Inspection Trends - April 2011

THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNELApril 2011 / Vol. 14 / No. 2www.aws.orgInterpretingRadiographsBridge InspectionQualifying Welders

For Info go to www.aws.org/ad-index

By Mary Ruth JohnsenEditor’s NoteDear Readers,My mother taught elementaryschool for more than 40 years. At onetime or another she taught every gradeexcept kindergarten, although fourthand fifth grades were her mainbailiwick. It was not an easy job. Iknow that firsthand because during myearly twenties, I did some substituteteaching. My mom loved to relate thestory of coming home to find me sprawled on my bed, sound asleepfrom exhaustion after my first day as a sub.One thing I always admired about my mother was that she wasconstantly utilizing new techniques in her classroom. That was true upto and through her final year of teaching. The subjects might havestayed the same, but she was always looking for a better way to deliverthe information to her students. That made me believe she was a reallyfine teacher; a belief confirmed through her students’ achievement testscores and reading level assessments. I don’t know about you, but I hadsome teachers, especially in high school, who taught the same subjectthe exact same way year after year. In their classrooms, the only wayyou could have guessed whether it was 1969, 1989, or 2009 would bethrough the students’ clothing styles, because what those teachers didnever changed. And I bet it’s no surprise that they weren’t the bestteachers at the school.So what does all that have to do with being a CWI? Well, I believethe best performers at any job are always trying to better themselves andtrying to find new ways to do their jobs better. My guess is that if you’rea CWI who holds more than one certification, who attends conferencesand seminars, who participates in your local AWS Section activities,who reads the latest literature about products and processes, or, yes, whoreads this magazine cover to cover, then you’re probably one of the bestinspectors around.Trying something new — and which quite possibly could fail — ishard. It’s a lot easier, and far less nerve-wracking, to do what you’vealways done. But does that advance your profession or you personally inyour career?I know change is intimidating. This is true with my own job. Yousee, I’m used to and quite fond of black type on white paper. But I’mworking in an era of e-readers, social media, and mobile phone apps. IfI’m going to get the information you need to you in the way you need it,I better prove myself to be my mother’s daughter.What about you? Are you Mr. or Ms. Same Old/Same Old Inspectoror are you Mr. or Ms. Lead the Way?If you have any questions or comments, please contact me at (800)443-9353, ext. 238, or mjohnsen@aws.org. I look forward to hearingfrom you — Mary Ruth Johnsen.PublisherAndrew Cullisoncullison@aws.orgEditorMary Ruth Johnsenmjohnsen@aws.orgAssociate EditorHoward Woodwardwoodward@aws.orgAssociate EditorKristin Campbellkcampbell@aws.orgProduction ManagerZaida Chavezzaida@aws.orgSenior Production CoordinatorBrenda Floresbflores@aws.orgNational Sales DirectorRob Saltzsteinsalty@aws.orgAdvertising Sales RepresentativeLea Garrigan Badwygarrigan@aws.orgSenior Advertising Production ManagerFrank Wilsonfwilson@aws.orgSubscriptions RepresentativeEdalia Suarezesuarez@aws.orgAmerican Welding Society550 NW LeJeune Rd.Miami, FL 33126(800/305) 443-9353CopyrightCopyright © 2011 by American Welding Society in bothprinted and electronic formats. The Society is notresponsible for any statement made or opinion expressedherein. Data and information developed by the authors ofspecific articles are for informational purposes only andare not intended for use without independent,substantiating investigation on the part of potential users.6Inspection Trends / April 2011

For Info go to www.aws.org/ad-index

conventional NDE processes such as film radiography,positive material identification, remote visual inspection,magnetic particle testing, penetrant testing, and hardnesstesting. It also provides welding engineering services such aswelding program development, weld procedure developmentand qualification, and project management.“From AIT’s perspective, we are pleased to expand theadvanced NDT services that we provide into Spitzer’sfabrication facilities,” said Jim Halley, who cofounded thecompany in March 2003 along with Michael Beard.NASA Prepares to Crush Giant ‘Can’NASA has been readying to crush an immensealuminum-lithium rocket fuel tank to generate new “shellbucklingdesign factors” that will enable lightweight, safe,and sturdy “skins” for future launch vehicles. The test theyhad planned to conduct in late March 2011 is much likeplacing a soda can upright on the floor then standing on ituntil the can collapses.Testing for this study is under way at NASA’s MarshallSpace Flight Center in Huntsville, Ala., where engineers aresupporting the test led by the NASA Engineering and SafetyCenter, based at NASA’s Langley Research Center inHampton, Va.The aerospace industry’s shell buckling knockdownfactors are a complex set of engineering data that dates backto Apollo-era studies of rocket structures, which was wellbefore modern composite materials, manufacturingprocesses, and advanced computer modeling.“Spacecraft structures, especially fuel tanks, areThe team moves the massive space shuttle external tank ‘can’into place for the shell buckling knockdown test at MarshallSpace Flight Center. (Photo courtesy of NASA/MSFC.)designed to be as thin as possible, as every pound of vehiclestructure sacrifices valuable payload weight and candramatically increase the cost of flying a rocket,” said MarkHilburger, a senior research engineer at Langley and theprincipal investigator on this project. Research to datesuggests a possible weight savings of as much as 20%.Technicians have moved a 27.5-ft-diameter and 20-ft-tallspace shuttle external tank barrel-shaped test piece into placeat Marshall’s Engineering Test Laboratory. It is sandwichedbetween two massive loading rings that will press down withalmost one million pounds of force on the central cylindricaltest article until it buckles. Leading up to the big crush, the10Inspection Trends / April 2011

