RTFI Assessment Presentation 5-23-05

Assessment of Radiographic
Film Interpretation
Jim Carswell
Presentation Outline
Morning 8:00am – 11:00
Interpretation/perception
Review
•Radiography
•Welding processes
•Appearance and classification of defects
•Scenarios
Afternoon 1:00pm – 3:00pm

•Review acceptance criteria:
ASME B31.1,
API 1104
AWS D1.1
This presentation reviews the
process of conducting
radiographic film assessments
on Saudi Aramco Projects.
Objective: Maintain Continuity

of Film Assessors
Getting Started
Attitude & professionalism
Fair but firm
Make Sure you are right! – second
opinion before you make the call
Factors affecting Interpretation
•Heredity/Genetics and visual perception
• Can you see it?
•What do you see?
•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
• Heredity/Genetics and visual perception
• Condition of the human eye
• Eye examinations 20/40
• Wear your glasses/contacts, if scratched –
replace.
• Equipment
• Viewer/densitometer
• Viewing conditions
• Tools
• 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
Terminology
Five Basic Weld Joints
Shielded Metal Arc Welding
(SMAW)
Welding is generated by an electric arc established between the flux
covered electrode and the base metal and melts the two together.
Benefits of the electrode coating
•Arc 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
with GMAW
Porosity
Cracks
Incomplete fusion
Undercut
lack of fill
Incomplete penetration
•The GMAW process is automated, semi-automated and

machine.
Gas Tungsten Arc Welding
(GTAW)
Welding is generated by an electric arc
between a tungsten electrode, a solid wire
consumable and the base metal.
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.
with SAW
Porosity
Cracks
Slag
Incomplete fusion
•The GMAW 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
Incomplete fusion - Sidewall
Incomplete Penetration
Longitudinal Root Crack
Longitudinal Root Crack
Interpass Slag
Interpass Slag
Burn Through
Cause:
•Welding technique
•Poor joint fit-up
Burn Through
Burn Through
Root Concavity
Cause:
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
Lack of Fill
Cause:
Lack of Fill
Lack of Fill
Tungsten Inclusion
Cause:
Tungsten Inclusions
Tungsten Inclusions
Mismatch - Hi low
Cause:
Mismatch
Mismatch
Weld Spatter
Cause:
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
Boiler and Pressure Vessel Code
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

criteria for pipelines
AWS D1.1

criteria for structures
Conducting Film Assessments
Getting Started:
•Attitude & professionalism

•Fair but firm
•Make Sure you are right! – second
Film Assessments
Quality System
•Obtain a copy of the Purchase Order or applicable

legal document for each assessment (project)
•Highest document in the pyramid
•Agreement that binds two parties
•Schedule Q & SAEP 1150
•Determine the applicable Codes and revisions for
the project
Film Assessments
Quality System
•Approved personnel
•Valid Saudi Aramco RTFI card
•Company certification
•Visual acuity examination
•Jaeger #1 & Ishara color plates
•Approved NDT procedures – approval letter from
NDTU for each project
Film Assessments
Quality System
•Condition of Equipment
•Sources
•Film Processing – tanks, dryer, chemicals,
timers, time/temperature conversion charts
•IQI’s number belts ect.
•Film Viewers
•Facility
Film Assessments
Film Quality - Guidelines
•Many things make up film quality

•Density, Sensitivity, IQI, ID, F, scratches,
crimp marks
•Density of weld is 2-4 & Parent material over 4.0
•Sensitivity – wire not required across entire weld
•IQI damage – bent, touching or crossing
Film Assessments
Film Quality - Guidelines
•ID - traceable with all required information

•F for film-side techniques
•Scratches & crimp marks
•Black letter “B” NOT required
•Weld spatter – use one inch to verify acceptability
Film Assessments
Weld Quality - Guidelines
•If the measurement it is on the line – give it to them

•When in doubt ask for a second opinion or re-shoot
•Use film digitizer for close calls
•Stay on solid ground
Film Assessments
Weld Quality - Guidelines
Use Acc/Rej straight from the applicable code –

avoid second-hand documents.
Ethics Discussion – recent unethical findings of NDT

contractor
•Duplication of radiographs
•NDT technicians not certified
•Conflict of interest
Getting Started
Attitude & professionalism
Fair but firm
Make Sure you are right! – second
END

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Assessment of Radiographic

Afternoon 1:00pm – 3:00pm

Objective: Maintain Continuity

How many faces can you detect?

•The SMAW process is almost totally operator dependant

•The GMAW process is automated, semi-automated and

•The GTAW process is almost totally operator dependant

•The GMAW process is automated, semi-automated and

They ensure uniform practices

Film interpretation acceptance

Film interpretation acceptance

Film interpretation acceptance

•Attitude & professionalism

•Obtain a copy of the Purchase Order or applicable

•Many things make up film quality

•ID - traceable with all required information

•If the measurement it is on the line – give it to them

Use Acc/Rej straight from the applicable code –

Ethics Discussion – recent unethical findings of NDT

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