RTFI Assessment Presentation 5-23-05

Assessment of Radiographic Film Interpretation

Jim Carswell

Presentation Outline

Morning 8:00am 11:00 Interpretation/perceptionReviewRadiographyWelding processesAppearance and classification of defectsScenarios

Afternoon 1:00pm 3:00pmReview acceptance criteria: ASME B31.1, API 1104 AWS D1.1

This presentation reviews the process of conducting radiographic film assessments on Saudi Aramco Projects.

Objective: Maintain Continuity of Film Assessors

Getting StartedAttitude & professionalism

Fair but firm

Make Sure you are right! second opinion before you make the call

Factors affecting Interpretation

Heredity/Genetics and visual perception Can you see it? What do you see? PerceptionDistortionIllusionDetection

Perception

Distortion

Illusion

DetectionHow many faces can you detect?

There are eleven faces

Scoring:

1-4 average8 extraordinary9 above average10 very observant11 extremely observant


Heredity/Genetics and visual perceptionCondition of the human eyeEye examinations 20/40Wear your glasses/contacts, if scratched replace.


Heredity/Genetics and visual perception Condition of the human eye EquipmentViewer/densitometerViewing conditionsTools


Heredity/Genetics and visual perception Condition of the human eye Equipment Film and radiographic techniquesDiscussing throughout

When in doubt Ask for 2nd opinionRe-shootGrind & re-shoot

Radiography

Contact - DWSV

Elliptical - DWDV

Single wall single view

Radiographic film

Film processing

Results: good technique

WELDINGJoining materials at the atomic/molecular level

Terminology

Five Basic Weld Joints

Shielded Metal Arc Welding(SMAW) Welding is generated by an electric arc established between the flux covered electrode and the base metal and melts the two together.

Benefits of the electrode coating

Arc stabilizationProvides gas shielding decomposition of cellulose and limestoneDe-oxidation of weld poolStrengthens the weld - adds alloying elementsIncreases deposition by adding iron filler Slag provides oxide barrier for solidifying metalSlag provides thermal insulation of the cooling weld

Common defects associated with SMAW

PorosityCracksSlagIncomplete fusionIncomplete penetrationBurn throughLack of fillRoot concavity UndercutExcessive penetration

The SMAW process is almost totally operator dependant

Gas Metal Arc Welding(GMAW) Welding is generated by an electric arc between a continuously fed solid wire consumable and the base metal

Common defects associated with GMAW

PorosityCracksIncomplete fusionUndercutlack of fillIncomplete penetration

The GMAW process is automated, semi-automated and machine.

Gas Tungsten Arc Welding(GTAW) Welding is generated by an electric arc between a tungsten electrode, a solid wire consumable and the base metal.

Common defects associated with GTAW

PorosityTungsten inclusionsCracksIncomplete fusionUndercut

The GTAW process is almost totally operator dependant

Submerged Arc Welding(SAW) Welding is generated by an electric arc between a continuously fed solid wire consumable and the base metal while totally submerged in a protective flux.

Common defects associated with SAW

PorosityCracksSlagIncomplete fusion

The GMAW process is automated, semi-automated and machine.

WELDING DEFECTS

Common causes of defects

Welder-techniqueCleaningJoint preparationJoint design

Welding technique

Cleaning(Porosity, Fusion, Tungsten & Slag)

Cleaning - slag removal

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

POROSITY

Causes:ContaminationMoistureEnvironment wind, etc.

Porosity

Incomplete fusion - Sidewall

Incomplete Penetration

Longitudinal Root Crack

Interpass Slag

Burn Through

Cause:Welding techniquePoor joint fit-up

Burn Through

Root Concavity

Cause:Welding techniquePoor joint fit-up

Root Concavity

Undercut

Cause:Welding technique excessive heat

Internal Undercut

External Undercut

Excessive Penetration

Cause:Welding technique excessive arc penetrationPoor joint fit-up

Excessive Penetration

Lack of Fill

Cause:Welding technique

Lack of Fill

Tungsten Inclusion

Cause:Welding technique

Tungsten Inclusions

Mismatch - Hi low

Cause:Poor joint fit-up

Mismatch

Weld Spatter

Cause:Poor joint fit-upWelding technique

Miscellaneous

Film Handling And Processing DefectsScratches 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 andAppendix 4Film interpretation acceptance criteria for Process Piping on-plot facilities

API 1104Film interpretation acceptance criteria for pipelines

AWS D1.1Film interpretation acceptance criteria for structures

Conducting Film AssessmentsGetting Started:

Attitude & professionalismFair but firmMake Sure you are right! second opinion before you make the call

Film AssessmentsQuality System

Obtain a copy of the Purchase Order or applicable legal document for each assessment (project)Highest document in the pyramidAgreement that binds two partiesSchedule Q & SAEP 1150Determine the applicable Codes and revisions for the project


Approved personnel Valid Saudi Aramco RTFI cardCompany certificationVisual acuity examinationJaeger #1 & Ishara color platesApproved NDT procedures approval letter from NDTU for each project


Condition of Equipment SourcesFilm Processing tanks, dryer, chemicals, timers, time/temperature conversion chartsIQIs number belts ect.Film ViewersFacility

Film AssessmentsFilm Quality - Guidelines

Many things make up film qualityDensity, Sensitivity, IQI, ID, F, scratches, crimp marksDensity of weld is 2-4 & Parent material over 4.0Sensitivity wire not required across entire weldIQI damage bent, touching or crossing

Film AssessmentsFilm Quality - Guidelines

ID - traceable with all required information F for film-side techniquesScratches & crimp marksBlack letter B NOT requiredWeld spatter use one inch to verify acceptability

Film AssessmentsWeld Quality - Guidelines

If the measurement it is on the line give it to themWhen in doubt ask for a second opinion or re-shoot Use film digitizer for close callsStay on solid ground

Film AssessmentsWeld Quality - Guidelines

Use Acc/Rej straight from the applicable code avoid second-hand documents.

Ethics Discussion recent unethical findings of NDT contractorDuplication of radiographsNDT technicians not certifiedConflict of interest

Getting StartedAttitude & professionalism

Fair but firm

Make Sure you are right! second opinion before you make the call

Documents

RTFI Assessment Presentation 5-23-05