Welding Inspection & Metallurgy API ICP Self Study Notes

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9 NON-DESTRUCTIVE EXAMINATION 9.1 Discontinuities 9.2 Materials Identification 9.3 Visual Examination (VT) 9.4 Magnetic Particle Examination (MT) 9.5 Alternating Current Field Measurement (ACFM) 9.6 Liquid Penetrant Examination (PT) 9.7 Eddy Current Inspection (ET) 9.8 Radiographic Inspection (RT) 9.9 Ultrasonic Inspection (UT) 9.10 Hardness Testing 9.11 Pressure and Leak Testing (LT) 9.12 Weld Inspection Data Recording
10 METALLURGY 10.1 General 10.2 The Structure of Metals and Alloys 10.3 Physical Properties 10.4 Mechanical Properties 10.5 Preheating 10.6 Post-weld Heat Treatment 10.7 Hardening 10.8 Material Test Reports 10.9 Weldability of Steels 10.10 Weldability of High-alloys
Page 1: Welding Inspection & Metallurgy API
Page 5 and 6: API 577 - Advanced Welding Inspecti
Page 7: This recommended practice provides
Page 10 and 11: Speaker: Fion Zhang 2014/5/4
Page 12 and 13: 5 WELDING PROCESSES 5.1 General 5.2
Page 16 and 17: 11 REFINERY AND PETROCHEMICAL PLANT
Page 18 and 19: Content: 1 SCOPE
Page 20 and 21: This recommended practice provides
Page 28 and 29: API 577 is to aid the inspector in
Page 30 and 31: API Std 653 Tank Inspection, Repair
Page 32 and 33: How this API Standard relates with
Page 34: Typical E&P services are vessels as
Page 49 and 50: Keywords: The level of learning and
Page 52 and 53: This recommended practice does not
Page 54 and 55: This recommended practice does not
Page 58 and 59: The importance, difficulty, and pro
Page 60: A welding engineer should be consul
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Content: 2 REFERENCES 2.1 Codes and
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API • API 510 Pressure Vessel Ins
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AWS • A2.4 Standard Symbols for W
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API • RP 572 Inspection of Pressu
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3 Definitions
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The following definitions apply for
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3.2 air carbon arc cutting (CAC-A):
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Arc blow
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3.6 arc welding (AW): A group of we
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Crack
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3.20 distortion: The change in shap
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HAZ
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HAZ
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HAZ http://www.twi-global.com/techn
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Hot Cracking
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Hot cracking These cracks are known
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Both solidification cracking and ho
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Inspector: An individual who is qua
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Qualified & Certified Inspectors
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Qualified & Certified Inspectors
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Figure A-1—Joint Types and Applic
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3.36 lack of fusion (LOF): A non-st
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Lamellar tear
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3.41 nondestructive examination (ND
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PMI
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PMI
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PMI
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This is API 577 special way of defi
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3.51 root face: The portion of the
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Slag Inclusion
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Slag Inclusions
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3.58 throat theoretical: The distan
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3.22 fillet weld size: For equal le
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Transverse Cracks
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Tungsten Inclusions - TIG Welding
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TIG Welding - Tungsten Inclusions
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3.64 welder certification: Written
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3.69 weld reinforcement: Weld metal
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weld toe weld reinforcement
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weld toe weld reinforcement
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Content: 4 WELDING INSPECTION 4.1 G
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4.2 TASKS PRIOR TO WELDING The impo
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4.2.1 Drawings, Codes, and Standard
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i. Preheat requirements and accepta
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Review requirements for the weldmen
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4.2.2.1 Quality control items to as
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4.2.4 NDE Information Confirm the N
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Welding Equipment and Instruments
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4.2.6 Heat Treatment and Pressure T
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4.2.7 Materials Ensure all filler m
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Materials
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Weld Preparation- Fit-up & Dimensio
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4.2.10 Welding Consumables Confirm
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4.3.1 Quality Assurance Establish a
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. Mock-up weldment, if required, me
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In-process ferrite measurement
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In-process ferrite measurement Why
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Schaeffer diagram
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4.4.1 Appearance and Finish Verify
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Field hardness check
