
5720 04 118 D3477 LS 1.2 SA299 FCAW 140 8250 30 2 07/07/ 193
3.76 05-06 Slag 55 65
5720 04 118 D3477 LS 1.2 SA299 FCAW 140 8250 30 2 07/07/ 193
3.76 06-07 Slag 20 65
5720 04 118 D3479 LS 2.1 SA299 FCAW 140 8250 30 2 08/04/ 193
1.09 29-30 Slag 40 15
5720 04 118 D3479 LS 2.1 SA299 FCAW 140 8250 30 2 08/04/ 193
1.09 02-03 Slag 50 60
5720 04 118 D3481 CS 2 SA299 SMAW 140 7140 24 2 10/28/ 193
1.26 05-06 Slag 40 20
5720 04 118 D3481 CS 2 SA299 SMAW 140 7140 24 2 10/28/ 193
1.26 12-13 Slag 50 50
5720 04 118 D3481 CS 2 SA299 SMAW 140 7140 24 2 10/28/ 193
1.26 05-06 Slag 40 20

46
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
5720 04 118 D3481 CS 2 SA299 SMAW 140 7140 24 2 10/28/ 193
1.26 12-13 Slag 50 50
5722 04 118 D3530 LS 1 SA299 SMAW 155 8250 30 2 11/10/ 193
2.18 29-30 Slag 150 40
5722 04 118 D3530 LS 1 SA299 SMAW 155 8250 30 2 11/10/ 193
2.18 27-28 Slag 30 30
5722 04 118 D3531 CS 2 SA299 SMAW 155 8250 30 6 11/10/ 193
3.39 08-09 Slag 60 60
5722 04 118 D3531 CS 2 SA299 SMAW 155 8250 30 6 11/10/ 193
3.39 01-02 Slag 20 65
5722 04 118 D3531 CS 2 SA299 SMAW 155 8250 30 6 11/10/ 193
3.39 07-08 Slag 30 60
5722 04 118 D3531 CS 2 SA299 SMAW 155 8250 30 6 11/10/ 193
3.39 00-01 Slag 90 50
5722 04 118 D3531 CS 2 SA299 SMAW 155 8250 30 6 11/10/ 193
3.39 11-12 Slag 20 35
5722 04 118 D3531 CS 2 SA299 SMAW 155 8250 30 6 11/10/ 193
3.39 28-29 Slag 60 35
5722 04 118 D3532 LS 3 SA299 FCAW 140 8250 30 3 10/16/ 193
25 10
5722 04 118 D3532 LS 3 SA299 FCAW 140 8250 30 3 10/16/ 193
5722 04 118 D3532 LS 3 SA299 FCAW 140 8250 30 3 10/16/ 193
5722 04 118 D3532 LS 3 SA299 FCAW 140 8250 30 3 10/16/ 193
5722 04 118 D3533 LS 4 select FCAW 140 8250 30 5 10/16/ 193
5722 04 118 D3533 LS 4 select FCAW 140 8250 30 5 10/16/ 193
5722 04 118 D3533 LS 4 select FCAW 140 8250 30 5 10/16/ 193
5722 04 118 D3533 LS 4 select FCAW 140 8250 30 5 10/16/ 193
50 10
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 24-25

Page 24 of 26

47
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 11-12
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 23-00
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 21-22
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 20-21
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 19-20
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 18-19
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 17-18 Pores 70 10
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 16-17
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 15-16 Pores 65 10
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 14-15
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 13-14
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 22-23
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 12-13
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 00-01
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 10-11
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 09-10
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 08-09
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 07-08
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 06-07
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 05-06

Page 25 of 26

48
cust_ pg_no ma_no rt_no seam_seam_mater weld_
thi wel tot def_s rt_date bay_nmachidef_p seg_n def_t
def_le def_depth
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 04-05
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 03-04
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 02-03
5722 04 118 D3535 CS 2 SA299 SMAW 155 6280 24 2 12/02/ 193
2.15 01-02
5723 04 118 D3540 LS 4 SA299 FCAW 140 8250 30 1 11/02/ 193
0.61 00-01 Slag 50 25