team has tested four, 8-ft-diameter aluminum-lithiumcylinders to failure.Thermo Fisher Scientific Wins Good DesignAwardThe Niton XL2 Series of XRF analyzers from ThermoFisher Scientific, Inc., Billerica, Mass., has been recognizedwith a Good Design award by the Chicago AthenaeumMuseum of Architecture and Design.The awards, the world’s oldest design competition of itskind, are conferred annually by the museum in conjunctionwith The European Centre for Architecture Art Design andUrban Studies. A record number of entries were received in2010; recipients represent more than 36 countries. TheChicago Anthenaeum Museum will hold the Good DesignShow in June 2011.The Niton XL2 analyzers also won an Editor’s ChoiceAward from Pollution Engineering magazine in theremediation category in 2010.Instron Renews Calibration LaboratoryAccreditationInstron, Norwood, Mass., a provider of test equipmentfor the materials and structural testing markets, recentlyachieved renewal of its ISO/IEC 17025 accreditation. Theaccreditation recognizes the laboratory has demonstrated thetechnical competence necessary to provide scientificallysound measurements in conducting a wide range ofcalibration services.The three-day re-accreditation assessment wasconducted by the National Voluntary LaboratoryAccreditation Program, which is administered by theNational Institute of Standards and Technology. For moreinformation on the company’s calibration services, visitwww.instron.us/wa/Services/Calibration.ASQ Celebrates 65th AnniversaryThe American Society for Quality (ASQ), headquarteredin Milwaukee, Wis., recently celebrated its 65th anniversary.The society was formed in 1946 during a time when qualityexperts and manufacturers sought ways to sustain the manyquality-improvement techniques used during World War II. Itbegan as The American Society for Quality Control with 253members from 17 quality-related societies. George Edwards,then director of quality assurance at Bell Telephone Labs,was elected its first president.Today, ASQ has expanded to more than 150 countriesand has more than 80,000 individual members. An ASQhistorical perspective of photos is available atwww.facebook.com/ASQ. In addition, throughout the year,the society’s member electronic newsletter, ASQ Weekly,will feature member stories about ASQ’s history.FERITSCOPE ® FMP30Measurementof the Ferrite Content in Austeniticand Duplex SteelFischer’s Feritscope ® FMP30Fast, precise measurement offerrite content of constructionalsteels, welded claddings,austenitic stainless steelsand duplex steels.FILLET WELD GAUGESFROM 1/8” TO 3”• Non-destructive measurementin the range of 80% Fe or 0-120WRC number.• Battery or AC powered• Large, backlit display• Automatic probe recognition• Statistical evaluation• USB interface• Multiple application memories1-860-683-0781 • Fax: 1-860-688-8496www.Fischer-Technology.com • info@fischer-technology.comFor info go to www.aws.org/ad-indexFor info go to www.aws.org/ad-indexInspection Trends / Spring 2011 11

Mail BagHow to Do Well on WrittenExamsJoseph Klapp — an AWS CWI whoworks at Collins & AssociatesTechnical Services Inc. (CATSI),Wheelersburg, Ohio, and has API 653as well as 510 Tank and PressureVessel Inspector credentials — thoughtthe readers of Inspection Trends couldbenefit from these test taking tips.Your Eye Inside Hawkeye ® Borescopes quickly identify the quality andintegrity of any weld, even in long tubes or complex parts!In combination with our Luxxor ® Video Systems, you can also capture, document,and e-mail inspection images. Our video systems are compatible with anyHawkeye Borescope, and most other borescopes as well.Weld in 3/4” stainlesssteel tube using aHawkeye Pro Hardy 7”Welded and drawn tubeviewed with aHawkeye Pro Slim 7”Made in USADefects in medicalarterial stent as seen witha Hawkeye Pro Slim 12”gradientlens.com 800.536.0790Doing well on written tests is avaluable skill that you can learn. Whenyou recertify, get an endorsement, oradd a new credential, the written test isimportant. It adds value to ouremployers and our careers bydemonstrating that we know our stuff.With skill and confidence, you canmanage about any test. If you’vealready passed the qualification test tobecome an AWS CWI, sharp weldersmay ask you about taking the exam.Here’s what you can tell them.Tests are a method to find out if youknow enough of the right information.They’re usually written by a committeeor person who has only read the book,so multiple choice questions arepopular. You can learn the technique ofdoing well on written tests byfollowing these guidelines.Before an exam, invest a few hoursin getting ready. Read the body ofknowledge. Get the current material,read it, and take notes. Find a practicetest, and take it; you’ll feel good aboutall the parts you pass, and the rest canbe fixed. Study these. If the test is openbook, use tabs, highlight a little, andput notes in the margin. This helps youreview the material and be ready.Carry your favorite calculator, if it’sallowed. If it’s solar powered, bring aspare basic calculator, and put in freshbatteries. Plan to get a good night’ssleep, and leave early. Give yourselftime for traffic, finding a parking spaceand the room, as well as a few minutesto sign in. A light breakfast with someprotein usually helps, and a littlecaffeine goes a long way.Bring a few fairly dull pencils. Dullis better because the tips don’t snap offor rip the paper, they’re okay to put inpockets, and if you must erase ananswer, it’s easier. In addition, wear awatch, and know how many minutesand questions you have. Estimate thetime per question. For example, if youhave two hours for 100 questions,that’s 120 minutes for 100 questions,about a minute for each one. So, if youFor info go to www.aws.org/ad-index12Inspection Trends / April 2011

