TRAINNING ON VISUAL

EXAMINATION OF STEEL
PRODUCTS
(Welded Pipes, Coils & Plates)

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 Contents

1. General guideline for visual Inspection

2. Visual Defects in Steel Plates & Coils
3. Visual Defects in Welding

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General guideline
for
Visual Inspection

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 Definition of Visual Inspection
Visual Inspection is the simplest, fastest, economical
and most commonly used test for detecting defect
on the surface of the weld and plate/pipe body.

Inspection may be carried out by the use of the

eye alone or can be enhanced by using optical
systems such as magnifiers and other visual
examination aids. A variety of equipments are
available for visual examination including mirrors,
video scopes etc.

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 Conditions for visual inspection

Visual inspection shall take place in a clean,

comfortable environment with adequate lighting.
There should be reasonable access to the parts to
be inspected and attention should be paid to safety,
working position, and atmospheric conditions. The
test piece should be clean and free from protective
coatings, oil grease etc. Any equipment to be used
should be calibrated and its operation should be
understood by the inspector.

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 Conditions for visual inspection

1. Sufficient Illumination
2. Correct eye distance from object and
correct angle between eye & object
3. Magnifying glasses to be use if
required

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 Conditions for visual inspection

1. Sufficient Illumination :

At least 300 Lux as per API 5L, 45th edition

At least 1000 Lux as per ASME Sec V/ API 5LD.

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 Near Vision Examination
The applicant shall be capable of reading a
minimum of Jaeger No.2 or equivalent type and
size of letter at a distance of not less than 12
inches on a standard Jaeger test chart.
The ability to interpret an Ortho-Rater 8 or better
or a similar test pattern is also acceptable. This
test should be administered annually. Candidates
must also be capable of differentiating different
shades of colors - this color vision must be tested
every 5 years.
This is specified in ASNT document number SNT-
TC-1A.

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 General guideline for Visual
Inspection
2. Correct eye distance from object and
correct angle between eye & object :

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 Access and viewing distance

If unaided visual inspection is to be carried out

accurately, observations must be made within 600
mm. (ASME Sec V, Article - 9)

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 Viewing angles and distances

The eye's resolving power is dependent on

the angle and distance from the test surface.
Direct visual examination observations may
usually be made within 600 mm of the
surface to be examined and and the angle
between the eye and test surface not less
than 30 (ASME Sec V Article 9).

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MEASURING
EQUIPMENT

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 Measuring Equipments / Instruments
Scale
Measuring Tapes
Vernier Calipers
Micrometers
Clock gauges
Pie Tape
Bevel Protector
Bead Height Gauge
Off Set Gauge

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Visual Defects
in
Steels

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Visual Defects in Steels
Sliver
Seam line
Scab
Lap
Rolled-in-Scale
Lamination
Roll Mark
Cracks
Tong mark
Arc Burn
Dents / Indentation
Hard Spot
Pitting
Excess Reinforcement
Pit
Under Cut
Stretch Mill Indentation
+ + + And So many
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 Visual Defects in Steels
Sliver
An extremely thin elongated piece of
metal that has been rolled into the
surface of the parent metal to
which it is attached usually by only
one end.

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Sliver

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 Visual Defects in Steels
Scab
An imperfection in the form of a
shell or veneer, generally attached
to the surface by sound metal. It
usually has its origin in an ingot
defect.

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Scab

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Visual Defects in Steels
Roll MARK
A term applied to surface
imperfections caused by improper
roll alignment or roll surface
damage.Such imperfections may be
periodic or continuous

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Roll Mark

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Roll Mark

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Dents
A local change in surface contour
caused by mechanical impact, but not
accompanied by loss of metal.

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 Visual Defects in Steels
Pitting
. Pitting, is a form of extremely localized
corrosion that leads to the creation of small
holes in the metal.

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Pitting

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Pit
A depression resulting from the removal of
foreign material rolled into the surface
during manufacture.

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 Visual Defects in Steels
Seam
Crevice in rolled metal which has been more or
less closed by rolling or other work but has not
been fused into sound metal

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Seam

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 Visual Defects in Steels
Cracks
A stress-induced separation of the metal which,
without any other influence, is insufficient in
extent to cause complete rupture of the material.
Quench cracks in steel result from stresses
produced during the austenite-to martensite
transformation, which is accompanied by an
increase in volume

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Cracks

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 Visual Defects
in
Pipes Body
(Due to Process and poor workmanship)

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STRETCH MILL INDENTATION:
Localized thinning of the pipe body
wall - usually located on the inside
surface

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EXCESSIVE REINFORCEMENT (EXCESSIVE
OVERFILL):
Outside weld beads which extend above the
prolongation of the original surface of the pipe (more
than 1/8 in. for pipe having a thickness of 1/2 in. and
under, and more than 3/16 in. for a pipe having a
thickness of over 1/2 in.

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ARC BURNS:
Localized points of surface melting caused
by arcing between electrode or ground and pipe
surface.

