TECHFILES

SELECTIONOFANNDTMETHODAND
THEEXTENTOFTESTING
GabrielRihar,D.Sc.,Institutzavarilstvo,Ptujska19,Ljubljana

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The 4th International Conference of Slovenian Society for Nondestructive Testing "Application of Contemporary Nondestructive Testing in
Engineering"2425April1997,Ljubljana,Slovenia.

INTRODUCTION

Each testing of welded joints should start with the selection of a suitable testing method and determination of the extent of
testing.Oneshouldbeawarethattheselectionofatestingmethodanddeterminationoftheextentoftestingareasimportant
astestingitselfwhenthefinalresultisconsidered.OwingtotheselectionofanunsuitabletestingmethodNDTmethodsoften
becomepurposeless.WhenplanningNDTtestingoneshouldtakeintoaccountanumberoffactorssuchas:

requirementsregardingreliableandsafeoperation,
qualityassurancelevelachieved,
characteristicsofweldingprocesses,propertiesofmaterialsused,
feasibilityofNDTmethodsavailable,
economiccriteria.

In the selectionof asuitable NDT method, welding technologists and NDT experts should be involved, and in determining the
extent of testing designers, who know best which are the intended operating conditions of a device to be tested and which
locationsmaybeloadedmost.

SELECTIONOFTESTINGMETHOD

TheselectionoftheNDTmethodisusuallytheconcernofNDTlaboratories,whichknowtheNDTmethodsandtheirfeasibility
in detecting defects. Regarding properties of materials and characteristics of a welding process it should be first established
what types of defects may occur and where. It should also be established which part of a structure may incur the highest
stresses.

Typesofinhomogeneity

Anexpertmay,withahighlevelofcertainty,predictwhichtypesof
defects may occur and at which locations are they most probable.
Attention should be paid to bonding defects and cracks, which are
in no case admissible. A little more toleration may be shown to
pores and nonmetal inclusions. But a careful examination of
heavilyloadedpartsofastructureshouldbecarriedout.

Hot cracks, i.e. crystallization cracks, usually occur in the middle of

the weld. Hotcracking sensibility is found in alloys, alloyed steels
andsteelscontainingahigherlevelofimpurities,usuallyinweldsof
larger dimensions. Cold cracks occur mostly in the heat affected
zone. They occur in steels susceptible to throughhardening and
hydrogenembrittlement.

A special attention should be paid to porosity in gasshielded welding, submerged arc welding, and welding with basic
electrodes.

TypicalcracksintheweldedjointandlocationoftheirappearanceisshowninFig.1.

Figure 1 - Typical weld defects

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Characteristicsoftestingmethods

Astotheirabilityofdetectingvariousgeometricalformsofdefects,theNDTmethodsappliedintestingofweldedjointsdiffer
onefromtheotherverymuch,i.e.theycomplementeachother
(1,2,3)
.Insomecasestheyareinterchangeable
(4)
.

In testing of welded joints, it is radiographic methods which are most frequently used and which permit a very reliable
detectionofthreedimensionaldiscontinuitiessuchaspores,nonmetallicinclusions,incompletepenetrationandundercutsat
the inaccessible root side. The method seems to be less reliable in detecting planar, i.e. twodimensional, defects such as
cracks.

The ultrasonic methods seem to be the most

universally applicable. They may be applied to
all types of defects but they are comparatively
complicated and sensitive to various
disturbances. They are less reliable, therefore,
they are making themselves valued in welding
veryslowly.

Simple and reliable methods are available for

detection of cracks reaching the surface.
Magnetic methods are suitable for
ferromagnetic materials, while penetrant
methodsaresuitableforallmetals.

Toolittleattentionis,however,paidtovisualinspectionwhichshouldbeperformedpriortoeachNDTexamination.Thevisual
inspectionprovidesbasicinformationonthestateofweldedjointsandthestructureconcerned.Thisisaguidelineforfurther
examinations.Fig.2schematicallyshowstheapplicationofvariousNDTmethodsintestingbuttandfilletwelds.

In addition to technical considerations, in the selection of testing

methods the cost of testing should be considered as well. The more
perfect weld is to be obtained, the more should be invested into NDT
methods(Fig.3).Fig.4showsmarketratesforNDTmethodsinSlovenia.

EXTENTOFTESTING

The extent of testing is a datum informing us what part of the total

lengthofweldedjointsandwhichlocationsistobetested.Theextentof
testingissometimesdeterminedbytheclientintheinvitationtoproject
tender, but most frequently by a designer taking into account technical
regulationsinforceandstressescalculatedforindividualweldedjoints.

