NOVEMBER 2016 / VOL. 19 / NO.

Inspection
Trends
THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL

AWS.ORG

Magnetic Particle
Testing Update

Inspecting Pipes
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of NOVEMBER 2016 / VOL. 19 / NO. 4

Inspection
Trends
THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL

Features

On the cover: Welding pipe for a power genera-

tion construction project. All of the multipass
GTA welds underwent radiographic testing. 14 17 22
(Photo courtesy of William LaPlante.)

INSPECTION TRENDS (ISSN 1523-7168) is

published quarterly by the American Welding How Coating Thickness Can Influence Magnetic Particle Test
Society. Editorial and advertising offices are located
at 8669 NW 36th St., #130, Miami, FL 33166;
Results
telephone (305) 443-9353. Printed by R. R. by A. J. Moore Jr. / The relationship between a part’s coating thickness
Donnelley & Sons Co., Senatobia, Miss. and magnetic particle testing using indirect magnetism are detailed / 14
Subscriptions $30.00 per year for noncertified,
nonmembers in the United States and its
possessions; $50.00 per year in foreign countries; Performing Visual Inspection of Pipe Systems
$20.00 per year for noncertified members and by W. C. LaPlante / A veteran inspector discusses the many duties of visu-
students; $10.00 single issue for nonmembers; and
$7.00 single issue for members. American Welding al welding inspectors on a pipeline/pipework job site / 17
Society is located at 8669 NW 36th St., #130,
Miami, FL 33166; telephone (305) 443-9353.
Periodicals postage paid in Miami, Fla., and
*Magnetic Particle Inspection
additional mailing offices. by J. Worman / Learn the basics of this commonly used nondestructive
POSTMASTER: Send address changes to examination process / 22
Inspection Trends c/o American Welding Society,
8669 NW 36th St., #130, Miami, FL 33166.

Readers of Inspection Trends may make copies of arti-

cles for personal, archival, educational, or
research purposes, and which are not for sale or
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and sources is made. Starred (*) items excluded from
copyright.

AWS MISSION STATEMENT

The mission of the American Welding Society
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application of welding and allied joining Departments
processes worldwide, including, brazing,
soldering, and thermal spraying.

AWS DIVERSITY AND INCLUSION Editor’s Note ................................6 Certification Schedule ...............30
STATEMENT
AWS values diversity, advocates equitable and inclusive News Bulletins .............................8 Just the Facts.............................32
practices, and engages its members and stakeholders in
establishing a culture in the welding community that
welcomes, learns from, and celebrates differences among Print and Product Showcase .....12 The Answer Is.............................34
people.
Technology Notes ......................26 Classifieds ..................................36
AWS recognizes that a commitment to diversity, equity,
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Association, its members, and employees. Mark Your Calendar ..................28 Advertiser Index ........................36

Inspection Trends / Fall 2016 5

 Editor’s Note
Publisher
Andrew Cullison, cullison@aws.org

Dear Readers, Editorial

Here at the American Welding Editor

Society, I have the privilege of wearing Mary Ruth Johnsen, mjohnsen@aws.org
two hats. Not only am I editor of
Inspection Trends, but also of the Welding Senior Editor
Journal. AWS only had one magazine Cindy Weihl, cweihl@aws.org
when I first joined the Society, so my Features Editor
association with the Welding Journal is Kristin Campbell, kcampbell@aws.org
longer, but I have been involved with
Inspection Trends since it was first Associate Editor
Mary Ruth Johnsen conceived. Katie Pacheco, kpacheco@aws.org
After I joined AWS, I was surprised
to learn that some CWIs are not
members. A majority of you are, but not all, and that never made much Design and Production
sense to me. I can understand why, if you’re a member of AWS and you
have zero involvement with inspection, you might not want to receive Production Editor
Zaida Chavez, zaida@aws.org
Inspection Trends, but I’ve never understood why a CWI wouldn’t want
to get the Welding Journal or any of the other benefits of membership. Assiatant Production Manager
After all, as a Certified Welding Inspector, your daily work involves Brenda Flores, bflores@aws.org
welding and I’d think you’d want to learn as much as you could about it.
And I believe there’s no better way to keep up to date on what’s Manager of International Periodicals
happening in the world of welding than through the pages of the and Electronic Media
Welding Journal. Carlos Guzman, cguzman@aws.org
Beside the magazine, and the member discount on AWS codes and
standards, members can benefit from Section meetings. I know most of
us are so busy we don’t want to put another thing on our schedules, but Advertising
Section meetings are usually only one night a month, nine months of the Manager of Sales Operations
year. Regulars at Section meetings tell me they’ve gotten work through Lea Paneca, lea@aws.org
contacts obtained through meeting attendance or found a resource for
solving a work-related problem, as well as getting to know a bunch of Senior Advertising Sales Executives
nice people. Sandra Jorgensen, sjorgensen@aws.org
AWS recently launched a new member benefit: the AWS Member Annette Delagrange, adelagrange@aws.org
Network (think LinkedIn for the welding industry). Even if you simply
can’t attend Section meetings — for instance if your closest Section is Senior Advertising Production Manager
just too far away — you can still connect with your peers through the Frank Wilson, fwilson@aws.org
AWS Member Network. You simply fill out a profile and then people
Subscriptions Representative
with similar backgrounds and interests can reach out to you or you can Evelyn Andino, eandino@aws.org
find someone you’d like to contact.
The online discussions are another key component of the network.
You may be familiar with the forums that have been on the AWS American Welding Society
website for many years. While those will continue so long as activity 8669 NW 36th St., #130
warrants it, the AWS Member Network contains functionality that the Miami, FL 33166-6672
forums do not have the technology to support. There is an especially (800/305) 443-9353
active CWI forum on the network. Recent discussions focused on how
best to study for and pass the CWI exam, how to set up business as a Copyright
CWI, Charpy V-notch test requirements, fillet weld requirements as per Copyright © 2016 by American Welding Society in both
AWS D1.4, Structural Welding Code — Reinforcing Steel, and fillet weld printed and electronic formats. The Society is not responsi-
ble for any statement made or opinion expressed herein.
requirements per AWS D1.1, Structural Welding Code — Steel, among Data and information developed by the authors of specific
many others. articles are for informational purposes only and are not
intended for use without independent, substantiating
If you are not an AWS member, I encourage you to become one. I investigation on the part of potential users.
believe you’ll get much more in value than you pay in dollars. And, if
you’re already a member, take advantage of the AWS Member Network.
I’ve always felt Inspection Trends should read as if one inspector is
talking to another. The AWS Member Network offers another avenue
for you to do so.

6 Inspection Trends / November 2016

American Welding Society®
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aws.org

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 News Bulletins
AREVA Unveils New Boiling Water Reactor
Weld Inspection Technique
During a recent outage,
AREVA demonstrated a
technique that paired phased
array ultrasonic testing (UT)
with a multiaxis manipulator
to generate UT at multiple
orientations. (Photo courtesy
of AREVA NP.)
8 Inspection Trends / November 2016
to generate UT at multiple orientations to help detect and
characterize all flaws surrounding the weld. According to the
company, the new technique and manipulator helps reduce
examination time and exposure to radiation for personnel.
AREVA NP, Charlotte,
N.C., demonstrated new ul-
trasonic testing (UT) tech- Premium Inspection & Testing Hires CEO
niques during a recent U.S.
Premium Inspection & Testing, Inc., Houston, Tex., re-
outage. The techniques in-
cently hired John Durkee to serve as chief executive officer.
cluded off-axis inspection for
Durkee has more than 25 years of leadership experience in
cracks in a boiling water reac-
the energy sector, most recently as president of the Products
tor’s core shroud welds using
business unit of Global Power.
an approach that paired
Premium Inspection & Testing provides inspection,
phased array ultrasonic test-
quality control, safety, and asset integrity services to cus-
ing with a specialized multi-
tomers across a range of industries and locations through its
axis manipulator.
operating subsidiaries, Capitol Ultrasonics, Quad City Test-
While the nuclear energy
ing Laboratories, and Permian NDT.
industry regularly uses UT to
inspect for cracks parallel to
the core shroud weld, some Willick Engineering Offering Computed
core shroud exams indicated Radiography Systems
perpendicular or “off-axis”
cracking. Therefore, the com- Willick Engineering, Santa Fe Springs, Calif., is now of-
pany developed the new tool fering the computed radiography product line from DÜRR
For info, go to aws.org/ad­index
NDT, Bietigheim-Bissingen, Germany, through a recent
partnership agreement.
Products being offered include 12.5-micron HD-CR 35
NDT lightweight, portable systems, and HD-CR 43 NDT au-
tomatic loading systems. Applications include inspection of
components in the aerospace sector, automotive castings,
and industrial pipelines for issues such as corrosion meas-
urement and weld inspections.

Sonatest and Creaform Form New Global

Distribution Partnership

Sonatest has added Creaform’s Pipecheck Analyze software to its

product line.