can answer a question in less than aminute, great. Read the whole questionand promptly pick the best answer, orjust circle it and move on.Don’t read too much into thequestions; doing well on tests is aboutthe best answer, not to question what if.A tempting distraction is “why wouldthey ask that?” Don’t go there now —save your editorial concerns for later.During the test, pay attention to answerwords including all, always, never,every, etc.Some questions have “except” inthem; that usually means find the onewrong answer. Please comment againsta poorly written question. You can helpeverybody with a written comment onhow to fix it. You’ll be recertifying in afew years and want good questionswhen taking that exam, thereby keepingyour career on track.When you finish the easy questions,relax and review your answers. Don’tchange your first answer unless you’rereally sure you marked the wrong spot.Very few changes are better.Next, work on the other questions —some should come to you. In fact, oneof the easy questions may give you astrong hint about the answer to a harderquestion. If you’re going to guess,improve your odds by guessing wisely.Here’s how:• Notice vague words and phrases;longer answers are good.• Just guess a letter. But, don’t guessdifferent choices. We’re looking for a 20or 25% chance, not a long shot atgetting them all right.• Pick one! No response is always thewrong choice. Take the free shot.During breaks, keep your attitude upand improve your chances by not takingbad advice — you prepared better thanthe talkers.Also, feel confident because youknow how to do well on written exams,and you know the material. You’llbecome a true professional by workingin the trade, deciding to prepare, takinga short course, studying, passing theAWS CWI exam, and continuing tolearn.Errata AWS D3.6M:2010Underwater Welding CodeThe following errata have been identifiedand will be incorporated into thenext reprinting of this document.Page 72. Table 8.1, note a — Correct“First position only. Qualification for additionalpositions will omit groove weldtension, macroetch, and fillet weld shearstrength tests.” to “First position only.Qualification for additional positionswill omit groove weld tension,macroetch, Charpy tests, and fillet weldshear strength tests.”Page 72. Table 8.1, note 1 — Correct“WM — Weld Metal; HAZ = Heat-AffectedZone.” to “HAZ Charpy ImpactTesting is not required for qualificationof wet welding procedures. WM = WeldMetal; HAZ = Heat-Affected Zone.”Page 75. Table 8.2, footnote b —Correct “See 5.11.5 and Table 8.1, Note5.” to “HAZ Charpy Impact Testing isnot required for qualification of wetwelding procedures. See 5.11.5 andTable 8.1, footnote d.”Page 79. Table 8.3, Column heading— Correct “Fillet Weld Break (SeeFigure 5.9)” to “Fillet Weld Break (SeeFigure 5.8)”.ErratumB2.1/B2.1M:2009Specification for Welding Procedureand Performance QualificationThe following erratum has been identifiedand will be incorporated into thenext reprinting of this document.Page 35 — 5.6.1.1(11) — Delete referenceto Table 5.9 so that sentencereads: “Tables 5.6, 5.7, and 5.8.”Official InterpretationD1.8/D1.8M:2009Structural Welding Code —Seismic SupplementSubject: Yield Strength and Filler MetalQualificationCode Edition: D1.8:2009Code Provision: Table A.2AWS Log: D1.8-09-I01Inquiry: For WPS Qualification, mustYield Strength (0.2% offset) be used tocomply with the requirements for YieldStrength in the D1.8 code?Response: Yes.For info go to www.aws.org/ad-indexInspection Trends / Spring 2011 13

Print and Product ShowcaseUltrasonic System Designed forPipe Weld InspectionThe USM Vision ultrasonic weldinspection system allows non-UT-trainedpersonnel to gather accurate pipe weldinspection data for subsequent remoteassessment by a qualified ultrasonicsexpert. This allows its use for situationsconventionally requiring radiography.The system can operate in phased arrayand time-of-flight-diffraction mode. Itcomes with its operating software, thecompany’s Rhythm analysis software, aswell as the probes and wedges necessaryfor the selected codes and pipe ranges.Setup is menu-directed, which allowsthe operating software to calculate theultrasonic parameters for each weld andpipe combination, and create an easy-tofollowinspection plan. The operator canthen scan the weld, and the inspectiondata are transmitted to a review station.GE Measurement & ControlSolutionswww.ge-mcs.com(866) 243-2638Track Lighting System Useful forNDE BoothsThe Spectroline® ONT-365 On-Trak overhead track-light-style NDEinspection system features powerfulUV-A and white light LEDs attached toa mountable platform. The systemworks well in NDE inspection booths,and for preinspections and screeningapplications requiring maximumuniformity of coverage over a largearea. The system features four broadbeamlamp heads, each with threeultrahigh-flux UV-A (365-nm) LEDsfor NDE inspection and one white lightOpportunity Knocks.AWS agreement withASNT offers ACCP toqualified CWIs & SCWIs.Do you need visual testing certificationwhich meets the guidelines for RecommendedPractice No. SNT-TC-1A as required by somesections of the ASME Code? Through thisagreement, qualified SCWIs and CWIscan obtain ACCP Level II VT certificationwithout examination.Enhance your credentials and satisfywork requirements with the additionof an ACCP credential.To apply and for more details visitwww.asnt.org or call 614.274.6003or 800.222.2768 US/Canada.Image © Longview InspectionFor info go to www.aws.org/ad-index14Inspection Trends / April 2011

for general illumination. Inspectors canmove the lamp heads anywhere alongthe track so beam patterns can be madeto fit specific needs. Lamp heads canalso be added for increased areacoverage. The light sources provide anominal steady-state UV-A intensity of9000 μW/cm 2 at 15 in.Spectronics Corp.www.spectroline.com(800) 274-8888Hand-Held Camera InspectsDifficult-to-Reach Areaspharmaceutical industries, or otherapplications that require a waterresistantterminal. It utilizes an Intel®Atom N270 1.6-GHz processor, dualinternal antennas, and 12- and 15-in.displays. Options include mountingsystems, external power supply, andpower adapter.Glacier Computerwww.glaciercomputer.com(603) 882-1560, ext. 219Materials Testing AccessoriesCatalog UpdatedInstron has released the 5th editionof its Materials Testing AccessoriesCatalog. The more than 375-pagecatalog features detailed informationon hundreds of grips, extensometers,fixtures, environmental chambers, loadcells, furnaces, and other materialstesting accessories. The catalog alsocontains information on how to selectThe Sidewinder push rod inspectioncamera weighs 4.5 lb and can snakethrough pipes as small as 19 mm. Itfeatures a stainless steel cable reel; highresolution720 × 480 pixel imager;waterproof 30-m fiberglass/stainlesssteel-reinforced push rod with watertightconnectors; brilliant, adjustableLED light; removable 16-GB SDmemory card; and an internal batterythat can be recharged for 3 h ofcontinuous operation. The camera has ascratch-resistant sapphire window andan adjustable-focus 70-deg lens that canbe easily swapped for a 40-, 55-, or 90-deg lens. Options include a right-anglemirror adapter for side viewing.Advanced Inspection Technologies, Inc.www.aitproducts.com(321) 610-8977Industrial Computer FeaturesWater-Resistant TerminalThe Everest S9000 computerterminal was designed for those whoneed a stainless steel, IP65/NEMA 4sealed unit to meet the hygienicstandards of the food processing,healthcare, chemical andFor info go to www.aws.org/ad-indexInspection Trends / Spring 2011 15

