WELD DISCONTINUITY EVALUATION GUIDE

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SPECIAL NOTES

1. Radiographic films only show defects in two dimensions. Depth cannot be easily
determined by R.T.

2. 100% radiography and spot radiography are quality level designations used by the
ASME Pressure Vessel Code and can be used to evaluate other methods of NDE.

3. For API 1104, The maximum accumulation of discontinuities is 2" in any 12" of weld
or 8% of weld length excluding High-low and undercutting. (9.3.12)


Codes and Regulations

1. ASME Section VIII, Division 1. "Pressure Vessels"

2. ASME B31.3 "Chemical Plant and Petroleum Refinery Piping"

3. API 650 "Welded Steel Tanks for Oil Storage ". Now follows ASME VIII Div. 1
requirements.

4. API 1104, "Standard for Welding Pipelines And Related Facilities"

5. ASME B31.4 "Liquid Transportation System for Hydrocarbons, Liquid Petroleum Gas,
Anhydrous Ammonia & Alcohols". Now Follows API 1104 Requirements.

6. ASME B31.8, "Gas Transmission and Distribution Piping Systems" Follows API 1104
Requirements.

Ing. Jorge Eliecer Rueda Daniels
Cel: 0416-8705030

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Internal Concavity

ASME Section VIII - Div 1
Smoothly contoured concavity permitted if equal
reinforcement is provided (UW-35.d)

ASME B31.3
Shall not reduce the total thickness of the joint,
including reinforcement to less than the thickness of
the thinner of the components being joined. Total joint
thickness including weld reinforcement > = t
(Table 341.3.2)

API 1104
Density of any area exceeding the density of the
thinnest adjacent base metal is unacceptable. (9.3.6.)


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Slag Inclusions

ASME Section VIII - Div 1 100% Radiography
Material thickness Max. slag length
<3/4" 1/4"
3/4" to 2 1/4" 1/3 t
> 2 1/4" 3/4"
Max total Length = t in 12t
(UW-51.b.2 and b.3)

ASME Section VIII - Div 1 Spot Radiography
Max length of 2/3t
Max total length t in 12t of weld
Max width of 3/32" or 1/3t (UW-52.c.2)

ASME B31.3 Severe Cyclic Conditions
Max length 1/3t
Max total length t in 12t of weld
Max width of 3/32" or 1/3t (The lesser)
(Table 341.3.2)

ASME B31.3 Normal Fluid Service
Max length 2t
Max total length 4t in 6" of weld
Max width of 1/8" or 1/2t (The lesser) (Table 341.3.2)

API 1104
Max width 1/13", The total accumulated length shall
not exceed 8% of the weld length. Isolated inclusions
are not exceed 2" in any continuous 12" for pipe 2
3/8" O.D. and larger. For pipe O.D. less than 2 3/8"
inclusions are limited to 3 times the thinnest of the
pipes being joined (9.3.8)

t = Wall thickness





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Slag Inclusions

ASME Section VIII - Div 1 100% Radiography
Material thickness Max. slag length
<3/4" 1/4"
3/4" to 2 1/4" 1/3 t
> 2 1/4" 3/4"
Max total Length = t in 12t
(UW-51.b.2 and b.3)

ASME Section VIII - Div 1 Spot Radiography
Max length of 2/3t
Max total length t in 12t of weld
Max width of 3/32" or 1/3t (UW-52.c.2)

ASME B31.3 Severe Cyclic Conditions
Max length 1/3t
Max total length t in 12t of weld
Max width of 3/32" or 1/3t (The lesser)
(Table 341.3.2)

ASME B31.3 Normal Fluid Service
Max length 2t
Max total length 4t in 6" of weld
Max width of 1/8" or 1/2t (The lesser)
(Table 341.3.2)

API 1104
Max width 1/13", The total accumulated length shall
not exceed 8% of the weld length. Isolated
inclusions are not exceed 2" in any continuous 12" for pipe 2 3/8" O.D. and larger. For
pipe O.D. less than 2 3/8" inclusions are limited to 3 times the thinnest of the pipes being
joined (9.3.8)

t = Wall thickness



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Excessive Root Penetration

ASME Section VIII - Div 1
Material thickness Max Height
1/16" to 3/32" 1/32"
>3/32" to 3/16" 1/16"
>3/16" to 1/2" 5/32"
>1/2" to 1" 3/16"
>1" to 2" 1/8"
>2" to 3" 5/32"
>3" to 4" 7/32"
>5" 5/16"
(UW-35,d)