Sonatest, Inc., San Antonio, Tex., has become an official

reseller of Pipecheck Analyze software from Creaform, Que-
bec, Canada. Pipecheck can identify potential issues such as
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Inspection Trends / Fall 2016 9

 corrosion, dents, or gouges on both the inner and outer sur-
faces of pipes.
The software is fully compatible with Sonatest’s ultra-
sonic testing equipment. Sonatest will offer the software to
its pipeline corrosion assessment market and plans to con-
tinue expanding it to other markets, such as nuclear plants
and geothermal facilities, where corrosion and erosion
caused by water vapor traveling at high speeds have been a
problem.

Metal Fatigue Solutions Receives National

Science Foundation Grant
Metal Fatigue Solutions, Las Vegas, Nev., was recently
awarded a $250,000 grant from the National Science Foun-
dation. The company produces nondestructive examination
systems for major civil and industrial infrastructure projects.
The grant, the company’s largest to date, will fund devel-
opment and fusion of its Fatigue Fuse™ system with new
piezoelectric energy harvesting technology and wireless sen-
sor communications. This system is designed to be affixed to
a metal structure to give indications of precalibrated percent-
ages of the structure’s fatigue life that has been expended.
The work from this grant will provide a wireless fatigue
life indicator for structures, such as military assets, shipping
cranes, bridges, and wind turbines. It is a sensor that should
indicate potential failure prior to occurrence.

For info, go to aws.org/ad­index

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 Print and Product Showcase

XRF Analyzer Built for Use in harsh environments for applications

such as positive material identifica-
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The Vanta™ line of handheld XRF dust and water, 4-ft drop tested, and
analyzers feature a rugged design that built to withstand a temperature range
allows the instruments to work in of 14° to 122°F. The analyzers feature

the company’s new Axon technology,

which utilizes ultralow-noise electron-
ics to deliver higher x-ray counts per
second and fast results. Other features
include a customizable home screen,
American Welding Society® vivid touch screen that is readable in
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analysis.

Olympus Scientific Solutions

ONE OF TTHHE MOST TRUSSTED Americas
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STTAANDARDS INI STRUCTURAL STEEL Inspection Lamp Quickly

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IS NOW EVEENN MORE ACCESSSIBLE. Fluorescent and White Light

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Código de soldadura Stru

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Spectroline’s QUADRAN™ 365

NDE lamp features four ultrahigh-flux
UV-A LEDs and a white light LED, so it
can quickly switch between fluorescent
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Traducción
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12 Inspection Trends / November 2016

Computed Tomography give the wearer a close-to-the-face fit
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Systems Feature New high-performance eyewear, designed
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All of the company’s computed

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YXLON International GmbH

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Probe Helps Reduce

Inspection Time
The company’s Surface Array Flex
Probe offers the ability to handle in-
spection coverage of up to 2 in. in one
pass for fast, accurate inspections. It
offers a flexible surface design and
proprietary X-Probe coil technology
that allow it to conform to surface
variations such as curvatures and weld
beads. It can accurately detect pitting
and surface cracks in any orientation.
The probe’s pad was tested on more
than 8000 ft of weld surface without
failure. It can be paired with the Mod-
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Inspection Trends / Fall 2016 13
 Feature By Albert J. Moore Jr.

How Coating Thickness Can

Influence Magnetic Particle
Test Results
The advantages of magnetic particle testing using indirect
magnetism may be offset by the part’s coating thickness

Fig. 1 — The lines of magnetic flux within the part subjected to MT

and the flux leakage that produces the magnetic particle indication
are depicted.
Magnetic particle testing (MT) is
one of several nondestructive exami-
nation (NDE) methods used to test
ferromagnetic metals. The test method
utilizes a magnetic field and flux leak-
age to detect surface-breaking and
slightly subsurface discontinuities
such as cracks, incomplete fusion, laps,
seams, etc., in castings, forgings, and
weldments. The item being tested can
be magnetized by direct magnetism
(passing electrical current through the
part) or indirect magnetism using
leeches (permanent magnets), a coil,
or electric solenoid.
When using direct magnetism,
direct electrical contact must be made
between a source of high current and
the part surface. The surface where the
electrical contact is made must be bare
metal to ensure positive electrical con-
tact when the system is energized and
deenergized or damaging arc burns
Fig. 2 — The magnetic particle indication formed with one layer of
electrician’s tape. The thickness of the tape was 0.006 in. Yellow
can result. The arc tape was used to improve the contrast between the steel plate,
burns are such a con- the tape, and the dry red magnetic particles used for the
cern that some weld- demonstration. The magnetic particle indication is equivalent to
the indications formed above and below the yellow tape.
ing standards will not
permit use of direct
magnetism if prods tained, i.e., no external power source is
are used. needed.
The possibility of an arc burn is Another advantage of using the in-
eliminated if indirect magnetism is direct method of magnetizing the test
used as an alternative to direct mag- piece is the test surface can be painted
netism. There is no need to pass elec- or hot-dipped galvanized. The coating
trical current through the part if indi- does not have to be completely removed
rect magnetism is used. There are before performing the magnetic particle
three common methods of magnetiz- test. However, there is a concern that
ing the part using indirect magnetism: coatings can diminish the sensitivity of
a magnetic yoke, leeches, or a coil. Two the magnetic particle test, causing rele-
common methods of testing welds are vant discontinuities to be missed. The
to use a yoke or leeches. While most concern is justified because the
yokes are powered with alternating strongest magnetic field is induced into
current (AC), occasionally a battery is the part when the legs of the yoke or the
used when AC power is unavailable. leeches are in direct contact with the
Leeches (strong permanent magnets) metal surface of the part being tested. If
have the advantage of being self-con- there is a space, i.e., an air gap or coat-

14 Inspection Trends / November 2016

 Fig. 3 — The magnetic particle indication
formed with two layers of electrician’s tape
applied. Total coating thickness is 0.012 in.
The magnetic particle indication is still
clear and well defined.
Fig. 6 — The magnetic particle indication
formed with five layers of tape. Coating
thickness is 0.030 in. The magnetic
indication is barely visible and weakly
held in place. (Note that there is a mistake
on the label; the slot depth is 0.250 in., not
0.025 in.)
ing between the end of the legs of the
yoke or the leeches and the part, the in-
tensity of the magnetic field drops off
rather quickly.
Regardless of whether direct or
indirect magnetism is used, the densi-
ty of the magnetic flux in the part
must be sufficient to produce a flux
leakage at the location of the disconti-
nuity to collect and hold the magnetic
particles — Fig. 1. When the space be-
tween the ends of the yoke and the
part or the coating thickness is too
great, the magnetic flux leakage can
be insufficient to hold the magnetic
particles in place. There is the nagging
question of whether a small but criti-
cal discontinuity is undetectable be-
cause of the coating thickness.
The following experiments
demonstrate there is a practical limit
to the coating thickness before a loss
of sensitivity makes magnetic parti-
cle testing impractical. A test plate
consisting of a 1  6  12-in. low-car-
bon steel plate contained two slots
that were saw cut into the plate. Each
slot was tested with the slot centered
between the yoke legs 6 in. apart.
Fig. 4 — The magnetic particle indication
formed with three layers of tape. The
indication is still clear with a “coating”
thickness of about 0.018 in.
Fig. 7 — Here a shallow slot measuring
0.085 in. deep is shown. The slot is now
about 0.024 in. wide. The magnetic
particle indication formed with one layer
of tape representing a coating thickness
of 0.006 in. is sharp and well defined.
One slot was cut 0.250 in. deep and
the second slot was cut with a taper
that went from 0.375 in. down to
0.085 in. (The taper measured 0.375
in. deep on one end and only 0.085
in. on the opposite end.) Once the
slots were cut, the plate was heated
and placed under a 30-ton compres-
sive load using a hydraulic press to
close the slots to 0.030 in. wide or
less to resemble a crack.
The magnetic particle test was
conducted with the slotted steel plate
in the vertical position. The magnetic
particles were applied while the yoke
was energized and the excess dry mag-
netic particles were allowed to fall
away. Only those magnetic particle
indications held in place by the rem-
nant field after the yoke was deener-
gized were considered.
Details of the Experiment
The experiments are shown in
Figs. 2–11. Following is the equip-
ment used for the demonstrations.
• 120-V AC MagnaFlux Model Y-6
magnetic particle yoke
• ArcMetal red magnetic particles
Inspection Trends / Fall 2016
Fig. 5 — The magnetic particle indication
formed with four layers of tape. The
magnetic particle indication is not well
defined and is loosely held in place.
• 50-ft-long heavy-duty extension
cord
• 1-in.-thick ASTM A-36 steel plate
measuring 1  6  12 in.
• 0.006-in.-thick yellow plastic
electrician’s tape.
As mentioned previously, two
slots were tested. One was 0.250 in.
deep and tight. The other was 0.085-
in.-deep and 0.024 in. wide.
Plastic electrical tape was ap-
plied to the test plate surface to sim-
ulate a coating such as paint or hot
dipped galvanizing. The upper limit
of coating thickness was determined
by adding layers of plastic tape until
the magnetic particles no longer re-
mained. Ultimately, five layers of
electrician’s tape were applied for a
total thickness of 0.030 in. as meas-
ured by a dial caliper.
The tapered slot provided an op-
portunity to see the interaction of
the crack depth and coating thick-
ness on the magnetic particle indica-
tion. Again, the magnetic indication
was judged too weak if the remnant
field would not hold the magnetic
particles in place after the yoke was
removed from the test surface.
You must decide whether the
magnetic particle test performed on
the coated surface using indirect mag-
netism provided sufficient sensitivity
for the application. Figures 2–6 show
the experiments with the 0.025-in.-
deep slot, and Figs. 7–11 show those
with the tapered 0.085-in. slot.
Tests on Real Coated
Parts
The photographs shown in Figs. 12
and 13 are images of magnetic particle
indications formed when actual coated
parts were tested using a magnetic par-
ticle yoke with dry magnetic particles.
15