the appropriate accessories based onapplication plus technical tips forgeneral materials testing.Instron Corp.www.instron.com(800) 564-8378Digital X-Ray Imaging Plates Comein Twenty SizesFlex XL Blue digital X-ray imagingplates feature more than 30% higherresolution than the company’s Flex HRplates. The flexible plates wrap aroundmost shapes and come in 20 sizes.They can be used in a flexible or rigidcassette. When used withINDUSTREX HPX-1 digital systems,all plates meet requirements for EN14784-1 and ASTM E 2446, but theiruse is not restricted to HPX-1 systems.The phosphor plates can be erased andreused thousands of times, and theimages can be optimized and stored orshared digitally. Applications includecomputed radiography of weldedfabrications, pipelines, erosion andcorrosion, and castings.Carestream Health, Inc.http://ndt.carestream.com(877) 865-6325, ext. 714Manual Pipe Scanner Operates inLimited-Access AreasThe Bracelet is a low-profilemanual scanner that can be used onpipe diameters from 0.5 to 4 in.nominal pipe size, and can operate inlimited-access areas with an envelopeof 0.5 in. The Bracelet mechanism fitssecurely to the pipe. That and itsrubber wheels provide a sure grip sothe scanner doesn’t slip duringoperation. It can operate with a singlephased array probe for pipe-to-fittinginspections or, with the extendedbracket, can be configured for dualsidedinspections. It is compatiblewith industry-standard small-borephased array probes and flawdetectors.Phoenix Inspection Systemswww.phoenixisl.co.uk44-1925-82600016Inspection Trends / April 2011

Reading RadiographsFeatureHere’s help in developing a systematic approach to reading radiographsThe interpretation of radiographsmay be divided into three major steps:• Determine the Quality• Analyze the Image• Report the ResultsDetermine the QualityIn this step, the quality of theradiograph itself is being assessed, notthe quality of the specimen beingradiographed. This requires anunderstanding of the applicable coderequirements regarding the followingitems. Here are the procedures youmust follow to determine the quality ofthe radiograph.Identification of theRadiographs. Verify that radiographsare properly identified with all requireditems. If any item of identification ismissing from, or not clearly visible on,the radiographs, then they are not incompliance with the code.Image Quality Indicator (IQI).Verify that the proper Image QualityIndicator was used (or an acceptablealternative), and that it was positionedproperly. Remember that in somecases, more than one IQI may berequired so you must verify that thecorrect number of IQIs has been used.The IQI is the device used to judge theadequacy of the radiographic techniqueto produce a radiograph with therequired sensitivity. The image of theIQI and the required hole (or requiredwire, if wire IQIs are used) areevidence that the radiographs have therequired sensitivity. The IQIidentification number must also bevisible on the radiographs.Radiographic Density. Verify thatall radiographs are within the specifieddensity range. A calibrateddensitometer should be used to verifydensity. The density should first bechecked on the body of the IQI andthen throughout the area of interest.When using wires, the IQI densityshould be taken near the essential wire.The density must fall within thespecified range or the radiograph is notacceptable.Radiographic Technique. Verifythat all technique parameters theradiographer used are in compliancewith the code requirements. Thisincludes the type of source used,energy level, source position, film type,type of screens, source-to-filmdistance, and geometric unsharpness(Ug). These items should all bereported by the radiographer on atechnique sheet or the radiographicreport. Remember that source-to-filmdistance (SFD) is used for exposurecalculations, while source-to-objectdistance (SOD) is utilized for Ugcalculations.Radiographic Coverage. Theradiographer uses location markers(sometimes referred to as stationmarkers) to indicate the area of the testspecimen each film represents. Verifythat location markers are displayed oneach radiograph and that eachradiograph in a series has adequateoverlap to ensure the requiredcoverage. This is especially importantwhen film side markers are used onheavy-wall pipes.Film Processing. The method offilm processing (i.e., manual orautomatic) should be included in theinformation on the RadiographicReport. Verify that radiographs are freeof film artifacts in the area of interestthat might interfere with interpretationof the radiograph.Analyze the ImageThe next step in the film readingprocess is to analyze the image. Thisinvolves interpretation andclassification of indications visible onthe radiographs. Interpretation ofindications involves determining thecause and classification of eachindication. Remember that not allindications are caused by adiscontinuity in the material; someindications are false indications, someare nonrelevant indications, and othersare relevant indications, sometimescalled true indications.Interpretation of IndicationsASTM E 1316 may be referencedfor standard terms and definitions usedin radiography. It is important that weunderstand the standard terminologyused in regard to radiographs. Theseterms include the following:Indication. A response, orevidence of a response, from anondestructive examination (i.e.,radiography) that requiresinterpretation to determine itsrelevance. An indication on theradiograph will appear as a change inthe film density that may be eitherdarker or lighter than the surroundingarea.Interpretation. The determinationof whether an indication is false,nonrelevant, or relevant.Discontinuities do not cause allindications; therefore, the interpretationwill allow the Radiographic Interpreter(RI) to classify the indication as eitherfalse, nonrelevant, or relevant.False Indication. An indicationcaused by some condition other than adiscontinuity in the test object, or by achange in the part geometry. Inradiography, false indications arereferred to as film artifacts and may becaused by improper handling of thefilm during loading and unloading ofthe cassettes. Failure to control filmprocessing is also a major cause ofartifacts.18Inspection Trends / April 2011