PracticeinSlovenia

InthetechnicalregulationsinforceprovisionsontheminimumextentofNDTtestingofweldedjointsmaybefound.

Althoughsomeareratheroldtheyarestillinforce
(5,6)
.Theyarenotconsistentwitheachotherandtheymaybeappliedonly
tocertainfields.Anexceptionisthestandardonqualitylevelswithageneralapplicability
(7)
.

Forsteamboilersandsteamsuperheatersa30%radiographicexaminationofbuttweldsisspecified
(5)
.Withweldedstructures
theextentoftestingdependsontheweldinglocationandthejointqualityclassselected
(6)
.

Welds made in a workshop require less testing than outofposition field welds. Regarding the load and the level of
requirements,threeclassesaredistinguished:special,firstandsecond.

Figure 2 - Application of NDT Methods

Figure 3 - Ratio between control cost and weld perfection

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Theregulationsonpressurevesselsarethemostelaborateones.The
extent of testing depends on operating conditions of the vessel
(vessel class) and the type of joint and strength calculation
(8, 9, 10)
.
There are four classes of welded joints. A selection may be made
amongvariouslevelsofperfectionofweldedjoints.

A similar division into four quality classes may be found in the

general quality standard
(7)
which is applied to pipelines, with the
exception of main pipelines for liquid and gas hydrocarbons where
the extent of testing is regulated in a different way
(11)
. The latter
depends on the distance from settlements, energy facilities and
trafficroutes.

Among the methods for testing welds, the radiographic method is preferred. In older regulations other methods are not
mentioned. More recent regulations permit application of ultrasonic methods instead of radiography. Other methods are
appliedonlyasacomplement.

TableIgivesasurveyofobligatoryapplicationofNDTmethodsinSlovenia.

Table I: Survey of testing methods specified

Field of application Level of requirements Extent and method of testing
Steam boilers and steam superheaters - 30 % RT
Steel structures S
I
II
100 % RT, MT and PT if required 10-50 % RT, MT and
PT if required RT of out-of-position welds
Pipelines
JUS C.T3.010
I
II
III
IV
100% RT or VT, 100 % MT or PT
50 % RT or VT, 100 % MT or PT
10 % RT or VT, 30 % MT or PT
-
Pressure vessels I
II A
II B
III A
III B
IV A
IV B
I C
II C
I D
II D
III D
100 % RT or VT, 100 % MT or PT
70 % RT or VT, 100 % MT or PT
50 % RT or VT, 100 % MT or PT
30 % RT or VT, 30 % MT or PT
10 % RT or VT, 30 % MT or PT
no requirements
30 % MT or PT
100 % UT, 100 % MT or PT
50 % UT, 50 % MT or PT
100 % UT, 100 % MT or PT
70 % UT, 100 % MT or PT
30%UT, 30%MT or PT
Main pipelines Zone I
Zone II
Zone III
10 % RT, MT or PT if required
50 % RT, MT or PT if required
100 % RT, MT or PT if required
- For all quality levels a 100 % visual inspection is required.
- MT and PT are performed only if there is a risk of cracks.

Influenceofqualityassurance(QA)andqualitycontrol(QC)

When selectingthe extent of testing, the levelof quality assurance achieved should be taken into account. This has not been
taken into account in Slovenia till now. Also some foreign regulations known in Slovenia do not take quality assurance into
account.

Figure 4 - Standard market rates for NDT methods in Slovania

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More recent standards specify three levels of quality assurance, which
permits, when selecting the extent of testing, to give consideration also
to the level of quality assurance achieved by the performer of welding
work. The weldedjoint quality (Q) may be defined as a sum of quality
assurance(QA)andqualitycontrol(QC).

The maximum quality in the instance selected may be achieved if all

means of quality assurance available are taken into account and all NDT
methods available are applied. The relation between quality assurance
(QA)andtheextentofqualitycontrol(QC)isgraphicallyshowninFig.5.

Quality assurance requires a number of operations usually expressed by

levels. The newEuropean standard specifies elementary (I), standard (II)
andcomprehensive(III)levels
(12)
.

Thelevelselectedmaybeachievedbyahigherlevelofqualityassurance
and less control (instance a) and vice versa (instance b). Both instances
areshowninFig.6.

Similarconclusionsmaybedrawnifqualityassuranceandqualitycontrol
are considered production costs and both together quality cost. In this
casethefollowingholdstrue:

Q=QA+QC(monetaryunit)

Fig.7showsacostmodelforquality.