ASME B31.3
Material thickness Max Height
<1/4" 1/16"
>1/4" to 1/2" 1/8"
>1/2" to 1" 5/32"
Over 1" 3/16"
(Table 341.3.2)

API 1104
Not Covered



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Incomplete Fusion

ASME Section VIII - Div 1
None Allowed (UW-51,b,1)

ASME B31.3
None Allowed (Table 341.3.2)

API 1104
Root pass: Maximum 1" length of 12" of weld or
9% of total weld length (9.3.4)
Sidewall of between beads (cold-lap): Max length
per indication < 2", 2" in 12" of weld and
total length or any indications not to exceed 8%
of total weld length (9.3.5)






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Incomplete Penetration

ASME Section VIII - Div 1
None allowed (UW-51,b,1)

ASME B31.3 Severe Cyclic Conditions
None allowed (Table 341.3.2)

ASME B31.3 Normal Fluid Service
Max depth of 1/32" or 20% of Wall Thickness,
whichever is smaller. Max length of 1 1/2" in 6" of
weld. None allowed for long seams.
(Table 341.3.2)

API 1104
Max 1" in 12" of weld or 8% of weld length if less
than 12" (9.3.1)
For inadequate cross penetration: Maximum of 2"
and cumulative 2" in 12" of continuous weld (9.3.3)



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Incomplete Penetration Due to High-Low

ASME Section VIII - Div 1
None allowed (UW-51,b,1)

ASME B31.3
None allowed (Table 341.3.2)

API 1104
Max individual length: 1"
Max accumulated length of 3" in 12" of continuous
weld (9.3.2)



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Cracks

ASME Section VIII - Div 1
None allowed (UW-51,b,1)

ASME B31.3
None allowed (Table 341.3.2)

API 1104
Shallow Crater crack or star crack not be
longer than 5/32". Shallow Crater crack or
star cracks are located at the stopping point of
weld beads and are result of weld metal
contractions during solidification.
Cracks of any size or location in the weld are
not allowed


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Cracks

ASME Section VIII - Div 1
None allowed (UW-51,b,1)

ASME B31.3
None allowed (Table 341.3.2)

API 1104
Shallow Crater crack or star crack not be
longer than 5/32". Shallow Crater crack or
star cracks are located at the stopping point of
weld beads and are result of weld metal
contractions during solidification.
Cracks of any size or location in the weld are
not allowed



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Cracks

ASME Section VIII - Div 1
None allowed (UW-51,b,1)

ASME B31.3
None allowed (Table 341.3.2)

API 1104
Shallow Crater crack or star crack not be longer
than 5/32". Shallow Crater crack or star cracks
are located at the stopping point of weld beads
and are result of weld metal contractions during
solidification.
Cracks of any size or location in the weld are
not allowed


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Misalignment

ASME Section VIII - Div 1
Mat. Thickness Long. Max. Circum. Max.
<1/2" 1/4t 1/4 t
>1/2" to 3/4" 1/8" 1/4 t
>3/4" to 1-1/2" 1/8" 3/16"
>1-1/2" to 2" 1/8" 1/8 t
>2" Lesser of 1/16 t or 3/8" 1/8t or 3/4"
(UW-33a)

ASME B31.3
Inside diameters of components at end to be joined
must be aligned within engineering desing and
welding procedure ( WPS ). (the lesser of 1/4 t or
3/16" recommended). If the external surfaces of the
two components are not aligned, the weld shall be
tapered between the surfaces. (328.4.3)

API 1104
The offset should not exceed 1/8"
Greater offset caused by dimensional variations
shall be equally distributed around the
circumference of the pipe. (7.2)



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Tungsten Inclusions

ASME Section VIII - Div 1 100% Radiography
Material thickness Max slag length
<3/4" 1/4"
3/4" to 2 1/4" 1/3 t
> 2 1/4" 3/4"
Max total Length = t in 12t
(UW-51.b.2 and b.3)

ASME Section VIII - Div 1 Spot Radiography
Max length of 2/3t
Max total length t in 12t of weld
Max width of 3/32" or 1/3t (UW-52.c.2)