49
 CHAPTER 4
SOFTWARE USED AND DATA ANALYSIS

50
51
52
53
54
55
4.7 MAJOR CAUSES OF DELAY:

Butt welds, RT defects: Already projects were done. A system to capture drum
defects were made ready,same results are extended to other newly added bays, v.iz.,
160 & 164.
• Aesthetics: Butt welds are
flush ground and there is not much of aesthetics related reworks. In case of fillet
welds, grinding is done in many shifts. The main reason is to merge undercuts, which
some times leads to rework welding, and bead merging and smoothing off of valleys.
Profile and appearance of fillet weldments.
• Shroud / Kerosene leak test
sweating: This is caused due to poor welding skill exhibited in case of sheet metal
welding.
• Parallel stubs leaks in hydro
test of boiler drums.
• Full throat Nozzle defects.
• The formation of Slag is
observed

56
4.8 CAUSE AND EFFECT DIAGRAM FOR SLAG INCLUSION

4.9

57
4.9 CAUSE AND EFFECT DIAGRAM FOR POROSITY

58
 CHAPTER 5
METHODOLOGY/PROCESS APPROACH

5.1 PROCESS APPROACH

A Study was undertaken to understand the process and the parameters that
affected the weldment, in terms of bead formation and correlate them to the defects/
deviations that were happening in drumshop welding. In the process approach following
study were done.

5.2 PROBLEM IDENTIFIED

Data was collected and processed in custom made software to understand the
defect occurrence. The occurrence were having a little increasing trend compared to past
year. The pattern of occurrence were same. The newly added bays were contributing to
defect percentage increase. The technique followed in drum shop is to fuse the root
completely in the lip matching line and to start off the next bead from the groove wall
tapering down to the adjacent wall leaving only 2 to 3 mm gap for next layer to be

59
accommodated in the end. This is achieved by controlling the amperage and also
increasing the voltage.

5.3 ACTION TO BE TAKEN:

Following were the actions initiated after conducting interaction discussion with
welders and other people in shop floors.

The Butt weld defect was increasing in trend in the past two months.
Newly added bays, Bay-160 and 164 had contributed to the increase.
(ii)It is decided to extend the use of defect detail capturing software to the other
bays as well (Bay 160 & Bay164).
(iii) To educate the welders in Bay 160 & 164 about staggering of beads
as advisd by WTC for drum shops.
(iv) To maintain depth logs of the machines, i.e., at the end of every
shift, how much dept has been welded and correlate the data with
the UT results obtained.
• Fillets,
(i)Fillet welds had the problems of leak observed of late,
(ii)A study was proposed with the following parameters to simulate the
extremes of welding (iii)practice that may occur in shop floor
realtime welding.
(iv)The problem of slag incurrence is identified and must be rectified.

5.4 PROPOSED STUDY:

Generally when welding process is carried out in the boilers, two types of welding is
carried out. First one is the long seam and the other one is the circumferential seam. Long
seam is done to join the two longitudinal shells of the boiler. Cir seam is used to join the

60
two dish ends of the boiler. The process parameters of a welding process include position
at which welding is carried out, current, voltage, electrode diameter and the type of
electrode movement followed. Therefore in order to reduce the rework and determine the
optimum process parameters, miniature models were designed. The first three specimens
are designed to determine the process parameters for cirseam and the last two for the long
seam process.

5.4.1 Specimen 1(Pipe + Plate) : (Transverse angle variation for every 120˚
using Φ4mm electrode)

1.1 1.2

1.3

1.3

Figure 5.1

Specimen 1.1

Figure 5.1(a)
Specimen 1.2

61
 Figure 5.1(b)
Specimen 1.3

Figure 5.1(c)

5.4.2 Specimen 2(Pipe):

2.1 2.2

2.3

2.3

Figure 5.2
Specimen 2.1 - Root stringer (Φ4mm electrode)

Specimen 2.2 - Root weaving fully (Φ4mm electrode)

Specimen 2.3 – Root stringer (Φ6mm electrode)

