Radiography
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Radiographic Film Interpretation of Welds ASNT Saudi Arabian Section Jim Carswell & Tom Scales
RTFI Presentation Outline Morning 8:00am – 12:00noon •Interpretation/perception •Radiography •Welding processes •Appearance and classification of defects •Review acceptance criteria: ASME B31.1 API 1104 AWS D1.1
Afternoon 1:00pm – 4:00pm •Interpret radiographs
This presentation reviews the process of detecting, classifying and evaluating to acceptance criteria discernable defects on radiographic film.
Factors affecting Interpretation •Heredity, Genetics and visual perception •Perception •Distortion •Illusion – (machs effect) •Detection
Perception
Distortion
Illusion
Detection
How many faces can you detect?
There are eleven faces Scoring: 1-4 8 9 10 11
average extraordinary above average very observant extremely observant
Factors affecting Interpretation •
Heredity/Genetics and visual perception
• Condition of the human eye • •
Eye examinations 20/40 Wear your glasses/contacts, if scratched – replace.
Factors affecting Interpretation • •
Heredity/Genetics and visual perception Condition of the human eye
•
Equipment • • •
Viewer/densitometer Viewing conditions Tools
Factors affecting Interpretation • • •
Heredity/Genetics and visual perception Condition of the human eye Equipment
•
Film and radiographic techniques •
Discussing throughout
When in doubt 2nd opinion Re-shoot or G/R/S
Radiography
Contact - DWSV
Elliptical - DWDV
Single wall single view
Radiographic film
Film processing
Results: good technique
WELDING Joining materials (coalescence)
Terminology
Basic Weld Joints
Design factors: cost, code requirement
Common Weld joints: V groove and Butt
Knowing the weld position and number of passes helps the interpreter anticipate the location of defects
Welding/Joining Processes •Oxyacetylene •Shielded metal arc (SMAW) •Gas metal arc (GMAW) •Gas tungsten arc (GTAW) •Submerged arc (SAW) •Electro slag (ESW) •Flux cored arc (FCAW) •Stud (SW) •Electron beam •Explosive •Brazing •Torch, furnace, induction, resistance, dip, infrared and diffusion •Soldering
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)
Shielded Metal Arc Welding (SMAW) Electric arc between the flux covered electrode and the base metal
Benefits of the electrode coating •Arc stabilization •Provides gas shielding – decomposition of cellulose and limestone •De-oxidation of weld pool •Strengthens the weld – alloying elements •Increases deposition – adds filler •Oxide barrier for solidifying metal - slag •Thermal insulation of the cooling weld
Common defects associated with SMAW Porosity Cracks Slag Incomplete fusion Incomplete penetration Burn through Lack of fill Root concavity Undercut Excessive penetration
•The SMAW process is almost totally operator dependant
Gas Metal Arc Welding (GMAW) Electric arc between a continuously fed solid wire consumable and the base metal
Common defects associated with GMAW Porosity Cracks Incomplete fusion Undercut lack of fill Incomplete penetration
•The GMAW process is automated, semi-automated and machine.
Gas Tungsten Arc Welding (GTAW) Electric arc between a tungsten electrode, a solid wire consumable and the base metal.
Common defects associated with GTAW Porosity Tungsten inclusions Cracks Incomplete fusion Undercut
•The GTAW process is almost totally operator dependant
Submerged Arc Welding (SAW) Electric arc between a continuously fed solid wire consumable and the base metal submerged in a protective flux.
Common defects associated with SAW Porosity Cracks Slag Incomplete fusion
The GMAW process is automated, semi-automated and machine.
WELDING DEFECTS
Defects cause stress which can result in joint failure
Common causes of defects •Welder-technique •Cleaning •Joint preparation •Joint design
Welding technique
Cleaning (Porosity, Fusion, Tungsten & Slag)
Cleaning - slag removal
Joint preparation - poor fit-up (Fusion, Penetration & Mismatch - Hi-Lo)
POROSITY
Causes: •Contamination •Moisture •Environment – wind, etc.
