Annex G to the Instructions for visual and measurement control (recommended)

ACT No. _____ from __________ visual and/or measuring control the quality of welds in the process of welding the joint ________________________________________________________________________ (name of the product and number of the joint) 1. This act certifies the fact that the welder ______________________________________________________________________ full name, brand _______________________ of the joint _________ (see the welding log), the type (s) of joints made welding method and position in accordance with the requirements of the welding technology ___________________________________ ________________________________________________________________________ indicate the code of the technology and inaccessible for control __________________________________________ indicate the method of control prescribed by ____________________________________________________________________________ design documentation ___ for category ______________________________________________________________________ (code or name of ND) it was found that the welded joint was recognized as fit and meets the requirements of ______________________________________________________________ (specify ND or design documentation) The control was carried out by: ___________________________________________________ Level of qualification, Surname, initials, signature No. qualification certificate Supervisor of visual and measurement control: ____________________________________________________________ Surname, initials, signature Note. The act is drawn up for each welded structure (joint or group of joints) subjected to control during the welding process. Requirements for the execution of the "Dimension Protocol _____________" (product) The protocol of dimensions is drawn up only if it is indicated in the RD or PKD for the controlled product. The protocol of product dimensions (table) must contain the actual dimensions of the product, made in certain sections, which are specified by the "Measurement Scheme ____________". The form of the Protocol of dimensions is determined (product) during design and technological preparation control works. The protocol is signed by the persons who performed the measurements and the head of the work on visual and measurement control, indicating the surname and initials.

Requirements for the content of the "Journal of work accounting and registration of the results of visual and measurement control"

The results of the control of products, products and objects are recorded in the "Journal of accounting for work and registration of the results of visual and measurement control", which indicates:

1) name and type (type) of the controlled object, its number or code;

2) the location and, if necessary, the size of the controlled areas at the control object;

3) conditions for conducting control;

4) production control document, its number;

5) the method of measuring control and the instruments (tools) used;

6) brand and batch number of the material of the object of control, as well as the designation of the standard or specifications on the material and drawing number of the object (the latter only for parts and assembly units);

7) the main characteristics of the defects identified during the inspection (shape, size, location or orientation relative to the base axes or inspection surfaces);

8) name or ND code, according to which the quality assessment was carried out;

9) assessment of control results;

10) date of control.

Note. It is allowed to use instead of the above other forms of documents developed by the organization in accordance with the requirements of the current regulatory and technical documentation, which provide identification and traceability of parts, assemblies, products in the manufacturing process (installation, repair), fixation of controlled parameters, volumes and methods of control, registration of reporting And accounting documentation for visual and measuring control.

In order to carry out a qualitative and complete assessment of the performance various systems and structures on industrial enterprises be sure to carry out control of welds using several methods, for example,. All methods are divided according to the principle of impact on the object under study into two broad groups: non-destructive testing methods and destructive testing methods. The methods of the first group are preferable and more practical to use, but many of them are quite expensive and have their own characteristics. Therefore, it is more economical to start any weld inspection with the simplest method - visual quality control.

This method of control is considered the most accessible and efficient, and therefore is a mandatory, preliminary examination method before any other method of testing the seam.

A simple optical method for confirming the quality of metal welding

The control of any welding joint begins to be carried out even with the direct creation of the weld. Visual control is part of the work of the welder, and he periodically conducts an external inspection (for lack of penetration, undercutting and fidelity of the leg) several times until the entire scope of work is completed. It is also the oldest method of monitoring the final work and its essence has not changed significantly, but the implementation methodology for last years improved. Weld Check

Theoretical definition and tools for implementation

Visual-measuring control (VIK) of welds is an external examination of sufficiently large welded structures, both with the naked eye and with the help of various technical devices to detect smaller defects that are not amenable to initial visualization, as well as using visual information to telemetric converters. VIC refers to organoleptic (conducted by the senses) methods of control and is carried out in the visible spectrum of radiation. A visual inspection in search of theoretical defects is carried out from the outside of the weld, where, if they are detected, it is possible to perform minimal measurements using optical instruments and instruments, to conclude an act of visual inspection.

When conducting visual inspection of welded joints, inspectors use several types of tools.

• Survey, telescopic, floor magnifiers;
• lenses;
• microscopes;
• endoscopes, etc.

For control in various conditions works:

1. Workshop equipment. Region operating temperature from +5 °С to +20 °С, conditions of complete rest, normal atmospheric pressure, moderate humidity.
2. Field devices. Operating temperature range from -55 °С to +60 °С, conditions of moderate shaking, vibration, weather precipitation.

