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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 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. 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.
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.
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.
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).
6
1.3.3 Drum Processing:
The drum processing is done in the following sequence of steps:
7
o Macro and Micro examinations.
1.6 COMPOSITION
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
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.
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.
11
• Cost and accessibility for repair etc.
• 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.
2.3.2 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.
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.
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.
14
• Impact Test
o Charpy impact test
o Izod impact test
• 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.
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
23
4.2 DATA COLLECTED
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
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.
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.
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.
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)
2.1 2.2
2.3
2.3
Figure 5.2
Specimen 2.1 - Root stringer (Φ4mm electrode)
3.1 3.2
4444
62
3.3
Figure 5.3
Figure 5.5
63
Specimen 5.1 – High Voltage
Welding was carried out in specimens with the parameters as shown in below table.
TABLE 5.1
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
65
CHAPTER 6
RESULTS AND DISCUSSIONS
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 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
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
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
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:
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:
4.3 4.4
76
FRONT VIEW
4.4.1
4.3 4.4
Table 6.9
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:
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
81
CHAPTER 7
CONCLUSION
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