Porosity
Porosity
Cluster Porosity
Cluster Porosity
Aligned Root-Pass Porosity
Aligned Root-Pass Porosity
Hollow Bead
Incomplete Fusion
Causes: •Incomplete penetration of arc •Inadequate welding current •Poor joint fit-up
Incomplete Penetration
Cause: •Poor joint design •Welding technique
Incomplete Penetration
Incomplete Penetration
Incomplete Penetration
Incomplete Penetration
Cracks
Causes: •Stress - thermal/mechanical •Welding technique •Electrode material (wrong alloy)
Transverse Cracks
Transverse Cracks
Longitudinal Root Crack
Longitudinal Root Crack
Slag Inclusions
Causes: •Non-removal •Welding technique
Elongated Slag
Elongated Slag
Interpass Slag
Interpass Slag
Burn Through
Cause: •Welding technique •Poor joint fit-up
Burn Through
Burn Through
Root Concavity
Cause: •Welding technique •Poor joint fit-up
Root Concavity
Root Concavity
Undercut
Cause: •Welding technique – excessive heat
Internal Undercut
Internal Undercut
External Undercut
External Undercut
Excessive Penetration
Cause: •Welding technique – excessive arc penetration •Poor joint fit-up
Excessive Penetration
Excessive Penetration
Lack of Fill
Cause: •Welding technique
Lack of Fill
Lack of Fill
Tungsten Inclusions
Cause: •Welding technique
Tungsten Inclusions
Tungsten Inclusions
Mismatch – Hi Low
Cause: •Poor joint fit-up
Mismatch
Mismatch
Weld Spatter Cause: •Poor joint fit-up •Welding technique
Miscellaneous
Excessive Weld Ripples
Unconsumed Insert
Oxidized Root
Film Handling And Processing Defects Scratches Finger prints Crimp marks Light Leaks Chemical Stains Roller Marks & Artifacts
Scratches
Chemical Stains
Light Leaks
Static Marks
Store film upright
Artifacts
Water marks
Crimp marks
CODES & STANDARDS in the petrochemical industry
What is the purpose for Codes & Standards? They ensure uniform practices throughout industry
Three common codes used in Saudi Arabia’s petrochemical industry ASME B31.3 Boiler and Pressure Vessel Code API 1104 Welding of Pipelines And Related Facilities
AWS D1.1 Structural Welding Code - Steel
ASME B31.3 and Appendix 4 Film interpretation acceptance criteria for Process Piping “onplot” facilities
API 1104
Film interpretation acceptance criteria for pipelines
AWS D1.1 Film interpretation acceptance criteria for structures
END
Radiographic Film Interpretation of Welds ASNT Saudi Arabian Section Jim Carswell & Tom Scales
RTFI Presentation Outline Morning 8:00am – 12:00noon •Interpretation/perception •Radiography •Welding processes •Appearance and classification of defects •Review acceptance criteria: ASME B31.1 API 1104 AWS D1.1
Afternoon 1:00pm – 4:00pm •Interpret radiographs
This presentation reviews the process of detecting, classifying and evaluating to acceptance criteria discernable defects on radiographic film.
Factors affecting Interpretation •Heredity, Genetics and visual perception •Perception •Distortion •Illusion – (machs effect) •Detection
Perception
Distortion
Illusion
Detection
How many faces can you detect?
There are eleven faces Scoring: 1-4 8 9 10 11
average extraordinary above average very observant extremely observant
Factors affecting Interpretation •
Heredity/Genetics and visual perception
• Condition of the human eye • •
Eye examinations 20/40 Wear your glasses/contacts, if scratched – replace.
Factors affecting Interpretation • •
Heredity/Genetics and visual perception Condition of the human eye
•
Equipment • • •
Viewer/densitometer Viewing conditions Tools
Factors affecting Interpretation • • •
Heredity/Genetics and visual perception Condition of the human eye Equipment
•
Film and radiographic techniques •
Discussing throughout
When in doubt 2nd opinion Re-shoot or G/R/S
Radiography
Contact - DWSV
Elliptical - DWDV
Single wall single view
Radiographic film
Film processing
Results: good technique
WELDING Joining materials (coalescence)
Terminology
Basic Weld Joints
Design factors: cost, code requirement
Common Weld joints: V groove and Butt
Knowing the weld position and number of passes helps the interpreter anticipate the location of defects
Welding/Joining Processes •Oxyacetylene •Shielded metal arc (SMAW) •Gas metal arc (GMAW) •Gas tungsten arc (GTAW) •Submerged arc (SAW) •Electro slag (ESW) •Flux cored arc (FCAW) •Stud (SW) •Electron beam •Explosive •Brazing •Torch, furnace, induction, resistance, dip, infrared and diffusion •Soldering
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)
Shielded Metal Arc Welding (SMAW) Electric arc between the flux covered electrode and the base metal
Benefits of the electrode coating •Arc stabilization •Provides gas shielding – decomposition of cellulose and limestone •De-oxidation of weld pool •Strengthens the weld – alloying elements •Increases deposition – adds filler •Oxide barrier for solidifying metal - slag •Thermal insulation of the cooling weld
Common defects associated with SMAW Porosity Cracks Slag Incomplete fusion Incomplete penetration Burn through Lack of fill Root concavity Undercut Excessive penetration
•The SMAW process is almost totally operator dependant
Gas Metal Arc Welding (GMAW) Electric arc between a continuously fed solid wire consumable and the base metal
Common defects associated with GMAW Porosity Cracks Incomplete fusion Undercut lack of fill Incomplete penetration
•The GMAW process is automated, semi-automated and machine.