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4.4.2 NDE Review Verify NDE is perf
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4.4.3 Post-weld Heat Treatment Veri
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PWHT Procedure
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Metal temperature of component meet
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4.5 NON-CONFORMANCES AND DEFECTS At
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4.7 SAFETY PRECAUTIONS Inspectors s
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Sevan Driller I
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5 Welding Processes
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Equipments & Piping
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Equipments & Piping
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Equipments & Piping
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Equipments & Piping
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5.2 SHIELDED METAL ARC WELDING (SMA
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5.2.2 Advantages of SMAW Some commo
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Shielded metal arc welding
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SMAW
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SMAW- Underwater Welding
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SMAW- Qualification of Underwater W
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SMAW- Structural Welding
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SMAW- Transmission Pipeline Welding
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SMAW- Weld Profile
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SMAW- Weld Profile
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SMAW- Weld Profile
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SMAW- Weld Profile
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SMAW- Grinding at Start-Stop
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SMAW- Root Pass + Hot Pass
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SMAW- Pipeline Tie-in Joint
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SMAW- WPQ Test Coupon
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SMAW- WPQ Test Coupon
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SMAW- Smiling Experts at Work
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Gas tungsten arc welding
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Gas tungsten arc welding
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GTAW
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5.3.1 Advantages of GTAW Some commo
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GTAW / TIG Weld a. Produces high pu
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GTAW / TIG Weld
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Tungsten Electrodes
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Tungsten Electrodes
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Tungsten- Automation
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Gas metal arc welding GMAW / MIG (m
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GMAW http://www.docslide.com/gmaw-f
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GMAW CV
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5.4.1 Short Circuiting Transfer (GM
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Short Circuit mode http://www.ualbe
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5.4.2 Globular Transfer This proces
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Globular transfer mode http://www.u
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Globular transfer mode http://www.w
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5.4.3 Spray Transfer The spray tran
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5.4.4 Advantages of GMAW Some commo
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Pulsed GMAW - Modified Spray Mode h
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GMAW-MIG CV
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GMAW-MIG CV
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GMAW-MIG CV
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GMAW- Automation
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GMAW- Automation
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GMAW- Stainless Steel Piping
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5.5 FLUX CORED ARC WELDING (FCAW) F
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FCAW CV
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FCAW-Self shield CV
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FCAW
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FCAW
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3G FCAW WPQT
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FCAW http://www.brewerweldingandfab
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5.6 SUBMERGED ARC WELDING (SAW) Sub
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SAW CV
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Submerged arc welding (SAW)
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SAW- Triple Electrodes Set-up (tilt
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SAW - Experts at Work
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Spiral Welded SAW Pipes
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SAW- Vessel Internal Welding
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SAW- Spiral Welded Pipes
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SAW- Serious Experts at Work
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SAW- Vessel Ellipsoidal Disk Head
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SAW- Pipe Can Welding
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SAW- Structural Welding
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5.7.1 Advantages of SW Some commonl
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Stud arc welding (SW)
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Stud arc welding (SW)
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Welding Transfer Modes: SMAW - CC T
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1.0 Considering the benefits of pul
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1.3 The short-circuit process In th
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The short-circuit process is not a
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By using 0.035- and 0.045-in.-dia.