The use of these devices allows for a more accurate search for defects and visual-optical control of the quality of welds on any objects.

Visual-optical control is the second stage of visual control with a wider, increased range of research through the use of optical instruments. Depending on the application, the method is intended for three main groups:

• To search and analyze hidden objects. Devices are used: endoscopes, borescopes, video systems, periscopic flaw detectors.
• For inspection of objects remote from the workplace of the flaw detector operator. The range of application is a distance of no more than 250 mm from the controller's eye. Instruments used: telescopic magnifiers, binoculars, spotting scopes.
• For inspection of small nearby objects. Application range from the eye of a specialist to a distance equal to or less than 250 mm. Devices used: magnifiers, microscopes.

Visual control of welds is also required in conditions unsuitable for the work of the human senses. In such areas as: elevated temperatures, dangerous radiation background, external chemically active environment and others. And also in conditions when the configuration of the object under study and its design does not allow to fully analyze the quality and measure the defects of welds (for example, due to the high height of the object or its underground location). Then, in addition to optical instruments for the search and analysis of hidden objects, the following are used:

• remote control platforms;
• thermal imaging installations;
• lighting devices;
• automatic systems transportation;
• controlled robots.

Thus, visual information converters make it possible to control the welding seams of a hot metal pool during the remelting process.

Measuring control is an important component of the VIC, which is carried out in accordance with strict rules control and normative documents regulating quality. It consists in assigning a category or type to a defect according to one of the characteristics in the form of a specific physical quantity obtained by practical measurement. Measuring instruments and their metrological indicators are indicated in normative documents.
measuring tool

During measurement control, the following tools are used, which may be included in the mandatory set of the technical supervision inspector or supplement it:

• measuring magnifiers;
• calibration squares 90 0 curved;
• goniometers with vernier;
• calipers, height gauges and depth gauges;
• probes;
• micrometers;
• pipe wall gauges and indicator thickness gauges;
• micrometers;
• calibers;
• metal length gauge (tape measure, steel measuring rulers);
• internal micrometric and indicator gauges;
• templates: special, radius, threaded, etc.;
• UShS-2, UShS-3 (templates for the geometric parameters of the seams);
• calibration plates;
• set of special accessories.

This method of control, VIC refers to methods that can be implemented with a minimum set of tools. It consists in collecting information and is based on the qualifications of a specialist, the human factor, but allows you to draw up an act of visual inspection of welds, which is considered an objective document.

The essence of external control

The quality of the formation of welds on the surface lends itself well to evaluation by professional inspection. The characteristic “high-quality” or “not high-quality” seam is rather conditional, since this is a comparative value.

Quality control of welds and inspection of structures, pipelines, buildings is carried out in three interrelated stages.

Step-by-step procedure for holding a VIC

1. Visual (measuring) control. Preliminary control of the seam for corrosion and possible defects with primitive measurements: width, thickness, leg.
2. Quality control of welded joints. Quality control is carried out to clarify the parameters of visible defects (after the conclusion of an act on preliminary examination), the size of defects and distortions of welds (percentage deviation from the permissible norm).
3. Detailed (instrumental) examination and recording of results. More precise methods are used:

• eddy current method for determining the degree of wear of the weld and metal fatigue on bends;
• ultrasonic testing of welded joints to detect serious deep defects;
• capillary flaw detection for surface and through defects and so on.

Timely and high-quality inspections make it possible to detect at an early stage the destruction of a seam or a marriage of weldability and, after that, to clarify the causes of the defect by any non-destructive method of flaw detection.

Advantages and disadvantages of this technique

Advantages of the VIC method:

1. A simple and affordable method.
2. When collecting information about the quality of the design, it allows you to get up to 50% of the total volume.
3. Not labor-intensive and does not require expensive equipment.
4. Easily tested and re-tested.

Disadvantages of VIC:

1. The human factor that affects 100% of the results.
2. Low reliability of the obtained results, subjectivity.
3. It is used only to search for large defects (at least 0.1 - 0.2 mm) and suspicions of possible ones.
4. The study is limited to only the visible part of the structure.
5. The technical literacy of employees is important, who must correctly select the measurement methodology, comparative template or standards and give an accurate assessment of the measurement results.

According to the method and quality of diagnostics, even imperfect visual inspection of seams is a necessary method, both at the stage of complex diagnostics, and throughout the entire technological process.
Universal Welding Template

Possibilities of the method for detecting defects

Welds are subjected to visual inspection:

1. when performing surfacing work at the stage of "acceptance - delivery", an act of visual inspection is mandatory;
2. when testing a multilayer welded joint (layer-by-layer testing);
3. during the final inspection of the places where the welding arc touches the surface of the base material.
4. when assembling parts from assembly units under;
5. in the automatic production of welded parts and technical evaluation of the quality of the material according to technical process;
6. after due date operation of welds.