Gas Tungsten Arc Welding (GTAW) Electric arc between a tungsten electrode, a solid wire consumable and the base metal.
Common defects associated with GTAW Porosity Tungsten inclusions Cracks Incomplete fusion Undercut
•The GTAW process is almost totally operator dependant
Submerged Arc Welding (SAW) Electric arc between a continuously fed solid wire consumable and the base metal submerged in a protective flux.
Common defects associated with SAW Porosity Cracks Slag Incomplete fusion
The GMAW process is automated, semi-automated and machine.
WELDING DEFECTS
Defects cause stress which can result in joint failure
Common causes of defects •Welder-technique •Cleaning •Joint preparation •Joint design
Welding technique
Cleaning (Porosity, Fusion, Tungsten & Slag)
Cleaning - slag removal
Joint preparation - poor fit-up (Fusion, Penetration & Mismatch - Hi-Lo)
POROSITY
Causes: •Contamination •Moisture •Environment – wind, etc.
Porosity
Porosity
Cluster Porosity
Cluster Porosity
Aligned Root-Pass Porosity
Aligned Root-Pass Porosity
Hollow Bead
Incomplete Fusion
Causes: •Incomplete penetration of arc •Inadequate welding current •Poor joint fit-up
Incomplete Penetration
Cause: •Poor joint design •Welding technique
Incomplete Penetration
Incomplete Penetration
Incomplete Penetration
Incomplete Penetration
Cracks
Causes: •Stress - thermal/mechanical •Welding technique •Electrode material (wrong alloy)
Transverse Cracks
Transverse Cracks
Longitudinal Root Crack
Longitudinal Root Crack
Slag Inclusions
Causes: •Non-removal •Welding technique
Elongated Slag
Elongated Slag
Interpass Slag
Interpass Slag
Burn Through
Cause: •Welding technique •Poor joint fit-up
Burn Through
Burn Through
Root Concavity
Cause: •Welding technique •Poor joint fit-up
Root Concavity
Root Concavity
Undercut
Cause: •Welding technique – excessive heat
Internal Undercut
Internal Undercut
External Undercut
External Undercut
Excessive Penetration
Cause: •Welding technique – excessive arc penetration •Poor joint fit-up
Excessive Penetration
Excessive Penetration
Lack of Fill
Cause: •Welding technique
Lack of Fill
Lack of Fill
Tungsten Inclusions
Cause: •Welding technique
Tungsten Inclusions
Tungsten Inclusions
Mismatch – Hi Low
Cause: •Poor joint fit-up
Mismatch
Mismatch
Weld Spatter Cause: •Poor joint fit-up •Welding technique
Miscellaneous
Excessive Weld Ripples
Unconsumed Insert
Oxidized Root
Film Handling And Processing Defects Scratches Finger prints Crimp marks Light Leaks Chemical Stains Roller Marks & Artifacts
Scratches
Chemical Stains
Light Leaks
Static Marks
Store film upright
Artifacts
Water marks
Crimp marks
CODES & STANDARDS in the petrochemical industry
What is the purpose for Codes & Standards? They ensure uniform practices throughout industry
Three common codes used in Saudi Arabia’s petrochemical industry ASME B31.3 Boiler and Pressure Vessel Code API 1104 Welding of Pipelines And Related Facilities
AWS D1.1 Structural Welding Code - Steel
ASME B31.3 and Appendix 4 Film interpretation acceptance criteria for Process Piping “onplot” facilities
API 1104
Film interpretation acceptance criteria for pipelines
AWS D1.1 Film interpretation acceptance criteria for structures
END
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