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Analysis for increased defect rate

1. Welding Defect Trend

 Defect rate rises over 1.00% starting from W31

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Defect Analysis
2. Defect Information
2.1 Defect Summary
NO. SECTION NO. INSPECTED LENGTH DEFECT LENGTH DEFECT RATE REMARKS
1 G002-M 176329 1260 0.71%
2 G003-M 176329 777 0.44%
3 G001-M 176329 1350 0.77%
4 G004-M 176329 340 0.19%
5 G002-B 150671 2065 1.37% INCLUDED DW
6 G001-B 144141 910 0.63% EXCLUDED DW
7 G006-M 176329 380 0.22%
8 G005-M 176329 5580 3.16%
9 G007-M 176329 115 0.07%
10 G008-M 176329 1415 0.80%
11 G003-B 144141 1716 1.19% EXCLUDED DW
12 G004-B 144141 2204 1.53% EXCLUDED DW
13 G009-M 176329 2655 1.51%
TOTAL OVERALL 2314196 21102 0.90%

Defect Length [mm]


No. Section ID Joint No. Welder ID Machine ID
IP LF Porosity SI Crack Etc Total
1 G005-M CS5 MY 001 CW1 / / / 4,730 / / 4,730
2 G008-M CS4 MY 001 CW1 / 265 550 220 / / 1,035
3 G004-B CS9 MY 003 CW2 / / 90 1,250 / / 1,340
4 G009-M CS11 MY 006 CW1 / / / 2,420 / / 2,420

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Defect Analysis
2. Defect Information
2.1 Defect Joint G004-B-CS9

2.2 Defect Length 1,340 mm


1.3 Defect Location D= (11) , Y= (-4.9)-(-5.5)
1.4 Defect Type Po(90mm), Slag(1,250mm)

1.5 Inspection Date 11. Aug. 2017


 Defect location at the base metal area(=Too high voltage at DC)
1.6 Significant Phenomenon  Intermittent defect
 Underfill was detected in visual
70°

7 4.9

Inside
3
10
23

20
9

Defect Location

5.73
65°

[ Fig.1 Defect Location ] [ Fig.2 Bead appearance ]

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Defect Analysis
2. Defect Root Cause
2.1 Unacquainted with bottom section
- Welders didn’t review bevel map(thickness, bevel depth, bevel angle) before welding.
- Lack of experience for melted amount as per parameter(=multi pass) and teaching point control.
2.2 Tendency to use high voltage
- Some welders are usually using high voltage(DC: 33V @root pass) to
remove any contaminant on bevel surface and root face.
2.3 Conclusion
- The welder who not fully understands how bevel looks like can’t
calculate and decide proper welding parameter.
⇒ Underfill
- Using high voltage of DC could make trapped slag from undercut.
⇒ SI, Po
[ Fig.3 Definition of teaching point ]

3. Corrective Action
3.1 Set standard parameter for the root pass(01. Aug. 2017)
DC AC
Travel speed
Location
V (mm/min)
A V A
(If cap bead)
Outside 650 ~ 750 27 ~ 28 520 ~ 600 31 ~ 32(34) 600

Inside 750 ~ 850 28 ~ 29 560 ~ 640 30 ~ 31(33) 600

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Defect Analysis
3. Corrective Action
3.2 Reminding training for WPS / Beveling map(15. Aug. 2017)
- Finalized standard welding parameter.
- Design of multi pass and teaching point location(keep 3mm from bevel surface)
- Design of BOSR thickness.
- How to review the bevel map / weld map.
- How to repair when burn through happened.
- How to repair when underfill happened(more welding with single wire SAW welding)

[ Fig.4 Bevel map / Weld map ] [ Fig.5 On going training ]