Nonrelevant Indication. Anindication caused by the test objectgeometry or other condition that doesnot require evaluation (e.g., an indicationof incomplete penetration appearing onthe radiograph of a weld that by designis a partial penetration weld).Relevant Indication. Anindication caused by a discontinuity ora condition that requires evaluation.Discontinuity. An intentional orunintentional interruption in thephysical structure or configuration of amaterial or component. All indicationsof discontinuities (relevant indications)require evaluation.Evaluation. A review, followinginterpretation of an indication, todetermine whether or not a relevantindication meets the acceptancecriteria. Following this review, theindication must be dispositioned aseither acceptable or not acceptable.Due to the diversity of requirements ofvarious industry standards, we do nothave uniform acceptance criteria.Therefore, it is important that the RIreview the acceptance criteria of theapplicable code prior to making anyevaluation of discontinuities.Defect. One or more discontinuitieswhose aggregate size, shape, number,orientation, location, or properties do notmeet the specified acceptance criteriaand are cause for rejection.False Indications (Film Artifacts)Improper processing techniques orcareless handling of the film during itsloading and unloading from thecassette are the usual causes of falseindications, normally referred to as filmartifacts. Occasionally, film artifactsmay be due to manufacturing defects inthe film. Film artifacts can often easilybe distinguished from true indications;however, some may have anappearance similar to a discontinuityand may lead to a misinterpretation.Taking the radiograph off of the viewerand looking at both sides underreflected light will often verify that anindication is a film artifact. Sometimesanother exposure of the same area,using different lead screens and adifferent cassette, is necessary todetermine if an indication on theoriginal radiograph was a film artifactor an indication of a discontinuity.False indications are not predictableand not repeatable when the originalIs the radiograph properlyidentified?Is the penetrameter (IQI):a. the proper one;b. positioned properly;c. clearly visible including therequired hole, or wire.Is the film density within therequired range?Is the radiograph technique usedin accordance with coderequirements?a. Source type and energyb. Source-to-film distancec. Screensd. Film typee. Geometric unsharpnessWas the required coverageachieved? Verified by locationmarkers.Was film processing adequate?Are radiographs free of artifactsin the area of interest?Fig. 1 — A systematic approach to reading radiographs.radiograph is reshot.Most codes and specifications willnot permit an artifact in the area ofinterest if, in the opinion of the RI, itmight be confused with the indicationof a discontinuity, may mask theindication of a discontinuity, or in anyway interferes with interpretation ofthe radiograph.Artifacts Occurring beforeProcessingRadiation fog occurs when thefilm is stored too close to a source ofradiation, or when a film isinadvertently left in the exposure areaduring the exposure of another film.Light fog is caused by storage offilm in a faulty storage box or bin,READING THE RADIOGRAPHSDETERMINE THE QUALITY ANALYZE THE IMAGE REPORT THE RESULTInterpretation and Classificationof IndicationsFalse IndicationsNonrelevant IndicationsTrue IndicationsFalse IndicationsDo any film artifacts in the areaof interest interfere in any waywith the interpretation of theradiograph?True Indications – DiscontinuitiesIdentify typeMeasure sizeCount numberDetermine locationDetermine distributionWritten Report:a. Is it complete?All data included?b. Is it clearly legible?c. Is it understandable?Standard terminology usedd. Are all technique parametersincluded?e. Is each film in a series listed?f. Are discontinuities identified?g. Has disposition been made oneach film?h. Has the interpreter signed anddated the report and indicated hisor her level of certification?leaving the lid off the box, exposure towhite light in a faulty darkroom, theuse of the wrong type of safelight, toostrong a bulb in the safelight, or to theuse of a faulty film holder. It is usuallylocal, but may be an overall fog.Crimp marks occur when the filmis allowed to bend abruptly during theloading and unloading of the cassette.If the crimp occurs during loading ofthe film into the cassette (i.e., prior toexposure), the crimp mark will appearlight. Dark crimp marks occur afterexposure while unloading the filmfrom the cassette prior to processing.Scratch marks may be caused bya fingernail or rough handling of thefilm while loading or unloading thecassette. Scratches are easily identifiedby holding the processed film on anInspection Trends / Spring 2011 19

angle and allowing light to reflect offthe surface at an angle.Pressure marks usually appear aslighter areas on the radiograph and mayhave any size or shape. They arecaused by improper film storage (i.e.,boxes of film stacked one on top ofanother rather than stored on edge), orpossibly by a heavy part resting on thefilm holder during the exposure. Apressure mark caused by a heavy objecton the cassette occurring after exposurecould result in a dark spot.Static are black indications causedby static electricity discharges on thesurface of the emulsion when the filmis removed rapidly from the film box.Static indications sometimes appear asdark branching lines (tree roots) or asjagged fine lines (lightning).Fingerprints result from handlingthe film with wet fingers (i.e.,developer, fixer, or water on yourfingers).Low density spots or smears aredue to splashes of fixer solution on thefilm prior to development of the film.Dark spots or smears are due tosplashes of developer on the film priorto it being developed.Lead screen marks are due todefects in the lead screens such asscratches or wrinkles. They usuallyappear as darker indications often witha lighter halo.Mottle/paper pattern is anoverall pattern on the radiographresulting from failure to remove theinterleaving paper from the film whenloading the cassette.Image reversal is due to excessiveoverexposure in which there is areversal in the image density. In otherwords, the normally dark areas appearlight, and the normally light areasappear dark. This is not a commonoccurrence as it is the result ofextremely excessive overexposure toradiation.Diffraction (mottle) appear on filmas numerous dark lines that are oftenaccompanied by light lines. Diffractionpatterns on weld radiographs may have adiscrete herringbone pattern. A change inbeam angle or kilovoltage alters thepattern and therefore allows diffractionmottling to be identified as a spuriousindication. Most commonly occur whenusing an X-ray machine to radiographcast materials with large grain structure,or materials with a high nickel content.White dots are due to dirt and duston the lead screens. Any foreignmaterial between the lead screens andthe film will block out the intensifyingaction, and appear as white spots on theradiograph.Artifacts Occurring duringProcessingScratches occur in the emulsionwhen a film hanger rubs the surface ofa film while being immersed in theprocessing solutions. They may alsooccur during agitation of the filmhangers when films are too closetogether in the solution tank.Air bells are shown as smallrounded areas of lower density, causedby air bubbles trapped on the surface ofthe film, usually during the early stagesof development, due to insufficientinitial agitation.Patches or streaks are due toinsufficient agitation duringdevelopment, or failure to agitate in thestop bath or rinsing bath. They mayalso be due to a residue of solutions inthe hanger clips from prior use.Reticulation is puckered ornetlike linkages, giving a pebbledsurface appearance similar to that of abasketball or football. This condition isdue to rupture of the emulsion causedby a sudden and extreme change in thetemperature of the solutions.Kiss marks may be either a darkor light patch on the radiograph causedwhen two films touch (kiss) in thedeveloper or fixer during manualprocessing.Dirt or scum is contamination inthe developer or fixer. Even thematerial in the rinse tank may adhere tothe film’s surface. This is easilyverified by allowing light to reflect offthe film surface.Drying marks are due to drops orstreaks of water remaining on thesurface of the film after it has beenpartially dried. They often occur whenattempting to dry films rapidly at ahigh temperature in a drying cabinet.Pi marks or Pi lines are lines thatrun across the film or are spots on thefilm that occur at regularly spacedintervals. Caused by dirty rollers(usually a buildup of processingchemicals) in an automatic processor.The spacing between these artifacts isequal to the circumference of the rollerin the processor. These can easily beidentified by allowing light to reflectoff the film surface.Pressure marks are a buildup offoreign material on the rollers in theautomatic processor. Insufficientclearance between the rollers in theprocessor will also cause pressuremarks that appear as lines on the filmsurface. These can easily be identifiedby allowing light to reflect off the filmsurface.Dirt deposits. Contaminated washwater in the automatic processor mayresult in deposits on the surface of thefilm that can easily be verified byallowing light to reflect off the filmsurface.Artifacts Occurring after ProcessingFingerprints result from handlingthe processed film with wet fingers.Scratches and abrasion marksresult from rough handling of the driedfilms. These can easily be identified byallowing light to reflect off the filmsurface.Water spots. Any liquid spilled onthe radiograph, or onto the table orbenchtop, will cause spots on the filmsurface if the film is laid down on awet benchtop. As with many other filmartifacts, these are easily identified byobserving the surface while allowinglight to reflect off the film surface.Nonrelevant IndicationsIndications in this classification arethe result of known conditions in thetest object. Changes in theconfiguration of the test object willresult in film density variations thatmay cause difficulties in interpretation.The RI must be able to identify thesenonrelevant indications, which arepredictable and repeatable if the part isreshot. These types of indications willalso appear on the radiographs of othersimilar parts.Familiarity of the test partconfiguration and a review of the partdrawings will help the RI identifynonrelevant indications. Sometimesanother radiograph taken with adifferent part alignment or differentangle of the incident radiation may benecessary to verify and confirm theinterpretation. Variations in filmdensity due to keyways, drilled holes,or any other change in part geometrywould be interpreted as nonrelevantindications.20Inspection Trends / April 2011