Visual control of welds requires mandatory measurement and elimination of the following defects:

• surface cracks;
• visible gross defects;
• poor quality of metal cleaning in welding zones (especially technological fasteners),

as well as control and confirmation of the presence of:

• branding (marking) of the seam and the fidelity of its production;
• width and height of the seam, convexity and concavity of the seam;
• the correct dimensions of the legs of the fillet weld.

Detectable Defects

When examining welds with the naked eye, one can evaluate:

• uneven height and width of the seams;
• excessive scaly;
• influxes;
• undercuts;
• excessive strengthening or weakening of the seams;
• not brewed craters;
• burns;
• parameters of fillet weld legs.

Magnifiers and microscopes allow you to detect: - a mandatory step in working with metal.

Turning of metal sheets and parts is used with the help of special equipment. Read more about this.

Do you need high-quality and fast cutting of metal? Effective method described in the link.

Areas of implementation of this methodology

External inspection of the weld is carried out before the cleaning, heat or treatment procedure, as well as after its implementation.

When assessing the quality of a weld, VIC is used:

1. As an informative method of describing the general external state.
2. As a theoretical method for evaluating the internal condition of a weld and as a reason to recommend a more accurate inspection.
3. As an evaluating method for the operating conditions of a given seam, structure, system and the entire product.
4. As a control method of detection gross violations technological process.
5. As a method for pre-trial detention during decommissioning or fixation emergency.
6. As a predictive method of possible places of destruction of structures for a specific set of visible defects found.
7. As a final method for assessing and concluding about the correctness, safety and stability of the technological process of manufacturing or repairing a structure.

Visual and measurement control is a very effective method of checking and re-checking the quality of industrial materials and welded joints when performing construction works and upon receipt of an act of completion of construction, an act of commissioning, as well as various other technical acts.

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REGULATION of the Gosgortekhnadzor of the Russian Federation dated 11-06-2003 92 ON APPROVAL OF INSTRUCTIONS FOR VISUAL AND MEASURING CONTROL (2020) Relevant in 2018

ACT OF VISUAL AND/OR MEASURING QUALITY CONTROL OF WELDED SEAMS DURING JOINT WELDING

______________________ (organization) ACT N _____ from __________ visual and / or measuring quality control of welds in the process of welding a joint __________________________________________________________________ (product name and joint number) (see the welding form), type (types) of joints made by _____________________________________________________ indicate the welding method and position in accordance with the requirements of the welding technology __________________ __________________________________________________________________ indicate the code of the technology and unavailable for control ______________________________________ indicate the method of control prescribed by _________________________________________________________________ design documentation 2. With layer-by-layer visual and measurement control with quality assessment according to the standards _________________________________ for category __________________________________________________________________ (code or name of ND) it was found that the welded joint was recognized as fit and meets the requirements of ____________________________________________ (specify ND or design documentation) The control was performed by: _______________________________________________ Level of qualification, Surname, initials, signature N of the qualification certificate Supervisor of works on visual and measuring control: ________________________________________________________ Surname, initials, signature Note. The act is drawn up for each welded structure (joint or group of joints) subjected to control during the welding process. Requirements for the execution of the "Dimension Protocol _____________" (product) The protocol of dimensions is drawn up only if it is indicated in the RD or PKD for the controlled product. The protocol of product dimensions (table) must contain the actual dimensions of the product, made in certain sections, which are specified by the "Measurement Scheme _____________". The form of the Protocol (product) of dimensions is determined during the design and technological preparation of control work. The protocol is signed by the persons who performed the measurements and the head of the work on visual and measurement control, indicating the surname and initials. Requirements for the content of the "Journal of work and registration of the results of visual and measurement control" The results of control of products, products and objects are recorded in the "Journal of work and registration of the results of visual and measurement control", which indicates: 1) name and type (type) of controlled object, its number or code; 2) the location and, if necessary, the size of the controlled areas at the control object; 3) conditions for conducting control; 4) production control document, its number; 5) the method of measuring control and the instruments (tools) used; 6) brand and batch number of the material of the control object, as well as the designation of the standard or technical specifications for the material and the drawing number of the object (the latter only for parts and assembly units); 7) the main characteristics of the defects identified during the inspection (shape, size, location or orientation relative to the base axes or inspection surfaces); 8) name or ND code, according to which the quality assessment was carried out; 9) assessment of control results; 10) date of control. Note. It is allowed to use instead of the above other forms of documents developed by the organization in accordance with the requirements of the current regulatory and technical documentation, which provide identification and traceability of parts, assemblies, products in the manufacturing process (installation, repair), fixation of controlled parameters, volumes and methods of control, registration of reporting and accounting documentation for visual and measuring control.