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Defect Analysis
3. Corrective Action
3.3 Distribution of “WPS Summary Card”(28. July. 2017)
Project Name : GE 08503MW50STWG400 (BODANGORA) Project Name : GE 08503MW50STWG400 (BODANGORA) Project Name : GE 08503MW50STWG400 (BODANGORA)
Section Name : Bottom Section Section Name : Middle Section Section Name : Top Section
Joint Thickness WPS No. Joint Thickness WPS No. Joint Thickness WPS No.
LS 01 33 LS 01 21 LS 01 15
CSMY-WPS-KSSA-033-R0
LS 02 33 LS 02 20 LS 02 15
LS 03 23 LS 03 19 LS 03 15
LS 04 23 LS 04 18 LS 04 15
CSMY-WPS-KSSA-3133A-R0
LS 05 22 LS 05 17 LS 05 15 CSMY-WPS-KSSA-029-R0
LS 06 21 LS 06 17 LS 06 15 CSMY-WPS-KSSA-031-R0
LS 07 21 LS 07 16 LS 07 15
LS 08 20 LS 08 15 CSMY-WPS-KSSA-029-R0 LS 08 15
CS 1 33/33 CSMY-WPS-KSSA-033-R0 LS 09 15 CSMY-WPS-KSSA-031-R0 LS 09 15
CS 2 33/33 LS 10 15 LS 10 15
CS 3 23/33 CS 1 21/21 CSMY-WPS-KSSA-3133A-R0 LS 11 20 CSMY-WPS-KSSA-033-R0
CS 4 23/33 CS 2 20/21 CSMY-WPS-KSSA-033-R0 CS 1 15/15
CS 5 22/23 CS 3 19/20 CS 2 15/15
CS 6 21/22 CS 4 18/19 CS 3 15/15
CSMY-WPS-KSSA-3133A-R0
CS 7 21/21 CS 5 17/18 CS 4 15/15
CS 8 20/21 CS 6 17/17 CS 5 15/15
CSMY-WPS-KSSA-029-R0
CS 9 23/20 CS 7 16/17 CSMY-WPS-KSSA-033-R0 CS 6 15/15
CSMY-WPS-KSSA-031-R0
CS 8 15/16 CS 7 15/15
CS 9 15/15 CSMY-WPS-KSSA-029-R0 CS 8 15/15
CS 10 15/15 CSMY-WPS-KSSA-031-R0 CS 9 15/15
CS 11 15/15 CS 10 15/15
CS 11 20/15
CS 12 20/20 CSMY-WPS-KSSA-033-R0

[ Fig.6 Welding Map Summary Card ]

3.4 SAW Daily Check List


3.4.1 Purpose SAW Daily Inspection Report Date : 12-Jul-17

- To control machine set up and consumable preparation.


1. Summary of inspection result

Check List

Clamping Of Earth And

- To inform BT of findings during inspection.


Contact Tip Replace Torch Set Up Welding Consumable
Sensor
Reason
No. Welder ID Machine ID Remarks
( If not OK )
Electrode DC/AC Earth Sensor
Lead Torch Trail Torch Laser Point Flux Flux Filter Wire Rust / Wire Reel

- To give understanding welders which point is critical to quality.


Spacing Torch Clamping Clamp
(DC) (AC) Alignment Temperature Cleaning Oil Check Check
(mm) Aligment Condition Condition

1 MY 002 MY 007 LW 1 OK OK 28 OK OK HOT OK OK OK OK OK -

- To listen welder’s voice.


2 MY 005 - LW 2 OK OK 28 OK OK HOT OK OK OK OK OK -
3 MY 003 - FW 1 N/A - ON LEAVE
4 MY 001 MY 006 CW 1 OK OK 30 OK OK HOT OK OK OK OK OK -
5 MY 004 MY 027 CW 2 NOT OK OK 28 OK OK HOT OK OK OK OK NOT OK - Sensor clamping damage.

2. Welder Comment
Welder
Welder Name Comment

3.4.2 Extent
ID
MY 001 Mohd. Zaini B. Mohd Zain - SAW Machine POWER WAVE unstable AC arc during welding
- SAW Machine POWER WAVE unstable AC arc during welding
MY 002 Mohd. Fuzaimi B. Maznan
- Long Seam welding, welder need end tape thickness equal or more than skirt thickness to prevent underfill during welding.

- Daily base
MY 003 Azian B. Abd. Aziz - SAW Machine POWER WAVE unstable AC arc during welding
MY 004 Mohamad B. Harun - SAW Machine POWER WAVE unstable AC arc during welding
- Welder need air blower or fan to blow the welding fume, grinding dust and heat during skirt welding (inside)
MY 005 Mohd. Syarifuddin B. Embong - SAW Machine POWER WAVE unstable AC arc during welding

- All SAW tandem machine


- Long Seam welding, welder need end tape thickness equal or more than skirt thickness to prevent underfill during welding.
MY 006 Mohd. Zainudin B. Mat Rani - SAW Machine POWER WAVE unstable AC arc during welding
- SAW Machine POWER WAVE unstable AC arc during welding
MY 007 Adnan B. Mustafa
- Long Seam welding, welder need end tape thickness equal or more than skirt thickness to prevent underfill during welding.
MY 027 Mohd. Azam B. Mohd Noor - SAW Machine POWER WAVE unstable AC arc during welding

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