Radiographic Film

Interpretation of Welds
RTFI Presentation Outline
Morning 8:00am – 12:00noon
• Interpretation/perception
• Welding processes
• Appearance and classification of defects
• Review acceptance criteria:
ASME B31.1
API 1104
AWS D1.1
• Interpret radiographs

Afternoon 1:00pm – 4:00pm

• Interpret radiographs
 This presentation reviews the
process of detecting, classifying
and evaluating to acceptance
criteria discernable defects on
radiographic film.
Factors affecting Interpretation
•Heredity/Genetics and visual perception
• Can you see it?
•What do you see?

•Perception
•Distortion
•Illusion
•Detection
Perception
Distortion
Illusion
 Detection

How many faces can you detect?

There are eleven faces

Scoring:
1-4 average
8 extraordinary
9 above average
10 very observant
11 extremely observant
Factors affecting Interpretation
• Heredity/Genetics and visual perception
• Condition of the human eye
• Eye examinations 20/40
• Wear your glasses/contacts, if scratched –
replace.
Factors affecting Interpretation
• Heredity/Genetics and visual perception
• Condition of the human eye
• Equipment
• Viewer/densitometer
• Viewing conditions
• Tools
Factors affecting Interpretation
• Heredity/Genetics and visual perception
• Condition of the human eye
• Equipment
• Film and radiographic techniques
• Discussing throughout
When in doubt
Ask for 2nd opinion
Re-shoot
Grind & re-shoot
Radiography
Contact - DWSV
Elliptical - DWDV
Single wall single view
Radiographic film
Film processing
Results: good technique
 Welding
Joining materials at the atomic/molecular level
Welding equipment

Welding is generated by an electric arc

Terminology
Five Basic Weld Joints
 Common Welding Processes Used
In The Petrochemical Industry

• SMAW (Shielded Metal Arc Welding)

• GMAW (Gas Metal Arc Welding)

• GTAW (Gas Tungsten Arc Welding)

• SAW (Submerged Arc Welding)

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

•Arc stabilization
•Provides gas shielding – decomposition of
cellulose and limestone
•De-oxidation of weld pool
•Strengthens the weld - adds alloying elements
•Increases deposition by adding iron filler
•Slag provides oxide barrier for solidifying metal
•Slag provides thermal insulation of the cooling weld
 Common defects associated
with SMAW
Porosity
Cracks
Slag
Incomplete fusion
Incomplete penetration
Burn through
Lack of fill
Root concavity
Undercut
Excessive penetration
• The SMAW process is almost totally operator dependant
Gas Metal Arc Welding
(GMAW)

Welding is generated by an electric arc between a

continuously fed solid wire consumable and the base metal
 Common defects associated
with GMAW
Porosity
Cracks
Incomplete fusion
Undercut
lack of fill
Incomplete penetration

•TheGMAW process is automated, semi-automated and

machine.
Gas Tungsten Arc Welding
(GTAW)

Welding is generated by an electric arc

between a tungsten electrode, a solid wire
consumable and the base metal.
 Common defects associated
with GTAW
Porosity
Tungsten inclusions
Cracks
Incomplete fusion
Undercut

•The GTAW process is almost totally operator dependant

Submerged Arc Welding
(SAW)

Welding is generated by an electric arc

between a continuously fed solid wire
consumable and the base metal while
totally submerged in a protective flux.
 Common defects associated
with SAW
Porosity
Cracks
Slag
Incomplete fusion

•TheGMAW process is automated, semi-automated and

machine.
Welding Defects
Common causes of defects
•Welder-technique
•Cleaning
•Joint preparation
•Joint design
Welding technique
 Cleaning
(Porosity, Fusion, Tungsten & Slag)
Cleaning - slag removal
Joint preparation - poor fit-up
(Fusion, Penetration & Mismatch - Hi-Lo)
POROSITY

Causes:
•Contamination
•Moisture
•Environment – wind, etc.
Porosity
Porosity
Cluster Porosity
Cluster Porosity
Aligned Root-Pass Porosity
Hollow Bead
Incomplete Fusion

Causes:
•Incomplete penetration of arc
•Inadequate welding current
•Poor joint fit-up
Incomplete fusion - Sidewall
Incomplete Penetration

Cause:
•Poor joint design
•Welding technique
Incomplete Penetration
Incomplete Penetration
Incomplete Penetration
Incomplete Penetration
Mismatch - Hi low

Cause:
•Poor joint fit-up
Mismatch
Mismatch
Cracks

Causes:
•Stress - thermal/mechanical
•Welding technique
•Electrode material (wrong alloy)
Transverse Cracks
Transverse Cracks
Longitudinal Root Crack
Longitudinal Root Crack
Slag Inclusion

Causes:
•Non-removal
•Welding technique
Interpass Slag
Interpass Slag
Burn Through

Cause:
•Welding technique
•Poor joint fit-up
Burn Through
Burn Through
Root Concavity

Cause:
•Welding technique
•Poor joint fit-up
Root Concavity
Root Concavity
Undercut

Cause:
•Welding technique – excessive heat
Internal Undercut
Internal Undercut
External Undercut
External Undercut
Excessive Penetration

Cause:
•Welding technique – excessive arc
penetration
•Poor joint fit-up
Excessive Penetration
Excessive Penetration
Lack of Fill

Cause:
•Welding technique
Lack of Fill
Lack of Fill
Tungsten Inclusion

Cause:
•Welding technique
Tungsten Inclusions
Tungsten Inclusions
Weld Spatter

Cause:
•Poor joint fit-up
•Welding technique
Miscellaneous
Film Handling And Processing
Defects
Scratches
Finger prints
Crimp marks
Light Leaks
Chemical Stains
Roller Marks & Artifacts
Scratches
Chemical Stains
Light Leaks
Static Marks
Store film upright
Artifacts
Water marks
Crimp marks
CODES & STANDARDS

in the petrochemical
industry
What is the purpose for Codes &
Standards?

They ensure uniform practices throughout

industry
Three common codes used in Saudi
Arabia’s petrochemical industry

ASME B31.3
In-Plant Process Pipe

API 1104
Welding of Pipelines And Related Facilities

AWS D1.1
Structural Welding Code - Steel
 ASME B31.3
and
Appendix 4

Film interpretation acceptance criteria for

Process Piping “on-plot” facilities
 API 1104

Film interpretation acceptance criteria for

pipelines
 AWS D1.1

Film interpretation acceptance criteria for

structures
END