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1.6 Summary Equipment for short-cir
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2.0 Understanding transfer modes fo
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2.1 Short-circuit Transfer In short
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Maintaining a constant contact tip-
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Stainless steel GMAW electrodes nor
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Spray Transfer Mode Shield Gas & Tr
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This transfer mode is used mostly i
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2.4 Pulse-Spray Transfer Mode In th
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3.0 Pulsed GMAW Pulsed GMAW is tech
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CV/CC Current Transfer Modes: Volta
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5. Other Interesting Reading: 5.1 C
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6: Welding Procedure
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WPS/PQR
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6.1 GENERAL Qualified welding proce
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construction codes and proprietary
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WPS 6.2 WELDING PROCEDURE SPECIFICA
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ASME B31.3, Chapter V Fabrication,
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6.2.1 Types of Essential Variables
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These requirements should be reflec
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Section IX requires that the manufa
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Mechanical Testing
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Mechanical testing- Tensile Testing
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Tensile testing: Stress Strain Diag
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Calculation of Tensile Properties o
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Weld Hardness Test
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Charpy Impact Testing
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Guided Bend Test
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Guided Bend Test
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6.4 REVIEWING A WPS AND PQR Inspect
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For simplicity purposes, the follow
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6.4.1 Items to be Included in the W
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y. Tungsten electrode size and type
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q. Electrical Characteristics. r. T
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WPS for Offshore Spar
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WPS for Offshore Spar
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WPS for Process Piping
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7: Welding Materials
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SAW
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7.2 P-NUMBER ASSIGNMENT TO BASE MET
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7.3 F-NUMBER ASSIGNMENT TO FILLER M
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Keywords: 1. Consideration should b
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F-Numbers
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7.5 A-NUMBER (filler metal) To mini
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7.6 FILLER METAL SELECTION Inspecto
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To reduce exposure to moisture, wel
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Content: 8 WELDER QUALIFICATION 8.1
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8.2 WELDER PERFORMANCE QUALIFICATIO
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Welder performance qualification ex
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j. Backing gas used. k. Metal trans
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9: Non-destructive Examination
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ASME V Article Numbers: Gen Article
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Discontinuities
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NDT Capability: Table 4
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NDT Capability: Table 5
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Table 6- Discontinuities Commonly E
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9.2 MATERIALS IDENTIFICATION During
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PMI
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9.3 VISUAL EXAMINATION (VT) 9.3.1 G
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ASME Section V, Article 9, (Paragra
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Vision Test
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Robotic Visual Inspection Crawler
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Remote Control Visual Inspection Cr
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3. Magnifiers- helpful in bringing
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Mirrors
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9.3.2.2 Mechanical Aids a. Steel ru
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Angle Ruler
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Feeler Gauge
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Vernier scale- a precision instrume
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Gap Gauge and Thickness Gauge
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Depth Gauge
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Bridge Cam Gage
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Adjustable fillet weld gauge
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Measures the angle of the vertical
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Weld fillet gauge being used to det
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d. Weld size gauge (see Figure 19)
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Hi-lo welding gauge
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Digital pyrometer
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What The Expert Say: http://youtu.b
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MPI
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The pattern formed by the particles
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MPI
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MPI
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Some of the requirements listed in
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Pie gauge
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Pie Gauge
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MT Calibration Shims
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MT-Calibration Shims
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MT- Wet fluorescent magnetic partic
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MT Magnetic Particle Testing
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Jack-up drilling rig
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Drilling Rig in Operations
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MT-Underwater
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Magnetic Particle Testing
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9.4.3 Demagnetization When the resi
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Demagnetization
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Gauss Meter
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9.5 ALTERNATING CURRENT FIELD MEASU
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ACFM uses a probe similar to an edd
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Two components of the magnetic fiel
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ACFM- Paint Removal is Not Necessar
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Further Reading on ACFM
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The ACFM Technique The ACFM method
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Figure 1 B z B Z
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Specialist Windows software is used
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Once a defect is identified the dep
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ACFM: This benefit is used to good
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ACFM http://www.tscinspectionsyste
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http://www.ndt.net/article/v08n09/w
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9.6 LIQUID PENETRANT EXAMINATION (P
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A limitation of PT is that standard
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Figure 28—Florescent Penetrant Te
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Some requirements listed in this ar
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PT- Color Contrast Method
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PT- Fluorescent Method
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Eddy current uses a magnetic field
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RT principles
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RT profile radiography
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RT- X Ray
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RT-Source http://tv.sohu.com/upload
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RT- Gamma Ray
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RT- Gamma Ray
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X-Ray Machine
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RT- Gamma Ray
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X-Ray Crawler
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Golden Joint
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RT- Techniques
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RT- Techniques
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RT- Interpretations
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Digital RT
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An NDT examiner interprets and eval
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Break Time mms://a588.l3944020587.c
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IQI- Image Quality Indicators
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IQI- Image Quality Indicators ASTM
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IQI Placement
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IQIs (penetrameters) are tools used
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Hole type IQI
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Hole type IQI
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RT Film coverage & overlaps Locatio
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Keywords: (exam questions) Ir 192 C
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Gamma Ray Radiography: Source
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Gamma Ray Radiography: Source
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Ir191- Ir 192 is typically supplied
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Ir192
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The gamma spectrum is shown in Fig.