Fig. 8 — The magnetic indication formed
with two layers of tape representing a
coating thickness of 0.012 in. The
indication is clear and well defined. The
slot represents a wide, shallow crack.
Fig. 11 — In this figure, five layers of tape
represent a coating thickness of 0.030 in.
The magnetic particle indication is barely
visible. Even with the magnetic yoke in
place and energized, the indication was
very weak. Only the fine magnetic
particles stayed in place.
Conclusions
When possible, it is best to con-
duct magnetic particle tests on un-
coated surfaces to optimize the proba-
bility of detecting small discontinu-
ities. However, inspectors are often
faced with situations where it is im-
practical to strip all coatings from the
surface of the component being exam-
ined. When it is necessary to perform
magnetic particle examination on a
coated component, the inspection re-
port should note the part’s surface
conditions and that there are practical
limitations to what is detectable due
to the coating.
Inspectors do not work in a vacu-
um. There are resources available that
can be used when the situation war-
rants it. Those resources include the
16 Inspection Trends / November 2016
Fig. 9 — The magnetic indication formed
with three layers of tape representing a
coating thickness of about 0.018 in. The
magnetic particle indication is well
defined and firmly held in place.
Fig. 12 — A crack in the radius of an access
hole. The beam was hot-dip galvanized.
Recent experience has made it apparent
that torch-cut access holes, copes, and
blocked flanges of ASTM A992 hot-rolled,
wide flange beams need to be tested for
cracks after hot-dip galvanizing.
Level III, the client, and the engineer.
If an inspector is concerned a coating
is too thick and the test results com-
promised, the client must be informed
and a decision made whether the coat-
ing must be removed or a different
test method used. The decision
whether to remove the coating should
be made by the owner, since the owner
will be paying the cost of removing the
coating and replacing it once the mag-
netic particle test is completed.
Magnetic particle testing, like
other NDE methods, has limitations.
Inspectors using the magnetic particle
test method need to have a working
knowledge of its limitations and its
advantages. One advantage of the
magnetic particle test method is that
it can detect surface-breaking and
slightly subsurface discontinuities. An
additional advantage is the magnetic
Fig. 10 — The magnetic particle indication
formed with four layers of tape
representing a coating thickness of 0.024
in. The indication is not as sharp, more
diffused, and weakly held in place.
Fig. 13 — A magnetic particle indication
caused by overlap at the toe of the fillet
weld. MT was performed using leeches,
which are the black bars located toward
the bottom of the photograph. The part
was painted, but the overlap was easily
detected using the leeches and dry
magnetic particles.
particle test method can detect discon-
tinuities that may be concealed by a
coating. However, the coating thick-
ness can be a limitation. The size of
the discontinuity of interest is one fac-
tor that limits the thickness of the
coating and the probability of detec-
tion.
ALBERT J. MOORE JR.
(AMoore999@comcast.net) is vice
president, Marion Testing & Inspection,
Canton, Conn. He is an AWS Senior
Certified Welding Inspector and an
ASNT ACCP NDT Level III in RT, UT, MT,
and PT. He is also a member of the AWS
Certification Committee and the
Committee on Methods of Inspection of
Welds.
By William C. LaPlante Feature

Performing Visual Inspection

of Pipe Systems
The many duties of visual welding inspectors on a pipeline/pipework job site are
discussed

A B

Fig. 1 — A — A Prudhoe Bay oilfield pipeline project; B — power generation pipework welding.

In the construction of pipelines/ discontinuities that could potentially

pipework (Fig. 1) for the transporting
of petroleum, gas, chemical, or other
fluids/slurries, it is critical to perform
nondestructive examination (NDE) of
the welds. Why? Comprehensive visual
weld inspection in conjunction with
other NDE inspection methods, such
as radiography (RT) and ultrasonic
(UT) inspection, mitigates the risk of a
containment breach as the result of a
weld/weldment failure.
Personal injury or death, property
damage, and/or an environmental dis-
aster could result from a containment
breach. Catastrophic weld/weldment
failure and service life deterioration are
affected by the type and extent of weld
defects present. A weld or heat-affected
zone (HAZ) crack and/or weld defects or
lead to a crack or fracture are the most
severe. Therefore, the performance of
in-process visual (VT) weld inspection
to identify weld defects as well as faulty
welding and fabrication practices as
they occur in production is crucial. Ad-
verse welding and fabrication practices
not recognized during production pose
a hidden threat to public safety and to
the service life and operational charac-
teristics of the weldment. The sooner a
weld defect and/or faulty welding and
fabrication practices are identified,
liability risks and rework costs decrease,
and weld/weldment integrity increases.
Although multiple NDE methods
exist for the inspection of pipe welds,
this article focuses on visual weld
inspection.
The Need for Qualified
Welding Inspectors
Qualified personnel are required
to perform pipeline and pipework weld
inspection. Fortunately, a number of
avenues are available for a person to
become qualified as a welding inspec-
tor. There are the AWS Senior Certified
Welding Inspector (SCWI) and Certi-
fied Welding Inspector (CWI) pro-
grams, the API 1169 Pipeline Inspec-
tor and API 570 Piping Inspector Pro-
grams, and the TWI CSWIP 3.1 and
3.2 Welding Inspector programs. For
present and future AWS SCWIs/CWIs,
AWS QC1, Standard for AWS Certifica-
tion of Welding Inspectors, is a key docu-
ment. The principles outlined within

Inspection Trends / Fall 2016 17

 Fig. 2 — Examples of pipe welding for a multimegawatt power generation construction project. All welds required multiple gas tungsten arc
welding (GTAW) passes. Afterward, the welds were inspected with RT.
paragraph 11.2, “Responsibility to
the Public” are important to remem-
ber, for welding inspectors hold the
public’s trust.
Inspection of Pipe Welds
Fundamentally, as a welding in-
spector, you are inspecting for compli-
ance. For example, in the construction
of a multimegawatt power generation
facility, there are several miles of
pipework being fabricated. The alloys
used for the pipework could include
Chrome-Moly A335, P-Grades P5, P9,
P11, P22, P91; austenitic stainless
steel pipe, Grades 304L, 316L, 317L;
and carbon steel pipe such as A106
and A333.
Production welds originate from
the qualification of project Procedure
Qualification Records (PQRs) and
Welding Procedure Specifications
(WPSs). On a power generation proj-
ect, welding inspectors are assigned
18 Inspection Trends / November 2016
the responsibility to visually inspect
pipework welds to do the following:
1) Determine if the weld meets
visual acceptance criteria in accor-
dance with the respective project
weld code(s) such as ASME B31.1,
Power Piping, and ASME B31.3, Process
Piping.
2) Verify that production welds
and weldments are in accordance with
pipe spool and structural drawings.
3) Verify that weld variables being
used in production are in accordance
with qualified WPSs. The variables
could include weld joint cleaning;
amps; volts; travel speed; heat input;
multipass weld bead sequence; weld
filler metal; preheat, interpass, and
postweld temperatures; and joint
geometry.
As with ensuring compliance, the
monitoring of welding and fabrication
practices and weld quality are vital ele-
ments of job-site responsibilities. Not
only are welding inspectors engaged in
the monitoring of pipe welding and fab-
rication practices (Fig. 2), their addi-
tional responsibilities entail developing
weld maps and maintaining weld trace-
ability documentation, witnessing/sup-
porting welder qualifications, resolving
weld rework/repair activities, and work-
ing with NDE inspection crews.
Pipeline Inspection
Welding inspectors on pipeline
projects are also inspecting for com-
pliance to visual weld code acceptance
criteria and are verifying that quali-
fied WPS weld variables are being
used during welding. Inspectors
working on a new pipeline construc-
tion project will support weld crews
as they advance down the line from
weld joint to weld joint — Fig. 3. Dur-
ing welding, the root pass, hot pass,
fill passes, and cover/cap passes are
inspected. Upon weld completion,
welding inspectors work with radiog-
 Fig. 3 — A Prudhoe Bay oilfield pipeline project. Fig. 4 — An in-service pipeline weld repair.