Radiographs of a dissimilar metalweld in which the two base membershave different material densities willhave variations in the film density ofthe two base members. Radiographs ofa weld that by design is a partialpenetration weld (PPW) will revealindications of incomplete penetration.Both of these conditions would beinterpreted as nonrelevant indicationssince the indications are the result ofpart design.Relevant IndicationsThis last classification ofindications is of primary concern to theRI. True indications are caused bysome type of unintentionaldiscontinuity. Discontinuities presentmust be identified as to type (i.e.,porosity, slag, incomplete penetration,etc.). The flaw geometry, or shape, willoften give clues as to the type ofdiscontinuity. Once the discontinuityhas been identified, it requiresevaluation. The evaluation of adiscontinuity involves comparing it tothe acceptance criteria, which areusually based on size, location, anddistribution, all of which must beconsidered in determiningacceptability. The RI should alwaysreview the acceptance criteria prior toreading the radiographs.Report the ResultsThe initial interpreter, often aLevel II radiographer, is responsible forgenerating the Radiographic Report.The individual performing the finalinterpretation must verify that thereport is complete; legibly signed bythe originator, including his or her levelof certification; and dated.Written Report: The individualgenerating the written report mustprepare the report with theunderstanding that it should be a“stand-alone” report. That is, it must beprepared in such a manner that it canbe easily read and understood by anyindividual who may review the report.The individual generating the reportmust sign and date it, and indicate hisor her level of certification.Report Actual Condition: It isimportant that the actual conditiondetected be reported even though thecondition may be acceptable, or mayeven be considered nonrelevant. Forexample, some codes consider porosityto be nonrelevant when spotradiography is required. A spotradiograph of a weld may reveal aconsiderable amount of porosity, andalthough the code may deem itnonrelevant, the cognizant engineermay consider it to be in excess of thecompany’s workmanship standard.Disposition: After all indicationshave been interpreted and relevantindications evaluated, the dispositionof the part must be determined. Thereare only two possible dispositions,accept or reject; however, there arefour possible events.1. Accept an acceptable condition.2. Reject an unacceptablecondition.3. Accept an unacceptablecondition.4. Reject an acceptable condition.Events 1 and 2 present no problemassuming that the decisions leading tothis event were accurate. Events 3 and4 do present problems. Event 3 couldresult in a catastrophic failure, whileEvent 4 may result in unnecessaryrepairs being performed, which resultsin unnecessary delays and added cost.Verbal Report: It is notuncommon to find that reports are notreviewed carefully or completely bythe individual receiving them. Thewelding engineer, quality engineer,production supervisor, project engineer,etc., may be primarily interested inwhether or not the weld is acceptable,and may only look at the“accept/reject” column on the report.In doing so, they may overlook someimportant notation in the “Remarks”column. A verbal report will helpeliminate these oversights.SummaryRadiographic Interpreters mustconsider all the items discussed in thisarticle. Undesirable results may result ifany item is ignored or overlooked. TheRI should never assume that theradiographer producing the radiographfollowed the procedure and dideverything correctly; every item must bechecked. Errors in interpretation canoften be attributed to the fact that theindividual interpreting the radiographsdid not have an organized or systematicapproach to reading the radiographs.Developing and following asystematic approach to reading theradiographs will help in avoiding someof the pitfalls others have experienced.For example, the individual reading theradiograph may be concentrating somuch on assessing the clarity of theImage Quality Indicator and the requiredhole that he or she fails to recognize theradiographer used the wrong IQI, or thatit was not placed properly.Radiographic Interpreters mustalso guard against allowing theirattention to be drawn so much tosomething rather obvious, such as aslag inclusion, or a cluster of porosity,that they overlook some more criticalitem such as a small transverse crackthat may be partially obscured by theripples of the weld. Figure 1 may behelpful in developing a systematicapproach to reading radiographs.www.worldspec.orgExcerpted from RadiographicInterpreter Textbook, published byAmerican Welding Society, EducationDepartment, Miami, Fla.YOURCLASSROOMAWAITS...Don't pay for travel oraccommodations forintense one weekcourses...ever againFully online NDT training to meetglobal standards!Register today and save $100dollars instantly.Enter aws59c2 in the discount code boxFor info go to www.aws.org/ad-indexInspection Trends / Spring 2011 21