ASME B31.3 Severe Cyclic Conditions
Max length 1/3t
Max total length t in 12t of weld
Max width of 3/32" or 1/3t (The lesser)
(Table 341.3.2)

ASME B31.3 Normal Fluid Service
Max length 2t
Max total length 4t in 6" of weld
Max width of 1/8" or 1/2t (The lesser)
(Table 341.3.2)

API 1104
Max width 1/13", The total accumulated length
shall not exceed 8% of the weld length. Isolated
inclusions are not exceed 2" in any continuous 12"
for pipe 2 3/8" O.D. and larger. For pipe O.D. less
than 2 3/8" inclusions are limited to 3 times the thinnest of the pipes being joined (9.3.8)

t = Wall thickness


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Porosity

ASME Section VIII - Div 1 100% Radiography
Maximum size for any indication shall be the
lesser of 1/4t or 5/32". Isolated indications
separated by at least 1" is the lesser of 1/3t or
1/4". For t >2" The maximum acceptable size is
3/8" (Appendix 4)

ASME Section VIII - Div 1. Spot Radiography
Rounded indications are not a factor in the
acceptability of welds if that welds not required
to be fully radiographed.
(UW-52,(c),(3))

ASME B31.3 Severe Cyclic Conditions
Maximum size for any indication shall be the
lesser of 1/4t or 5/32". Isolated indications
separated by at least 1" is the lesser of 1/3t or
1/4". For t >2" The maximum acceptable size is
3/8". Not surface porosity allowed.

ASME B31.3 Normal Fluid Service
For t < 1/4", requirements are the same as for
severe cyclic conditions. For t > 1/4"
requirements are 1.5 times those for severe cyclic
conditions. Not surface porosity allowed.

API 1104
Max dimension 1/8" or 25% of weld thickness,
whichever is smaller, (9.3.9.2) Cluster: Max
area of 1/2" diameter. Max individual pore 1/16". Max 1/2" length in 12" of weld.
(9.3.9.3) Hollow bead: Max length 1/2". Max 2" length in 12" of weld with individual
discontinuities exceeding 1/4" in length separated by at least 2". The total accumulated
length shall not exceed 8% of weld length (9.3.9.4)



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External Concavity

ASME Section VIII - Div 1
Smoothly contoured concavity permitted if equal
reinforcement is provided (UW-35.d)

ASME B31.3
Shall not reduce the total thickness of the joint,
including reinforcement to less than the thickness of
the thinner of the components being joined. Total
joint thickness including weld reinforcement > = t
(Table 341.3.2)

API 1104
Density of any area exceeding the density of the
thinnest adjacent base metal is unacceptable. (9.3.6.)




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Burn - Through

ASME Section VIII - Div 1
Not Covered, see Undercut

ASME B31.3
Not covered, see Incomplete penetration

API 1104
Maximum dimension shall not exceed 1/4" or
the thinnest of the pipe wall thickness being
joined. Not film density exceed that of
thinnest adjacent base material. Total of
maximum dimensions in 12" of weld shall not
exceed 1/2"
(9.3.7.2)



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Undercut - Cap Pass

ASME Section VIII - Div 1
The weld must be free of coarse ripples, grooves,
over laps, abrupt ridges or valleys. Any thickness
reduction due to welding shall not exceed the lesser
of 1/32" or 10% of adjoining wall thickness.
(UW-35(a) and (b)(1) and (2))

ASME B31.3 Severe Cyclic Conditions
Not allowed (Table 341.3.2)

ASME B31.3 Normal Fluid Service
Max Depth of 1/32" or 25% of wall Thickness,
whichever is smaller, Not allowed longitudinal butt
joints. (Table 341.3.2)

API 1104
Total length of undercut shall not exceed 2" in 12"
of weld.
The total accumulations shall not exceed 1/6 of the
weld length (9.3.11)
For mechanical measurement when is available
Depth > 1/32" o >12.5% of wall thickness,
whichever is smaller, the undercut is not allowed.
Depth >1/64" or between 6% and 12.5% of wall
thickness whichever is smaller, length: 2" I any
continuous 12" weld length or 1/6 the weld length,
whichever is smaller.
Depth =< 1/64" or =< 6% of pipe wall thickness
whichever is smaller, the undercut is acceptable,
regardless of length. (9.7.1)