A B

Fig. 5 — A pipeline hot-tapping application. A — Branch stub welding utilizing shielded metal arc welding; B — fitup of a full-reinforcement
saddle placed over the just-completed branch stub weld.

raphy inspection crews as they test
designated welds.
The primary codes used for oil-
field pipeline construction are API
1104, Welding of Pipelines and Related
Facilities; ASME B31.4, Pipeline Trans-
portation Systems for Liquids and Slur-
ries; and ASME B31.8, Gas Transmis-
sion and Distribution Piping Systems.
Carbon steel alloys as specified within
API 5L, Specification for Line Pipe, in-
cluding Grades X42, X46, X52, X56,
X60, and X65 through X120, com-
prise most pipeline materials.
For pipelines in operation, weld-
ing inspectors are involved with in-
service weld repairs in accordance with
API 1104, Section B. In-service weld
repairs mean that welding transpires
while the pipeline is in operation —
Fig. 4. In-service weld repairs are com-
plex, involving variables such as fluid
and pipe temperature, pressure, flow
rates, and pipe wall thickness.
In addition, welding inspectors
are involved with hot-tapping applica-
tions — Fig. 5. As with in-service weld
repairs, hot tapping is performed
while the pipeline is in operation.
In addition, it is not uncommon
for welding inspectors to be involved
in nonwelding activities such as the in-
spection of a pipeline for corrosion
(Fig. 6) or hydrostatic testing of
pipeline sections.
In-Service Pipeline
Welding
Due to the seriousness of pipeline
in-service weld repairs and hot-
tapping welding applications, a weld-
ing inspector will be given responsibil-
ity for witnessing and documenting
the weld variables (e.g., volts, amps)
employed for each individual weld
bead during welding (i.e., root pass,
hot pass, fill passes, and cap/cover
passes). This is done to ensure the con-
tractor’s compliance with the qualified
WPS. The inspector will also perform
visual inspection of each individual
weld bead during welding and of the
completed weld. Upon final comple-
tion of the weld repair and/or hot-
tapped welds, the welding inspector
witnesses RT of complete-joint-pene-
tration welds and magnetic particle
inspection of fillet welds. The inspec-
tor also documents test results.
In-service pipeline weld repairs
are performed in accordance with API
1104 Section B. Additionally, API RP
2201, Procedure for Welding or Hot-Tap-
ping on Equipment in Service, is an au-
thoritative document referenced for
in-service welding and hot-tapping
applications.

Inspection Trends / Fall 2016 19

 A B

Fig. 7 — Inspecting the root weld. A — An inspector uses a Hi-

Fig. 6 — Welding inspectors are often tasked with nonwelding jobs, Lo gauge to check for mismatch; B — measuring a root
such as checking for corrosion. Shown here is the remnants of a valve opening; C — inspecting a completed root weld with a 4-to-1
with corrosion under insulation. taper weld joint prep.

A B C D

Fig. 8 — Weld inspection examples: the good, the bad, the ugly (structural weld on a pipe bridge), and the very ugly.

fect will result. For piping applica- steels and carbon steel line pipe. When
The Root Weld tions, an inspection mirror and a high- reviewing project WPSs, possessing a
quality flashlight are essential tools for basic understanding of low-hydrogen
The pivotal weld in all pipeline
a welding inspector. practices and being able to ask relevant
and pipework welding is the root weld
questions could ultimately prevent the
— Fig. 7. The root surface contour and
Practicing Your Craft occurrence of weld metal/HAZ cracking.
amount of root weld reinforcement are
It is pertinent as well that welding in-
crucial. To facilitate successful welding
Keep in mind that welding inspec- spectors understand applicable weld
of the root weld, proper weld joint fit-
tors need a variety of tools and should codes, be adept in pipe drawing inter-
up is required. When an open root
be aware of what’s happening all pretation, be familiar with weld sym-
weld joint is used, welders and weld
around the welding environment. bols, and be able to recognize various
inspectors employ flashlights to peer
While their primary job is to inspect types of pipe and pipe fittings.
through the root opening to inspect
welds, they’ll also be called upon to Tools this author carries to a job
the weld. Root weld underfill/concavi-
perform a variety of other tasks. site include a professional and objective
ty, incomplete penetration, excessive
For instance, it is pertinent for attitude; various types of gauges to
mismatch, internal undercut, or exces-
welding inspectors to be cognizant of measure weld reinforcement, fillet weld
sive root weld reinforcement will re-
the welding environment and the alloy sizes, mismatch, undercut, pit depth,
sult in a failure to pass RT. Also, if the
being welded. For example, they should root openings, porosity, and bevel an-
root surface contour is such that the
be aware of the potential for hydrogen- gles; as well as a flashlight, mirrors,
weld toes are not fused with the base
induced cracking in the welding of alloy camera, stopwatch, 6-in. scale, loupes
metal, an incomplete fusion weld de-

20 Inspection Trends / November 2016

 — by welders, pipefitters, site engi-
neers, and so on to provide weld
process and fabrication troubleshoot-
ing and to participate in root cause
analysis inquiries.

Summary
In the fabrication of pipelines/
pipework, comprehensive visual weld
inspection in conjunction with other
NDE methods, such as RT and UT,
mitigate the risk of a containment
breach as the result of a weld or weld-
ment failure. The performance of dili-
gent in-process visual weld inspection
facilitates identification of weld de-
fects as well as faulty welding and fab-
rication practices as they occur in pro-
duction. The sooner a weld defect
and/or faulty welding and fabrication
practices are identified, liability risks
and rework costs decrease, and
Fig. 9 — Measurement of weld reinforcement.
weld/weldment integrity increases.

with 5× and 10× magnification, 25-ft When on a job site, in addition to WILLIAM C. LAPLANTE
tape measure, welding helmet, calcula- visually inspecting welds (Figs. 8, 9), (wlaplante.cwi@gmail.com) is a welding
tor, a calibrated volt/amp meter, and a welding inspectors are often called engineer, and AWS CWI and CWE,
contact pyrometer. upon — especially in remote locations Anchorage/Prudhoe Bay, Alaska.

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Inspection Trends / Fall 2016 21