It may be concluded
that quality assurance and control complement each other and jointly
producequality.Inpracticebothmeans,however,arenotbalanced,whichis
shown by the model (Fig. 7). In certain cases quality assurance is a more
efficientmeansthanqualitycontrolandviceversa;therefore,eachisusedas
appropriate.

In practical applications a certain lower threshold is more and more being

taken into account; these are a welder's approval test certificate in quality
assurance and the visual examination in quality control. For pressure vessels
andloadbearingweldedstructuresthelowerthresholdisdeterminedbythe
requirements related to the issue of a certificate of qualification to the
workshopconcerned.

Proposal for determination of

theextentoftesting

When determining the extent of testing, beside requirements for reliable and
safe operation of the structure, also the level of quality assurance already
achievedbytheperformerofweldingworkshouldbeconsidered.Structuresmay
bedividedintothreeclasses,i.e.veryexacting,exacting,andlessexacting.

Theratiobetweenthelevelofqualityassuranceachieved,therequirements,and
the extent of testing may be graphically presented (Fig. 8). Table II shows how
the extent of testing may be determined as a function of the level of quality
assuranceachieved.

We have been used to standards determining quality classes as well as the

Figure 5 - Ratio between quality assurance (QA) and quality control (QC).

Figure 6 - Quality selection between QA and QC

Figure 7 - Cost model for quality.

Figure 8 - Extent of testing as a function of QA and

requirements
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minimum extent of testing. Recent standards have no such provisions because the
level of acceptance of defects, which is determined by their size and number, has
nothing to do with the extent of testing. But in any case a higher level indicates a
higherqualityoftheweldedjoint(Fig.9).QualitylevelsB,C,andDweretakenfrom
thenewEuropeanstandard
(13)
.

CONCLUSIONS

Qualityassuranceandqualitycontrolcomplementeachother.Withahigherlevelof
quality assurance the extent of testing may be reduced. The abovementioned
principle would certainly stimulate performers of welding work to invest more into
qualityassurance.

It is suggested that the abovementioned principle of determining the extent of

testingbeimplementedintheelaborationofnewSloveniantechnicalregulations.


Table II: Extent of testing as a function of QA and requirements



REFERENCES

1) IlW Guidance on Assessment of the Fitness for Purpose of Welded Structures. Doc. IIS/IlW-SST-1 157-90 (pp. 67-74, 229-296).
2) P. Klug: Quality Management in the Field of Welding.
3) H. Granjon: Metalurske osnove varjenja, Zveza drustev za varilno, tehniko Slovenije, Ljubljana 1994 (pp. 238-241).
4) Guidelines for Replacing NDE Techniques with one another. IIS/IIW Doc. V- 1062-96.
5) Pravilnik o tehnicnih predpisih za izdelavo in uporabo parnih kotlov, parnih posod, pregrevalcev pare inogrevalcev vode. Ur. 1. SFRJ st. 7-157/57.
6) Pravilnik o tehnicnih pogojih in normativih za varen transport tekocih in plinastih ogljikovodikov, clen 61. Ur. 1. SFRJ st. 26/85.
7) JUS C.T3.010: Zavarivanje i srodni postupci. Klase kvaliteta zavarenih spojeva izvedenih topljenjem na celiku.
8) Pravilnik o tehnicnih normativih za stabilne tlacne posode. Ur. 1. SFRJ st. 16/83.
9) Pravilnik o tehnicnih normativih za premicne zaprte posode za komprimirane, utekocinjene in pod tlakomraztopljene pline. Ur. 1. SFRJ st. 25/80 in 9/86.
10) JUS M.E2.159: Posude pod pritiskom. Kontrola i ispitivanje zavarenih spojeva.
11) Tehnicni predpisi o kvaliteti zvarnih spojev za nosilne jeklene konstrukcije. Ur. 1. SFRJ 19/64.
12) SIST EN 729: Zahteve po kakovosti pri varenju - Talilno varjenje kovinskih materialov
1. del: Smernice za izbiro in uporabo
2. del: Obsimejse zahteve po kakovosti
3. del: Standardne zahteve po kakovosti
4. del: Osnovne zahteve po kakovosti.
13) SIST EN 25817: Oblocni zvarni spoji na jeklu - Smernice za stopnje sprejemljivosti napak.


NDT.net, info@ndt.net
/DB:Article /DT:tutor /AU:Rihar_G /CN:LT /CT:NDT /CT:reliability /ED:1999-05


Compiled by: RANDY R. RUFINO
Metallurgist
randyrufino@gmail.com

Figure 9 - Schematic representation of quality

levels of welded joints
QA Level Requirements
Low Medium High
III 0% 25% 50%
II 0% 50% 75%
I 25% 75% 100%