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Co 60
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Search dosimeter-radiometer MKS-11
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Film processing
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9.8.6 Surface Preparation Where a s
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RT Films
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9.8.8 Radiographic Techniques The m
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Planar defects
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Planar & Volumetric defects
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9.8.8.1 Single-wall Technique A sin
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9.8.8.3 Double-wall Technique When
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For double-wall viewing of welds, t
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DWDI-DWV Double wall, double images
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DWDI- Superimposed
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9.8.9.1 Facilities for Viewing Radi
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9.8.9.2 Quality of Radiographs Radi
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Radiographic Density Radiographic d
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Radiographic Density I o I t https:
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Densitometer
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9.8.9.4 Excessive Backscatter A lea
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Because radiographic interpreters h
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i. Film manufacturer and type/desig
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X-Ray
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X-ray
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Figure 34—Interpass Slag Inclusio
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Figure 36—Lack of Side Wall Fusio
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LOF- Lack of Side wall Fusion
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Wagon Track
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Figure 38—Burn-through 1. A sever
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Burn Through
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Burn Through
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Figure 40—Excessive Penetration (
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Weld Joint
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Figure 42—Transverse Crack 1. A f
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Figure 44—Root Pass Aligned Poros
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Gen Article 1 RT Article 2 Nil Arti
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9.9 ULTRASONIC INSPECTION (UT) UT i
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Straight beam techniques are used f
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Straight beam UT
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B-Scan
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Figure 47—C-scan
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The A-scan, as shown in Figure 45,
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UT Testing- A-Scan
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Article 4 requires a written proced
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The reference standard (calibration
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Calibration Blocks
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Calibration Blocks
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Calibration Blocks
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Calibration Blocks
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Calibration Blocks
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Calibration Blocks
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Calibration Blocks
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Calibration Blocks
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Calibration system checks should be
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System checks are typically perform
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9.9.1.1 Echo Evaluation with DAC Th
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Figure 48—DAC Curve for a Specifi
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DAC Plots
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DAC / TCG
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DAC Curve with a specific reflector
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Unknown reflectors (flaws) are eval
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UT testing
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Reading Ultrasonic testing and imag
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Numbers to remember • Each pass o
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UT Transducers
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UT Transducers
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• 10% scanning overlapped Min of
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9.9.4 Straight Beam Examination A s
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Plate lamination checks
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Lamination Checks
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Lamination Checks
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Lamination Checks
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Lamination Checks
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Angle Beam UT http://www.ndt-ed.org
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9.9.5 Angle Beam Examination Typica
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UT Scanning Patterns
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Fillet weld defects
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9.9.7 Discontinuity Evaluation and
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The 6 dB drop technique is commonly
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Other through-thickness sizing tech
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The 6 dB drop technique Material Pr
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Other through-thickness sizing tech
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The ID Creeping wave method
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9.9.7.3 The High Angle Longitudinal
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AUT Vs RT http://www.olympus-ims.co
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AUT Vs RT
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TOFD
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The Tip Diffraction Method http://w
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Angle Beam Transducer http://www.ol
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9.10 HARDNESS TESTING Hardness test
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API 582- Vickers Hardness Test Prof
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Hardness Testing
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Hardness Testing
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Hardness Testing
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Weld Macro
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Hardness Testing
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Hardness Testing
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Portable Hardness Testing
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9.11 PRESSURE AND LEAK TESTING (LT)
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Pressure Testing
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Pressure Testing
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Pressure Testing
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Pressure Testing
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Pressure Testing
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Pressure Testing
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Pressure Testing
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Pressure Testing
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Pressure Testing- Incidence
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Pressure Testing- Risk
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Leak testing Leak testing may be re
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A wide variety of fluids and method
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Bubble Leak Test- Vacuum Box
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Leak Testing- Sensitive Leak Test
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9.12.1.2 Inspection Information a.
