Aramco-RTFI Presentation 10-1-21

5/22/2018 Aramco-RTFI Presentation 10-1-21

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R

Radiographic Film

Interpretation of Welds

ASNT

Saudi Arabian Section

Jim Carswell


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RTFI Presentation Outline

Morning8:00am 12:00noon

Interpretation/perception

Welding processes

Appearance and classification of defects

Review acceptance criteria:ASME B31.1

API 1104

AWS D1.1

Interpret radiographs

Afternoon1:00pm 4:00pm

Interpret radiographs


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This presentation reviews the

process of detecting, classifying

and evaluating to acceptance

criteria discernable defects onradiographic film.


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Factors affecting Interpretation

Heredity/Genetics and visual perceptionCan you see it?

What do you see?

Perception

Distortion

Illusion

Detection


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Perception


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Distortion


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Illusion


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Detection

How many faces can you detect?


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There are eleven faces

Scoring:

1-4 average

8 extraordinary9 above average

10 very observant

11 extremely observant


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Heredity/Genetics and visual perception

Condition of the human eye Eye examinations 20/40

Wear your glasses/contacts, if scratched

replace.


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Condition of the human eye

Equipment Viewer/densitometer

Viewing conditions

Tools


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Condition of the human eye

Equipment

Film and radiographic techniques

Discussing throughout


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When in doubt

Ask for 2nd opinion

Re-shoot

Grind & re-shoot


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Radiography


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Contact - DWSV


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Elliptical - DWDV


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Single wall single view


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Radiographic film


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Film processing


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Results: good technique


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WeldingJoining materials at the atomic/molecular level


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Welding equipment

Welding is generated by an electric arc


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Terminology


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Five Basic Weld Joints


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Common Welding Processes Used

In The Petrochemical Industry

SMAW(Shielded Metal Arc Welding)

GMAW(Gas Metal Arc Welding)

GTAW(Gas Tungsten Arc Welding)

SAW(Submerged Arc Welding)


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Shielded Metal Arc Welding(SMAW)

Welding is generated by an electric arc establishedbetween the flux covered electrode and the base

metal and melts the two together.


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Benefits of the electrode coating

Arc stabilization

Provides gas shielding decomposition of

cellulose and limestoneDe-oxidation of weld pool

Strengthens the weld - adds alloying elements

Increases deposition by adding iron filler

Slag provides oxide barrier for solidifying metal

Slag provides thermal insulation of the cooling weld


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Common defects associated

with SMAWPorosity

Cracks

SlagIncomplete fusion

Incomplete penetration

Burn through

Lack of fill

Root concavity

Undercut

Excessive penetration

The SMAW process is almost totally operator dependant


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Gas Metal Arc Welding(GMAW)

Welding is generated by an electric arcbetween a continuously fed solid wire

consumable and the base metal


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with GMAWPorosity

Cracks

Incomplete fusionUndercut

lack of fill

Incomplete penetration

The GMAW process is automated, semi-automated and

machine.


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Gas Tungsten Arc Welding(GTAW)

Welding is generated by an electric arcbetween a tungsten electrode, a solid wire

consumable and the base metal.


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with GTAWPorosity

Tungsten inclusions

CracksIncomplete fusion

Undercut

The GTAW process is almost totally operator dependant


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Submerged Arc Welding(SAW)

Welding is generated by an electric arcbetween a continuously fed solid wireconsumable and the base metal whiletotally submerged in a protective flux.


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with SAWPorosity

Cracks

SlagIncomplete fusion

The GMAW process is automated, semi-automated and

machine.


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Welding Defects


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Common causes of defects

Welder-technique

Cleaning

Joint preparationJoint design


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Welding technique


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Cleaning(Porosity, Fusion, Tungsten & Slag)


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Cleaning - slag removal


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Joint preparation - poor fit-up(Fusion, Penetration & Mismatch - Hi-Lo)


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POROSITY

Causes:

Contamination

MoistureEnvironment wind, etc.


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Porosity


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Porosity


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Cluster Porosity


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Cluster Porosity


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Aligned Root-Pass Porosity


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Hollow Bead


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Incomplete Fusion

Causes:

Incomplete penetration of arcInadequate welding current

Poor joint fit-up


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Incomplete fusion - Sidewall


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Incomplete Penetration

Cause:Poor joint design

Welding technique


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I l t P t ti


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Mismatch - Hi low

Cause:Poor joint fit-up


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Mismatch


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Mismatch

Mismatch


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Mismatch


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Cracks

Causes:

Stress - thermal/mechanical

Welding techniqueElectrode material (wrong alloy)

Transverse Cracks


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Transverse Cracks

Transverse Cracks


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Transverse Cracks


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Longitudinal Root Crack


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Slag Inclusion

Causes:

Non-removal

Welding technique


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Interpass Slag


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Interpass Slag

Interpass Slag


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Interpass Slag


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Burn Through

Cause:

Welding technique

Poor joint fit-up

Burn Through


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Burn Through

Burn Through


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Burn Through


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R t C it


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Root Concavity

Cause:

Welding technique

Poor joint fit-up


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Root Concavity


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Root Concavity

Root Concavity


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Root Concavity

U d t


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Undercut

Cause:Welding technique excessive heat


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Internal Undercut


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Internal Undercut


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External Undercut


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External Undercut


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Excessive Penetration


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Cause:Welding technique excessive arc

penetration

Poor joint fit-up


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Lack of Fill


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Lack of Fill

Cause:Welding technique


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Lack of Fill


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Lack of Fill


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Tungsten Inclusion


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Tungsten Inclusion

Cause:Welding technique

Tungsten Inclusions


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Tungsten Inclusions


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Weld Spatter


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Weld Spatter

Cause:

Poor joint fit-up

Welding technique


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Miscellaneous


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Film Handling And Processing


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Film Handling And ProcessingDefects

Scratches

Finger prints

Crimp marksLight Leaks

Chemical Stains

Roller Marks & Artifacts


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h


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Scratches

Chemical Stains


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Chemical Stains


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Light Leaks


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Static Marks


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Store film upright

if


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Artifacts


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W k


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Water marks


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C i k


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Crimp marks


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CODES & STANDARDSin the petrochemical

industry


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What is the purpose for Codes &Standards?

They ensure uniform practices throughoutindustry

Three common codes used in SaudiA bi t h i l i d t


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Arabias petrochemical industry

ASME B31.3In-Plant Process Pipe

API 1104Welding of Pipelines And Related Facilities

AWS D1.1Structural Welding Code - Steel

ASME B31 3


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ASME B31.3

andAppendix 4

Film interpretation acceptance criteria forProcess Piping on-plot facilities


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API 1104

Film interpretation acceptance criteria forpipelines


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AWS D1.1

Film interpretation acceptance criteria forstructures


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END

Aramco-RTFI Presentation 10-1-21

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