By Mike ForbesFeatureBridge Inspection UpdateThe changes included in the most recent version of AWS D1.5 are outlinedwelding. This revision is also the directresult of recognition by highway andtransportation officials in all 50 states,District of Columbia, and Puerto Rico,which make up AASHTO, of a need fora single document that can address theissues of public safety with structuralintegrity in bridge fabrication.The changes incorporated inD1.5M/D1.5:2010, Bridge WeldingCode, include the following:Electroslag Welding ChangesFig. 1 — Bridges undergo nondestructive examinations in order to assess their currentcondition and to help predict their useful lifespan.Nondestructive evaluation (NDE) ofaging bridge structures is used to assistin determining the current condition ofthe structure and is a great tool foreliciting recommendations regardingmaking repairs and in calculating theremaining life of the bridge — Fig. 1.Some of the more common typesof nondestructive methods that areperformed are ultrasonic testing,magnetic particle examination, and dyepenetrant inspections. The type of NDEused is dependent on what part of thestructure needs evaluation.Ultrasonic examination can beutilized to monitor and detect crackingin the completely penetrated weldedareas as well as to examine the pins ona pin and hanger bridge — Fig. 2.Magnetic particle examination isutilized on fillet welds, as well as avariety of components such as eye bars(Figs. 3, 4), to detect anydiscontinuities that may arise.Dye penetrant inspection iscommonly used in monitoring therepair process of bridge welding.Bridge inspections are carried outaccording to the requirements of AWSD1.5, Bridge Welding Code. Followingis an outline of the changes that weremade to the most recent edition of thecode.Changes to AWS D1.5AWS D1.5, Bridge Welding Code,covers the welding requirements forAASHTO welded highway bridgesutilizing carbon and low-alloyconstruction steels. The 2010 revisededition supersedes the 2008 edition. Thisrevision was undertaken as a directresponse to a need to establish acommon welding specification for thefabrication of steel highway bridges by• The requirements for electroslagwelding (ESW) were separated fromthose for electrogas welding (EGW).• The ESW requirements now includethe narrow gap improved electroslagwelding process (ESW-NG).• Commentary for the new Annex Iwas added for electrodeconsumables.• A new Annex J was added to addressthe guidelines for alternative ESWprocess.• New information (Annex Q) wasadded as a guide for the use of ESW-NG.Matching Filler Metal Tables• Tables 4.1 and 4.2 have beenconsolidated into one table 4.1.Clause 5 — Qualification• The qualification methods of 5.12and 5.13 were consolidated under thenewly revised 5.12 with modifiedand improved language that detailsmaximum heat input andmaximum/minimum heat inputproduction qualification.• Provisions were added to addressqualification of hybrid joints (e.g.,22Inspection Trends / April 2011

Fig. 2 — An inspector performs an ultrasonic inspection of acable component.Fig. 3 — Magnetic particle inspection was conducted onthe eyebar on this bridge in New York.50W to HPS 70W).• Section 5.12 was revised to specifyheat input requirements fornonstandard groove weld jointdetails.• Section 5.7.7 was extensively revisedfor clarification and now includes asubclause covering exceptions forcombining FCAW WeldingProcedure Specifications.Clause 6 — Inspection• Section 6.1.3.7 was revised to acceptonly Jaeger J-2 vision acuity forqualification of inspection personnel.• Inspectors, assistant inspectors, andpersonnel performing nondestructivetesting are to have passed an eyeexamination, with or withoutcorrective lenses, to prove: 1) nearvision acuity of Snellen English, orequivalent, at 12 in.; and 2) far visionacuity of 20/40 or better. This isrequired every three (3) years, orsooner if necessary, to demonstrateadequacy.• Section 6.17.1 was modified to requiretest equipment qualification every two(2) months instead of every forty (40)h. Also, the horizontal linearity of thetest instrument is to be prequalifiedafter each 40 h of use in each of thedistance ranges over which theinstrument will be used. Thequalification procedure must be inconformance with 6.22.1 (see AnnexFig. 4 — The eyebar of this railroad bridge underwent magnetic particle inspection.F, FA3 for alternative method).• Section 6.18.3 was modified to requirerecalibration after change of operatorsevery two (2) h instead of every thirty(30) min. Recalibration must be madeafter a change of operators, after each30-min maximum time interval, orwhen the electrical circuitry isdisturbed in any way, inclusive oftransducer change, battery change,electrical outlet change, coaxial cablechange, and power outage failure.Fracture Critical (Section 12)• Grades 345S [50S] and HPS 345W[HPS 50W] were added to Table 12.1.Commentary• Commentary for Clause 4 was addedto address all of the provisions ofClause 4. Chapter 4 — Technique,describes details of filler metals,preheat, and procedures forconsumables.MIKE FORBES(mforbes@ndtg.net) is national salesmanager, TÜV Rheinland IndustrialSolutions, Caledonia, Mich.Inspection Trends / Spring 2011 23

By Ankit VajpayeeFeatureUsing a Robotic System to Inspect Boiler TubesA robotic wall crawling system utilizing electromagnetic inspection techniques inspects boiler water wallsfrom the outside of the tubeFig. 1 — A typical RFT probe. In comparison with conventional eddy current,RFT coils are widely spaced in order to measure the through-transmission field.Tube failures continue to be theleading cause of forced outages inboilers. To get your boiler back on lineand reduce or eliminate future forcedoutages due to tube failure, it isextremely important to determine andcorrect the root cause. Detecting flawsbefore they cause failures is of criticalimportance in boiler maintenance.Localized wall thinning due tocorrosion in boiler water-wall tubing isa significant inspection concern forboiler operators.The typical methods used forinspecting boiler water walls includespot check ultrasonic testing (UT), A-scan UT, electromagnetic acoustictransducer (EMAT) UT, and scanningthermograpy. Spot check UT only givesthickness readings and gets veryminimal coverage of the total surfacearea of the furnace water walls; thechances of finding ID flaw mechanismsusing spot check UT are minimal at best.If boiler water walls have beensandblasted, A-scan UT may be used toinspect larger areas of the furnace walls;in these cases, a steady flow of water ismost often used as the couplant. TheEMAT technique requires sandblastingof any boiler water wall surfaces, anddoes not inherently get good surface areacoverage unless the inspection teamperforms multiple passes using theEMAT probe. Scanning thermography isthe most recent development for theinspection of boiler water walls;however, it is not yet commerciallyavailable in enough capacity.This article explains thedeployment of a robotic wall crawlerusing an electromagnetic technique toinspect boiler water walls from outsideof the tube as well as the theoreticalbackground of the technique, whichexplains the quantitative nature of theinspection.Further, a case study is presentedfor the technique that allows theextraction of thickness informationfrom the inspection data.Theoretical Background ofRemote Field TechnologyIn the 1950s, the Shell DevelopmentCo. pioneered an electromagneticnondestructive examination techniqueknown as remote field testing (RFT). Itwas first used to inspect well casings forcorrosion and wall thinning, and for anumber of years was used primarily inthe petroleum and pipeline industries. Inthe mid-1980s, this technology became asubject of sophisticated research, and thecombination of basic research andindustrial innovation has resulted inelegant theoretical models thatFig. 2 — An inspector using UT to dothickness measurements on boiler waterwall tubes.eventually developed into stronganalytical methods that enable a greatervariety of anomalies to be detected andquantified. Remote field testing is now awell-established inspection method forcondition assessment of ferromagnetictubes.Principles of RFTRemote field testing is based on athrough-transmission principle. Thefield passes from the exciter coilthrough the tube wall, along the outsideof the tube, and back in through thetube wall at the location of the detectorcoil — Fig. 1. Metal loss causes thefield to arrive at the detector coil withless travel time and less attenuation,resulting in a change in signal phaseand amplitude. The signal values ofphase (time of flight) and logamplitude(signal strength) are directlyrelated to wall thickness in the area ofthe detector coil(s).The RFT technique can be used forall conventional carbon steel materials,diameters, and wall thicknesses. It is,therefore, used in many different types24Inspection Trends / April 2011