 Feature
Magnetic Particle Inspection
The basics of this often-used nondestructive examination
method are explained
Fig. 1 — During inspection, if the ferromagnetic material is defect free,
lines of magnetic flux are transferred through the material without interruption.
Fig. 2 — If a disconuity is present during MT, the flux leaks out of the material. As it leaks,
ferromagnetic particles collect, making the shape and size of the discontinuity easily visible.
Magnetic particle examination
(MT) is a popular, low-cost method
used to perform nondestructive exam-
ination (NDE) of ferromagnetic mate-
rial. Ferromagnetic is defined in ASME
Boiler and Pressure Vessel Code Section
V as “a term applied to materials that
can be magnetized or strongly attract-
ed by a magnetic field.” MT is an NDE
method that checks for surface discon-
tinuities but can also reveal disconti-
nuities slightly below the surface.
22 Inspection Trends / November 2016
How Magnetic Particle
Examination Works
When ferromagnetic material
(typically iron or steel) is defect free, it
will transfer lines of magnetic flux
(field) through the material without
any interruption — Fig. 1.
But when a crack or other discon-
tinuity is present, the magnetic flux
leaks out of the material. As it leaks,
By Jim Worman
magnetic flux (magnetic field) will col-
lect ferromagnetic particles (iron pow-
der), making the size and shape of the
discontinuity easily visible — Fig. 2.
However, the magnetic flux will
only leak out of the material if the
discontinuity is generally perpendicu-
lar to its flow. If the discontinuity,
such as a crack, is parallel to the lines
of magnetic flux, there will be no
leakage and therefore no indication
observed. To resolve this issue, each
area needs to be examined twice. The
second examination needs to be per-
pendicular to the first so discontinu-
ities in any direction are detected.
The examiner must ensure that
enough overlap of the areas of mag-
netic flux is maintained throughout
the examination process so disconti-
nuities are not missed.
History of Magnetic
Particle Examination
Magnetism was first used as early
as 1868 to check for cannon barrel de-
fects. Cannon barrels were first mag-
netized, and then a magnetic compass
was moved down the length of the
barrel. If a discontinuity was present,
the magnetic flux would leak out and
cause the compass needle to move. De-
fects could be easily located with this
technique.
In the early 1920s, William Hoke
noticed metallic grindings from hard
steel parts (held by a magnetic chuck
while being ground) formed patterns
that followed the cracks in the surface
of parts he was machining. He also
found that by applying fine ferromag-
netic powder to the parts, there was a
buildup of powder at the discontinuities
that formed a more visible indication.
 Fig. 3 — A stationary magnetic particle examination system set
up for longitudinal and circular magnetization using wet
fluorescent particles.
By the 1930s, MT was quickly re-
placing the oil and whiting method of
NDE [liquid penetrant (PT)] in the
railroad industry. It was quicker and
did not leave behind the white powder
that required cleanup. After an MT
evaluation, only iron powder was left
behind, which could easily fall off the
part or be blown away.
Different Techniques
There are many different tech-
niques and combinations of tech-
niques of MT. The ASME Boiler and
Pressure Vessel Code, Section V, Article
7, recognizes five different techniques
of magnetization:
1. Prod technique
2. Longitudinal magnetization
technique
3. Circular magnetization tech-
nique
4. Yoke technique
5. Multidirectional magnetization
technique.
There are two different ferromag-
netic examination media: dry particles
and wet particles. Both forms can be
either fluorescent or nonfluorescent
(visible, color contrast) and come in a
variety of colors to contrast with the
tested material.
Most-Used Methods
Two of the most-used methods
are the stationary horizontal system,
using longitudinal and circular magne-
tization techniques, and the portable
yoke technique.
Stationary systems are generally
Fig. 4 — External longitudinal seam of an in-service boiler being
checked with magnetic particle examination using an AC yoke with
dry powder.
used for smaller parts such as crank
shafts and valve stems. They are often
found indoors around machine shops
and heat-treating facilities. Typically
they have a headstock and tailstock.
Parts can be clamped between stocks for
magnetization. There is also a coil
placed around the part to magnetize it
in the perpendicular direction. Station-
ary horizontal systems use the wet par-
ticle technique with a circulation tank
below the equipment — Fig. 3. Wet par-
ticles flow over the examined part and
drain into the circulation tank. Wet par-
ticles have more mobility flowing in a
liquid than do dry particles. This mobili-
ty helps sensitivity by allowing particles
to easily move to the discontinuities.
Fluorescent particles are commonly
used with stationary horizontal systems
because indoor operation makes it easy
to darken the area; required ultraviolet
(black) light can then be used to evalu-
ate the parts. Both wet method exami-
nations have about the same sensitivity,
but under correct lighting conditions,
fluorescent indications are much easier
to see. This type of stationary system
can cost $15,000 or more.
The MT yoke technique is the most
portable and lowest-cost method, and
therefore the most popular — Fig. 4. A
typical yoke kit would cost around $750.
Most yokes can operate in alternating
current (AC) or direct current (DC)
modes. DC gives the most penetration
and is recommended if subsurface dis-
continuities need to be detected. AC is
recommended if the surface is rough,
because AC gives the particles more mo-
bility than DC. A yoke has an electric
coil in the unit, creating a longitudinal
magnetic field that transfers through
Inspection Trends / Fall 2016
the legs to the examined part. The yoke
technique is easy to use with minimal
training. It can be used indoors, out-
doors, inside vessels and tanks, and in
all positions. Prior to use, the magnetiz-
ing power of the electromagnetic yoke
shall have been checked within the past
year. An AC yoke must have a lifting
power of at least 10 lb and a DC yoke of
at least 40 lb.
Basic Steps
The following illustrate steps to
use with the dry powder, nonfluores-
cent, yoke technique. Prior to the start
of examination, all equipment and me-
ters shall be calibrated in accordance
with ASME Section V, Article 7.
1. Clean the surface to be exam-
ined. This may be accomplished using
detergents, organic solvents, descaling
solutions, paint removers, vapor de-
greasing, sand or grit blasting, or ul-
trasonic cleaning methods — Fig. 5A.
2. Introduce a magnetic field into
the part — Fig. 5B.
3. Apply the ferromagnetic medi-
um while the part is still magnetized
— Fig. 5C.
4. Remove excess ferromagnetic
medium with a light air stream from a
bulb, syringe, or other source of low-
pressure dry air — Fig. 5D.
5. Interpret and evaluate any indi-
cations to the applicable acceptance
standard — Fig. 5E.
6. Turn the yoke 90 deg from the
original position and repeat steps 2–5.
Clean and demagnetize if necessary —
Fig. 5F.
ASME Section V, Article 7 requires
the magnetic particle visible method
23

A B
C D
E F
Fig. 5A–F — Shown are the basic steps for magnetic particle examination.
Fig. 6 — Light meter showing 107.0 foot-candles of light.
(color contrast) be evaluated with a
minimum light intensity of 100 foot-
candles on the part surface. The proper
quantity of light must be verified us-
ing some type of calibrated light meter
and witnessed and accepted by the in-
24 Inspection Trends / November 2016
spector — Fig. 6. If fluorescent mag-
netic particles are being used, a black
light shall achieve a minimum of 1000
microwatts per square centimeter on
the examined surface. If alternate
wavelength light sources are used to
provide ultraviolet light, causing fluo-
rescence in the particles, it shall be
qualified in accordance with ASME
Section V, Article 7, Appendix IV.
Typical Examples of ASME
Code-Required Inspections
In the ASME codes of construction,
magnetic particle examination or liquid
penetrant examination is specified
many times to detect the possibility of
surface defects. If material is nonmag-
netic, the only choice is liquid penetrant
examination. However, if material is fer-
romagnetic, magnetic particle examina-
tion is generally used. Some typical ex-
amples of ASME code-required inspec-
tions include, but are not limited to,
• Castings for surface defects
• Plates for laminations in corner
joints when the edge of one plate is
exposed and not fused into the weld
joint
• Head spin hole plug welds
• Weld metal buildup on plates
• Areas where defects have been
removed before weld repair.
Once boilers and pressure vessels
are in service, MT can be a widely used
examination method — Fig. 7. The Na-
tional Board Inspection Code (NBIC)
specifies MT may be used for the in-
spection of items such as:
• Internal and external surfaces of
boilers and pressure vessels
• Vessels in liquid ammonia service
• Components subjected to fire
damage
• Locomotive and historical boilers
• Yankee dryers
• Cargo tanks
• Vessels in LP gas service
• Weld repairs and alterations to
pressure-retaining items.
Typical In-Service
Inspection
Watertube Inspection
During visual examination, a boiler
watertube exhibited unusual trans-
verse marks in the fireside deposits —
Fig. 8A. The tube was wire brushed to
prepare for MT examination.
Magnetic particle examination re-
vealed transverse indications, which
were determined upon further inves-
tigation to be heat stress cracks —
Fig. 8B.
 A B
D E
Fig. 7 — Typical in-service inspections: A — MT examination of the longitudinal seam on an
in-service boiler; B — MT examination of a lifting lug weld on an in-service boiler; C — use of
an AC yoke in the MT process to detect fatigue-type discontinuities in welded seams of a
steam drum during in-service evaluation; D — crack in seal weld of boiler tube to steam
drum discovered with MT (this was the result of improper repair procedures); E — wet
fluorescent MT process showing a crack in a steam drum circumferential weld seam.
A B
C Fig. 8 — A — The tube prepared for MT
examination; B — MT examination showed
transverse indications that were identified
later as heat stress cracks; C — video
probe inside the watertube. (Photos
courtesy of Coastal Inspection Services.)
• Surface preparation is not as critical
as with other NDE methods. Most
surface contaminants will not hinder
detection of a discontinuity.
A video probe inside the watertube • A relatively fast method of
revealed scale plugging, which led to examination.
overheating of the tube — Fig. 8C. • Indications are visible directly on
the surface.
• Low-cost compared to many other
Advantages and NDE methods.
Disadvantages of Magnetic • A portable NDE method, especially
Particle Examination when used with battery-powered
yoke equipment.
• Postcleaning generally not necessary.
Advantages • A relatively safe technique; materials
generally not combustible or
• Can detect both surface and near- hazardous.
surface indications. • Indications can show relative size
Inspection Trends / Fall 2016
C
and shape of the discontinuity.
• Easy to use and requires minimal
amount of training.
Disadvantages
• Nonferrous materials, such as
aluminum, magnesium, or most
stainless steels, cannot be inspected.
• Examination of large parts may
require use of equipment with
special power requirements.
• May require removal of coating or
plating to achieve desired sensitivity.
• Limited subsurface discontinuity
detection capabilities.
• Postdemagnetization is often
necessary.
• Alignment between magnetic flux
and indications is important.
• Each part needs to be examined in
two different directions.
• Only small sections or small parts
can be examined at one time.
In conclusion, magnetic particle
examination can be a useful nonde-
structive examination method during
new construction and in-service
inspections. It can only be used on fer-
romagnetic materials; therefore, it is
not the best method for all applica-
tions. For quick, low-cost inspections,
MT is often the best NDE method for
detecting surface and slightly subsur-
face discontinuities.
JIM WORMAN
(jworman@nationalboard.org) is senior
staff engineer, The National Board of
Boiler and Pressure Vessel Inspectors,
Columbus, Ohio. He is also an AWS
Certified Welding Inspector and an ASNT
Level II in liquid penetrant and magnetic
particle inspection.
This article is reprinted with permission
from The National Board of Boiler and
Pressure Vessel Inspectors,
nationalboard.org.
25
 Technology Notes

Interpretations AWS Log: D1.1-08-112 A5.5/A5.5M:2014, Specification for

Inquiry: If the length of the weld con- Low-Alloy Steel Electrodes for
AWS D1.1, Structural Welding forms to size and the crater is under- Shielded Metal Arc Welding
Code — Steel sized but within the limits of the un-
dersizedness as established in Catego- Subject: Filler metal impact testing at
Subject: Undersized Crater ry (6), is the weld defective because a temperature lower than specified.
Code Edition: D1.1:2008 Category (3) is not satisfied? Code Edition: A5.5M:2006 and subse-
Code Provision: Table 6.1 Categories Response: Yes. quent editions; A5.18:2005 and subse-
(3) and (6) quent editions; A5.20/M:2005 and sub-
sequent editions; A5.28M:2005 and
subsequent editions; and A5.29M:2005
and subsequent editions
AWS Log: A5.5-A5.18-A5.20-A5.28-
A5.29-102
Inquiry: For the filler metal specifica-
tion listed herein, is it the intent of the
American Welding Society®
CERTIFICAATTION
committee that filler metal classifica-
tion testing to demonstrate comfor-
aws.org mance to a specified minimum accept-
able level for impact testing (i.e., mini-
mum energy specified temperature) can
be met by testing and meeting the re-
quirement at any lower temperature?
Response: Yes. However, the actual
temperature used for testing shall be
listed on the documentation when
AWS
W CERTIFIC
T ATTION PROOGR
GRAMS
MS issued.