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Visual Defects in Pipe Body

Improper Grinding
Deep Grinding
Roller Mark
Chip Mark
Scratches
Mechanical Damage

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Improper Grinding

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Deep Grinding

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Chips Mark

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Mechanical Damage

Chisel Marks
Chisel Marks

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Visual Defects
in
Weld

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Visual Defects in Weld
Under Cut:
Under-cutting on submerged-arc welded pipe is
the reduction in thickness of the pipe wall adjacent
to the weld where it is fused to the surface of the
pipe

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Visual Defects in Weld
Porosity:
Voids in a metal, usually resulting from shrinkage
or gas entrapment occurring during solidification of
a casting or weldment

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Visual Defects in Weld
Under fill:

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Visual Defects in Weld
IR-REGULAR WELD:
Bead Out, Bead Bend ,Narrow Bead

Bead Out
Bead Bend

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Visual Defects in Weld
Crack:
A stress-induced separation of the metal which,
without any other influence, is insufficient in extent
to cause complete rupture of the material. Quench
cracks in steel result from stresses produced during
the austenite-to martensite transformation, which is
accompanied by an increase in volume

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Visual Defects
in
Coil

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Visual Defects in Coil
Telescopic:

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Visual Defects in Coil
Camber:

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Visual Defects in Coil
Fish Tail:

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 API 5L
th
45 EDITION
REQUIRMENTS

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SURFACE CONDITIONS, IMPERFECTION AND
DEFECTS

All pipes shall be free from defects in finished condition

All pipes shall be free from cracks, sweats and leaks

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 Undercuts in SAW pipes shall be investigated, classified,
UNDERCUT
and treated as follows.
a) Undercuts that have a depth 0,4 mm (0.016 in) are
acceptable, regardless of length, and shall be treated in
accordance with Clause C.1.
b) Undercuts that have a depth > 0,4 mm (0.016 in) but
0,8 mm (0.031 in) are acceptable provided they are treated in
accordance with Clause C.2 and provided that:
1) their individual lengths are 0,5 t,
2) their individual depths are 0,1 t, and
3) there are no more than two such undercuts in any 300
mm (12.0 in) length of weld.

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ARC BURN
Arc burn shall be considered as defects.
Arc burns shall be treated in accordance with Clause C.2,
C.3 b) or C.3 c), except that they may be removed by
grinding, chipping or machining, provided that the resultant
cavity is thoroughly cleaned and checked for complete
removal of damaged material by etching with a 10%
solution of ammonium persulfate or a 5% solution of nital.

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LAMINATIONS
Lamination having visually determined length the
circumferential direction > 6.4mm shall be considered as
defects

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FLAT SPOTS AND PEAKING

3.2mm maximum in depth

Measured as the gap between the extreme point of the
deviation and the prolongation of the normal contour of the
pipe, shall be considered defects and shall be
treated in accordance with C.3 b) or C.3 c).

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HARD SPOT
Maximum 345 HV10 or 327 HBW in 50mm length in any
direction shall be classified as a defect . Pipes that contain
such defects shall be treated in accordance with C.3 b) or
C.3 c).

OTHER DEFECTS
Maximum 0.125 x WT, but not exceed minimum wall
thickness. Pipes that contain such defects shall be treated in
accordance with C.3

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 DENT
For dents, the length in any direction shall be 0.5 D and the depth,
measured as the gap between the extreme point of the dent and the
prolongation of the normal contour of the pipe, shall not exceed the
following:

a) 3,2 mm (0.125 in) for cold-formed dents with sharp-bottom gouges;

b) 6,4 mm (0.250 in) for other dents.
Dents that exceed the specified limits shall be considered defects and
shall be treated in accordance with C.3 b) or C.3 c).

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STRAIGHTNESS
The total deviation from a straight line over the entire
pipe length shall be 0,15 % of the pipe length. for sour
service and/or offshore service
The total deviation from a straight line, over the entire
pipe length, shall be 0,2 % of the pipe length For other
than sour service or offshore service.

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STRAIGHTNESS
The local deviation from a straight line in the 1,0 m (3.0
ft) portion at each pipe end shall be 3,0 mm (0.120 in)
for sour service and/or offshore service.
The local deviation from a straight line in the 1,0 m (3.0
ft) portion at each pipe end shall be 4,0 mm (0.156 in).
For other than sour service or offshore service

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WALL THICKNESS

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PIPE LENGTH

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 STRAIGHTNESS
OUT OF SQUARENESS:

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RADIAL
PIPE ENDSOFFSET:
For SAW and COW pipes, the radial offset of the
strip/plate edges shall not exceed the applicable value
given in Table

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HEIGHT OF WELD BEAD
For ID weld Bead
At least 100 mm (4.0 in) from each pipe end.
Bead height removed by grinding such that it does not extend above the
adjacent pipe surface by more than 0.5 mm.
For OD weld Bead
If agreed,
At least 150 mm (6.0 in) from each pipe end.
Bead height removed by grinding such that it does not extend above the
adjacent pipe surface by more than
0.5 mm (0.020 in).

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HEIGHT OF WELD BEAD
For the remainder of the pipe, the inside weld bead and
out side weld bead shall not extend above the adjacent
pipe surface by more than the applicable value given in
Table

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 MISALIGNMENT OF WELD BEAD
Complete fusion and penetration to be achieved
Max. 3 mm for WT 20mm
Max. 4 mm for wt > 20mm

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 MESUREMENT OF PIPE LENGTH:
For convenience pipe length shall be measured from un-
beveled end to beveled face.

Pipe Length

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OUT OF ROUNDNESS:
The greatest distance from a surrounding circle of points
on the actual cross-sectional profile of a cylindrical
surface

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BEVEL ANGLE:

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MASS

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MASS
If the purchase order specifies a minus tolerance for
wall thickness smaller than the applicable value given in
Table 11, the plus tolerance for mass shall be increased
by a percentage equivalent to the applicable percentage
reduction of the minus tolerance for wall thickness.
For each order item with a mass of 18 tonnes (20 ton)
or more, the mass of the order item shall not deviate
from its nominal mass, determined by multiplying the
total length of pipe in the order item by its mass per unit
length (as per above formula), by more than the
following:
a) for Grades L175, L175P, A25 and A25P: 3,5 %;
b) for all other grades: 1,75 %.
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Thank you

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