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10 Metallurgy
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10 Metallurgy 10.1 GENERAL Metallur
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Knowledge of cast structures is imp
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Fe-4Mo Phase Diagram
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Phase Diagram http://www.slideshare
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Weld Grains
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HAZ Weld region Fusion Boundary Coa
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http://encyclopedia2.thefreediction
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The properties of the cast structur
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Steel & Alloy- Grains
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http://www.power-eng.com/articles/p
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Gases, such as hydrogen, which beco
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10.2.2 The Structure of Wrought Mat
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Cast VS. Wrought 1. Cast ingot has
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Alloys may also consist of more tha
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Steel & Alloy- Annealed Pearlite
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Hypoeutectic Steel
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1055 Steel Q&T 1055, used in swords
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4140 Steel Annealed Ferrite Pearlit
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10.2.3 Welding Metallurgy Welding m
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SAW Welding
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Dendritic- usually solidify in the
Page 1024 and 1025:
INCONEL alloy 690 is a high-chromiu
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Overlay Welding
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Each weld pass applied will have it
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Overlay Welding
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Weld Macro- Fillet Welds
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An important aspect of welding meta
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10.3 PHYSICAL PROPERTIES The physic
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Alloyed metals start to melt at a t
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Solidus/Liquidus
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10.3.2 Thermal Conductivity The the
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The thermal conductivity of a mater
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10.3.4 Coefficient of Thermal Expan
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10.3.5 Density The density of a mat
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Casting Defects
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10.4 MECHANICAL PROPERTIES The mech
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Tensile testing - Tensile /Yield St
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Tensile testing - Tensile /Yield St
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Charpy impact testing
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Hardness testing- Sample polishing
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Hardness testing
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Hardness testing
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Ductility
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Ductility- Bend Tests
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When the specimen is subjected to s
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Tensile Testing
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Tensile Testing Yield point Sample
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http://practicalmaintenance.net/?p=
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10.4.2 Ductility In tensile testing
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The tensile specimen is punch marke
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One of the most common tests used i
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Bend Test Jig
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ASTM E290- Guided bend testing
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Bend Testing
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10.4.3 Hardness The hardness of a m
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Knoop and Vickers Hardness Tester .
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One Brinell test consists of applyi
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The Rockwell test is simple and rap
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The Vickers hardness value is prece
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10.4.4 Toughness The toughness is t
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Further Reading
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Online Metallurgy Course http://hyp
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Online Metallurgy Information http:
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Online Metallurgy Course http://fre
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Further Reading: http://practicalma
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Introduction The component elements
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Phase Diagram
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Austenite Austenite (γ), is a soli
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Shows the grain structure of an aus
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This secondary electron SEM image s
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Low carbon steel with a microstruct
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Figure 1. Part of the equilibrium d
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Martensite Martensite is commonly f
Page 1143 and 1144:
Martensite https://www.flickr.com/s
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The strain energy involved in the m
Page 1147 and 1148:
Figure 1. Part of the equilibrium d
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Bainite https://www.flickr.com/phot