SERIOUS
US WORK. SIGNIFICANTT IMP
MPPA
PAACCTT. Errata
The following Errata have been iden-
With “manufacturingg sskills gap” tified for AWS D1.1/D1.1M:2000, Struc-
co
conversa tions becocoming mmore and more tural Welding Code — Steel.
Page 42, Table 3.1, Group I, Steel
comm
mmonplace, e, it’
i s hard too ignore the Specification, ASTM A 53 A5.5. Change
need forr ccre
credentialed skills. ASTM A 53 A5.5 to ASTM A 53 Grade B.
Pages 80, 83, Figure 3.4, Detail B-
U3a-S, B-U5b, and TC-U5a. Change “3 X
AWS Certificatio
tions are thhe most R” to “18⁄ X R” and “6 X R” to “14⁄ X R”.
recognized credential
tials in the welding Pages 139, 141, Table 4.9, under (1)
industry; created and baccked by a Test on Plate, Type of Test Weld (Applic-
able Figures): Change “Groove (Fig. 4.30
collective of experience aandd ddistinction.
n. or 4.31)” for 38⁄ < T < 1 to “Groove (Fig.
4.21, 4.22 or 4.29).”
So, by earning an AWS Certification
C ca on, Page 176, Table 6.1 under “(6) Un-
dersized welds.” Change “In all cases,
you’re positioning yoursellf fo
for success.
s the undersize portion of the shall…” to
Why wait? Secure yourr fuuture now. “In all cases, the undersize portion of
the weld shall…”
Page 226, Clause 7.5.5.7, change
Start your
ur path to
t ward reference to subclause 6.6.1 to sub-
AWS Certification at clause 6.9.
Annex M, page 342 – Bottom Row,
go.aws.org/pa
ws thtoceertification under “Electrode Classification.”
Change “E10018-X” to “E11018-X.”

26 Inspection Trends / November 2016

 Mark Your Calendar
NDT in Canada 2016 Conference
November 15–17. Holiday Inn Hotel & Conference Centre,
Burlington, ON, Canada. Held in conjunction with the 6th In-
ternational CANDU In-Service Inspection Workshop. Contact
Canadian Institute for Non-Destructive Evaluation (CINDE),
(905) 387-1655, ext. 238, or events@cinde.ca.
FABTECH 2016 (AWS-sponsored event)
November 16–18. Las Vegas Convention Center, Las Vegas,
Nev. Contact American Welding Society, (800) 443-9353, or
fabtechexpo.com.
Destructive and Non-Destructive Testing Conference
(AWS-sponsored event)
November 16. Held during FABTECH at the Las Vegas Con-
vention Center, Las Vegas, Nev. Contact American Welding
Society, (800) 443-9353, ext. 224, or aws.org.
2017 API Inspection Summit
January 30–February 2, 2017. Galveston Island Convention
Center, Galveston, Tex. Contact American Petroleum Insti-
tute (API), (202) 682-8000 or api.org.
26th ASNT Research Symposium 2017
March 13–16, 2017. Jacksonville, Fla. Contact American So-
For info, go to aws.org/ad­index
28 Inspection Trends / November 2016
ciety for Nondestructive Testing, (800) 222-2768 or
asnt.org.
ASNT Annual Conference 2017
October 30–November 2, 2017. Gaylord Opryland Resort and
Convention Center, Nashville, Tenn. Contact American Society
for Nondestructive Testing, (800) 222-2768 or asnt.org.
Educational Opportunities
GE Inspection Academy Courses. Online e-courses, on-site
classes, and week-long classroom programs in the major in-
dustrial evaluation techniques. For information, visit gein-
spectionacademy.com.
NDE Classes. Moraine Valley Community College, Palos
Hills, Ill., offers NDE classes in PT, MT, UT, RT, radiation
safety, and eddy current, as well as API 510 exam prep and
weld inspection. For more information, contact (708) 974-
5735; wdcs@morainevalley.edu; morainevalley.edu/NDE.
EPRI NDE Training Seminars. EPRI offers NDE technical
skills training in visual examination, ultrasonic examina-
tion, ASME Section XI, UT operator training, etc. Contact
Sherryl Stogner, (704) 547-6174, e-mail: sstogner@epri.com.
American Welding Society®
aws.org
IMAGIN
INEE IT.
Direct access to an enccyclopedia
of weldingg kno
kn wledge,
g writtetten by
subject-m
-matter experts, at any tim
ime.
go.aws.org/awshandboo
w book
Nondestructive Examination Courses. A course schedule is
available from Hellier, 277 W. Main St., Ste. 2, Niantic, CT
06357; (860) 739-8950; FAX (860) 739-6732.

Preparatory and Visual Weld Inspection Courses. One- and

two-week courses presented in Pascagoula, Miss., Houston,
Tex., and Houma and Sulphur, La. Contact Real Educational
Services, Inc.; (800) 489-2890; info@realeducational.com.

CWI/CWE Course and Exam. A ten-day program presented

in Troy, Ohio. Contact Hobart Institute of Welding Technol-
ogy, (800) 332-9448; hiwt@welding.org; welding.org.

T.E.S.T. NDT, Inc., Courses. CWI preparation, NDE courses,

including ultrasonic thickness testing and advanced phased
array. On-site training available. T.E.S.T. NDT, Inc., 193
Viking Ave., Brea, CA 92821; (714) 255-1500; FAX (714)
255-1580; ndtguru@aol.com; testndt.com.

NDE Training. NDE training at the company’s St. Louis-area

facility or on-site. Level III services available. For a schedule
of upcoming courses, contact Quality Testing Services, Inc.,
2305 Millpark Dr., Maryland Heights, MO 63043; (888)
770-0103; training@qualitytesting.net; qualitytesting.net.

CWI/CWE Prep Course and Exam and NDT Inspector

Training Courses. An AWS Accredited Testing Facility.
Courses held year-round in Allentown, Pa., and at cus-
tomers’ facilities. Contact Welder Training & Testing Insti-
tute (WTTI); (800) 223-9884; info@wtti.edu; wtti.edu.

For info, go to aws.org/ad­index

American Welding Society®

STTANDARDS
A
aws.org

THE LA
ATTEST RELEASES
ARE HERE!
The AWS Volunteer Committeees work tirelessly to ensure
AWS Standards remain at the forefront
f of advancements
in welding technology. Each month,
m new or revised
standards are featured on the AWS Bookstore website.
This month’s featured releases incclude:
z B4.0:2016, Standard Method ds for Mechanical Teesting of
Weelds
z C3:4M/C3.4:2016, Specification for To orch Brazing
z C3:5M/C3.5:2016,, Specifica
p tion for Induction Brazingg
z D1.8/D1.8M:2016, Structura al Weelding Code – Seismic
Supplement
z D17.3/D17.3:2016, Specifica ation for Frriction Stir Weelding
of Aluminum Alloys for Aerosspace Applications
Keep an eye on the latest releaases on the AWS Bookstore
website, under the “Pick ofo the Month” section
at go..aws.orgg/awwsstandardds
For info, go to aws.org/ad­index

