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ARAMCO RTFI
Citation preview
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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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Factors affecting Interpretation
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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Factors affecting Interpretation
Heredity/Genetics and visual perception
Condition of the human eye
Equipment Viewer/densitometer
Viewing conditions
Tools
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Factors affecting Interpretation
Heredity/Genetics and visual perception
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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Common defects associated
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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Common defects associated
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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Common defects associated
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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Incomplete Penetration
Incomplete Penetration
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Incomplete Penetration
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Incomplete Penetration
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Incomplete Penetration
Incomplete Penetration
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Incomplete Penetration
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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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Longitudinal Root Crack
Longitudinal Root Crack
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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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Excessive Penetration
Cause:Welding technique excessive arc
penetration
Poor joint fit-up
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Excessive Penetration
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Excessive Penetration
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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
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