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Proof Stress Re0.2% Since it is dif
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STEEL Steel is an alloy of iron, wi
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Aluminum Cables
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10.5 PREHEATING
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Preheating
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Preheating
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• Bring temperature up to preheat
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Preheat can be applied using severa
Page 1167 and 1168:
The temperature of PWHT is selected
Page 1169 and 1170:
Discussion: However there may also
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Typical PWHT Chart Insertion temper
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PWHT Chart
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT
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PWHT- Local
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PWHT- Local
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PWHT- Local
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PWHT- Local
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PWHT- Equipments
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PWHT- Equipments
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PWHT- Equipments
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PWHT- Equipments
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Fun-Photo: Induction Bending Pipe b
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Fun-Photo: Induction Bending Pipe b
Page 1207 and 1208:
Other factors can also affect harde
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http://www.azom.com/article.aspx?Ar
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Welding variables, such as heat inp
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Welding- Plate thickness & Weld Geo
Page 1216 and 1217:
Weld Macro- Geometry
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The simplest means to determine har
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Jominy Bar
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Jominy Bar
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It may be important for the welding
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Typical Hardness Values Table 11—
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HIC
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HIC- Hydrogen Induced Cracking
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TTT Curve
Page 1238 and 1239:
Martensite
Page 1240 and 1241:
10.8 MATERIAL TEST REPORTS Material
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Billets/Ingots
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Billets/Ingots
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Billets/Ingots
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Billets/Ingots
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Billets/Ingots
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Billets/Ingots
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Product analysis- Pipe
Page 1256 and 1257:
For the purposes of this publicatio
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Ductile to brittle transition tempe
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Fracture toughness
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Page 1264 and 1265:
Elevated mechanical property testin
Page 1266 and 1267:
Further Reading
Page 1268 and 1269:
Quiz 1) See the figure below for po
Page 1270 and 1271:
c) 50% coarse pearlite + 25% bainit
Page 1272 and 1273:
10.9 WELDABILITY OF STEELS
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Weldability is related to many fact
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The addition of carbon generally ma
Page 1278 and 1279:
Typically, ■ ■ ■ Steels with
Page 1280 and 1281:
The simplest weldability tests are
Page 1282 and 1283:
Weldability Test- Cruciform testing
Page 1284 and 1285:
Another approach to measuring susce
Page 1286 and 1287:
10.10 WELDABILITY OF HIGH-ALLOYS Th
Page 1288 and 1289:
Hot Shortness: • solidification c
Page 1290 and 1291:
Ferrite Meter
Page 1293 and 1294:
Coefficients of Linear Thermal Expa
Page 1295 and 1296:
Sensitized Austenitic SS Common to
Page 1297 and 1298:
Weld Decay http://www.corrosionclin
Page 1299 and 1300:
Inert Backing Gas
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Inert Backing Gas
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Inert Backing Gas
Page 1305:
Inert Backing Gas http://www.foodpr
Page 1308 and 1309:
Inert Backing Gas
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Inert Backing Gas http://www.juncti
Page 1312 and 1313:
Inert Backing Gas
Page 1314 and 1315:
Inert Backing Gas
Page 1316 and 1317:
One of the main differences between
Page 1318 and 1319:
Sluggish tendency- LOF
Page 1320 and 1321:
Wider Bevel Angle & Thinner Root Fa
Page 1322 and 1323:
Nickel Welding: The faster a nickel
Page 1324 and 1325:
Content: 11 REFINERY AND PETROCHEMI
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11.2 HOT TAPPING AND IN-SERVICE WEL
Page 1328 and 1329:
Hot Tapping
Page 1330 and 1331:
Hot Tapping
Page 1332 and 1333:
Hot Tapping
Page 1334 and 1335:
Hot Tapping
Page 1336 and 1337:
Hot Tapping
Page 1338 and 1339:
Burn Through
Page 1340 and 1341:
11.2.1 Electrode Considerations Hot
Page 1342 and 1343:
Cellulosic type electrodes (e.g., E
Page 1344 and 1345:
If the normal flow of liquids excee
Page 1346 and 1347:
Points to consider: Is it 36” or
Page 1348 and 1349:
Case Study: 1. Is it 36” or great
Page 1350 and 1351:
Case Study: Is it 36” or greater
Page 1352 and 1353:
Page 1354 and 1355:
Page 1356 and 1357:
Page 1358 and 1359:
11.2.3 Other Considerations To avoi
Page 1361 and 1362:
11.2.4 Inspection Inspection tasks
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GMAW-S LOF
Page 1365 and 1366:
Due to this inherent nature of the
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The quick freeze characteristic, wh
Page 1369 and 1370:
Hazards
Page 1371 and 1372:
Mechanical Integrity
Page 1373 and 1374:
Happy Inspectors
Page 1375:
ICP Status http://myicp.api.org/Dir
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Welding Inspection & Metallurgy API ICP Self Study Notes

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