5.4.3 Specimen 3(Pipe):

3.1 3.2

4444
62

3.3
 Figure 5.3

Specimen 3.1 – Low Current

Specimen 3.2 – Current within range

Specimen 3.3 – High Current

5.4.4 Specimen 4(Tee):

4.1 4.2 4.3 4.4

Figure 5.4 Figure 5.5

Specimen 4.1 – High Voltage Specimen 4.3 – High Current

Specimen 4.2 – Low Voltage Specimen 4.4 – Low Current

5.4.5 Specimen 5: Voltage overlay

5.1 5.2 5.3

Figure 5.5

63
Specimen 5.1 – High Voltage

Specimen 5.2 – Low Voltage

Specimen 5.3 – High Current

5.5 OBSERVED PARAMETERS

Welding was carried out in specimens with the parameters as shown in below table.
TABLE 5.1

Specimen Current Voltage Electrod Root Pass (one Layer) Capping

(A) (V) e Size Layers
1.1 185 67.4 Φ 4mm Transverse Position as 1st layer-250A
shown in specimen1.1 2nd layer-250A
1.2 185 67.4 Φ 4mm Transverse Position as 3rd layer-175A
shown in specimen1.2
1.3 185 67.4 Φ 4mm Transverse Position as
shown in specimen1.3
2.1 185 67.4 Φ 4mm Root stringer 1st layer-220A
2.2 185 67.4 Φ 4mm Full root Weaving 2nd layer-250A
2.3 185 67.4 Φ Root stringer 3rd layer-175A
6.3mm
3.1 140 67.4 Φ 4mm Low current 1st layer-250A

64
 3.2 160 67.4 Φ 4mm Current within range 2nd layer-250A
3.3 180 67.4 Φ 4mm High Current 3rd layer-175A
4.1 160 35-38 Φ 4mm High Voltage
4.2 160 23-25.5 Φ 4mm Low Voltage N.A.
4.3 140 67.4 Φ 4mm High Current
4.4 180 67.4 Φ 4mm Low Current
5.1 160 23.1 - 25.5Φ 4mm Minimum arc length
5.2 160 26.5- Φ 4mm Medium arc length N.A.
29.5
5.3 160 32-36 Φ 4mm Maximum arc length

5.6 MPI AND HEAT TREATMENT

After completing the welding the fillet area was ground and MPI was conducted
on weldment. The indications observed during MPI have been tabulated below.
TABLE 5.2
Specimen Indication observed
1.1 Undercut
1.2 Slag
1.3 Stub side undercut
2.1 Slag
2.2 Slag
2.3 Undercut
3.1 Slag & Undercut
3.2 Slag & Undercut
3.3 Slag
4.1 Lack of fusion & Slag
4.2 Slag
4.3 No indication
4.4 Lack of fusion
5.1 No indication
5.2 No indication
5.3 No indication

65
 CHAPTER 6
RESULTS AND DISCUSSIONS

6.1 CUTTING PLAN & MACRO EXAMINATION REPORT

Cutting plan has been shown in dotted line.

6.1.1 Specimen1: (Transverse angle variation)

1.1.1

1.2.1

1.1 1.2

1.3

1.3
1.3.1

Figure 6.1

66
 Table 6.1

Specimen Current Voltage Electro Root Pass (one Capping

(A) (V) de Size Layer) Layers
Transverse
Φ
1.1 185 67.4 Position as shown 1st layer-
4mm
in specimen1.1 250A
Transverse
Φ 2nd layer-
1.2 185 67.4 Position as shown
4mm 250A
in specimen1.2
Transverse 3rd layer-
Φ
1.3 185 67.4 Position as shown 175A
4mm
in specimen1.3

Specimen 1.1.1:

67
 Figure 6.2

When the welding is carried out in the transverse position as shown in 1.1, the x ray view
of the specimen reveals the presence of slag.
Specimen 1.2.1:

Figure 6.3
When the welding is carried out in the transverse position as shown in 1.2, the x ray view
of the specimen reveals that the fusion is satisfactory
Specimen1.3.1:

Figure 6.4

68
When the welding is carried out in the transverse position as shown in 1.2, the x ray view
of the specimen reveals that the fusion is satisfactory

