Weld Indication and Pressure to Release for Hydrotest
You are a certified welding inspector on a fuel terminal pipe replacement. A 6-inch carbon steel girth weld is examined by magnetic particle testing. You find a 10 mm linear indication at the weld toe, oriented transverse to the weld. The project specification invokes ASME B31.3 Normal Fluid Service and requires 100% MT of finished girth welds. The contractor's QC inspector says the indication is 'surface only' and proposes to blend it with a grinder and paint over it. No repair procedure has been submitted, and no re-examination is planned. The client's construction manager tells you the line is scheduled for hydrotest tomorrow and asks you to record the weld as 'acceptable after dressing' in your report. The weld is in a pipe rack where rework would add two days and require a crane. You have not yet signed the report.
1. What should you do about the indication, and what does the code/specification require?
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Do not accept the weld on a verbal dressing proposal. A 10 mm linear indication at the weld toe is a relevant indication under MT; B31.3 requires evaluation against the acceptance criteria for the service and, if unacceptable, repair or engineering evaluation. Grinding may be an acceptable repair method only with an approved procedure, controlled depth, and re-examination by MT after blending. Painting over an unevaluated indication conceals it. I would mark the weld as rejected pending repair, issue a nonconformance, and require a repair procedure and re-test. The hydrotest schedule does not change the acceptance criteria.
2. The construction manager says 'just record it as dressed and we will fix it later if the hydrotest leaks.' How do you respond?
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Refuse. A hydrotest is not a substitute for weld acceptance, and a report that says 'acceptable' would be false. Recording a known relevant indication as accepted after an unverified dressing would mislead the owner and the authority having jurisdiction. If the weld is repaired later, the record would not match the as-built condition. I would document the request in the inspection log and escalate to the client's quality manager. My signature must reflect what I actually verified.
3. What documentation should the final report contain for this weld?
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The report should identify the weld number, drawing/line number, examination method and technique, the 10 mm linear indication, the acceptance criteria, the nonconformance number, the repair procedure reference, grinder depth checks if applicable, and the re-examination results after repair. It should include the date, inspector certification, and equipment calibration. If repair is pending, the report should state 'rejected-repair required,' not 'accepted.' The final turnover package should include the repair record and re-test, so the as-built traceability is complete.