R

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 average
8 extraordinary
9 above average
10 very observant
11 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
Arabias 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 on-
plot facilities
 API 1104

Film interpretation acceptance

criteria for pipelines
 AWS D1.1

Film interpretation acceptance

criteria for structures
END