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Porosity

ASME Section VIII - Div 1 100%
Radiography
Maximum size for any indication shall be the
lesser of 1/4t or 5/32". Isolated indications
separated by at least 1" is the lesser of 1/3t or
1/4". For t >2" The maximum acceptable size
is 3/8" (Appendix 4)

ASME Section VIII - Div 1 Spot Radiography
Rounded indications are not a factor in the
acceptability of welds if that welds not
required to be fully radiographed.
(UW-52,(c),(3))

ASME B31.3 Severe Cyclic Conditions
Maximum size for any indication shall be the
lesser of 1/4t or 5/32". Isolated indications
separated by at least 1" is the lesser of 1/3t or
1/4". For t >2" The maximum acceptable size
is 3/8". Not surface porosity allowed.
(Table 341.3.2)

ASME B31.3 Normal Fluid Service
For t < 1/4", requirements are the same as for
severe cyclic conditions. For t > 1/4"
requirements are 1.5 times those for severe
cyclic conditions. Not surface porosity
allowed. (Table 341.3.2)

API 1104
Max dimension 1/8" or 25% of weld thickness, whichever is smaller, (9.3.9.2) Cluster:
Max area of 1/2" diameter. Max individual pore 1/16".
Max 1/2" length in 12" of weld. (9.3.9.3)
Hollow bead: Max length 1/2". Max 2" length in 12" of weld with individual
discontinuities exceeding 1/4" in length separated by at least 2".
The total accumulated length shall not exceed 8% of weld length (9.3.9.4)


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Undercut - Root Pass

ASME Section VIII - Div 1
The weld must be free of coarse ripples, grooves,
over laps, abrupt ridges or valleys. Any thickness
reduction due to welding shall not exceed the lesser
of 1/32" or 10% of adjoining wall thickness.
(UW-35(a) and (b)(1) and (2))

ASME B31.3 Severe Cyclic Conditions
Not allowed (Table 341.3.2)

ASME B31.3 Normal Fluid Service
Max Depth of 1/32" or 25% of wall Thickness,
whichever is smaller, Not allowed longitudinal butt
joints. (Table 341.3.2)

API 1104
Total length of undercut shall not exceed 2" in 12"
of weld.
The total accumulations shall not exceed 1/6 of the
weld length (9.3.11)
For mechanical measurement when is available
Depth > 1/32" o >12.5% of wall thickness,
whichever is smaller, the undercut is not allowed.
Depth >1/64" or between 6% and 12.5% of wall
thickness whichever is smaller, length: 2" I any
continuous 12" weld length or 1/6 the weld length,
whichever is smaller.
Depth =< 1/64" or =< 6% of pipe wall thickness
whichever is smaller, the undercut is acceptable,
regardless of length. (9.7.1)




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Porosity

ASME Section VIII - Div 1 100% Radiography
Maximum size for any indication shall be the
lesser of 1/4t or 5/32". Isolated indications
separated by at least 1" is the lesser of 1/3t or
1/4". For t >2"
The maximum acceptable size is 3/8"
(Appendix 4)

ASME Section VIII - Div 1 Spot Radiography
Rounded indications are not a factor in the
acceptability of welds if that welds not required to
be fully radiographed.
(UW-52,(c),(3))

ASME B31.3 Severe Cyclic Conditions
Maximum size for any indication shall be the
lesser of 1/4t or 5/32". Isolated indications
separated by at least 1" is the lesser of 1/3t or
1/4". For t >2" The maximum acceptable size is
3/8". Not surface porosity allowed.
(Table 341.3.2)

ASME B31.3 Normal Fluid Service
For t < 1/4", requirements are the same as for
severe cyclic conditions. For t > 1/4"
requirements are 1.5 times those for severe cyclic
conditions. Not surface porosity allowed.
(Table 341.3.2)

API 1104
Max dimension 1/8" or 25% of weld thickness, whichever is smaller, (9.3.9.2) Cluster:
Max area of 1/2" diameter. Max individual pore 1/16".
Max 1/2" length in 12" of weld. (9.3.9.3)
Hollow bead: Max length 1/2". Max 2" length in 12" of weld with individual
discontinuities exceeding 1/4" in length separated by at least 2".
The total accumulated length shall not exceed 8% of weld length (9.3.9.4)