rtfi assessment presentation 5-23-05
DESCRIPTION
RTFITRANSCRIPT
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Assessment of Radiographic Film Interpretation
Jim Carswell
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Presentation Outline
Morning 8:00am 11:00 Interpretation/perceptionReviewRadiographyWelding processesAppearance and classification of defectsScenarios
Afternoon 1:00pm 3:00pmReview acceptance criteria: ASME B31.1, API 1104 AWS D1.1
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This presentation reviews the process of conducting radiographic film assessments on Saudi Aramco Projects.
Objective: Maintain Continuity of Film Assessors
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Getting StartedAttitude & professionalism
Fair but firm
Make Sure you are right! second opinion before you make the call
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Factors affecting Interpretation
Heredity/Genetics and visual perception Can you see it? What do you see? PerceptionDistortionIllusionDetection
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Perception
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Distortion
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Illusion
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DetectionHow many faces can you detect?
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There are eleven faces
Scoring:
1-4 average8 extraordinary9 above average10 very observant11 extremely observant
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Factors affecting Interpretation
Heredity/Genetics and visual perceptionCondition of the human eyeEye examinations 20/40Wear your glasses/contacts, if scratched replace.
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Factors affecting Interpretation
Heredity/Genetics and visual perception Condition of the human eye EquipmentViewer/densitometerViewing conditionsTools
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Factors affecting Interpretation
Heredity/Genetics and visual perception Condition of the human eye Equipment Film and radiographic techniquesDiscussing throughout
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When in doubt Ask for 2nd opinionRe-shootGrind & re-shoot
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Radiography
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Contact - DWSV
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Elliptical - DWDV
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Single wall single view
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Radiographic film
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Film processing
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Results: good technique
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WELDINGJoining materials at the atomic/molecular level
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Terminology
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Five Basic Weld Joints
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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.
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Benefits of the electrode coating
Arc stabilizationProvides gas shielding decomposition of cellulose and limestoneDe-oxidation of weld poolStrengthens the weld - adds alloying elementsIncreases deposition by adding iron filler Slag provides oxide barrier for solidifying metalSlag provides thermal insulation of the cooling weld
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Common defects associated with SMAW
PorosityCracksSlagIncomplete fusionIncomplete penetrationBurn throughLack of fillRoot concavity UndercutExcessive penetration
The SMAW process is almost totally operator dependant
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Gas Metal Arc Welding(GMAW) Welding is generated by an electric arc between a continuously fed solid wire consumable and the base metal
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Common defects associated with GMAW
PorosityCracksIncomplete fusionUndercutlack of fillIncomplete penetration
The GMAW process is automated, semi-automated and machine.
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Gas Tungsten Arc Welding(GTAW) Welding is generated by an electric arc between a tungsten electrode, a solid wire consumable and the base metal.
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Common defects associated with GTAW
PorosityTungsten inclusionsCracksIncomplete fusionUndercut
The GTAW process is almost totally operator dependant
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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.
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Common defects associated with SAW
PorosityCracksSlagIncomplete fusion
The GMAW process is automated, semi-automated and machine.
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WELDING DEFECTS
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Common causes of defects
Welder-techniqueCleaningJoint preparationJoint design
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Welding technique
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Cleaning(Porosity, Fusion, Tungsten & Slag)
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Cleaning - slag removal
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Joint preparation - poor fit-up(Fusion, Penetration & Mismatch - Hi-Lo)
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POROSITY
Causes:ContaminationMoistureEnvironment wind, etc.
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Porosity
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Porosity
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Incomplete fusion - Sidewall
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Incomplete Penetration
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Incomplete Penetration
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Incomplete Penetration
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Incomplete Penetration
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Longitudinal Root Crack
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Longitudinal Root Crack
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Interpass Slag
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Interpass Slag
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Burn Through
Cause:Welding techniquePoor joint fit-up
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Burn Through
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Burn Through
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Root Concavity
Cause:Welding techniquePoor joint fit-up
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Root Concavity
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Root Concavity
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Undercut
Cause:Welding technique excessive heat
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Internal Undercut
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Internal Undercut
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External Undercut
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External Undercut
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Excessive Penetration
Cause:Welding technique excessive arc penetrationPoor joint fit-up
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Excessive Penetration
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Excessive Penetration
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Lack of Fill
Cause:Welding technique
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Lack of Fill
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Lack of Fill
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Tungsten Inclusion
Cause:Welding technique
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Tungsten Inclusions
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Tungsten Inclusions
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Mismatch - Hi low
Cause:Poor joint fit-up
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Mismatch
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Mismatch
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Weld Spatter
Cause:Poor joint fit-upWelding technique
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Miscellaneous
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Film Handling And Processing DefectsScratches Finger prints Crimp marks Light Leaks Chemical Stains Roller Marks & Artifacts
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Scratches
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Chemical Stains
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Light Leaks
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Static Marks
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Store film upright
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Artifacts
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Water marks
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Crimp marks
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CODES & STANDARDS in the petrochemical industry
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What is the purpose for Codes & Standards?They ensure uniform practices throughout industry
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Three common codes used in Saudi Arabias petrochemical industry ASME B31.3 Boiler and Pressure Vessel Code API 1104 Welding of Pipelines And Related Facilities AWS D1.1 Structural Welding Code - Steel
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ASME B31.3 andAppendix 4Film interpretation acceptance criteria for Process Piping on-plot facilities
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API 1104Film interpretation acceptance criteria for pipelines
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AWS D1.1Film interpretation acceptance criteria for structures
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Conducting Film AssessmentsGetting Started:
Attitude & professionalismFair but firmMake Sure you are right! second opinion before you make the call
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Film AssessmentsQuality System
Obtain a copy of the Purchase Order or applicable legal document for each assessment (project)Highest document in the pyramidAgreement that binds two partiesSchedule Q & SAEP 1150Determine the applicable Codes and revisions for the project
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Film AssessmentsQuality System
Approved personnel Valid Saudi Aramco RTFI cardCompany certificationVisual acuity examinationJaeger #1 & Ishara color platesApproved NDT procedures approval letter from NDTU for each project
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Film AssessmentsQuality System
Condition of Equipment SourcesFilm Processing tanks, dryer, chemicals, timers, time/temperature conversion chartsIQIs number belts ect.Film ViewersFacility
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Film AssessmentsFilm Quality - Guidelines
Many things make up film qualityDensity, Sensitivity, IQI, ID, F, scratches, crimp marksDensity of weld is 2-4 & Parent material over 4.0Sensitivity wire not required across entire weldIQI damage bent, touching or crossing
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Film AssessmentsFilm Quality - Guidelines
ID - traceable with all required information F for film-side techniquesScratches & crimp marksBlack letter B NOT requiredWeld spatter use one inch to verify acceptability
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Film AssessmentsWeld Quality - Guidelines
If the measurement it is on the line give it to themWhen in doubt ask for a second opinion or re-shoot Use film digitizer for close callsStay on solid ground
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Film AssessmentsWeld Quality - Guidelines
Use Acc/Rej straight from the applicable code avoid second-hand documents.
Ethics Discussion recent unethical findings of NDT contractorDuplication of radiographsNDT technicians not certifiedConflict of interest
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Getting StartedAttitude & professionalism
Fair but firm
Make Sure you are right! second opinion before you make the call
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END