Table 6.2
Plant Lab Comments:
Sample no. Observation
1.1.1 Root slag is observed
1.2.1 Fusion satisfactory
1.3.1 Fusion satisfactory

6.1.2 Specimen 2

2.1.1

2.2.1

2.1 2.2

2.3

2.3
2.3.1

Figure 6.5

Table 6.3

Specimen Current Voltage Electrode Root Pass (one Capping

(A) (V) Size Layer) Layers
2.1 185 67.4 Φ 4mm Root stringer 1st layer-
2.2 185 67.4 Φ 4mm Full root 220A
Weaving

69
 2.3 185 67.4 Φ 6.3mm Root stringer
2nd layer-
250A
3rd layer-

Specimen2.1.1:

Figure 6.6

When welding is carried by means of root stringer movement with a electrode of 4mm
dia poor joint tip is observed

Specimen 2.2.1:

70
 Figure 6.7

When welding is carried by giving the electrode(4mm dia) a full root weaving movement,
slag is observed
Specimen2.3.1:

Figure 6.8

When welding is carried by means of root stringer movement with a electrode of 6 mm

dia, slag is observed

71
 Table 6.4
Plant Lab Comments:
Sample no. Observation
2.1.1 Poor joint fit-up
2.2.1 Root slag is observed
2.3.1 Root slag is observed

6.1.3 Specimen 3:
3.1.1

3.2.1

3.1 3.2

3.3

3.3.1 4.3
Figure 6.9

Table 6.5

Specimen Current Voltage Electrode Root Pass Capping

(A) (V) Size (one Layer) Layers

3.1 140 67.4 Φ 4mm Low current 1st layer-

3.2 160 67.4 Φ 4mm Current 250A
within 2nd layer-

72
 range
High
3.3 180 67.4 Φ 4mm 250A
Current
3rd layer-

Specimen 3.1.1:

Slag

Figure 6.10

When welding is carried out by suppling a low current(140 A), slag is observed

Specimen 3.2.1:

73
 Slag

Figure 6.11

When welding is carried out by suppling current within the range(160 A), poor joint
tip and root slag is observed

Specimen3.3.1:

Figure 6.12

When welding is carried out by suppling high current(180 A), fusion is satisfactory.
Table 6.6
Plant Lab Comments:
74
 Sample no. Observation
3.1.1 Root slag is observed
3.2.1 Poor joint fit up , Root slag is observed
3.3.1 Fusion satisfactory

6.1.4 Specimen 4:

Specimen 4.1 & 4.2:

4.1 4.2

FRONT VIEW

4.1.1 4.2.1

4.1 4.2

TOP VIEW

Table 6.7

75
Specimen Current Voltage Electrode Root Pass (one Capping
(A) (V) Size Layer) Layers
4.1 160 35-38 Φ 4mm High Voltage
N.A.
4.2 160 23-25.5 Φ 4mm Low Voltage

Under
cut

Figure 6.13
When welding is carried out by supplying a high voltage(35-38V), undercut is observed

Table 6.8
Plant Lab Comments:

Sample no. Observation

4.1.1 & 4.2.1 Under cut, insufficient root penetration on one side is observed

Specimen 4.3 & 4.4:

4.3 4.4

76
 FRONT VIEW
4.4.1

4.3 4.4

4.4.2 TOP VIEW

Table 6.9

Specimen Current Voltage Electrode Root Pass (one Capping

(A) (V) Size Layer) Layers
4.3 180 67.4 Φ 4mm High Current
N.A.
4.4 140 67.4 Φ 4mm Low Current

Specimen 4.4.1:

Figure 6.14
77
When welding process is carried out by supplying a high current (180A) undercut and
insufficient penetration is observed

Specimen 4.4.2:

Under cut

Figure 6.15
When welding process is carried out by supplying a high current (140A) insufficient
root penetration is observed.