Inspection Trends / Fall 2016 29

 Certification Schedule

Certified Welding Inspector (CWI) 9-Year Recertification Seminar for CWI/SCWI

For current CWIs and SCWIs needing to meet education re-
Location Seminar Dates Exam Date quirements without taking the exam. The exam can be taken
Las Vegas, NV FABTECH Nov. 18 at any site listed under Certified Welding Inspector.
Miami, FL Exam only Dec. 8
St. Louis, MO Exam only Dec. 10 Location Seminar Dates
Los Angeles, CA Dec. 4–9 Dec. 10 Miami, FL Dec. 4–9
Orlando, FL Dec. 4–9 Dec. 10 New Orleans, LA Jan. 8–13
Reno, NV Dec. 4–9 Dec. 10 Denver, CO Feb. 26–March 3
Houston, TX Dec. 4–9 Dec. 10 Dallas, TX March 5–10
Charlotte, NC Jan. 8–13 Jan. 14 Miami, FL March 5–10
Dallas, TX Jan. 8–13 Jan. 14
Huntsville, AL Jan. 8–13 Jan. 14 Certified Welding Educator (CWE)
Beaumont, TX Jan. 15–20 Jan. 21 Seminar and exam are given at all sites listed under Certified
Pittsburgh, PA Jan. 22–27 Jan. 28 Welding Inspector. Seminar attendees will not attend the Code
Denver, CO Jan. 22–27 Jan. 28 Clinic portion of the seminar (usually the first two days).
Long Beach, CA Jan. 22–27 Jan. 28
Atlanta, GA Jan. 29–Feb. 3 Feb. 4 Certified Welding Sales Representative (CWSR)
Seattle, WA Jan. 29–Feb. 3 Feb. 4 CWSR exams are given at Prometric testing centers. More
Milwaukee, WI Jan. 29–Feb. 3 Feb. 4 information at aws.org/certification/detail/certified-welding-
New Orleans, LA Feb. 5–10 Feb. 11 sales-representative.
Waco, TX Feb. 5–10 Feb. 11
San Diego, CA Feb. 5–10 Feb. 11 Certified Welding Supervisor (CWS)
Little Rock, AR Feb. 5–10 Feb. 11 CWS exams are given at Prometric testing centers. More in-
Houston, TX Feb. 26–March 3 March 4 formation at aws.org/certification/detail/certified-welding-
Kansas City, MO Feb. 26–March 3 March 4 supervisor.
Norfolk, VA Feb. 26–March 3 March 4
Boston, MA March 5–10 March 11
Sacramento, CA March 5–10 March 11 Certified Radiographic Interpreter (CRI)
Salt Lake City, UT March 5–10 March 11 The CRI certification can be a stand-alone credential or can
Orlando, FL March 5–10 March 11 exempt you from your next 9-Year Recertification.
Chicago, IL March 12–17 March 18
San Antonio, TX March 12–17 March 18 Location Seminar Dates Exam Date
Springfield, MO March 19–24 March 25 Miami, FL Exam Only Nov. 19
Portland, OR March 19–24 March 25 Seattle, WA Feb. 27–March 3 March 4
Las Vegas, NV March 19–24 March 25 Houston, TX March 13–17 March 18
Dallas, TX March 26–31 April 1 San Francisco, CA April 10–14 April 15
Minneapolis, MN March 26–31 April 1 Las Vegas, NV May 1–6 May 7
Pittsburgh, PA March 26–31 April 1 Cleveland, OH June 5–9 June 10
Atlanta, GA April 2–7 April 8 Dallas, TX July 17–21 July 22
San Franciso, CA April 2–7 April 8 Kansas City, MO Aug. 21–25 Aug. 26
Detroit, MI April 2–7 April 8 Chicago, IL Sept. 11–15 Sept. 16
Syracuse, NY April 23–28 April 29 Pittsburgh, PA Oct. 9–13 Oct. 14
Beaumont, TX April 23–28 April 29
Pittsburgh, PA May 7–12 May 13 Certified Robotic Arc Welding (CRAW)
Orlando, FL May 7–12 May 13 ABB, Inc., Auburn Hills, MI; (248) 391-8421
Tulsa, OK May 7–12 May 13 OTC Daihen, Inc., Tipp City, OH; (937) 667-0800, ext. 218
Biloxi, MS May 7–12 May 13 Lincoln Electric Co., Cleveland, OH; (216) 383-8542
Des Moines, IA May 7–12 May 13 Genesis-Systems Group, Davenport, IA; (563) 445-5688
Houston, TX May 14–19 May 20 Wolf Robotics, Fort Collins, CO; (970) 225-7736
Cleveland, OH May 14–19 May 20 On request at MATC, Milwaukee, WI; (414) 456-5454

IMPORTANT: This schedule is subject to change without notice. Please verify your event dates with the Certification Dept. to confirm your
course status before making travel plans. Applications are to be received at least six weeks prior to the seminar/exam or exam. Applications
received after that time will be assessed a $250 Fast Track fee. Please verify application deadline dates by visiting our website
aws.org/certification/docs/schedules.html. For information on AWS seminars and certification programs, or to register online, visit
aws.org/certification or call (800/305) 443-9353, ext. 273, for Certification; or ext. 455 for Seminars.

30 Inspection Trends / November 2016

 American Welding Society®
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 Just the Facts
Do We Need to Visually Examine the Inside Surfaces of
Piping Welds?
Fig. 1 — Do the inside surfaces of pipe welds, such as these pipe-to-elbow and
elbow-to-flange welds, need to be visually examined?
When called upon to visually ex-
amine welds in a piping system (Fig.
1), what surfaces of the welds must be
examined? Is it just the external, out-
side surfaces of the welds and heat-
affected zones (HAZs), or also the inter-
nal, inside surfaces? Is a mirror or
borescope required to visually examine?
Several codes and standards are evalu-
ated here to determine the answer.
ASME B31.3-2014, Process Pip-
ing Code. This code contains require-
ments for visual examination of welds
in piping systems. Visual examination
is defined in paragraph 344.2.1 as
“…observation of the portion of com-
ponents, joints, and other piping ele-
ments that are or can be exposed to
view before, during, or after manufac-
ture, fabrication, assembly, erection,
examination, or testing.” For welding,
“This examination includes…require-
32 Inspection Trends / November 2016
ments for…joint preparation, align-
ment, welding…assembly, and erec-
tion.” The method and procedure are
described in paragraph 344.2.2 as vi-
sual examination that “shall be per-
formed in accordance with the (ASME
Boiler & Pressure Vessel) Code, Section
V, Article 9.”
But, does this mean visual exami-
nation of the internal surfaces in addi-
tion to the external surfaces is re-
quired? Just what does “…can be ex-
posed to view…” mean? These were an-
swered through a number of interpre-
tations from the ASME B31.3 code
committee, including Interpretation
8-10 from 1989 in which the question
asked “Is it the intent (of this para-
graph) that…visual examination of weld
internal surfaces requires indirect ob-
servation by aids such as borescopes?”
The reply was “No. The intent…is that
By Rich Campbell
the phrase ‘…or can be exposed to
view…’ refers to direct visual examina-
tion.” Thus, this code does not require
examination of any surfaces that cannot
be examined by direct visual examina-
tion. This means the external surfaces
as well as internal surfaces, if they can
be examined by direct visual examina-
tion, such as the internal surface of a
weld on a flange.
ASME B31.1-2016, Power Piping
Code. The Power Piping Code provides
better clarity. Paragraph 136.4.2 Visu-
al Examination requires visual exami-
nation of piping welds in accordance
with the methods in ASME Section V,
Article 9. But, visual examination is
defined in paragraph 100.2 as “the ob-
servation of whatever portions of
components, joints, and other piping
elements that are exposed to such ob-
servation either before, during, or af-
ter manufacture, fabrication, assem-
bly, erection, inspection, or testing.”
Subparagraph (A) addresses accept-
ance criteria, which for incomplete
penetration includes a statement of
“applies only when inside surface is
readily accessible.” Readily accessible
as defined in 100.2 is “for visual exam-
ination, readily accessible inside sur-
faces are defined as those inside sur-
faces that can be examined without
the aid of optical devices. (This defini-
tion does not prohibit the use of opti-
cal devices for a visual examination;
however, the selection of the device
should be a matter of mutual agree-
ment between the owner and the fab-
ricator or erector.)”
2015 ASME Boiler and Pressure
Vessel Code, Section V, Nondestruc-
tive Examination. Since the ASME
codes are being discussed, the defini-
tions in ASME Section V, Article 9,
Mandatory Appendix I — Glossary of
Terms for Visual Examination, are im-
portant (limiting this to visual exami-
nation of metallic pipe). In this, visual
examination is defined as “a nonde-
structive examination method used to
 Fig. 2 — A mirror is used as an aid for the visual examination of
pipe welds.
evaluate an item by observation, such
as the correct assembly, surface condi-
tions, or cleanliness of materials,
parts, and components used in the
fabrication and construction of ASME
Code vessels and hardware.” This fur-
ther clarifies direct visual examination
as “a visual examination technique
performed by eye and without any vi-
sual aids (excluding light source, mir-
rors, and/or corrective lenses).” This is
compared with remote visual examina-
tion, which is defined as “a visual ex-
amination technique used with visual
aids for conditions where the area to
be examined is inaccessible for direct
visual examination” and with en-
hanced visual examination, which is
defined as “a visual examination tech-
nique using visual aids to improve the
viewing capability, e.g., magnifying
aids, borescopes, video probes, fiber
optics, etc.”
In paragraph T-952, Direct Visual
Examination, it states: “Mirrors may
be used to improve the angle of vision,
and aids such as a magnifying lens
may be used to assist examinations.”
Paragraph T-953, Remote Visual Ex-
amination, states: This “…may use vi-
sual aids such as mirrors, telescopes,
borescopes, fiber optics, cameras, or
other suitable instruments.” Thus, di-
rect visual examination may include
mirrors but other aids like magnifying
lenses or borescopes are not part of
this — Fig. 2.
ASME BPE-2016, Bioprocessing
Equipment Standard. In the biotech-
nology and pharmaceutical industries,
stainless steel and nickel-alloy piping
and tubing systems are utilized in the
manufacture of drug products, and the
governing standard is ASME BPE. The
Fig. 3 — Borescope examination of a tube weld (left side) in the
biotechnology industry.
requirements in this standard include
not only the normal welding accept-
ance criteria of no cracks, incomplete
penetration, incomplete fusion, and
limits on misalignment, but also oxi-
dation or color limitations on the in-
ternal surfaces of the weld and HAZ,
to ensure the drug product is not con-
taminated. This standard includes col-
or comparison charts that can be used
to evaluate these welds.
Paragraph MJ-7.3.3 requires that
“The external surfaces of all welds shall
be visually examined.” This also re-
quires “…borescopic or direct visual in-
spection of the process contact sur-
faces on at least 20% of the welds in
each system…” (typically the internal
surfaces of tube or pipe welds) — Fig.
3. Thus, this standard requires some
means of visual inspection of the in-
ternal surfaces.
AWS D18.1/D18.1M:2009, Speci-
fication for Welding of Austenitic Stain-
less Steel Tube and Pipe Systems in
Sanitary (Hygienic) Applications. The
AWS D18.1 specification was devel-
oped for gas tungsten arc welding and
plasma arc welding of stainless steel
and nickel alloy tubing and piping sys-
tems in the hygienic food, dairy, and
beverage industries. Paragraph 6.1.1
requires visual examination of the out-
side surfaces of all welds. For those
welds that do not meet the acceptance
criteria for the external surfaces, the
internal surfaces are to be examined.
The specification states: “Internal ex-
amination of weld surfaces shall be
performed with a borescope or other
device acceptable to the Owner….” In
addition, paragraph 6.1.3 states that
the internal surfaces of welds “which
are…in easily accessible areas (such as
Inspection Trends / Fall 2016
elbows, ferrules, etc.) and can easily be
examined with simple tools (such as in-
spection mirrors and flashlights) shall
be visually examined.”
Summary
Piping codes such as ASME B31.1
and B31.3 only require visual examina-
tion of the external surfaces of welds,
plus examination of the internal sur-
faces when accessible for direct visual
examination only. Additional visual
aids such as mirrors may be used, but
remote visual examination is not re-
quired. Several high-purity piping
standards, such as ASME BPE and
AWS D18.1, require visual examina-
tion of the external surfaces plus di-
rect or remote (e.g., borescope) visual
examination of the internal surfaces
for a percentage of welds on tubing
and piping systems or if the external
surface does not meet the acceptance
criteria.
RICH CAMPBELL, PhD, PE
(rdcampbe@bechtel.com), is a Bechtel
Fellow and Welding Technical Specialist
with Bechtel Corp., Houston, Tex. He is an
AWS Senior Certified Welding Inspector,
a CWB Level 2 Welding Inspector, an
ASNT NDT Level III Visual Testing
Inspector, a registered metallurgical
engineer, member of the AWS D1
Committee on Structural Welding, chair
of the D1K Subcommittee on Stainless
Steel, member of the D1H Subcommittee
on Sheet Steel, member of the ASME
B31.3 Process Piping Section Committee,
vice chair of the ASME B31.3 Subgroup E
on Fabrication, Examination, and Testing,
and member of the ASME B31 Fabrication
and Examination Committee and the
ASME Board on Conformity Assessment.
33
 The Answer Is By K. Erickson and A. Moore