ACT No. _____ from __________ visual and / or measuring quality control of welds in the process of welding a joint

________________________________________________________________________ (product name and connection number)

1. This act certifies the fact that the welder has fulfilled ______________________________________________________________________ full name, brand

Connections _________ (see welding list), connection type(s)

Completed by _________________________________________________________ indicate the method of welding and the position

In accordance with the requirements of the welding technology ______________________ ________________________________________________________________________ specify the technology code

And inaccessible to control __________________________________________ indicate the method of control prescribed

Design documentation

2. In case of layer-by-layer visual and measuring control with quality assessment according to the standards _____________________________________ for category ____________________________________________________________________________ (code or name of ND)

It has been established that the welded joint is recognized as fit and meets the requirements of __________________________________________________________ (specify RD or design documentation)

The control was carried out by: _________________________________________________ Level of qualification, Surname, initials, signature No. qualification certificate

Head of work on visual and measuring control: ______________________________________________________________ Surname, initials, signature

Note. The act is drawn up for each welded structure (joint or group of joints) subjected to control during the welding process.

Requirements for the execution of the "Protocol of dimensions _____________" (product)

The protocol of dimensions is drawn up only if it is indicated in the ND or PKD for the controlled product. The protocol of product dimensions (table) must contain the actual dimensions of the product, made in certain sections, which are specified by the "Measurement Scheme ____________". The form of the Protocol of dimensions is determined by (product)

During the design and technological preparation of control works. The protocol is signed by the persons who performed the measurements and the head of the work on visual and measurement control, indicating the surname and initials.

Requirements for the content of the "Journal of accounting for work

and registration of the results of visual

and measuring control"

The results of the control of products, products and objects are recorded in the "Journal of accounting for work and registration of the results of visual and measurement control", which indicates:

1) name and type (type) of the controlled object, its number or code;

2) the location and, if necessary, the size of the controlled areas at the control object;

3) conditions for conducting control;

4) production control document, its number;

5) the method of measuring control and the instruments (tools) used;

6) brand and batch number of the material of the control object, as well as the designation of the standard or technical specifications for the material and the drawing number of the object (the latter only for parts and assembly units);

7) the main characteristics of the defects identified during the inspection (shape, size, location or orientation relative to the base axes or inspection surfaces);

8) name or ND code, according to which the quality assessment was carried out;

9) assessment of control results;

10) date of control.

Note. It is allowed to use instead of the above other forms of documents developed by the organization in accordance with the requirements of the current regulatory and technical documentation, which provide identification and traceability of parts, assemblies, products in the manufacturing process (installation, repair), fixation of controlled parameters, volumes and methods of control, registration of reporting and accounting documentation for visual and measuring control.

To assess the quality of welded joints, the concept of a control welded joint is established. A control weld is considered to be a welded joint that is identical to the controlled production welded joints: the steel grades of the elements to be joined, their thickness and diameter, the type and design of the joint, and the shape of the groove must be the same. When testing joints of the same type, the thickness and diameter of the control welded joint must correspond to one of the standard sizes of welded joints. The technological process for making a control welded joint must comply with technological process used in the manufacture of controlled fittings or when connecting it to a pipeline. The same welding method, in the same position, the same welding consumables, the same brand and the same diameter, under the same modes, with the same heating, with the same heat treatment, etc. welded joints must be performed in the same period of time as the production welded joints controlled by them, by the same welder, on the same equipment and using the same technology, under the supervision of specially designated responsible persons.

Heat treatment of control compounds should be carried out together with the product (during general heat treatment in a furnace), and if this is not possible, separately using heating and cooling methods and temperature conditions established by the PDD for production connections. If the controlled welded joints are subjected to repeated heat treatment, then the control joint must also undergo the same number of heat treatments in the same modes. If the production connection has been subjected to repeated high tempering, then the control connection can be subjected to a single tempering with a holding time of at least 80% of the total holding time for all high temperings of the production connection.

The control welded joint must be inspected to the extent of 100% by the same non-destructive testing methods that are provided for production welded joints. In case of unsatisfactory results of the control, the control compounds should be made again in a double quantity. If on repeated non-destructive testing unsatisfactory results are obtained, then the overall result is considered unsatisfactory. In this case, the quality of materials, equipment and qualifications of the welder must be subjected to additional checks.

All welded joints must be branded or otherwise symbol, allowing you to set the name of the welder who made this connection.