Table 6.10
Plant Lab Comments:
Sample no. Observation
4.3 Undercut and insufficient root penetration is observed
4.4 Insufficient root penetration is observed

78
6.1.5 Specimen 5:

5.1 5.2 5.3

5.1.1 5.2.1 5.3.1

Figure 6.16

Table 6.11
Specimen Current Voltage Electrode Root Pass (one Capping
(A) (V) Size Layer) Layers
5.1 160 23.1 - 25.5Φ 4mm Minimum arc
length N.A.
5.2 160 26.5- Φ 4mm Medium arc length
29.5
5.3 160 32-36 Φ 4mm Maximum arc
length

Specimen 5.1.1:

79
 Figure 6.17
When welding process is carried out by supplying a low voltage (23.1-25.5 V)
fusion is satisfactory.

Specimen 5.2.1:
Slag

Figure 6.18
When welding process is carried out by supplying a low voltage (26.5-29.5 V) side wall
slag is observed.

Specimen 5.3.1:
Pore Slag

Figure 6.19
When welding process is carried out by supplying a low voltage (32-36 V) pore and slag
are observed

80
 Table 6.12
Plant Lab Comments:
Sample no. Observation
6.1.1 Fusion satisfactory
6.2.1 Side wall slag is observed
6.3.1 Pores & slag is observed

6.2 INFERENCES OF THE PROPOSED STUDY

• Defect distribution is studied in Butt welding using a stratification software, the

defect depth is predominant in root plus 1,2 layers in butt welding. Sporadic
occurrence of slag in other layer can be attributed to cleaning deficiencies and too
small powdery slag particles.
• In welding fillets, when the Electrode position is on the tube, the fusion profile is
better. How ever there is slag inclusion which is at the base of the groove.
• The root stringer bead has good fusion, the weaving in the root and higher size
electrode has enabled slag entrapment and is undesirable.
• The header fillet weld using current variation shows that, root weld with current
on the higher side gives maximum depth of minimum leak path, by fusing
maximum length of throat.
• High current and out of range voltage causes undercut in the attachment fillets.
• In 1G/ 1F position welding done on specimens using voltage variations, it is seen
that higher the voltage shallower and wider the bead, with pores caused due to
improper shielding in higher voltage welding as arc length is elongated in higher
voltage ranges.

81
 CHAPTER 7
CONCLUSION

CONCLUSIONS OF THE STUDY

• Defect distribution for the past years can be studied with the use of stratification
software, it is recommended that the welder number and name be incorporated and
periodic monitoring and feedback given to the welders regarding the defect
occurrence.
• The header fillet welds is to be welded using following parameters,
a. Higher side amperage selection for stringer bead root welding.
b. Root welding as per WT407 sequence.
c. “Skill of the Welder” to be uantified as combination of transverse and
travel angles, the lesser of travel angle and more of traverse angle enables
welder to fuse well, in places of constraint where this is not possible,
shorter electrode stubs to be used to facilitate the same.
d. Weld map to be maintained and welder number punches to be introduced to
maintain traceability in-situ in cases of reported leaks.
e. Use middle range of voltage, or ensure that excess arc length is not used in
welding SMAW as found in the study, as it causes pores, which is presently
observed in full throat welding root layers.

82
• Use of CO2 welding in attachment as it is a process wherein a larger parameter
window can be employed. and the demanding skills in SMAW welding can be
eased out, also improving productivity.
• Parameters for welding from the proposed study for better performance are
below: Current  High- 18.5 A
Voltage  67.4 V
Position  Transverse with Arc Length minimum
REFERENCES
 Jefferson’s welding encyclopedia on Eighteenth Edition, Edited by Robert L.
O’Brien, American Welding Society, 1997
 Lukačević Z., Samardžić I. Possibilities of dynamic monitoring of the main
parameters in arc welding process, Zavarivanje , Vol. 42, No. 1–2, 1999, pp.
11–16.
 Dunđer M., SamardžiĆ I. Monitoring of welding processes, Proc. on Trends
in the Development of Machinery and Associated Technology , Zenica, Bosna i
Hercegovina, 2000, pp. 222–230.
 BHEL’s WELD TESTING CENTRE manuals.
 Arc welding, IEEE Transactions on. Industry Applications, Vol. 29, No. 2,
pp.250–255. Cary, H.B. (1979)

83