Q: I was asked a question that I’m

not really sure how to answer.
Here’s the scenario: A welder is us-
ing the gas metal arc welding
(GMAW) or flux cored arc welding
(FCAW) process, and he tries to
strike an arc on the side of the root
area. He misses the material, the
wire goes through the root opening,
and a little piece of wire is left on the
inside of the pipe that is fused to the
metal when he finally strikes the arc
(see Fig. 1).
My questions are as follows: When
the wire that is left behind in the
joint is noted either visually or with
radiography, what type of disconti-
nuity would it be classified as? Be-
cause it is fused into the weld and
base material, is it considered to be
excessive penetration? Would the
wire sticking into a pipe or a pres-
sure vessel be rejectable if you are Fig. 1 — Gas metal arc welding wire sticking to a circumferential weld.
using the acceptance criteria in the
ASME Boiler and Pressure Vessel
Code, Section VIII; B31.3, Process It is not the inspector’s job to de- tograph of a whisker is included in the
Piping Code; or some other accept- termine what constitutes a good presentation on defects in the ASME
ance criteria for pressure-contain-
weld. An inspector does not develop seminar titled Practical Welding
ing equipment? Or would it be ac-
ceptable? — Leif Woodman, the inspection criteria; the inspector Technology.
Batavia, N.Y. applies the criteria provided. It is While in service, the electrode
someone other than the inspector protruding past the root surface can
who develops the acceptance criteria. break off and damage valve seats,
A: (from A. Moore) Mr. Woodman, The visual welding inspector makes pumps, turbines, and other equipment
this is an interesting question. API the decision to accept or reject a weld located downstream. The designer can
1104 is the only welding standard I based on the visual criteria provided install a strainer on the upstream side
am familiar with that addresses the by the applicable welding/fabrication of equipment to keep debris from
issue of filler metal extending into standard as modified by the specifica- flowing downstream. Were the strain-
the inside of the pipe. The visual ac- tions. Codes provide minimal accept- er not installed, pieces of electrode,
ceptance criteria for welder qualifica- ance criteria to ensure the system can slag, spatter, etc., ingested by the
tion includes the following: be used without endangering the user equipment could damage it beyond
“When semiautomatic or mecha- or public. When the manufacturer, repair.
nized welding is used, filler metal contractor, or the owner recognizes a I was involved in a case where the
protruding into the inside of the pipe condition that may materially affect contractor mistakenly installed the
shall be kept to a minimum.” the safety of the user or interfere strainer on the downstream side of a
Provision 6.4 is included in both with the serviceability of the system, Roots sour gas rotary blower. A piece
the 20th edition and the 21st edition it is incumbent upon them to impose of electrode — a whisker — passed
of API 1104. The restriction is not in- additional requirements or take steps into the pump and severely damaged
cluded in the acceptance criteria for that will ensure the system is safe to the pump housing after about 10 min
production welds. operate and ensure the service life is of operation. The pump had to be
ASME B31.1, Power Piping Code, not impaired. Additional require- shipped back from the Middle East to
does not address the issue nor does ments or restrictions imposed by the the manufacturer in upstate New
B31.3, Process Piping Code. We could try owner are usually addressed in the York for a new housing.
to hang our hats on the limitation of project specifications. Even though the piping was in-
“internal protrusion,” although that Filler metal protruding past the stalled in accordance with API 1104, I
usually applies to “excessive melt- root surface is something many of us guess holding the filler metal pro-
through” on the root surface and applies have seen in the field. The wire pro- truding inside the pipe to a minimum
only to B31.3 piping categorized as truding past the root surface is some- wasn’t good enough.
“high pressure” fluid service. times referred to as a “whisker.” A pho- Got a problem with filler metal

34 Inspection Trends / November 2016

protruding inside the pipe? You bet-
ter make sure it is properly addressed
by the project specification, because
the codes pay it scant attention.
Q: Our shop performs welder quali-
fication bend tests for several weld-
ing companies in the area. At times,
we receive weld straps for bending
that are less than 1½ in. wide. Is
there a minimum or maximum width
to these samples for bending?
A: (from K. Erickson) You are refer-
ring to transverse root and face bends.
As per AWS D1.1, the required test
specimen width is 1½ in. These straps
can be removed from the plate or pipe
by several different means, including
thermal cutting, saw cutting, cutting
blades, etc. When marking the test
coupon for separation, you should al-
ways mark and advise the individual
performing this operation to remove
the straps a bit larger, and then they
can be ground down to the 1½-in. re-
quired dimension.
In your case, where you are not part
of the sectioning process, it would be
difficult to always receive straps meas-
ured at 1½ in. for the entire width of the
sample within the bend radius area. I
would advise your customers of the 1½-
in. criteria and not accept any straps
that are 13⁄ 2 in. less than the 1½ in.
Larger width straps can be accept-
ed and tested provided they can still
satisfactorily be positioned within the
bending jig correctly. Any strap wider
than 1½ in. would still need to be eval-
uated per the entire width tested.
Both the root and face bends must
pass for the welder to be qualified. Any
open relevant surface discontinuities
that exceed the acceptance criteria for
bend tests per AWS D1.1 would result
in a failure for the entire bend sample.
The Society is not responsible for any
statements made or opinion expressed herein.
Data and information developed by the authors
are for specific informational purposes only
and are not intended for use without
independent, substantiating investigation on
the part of potential users.
KENNETH ERICKSON is manager of
quality at National Inspection &
Consultants, Inc., Ft. Myers, Fla. He is an
AWS Senior Certified Welding Inspector,
an ASNT National NDT Level III Inspector
in four methods, and provides expert
witness review and analysis for legal
considerations.
ALBERT J. MOORE JR. is vice president,
Marion Testing & Inspection, Canton,
Conn. He is an AWS Senior Certified
Welding Inspector and an ASNT ACCP
NDT Level III. He is also a member of the
AWS Certification Committee and the
Committee on Methods of Inspection of
Welds.

American Welding Society® American Welding Society®

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