of heat exchangers, including fossilfuel boilers (especially in water walland generator bank tubes), black liquorrecovery boilers, shell and tubeexchangers, and air fin coolers. Remotefield testing operates at relatively lowfrequencies and is a noncontacttechnique, so the probes have minimalfriction with the pipe wall and requireno couplant.The accuracy for remote fieldtesting in the straight part of the tubesis about 10% of wall thickness forgeneral wall loss. Accuracy is generallyless (20% of wall) for highly localizeddiscontinuities and near externalconducting objects because of thechanges in magnetic properties of thetube in that area and because ofshielding effects of external objects.Remote field testing is also equallysensitive to inside and outside surfacediscontinuities but usually cannotdiscriminate between them without thehelp of near-field coils. It is relativelyinsensitive to scale and magneticdebris.Deployment of a Robotic WallCrawler Using RFTIt is very difficult to obtain accessto the inside of boiler tubes so that aninspection tool can be inserted;therefore, all inspection must beperformed from the outside of thetubes, inside the boiler. In this case, itis desirable to have an external toolthat can detect corrosion or wallthinning without exhaustive cleaning ofthe surface, or removal of coatings.The traditional method ofinspecting boiler water wall tubes forloss of wall thickness is by takingmany thousands of ultrasonic thicknessreadings spaced several feet apart inelevation — Fig. 2. In order to do this,the boiler must be scaffolded and thetubes must be cleaned to bare metalwhere the readings are to be taken.Scaffolding and cleaning costsoften exceed $100,000, and theultrasonic inspection can cost the sameamount again.If the boiler will be scaffoldedanyway, the tubes can be inspectedrapidly with a hand-held scanning toolthat delivers the equivalent of up to 2000thickness readings per foot, at a scanningspeed of up to 10 ft/min — Fig. 3.For boilers that are not scaffolded,Fig. 3 — For scaffolded boilers,inspectors can use a hand-held tool toperform up to 2000 thickness readings perfoot at a scanning speed of up to 10 ft/min.Fig. 5 — Heavy scaling.a magnetic “wall crawler” can be usedto carry the external pipeline integritytool (E-PIT) RFT probe up the waterwall. The crawler can handle waterwalls up to 200 ft in height and tubesizes from 1.5 to 3.5 in. in diameter.Inspection speed is 10 ft/min so anentire wall that is 100 ft high and 100tubes wide can be inspected in lessthan three 12-h shifts. The E-PIT probeinspects the flame side of the tube towithin 3 ⁄8 in. of each web, using 12detection coils for high precision —Fig. 4. Pits, as small as 1 ⁄8 in. diameter,can be detected.Fig. 4 — An example of a roboticcrawler being used to inspectboiler tubes.Fig. 6 — The Vertiscan system in place.Case StudyUnit #1 of the generation station atABC Power in Canada usesOrimulsion as fuel. Orimulsion is abitumen-in-water emulsion producedfrom the vast reserves of the Orinocobelt in Venezuela. The emulsion contains70% natural bitumen and 30% water.This liquid fuel, resembling a black latexpaint, has relatively high energy contenton a weight basis (i.e., about 110% ofcoal and 70% of heavy fuel oil). Thescale deposition on the tubes and web insuch boilers is worse than coal-firedboilers. Figure 5 shows an example ofscale. Note that the crown is often scalefree but the spaces between the tubesalways have heavy scale.A Vertiscan system from RussellNDE Systems, Inc., Edmonton, Alb.,Canada, was used to inspect the waterwall tubes in boiler #1 in the fall of2006 — Fig. 6. The system consistedof a TubeCAT magnetic crawler withInspection Trends / Spring 2011 25

Fig. 7 — Calibration graph for area F1. Fig. 8 — Calibration graph for area F2.Fig. 9 — The water wall of boiler #1 is shown zoomed out. It shows the area from elevation 70 ft (below burners) to elevation 99.5ft (just below the superheater tubes). The dark area below the line showing the top of the burners was confirmed by ultrasonicreadings to be 0.098 to 0.150 in. (black to yellow colors, respectively). The dark area to the right (south corner) is due to heavyscale that lifted the scanner away from the wall. Individual tube numbers are shown at the top, and the distance scale and elevationare shown to the left.odometer; E-PIT tool capable ofinspecting five tubes simultaneously;E-PIT hand-held scanner for theinspection of individual tubes;Ferroscope 308, 16-channel RFTinstrument; remote vision system; 200-ft umbilical; and an industrial laptopcomputer.Calibration. The equipment wascalibrated on-site by taking ultrasonicthickness readings on at least twoseparate elevations of the same tubehaving both nominal thickness andknown wall loss. In this instance, thethinned area of tubes on one of thewalls at the burner elevation was usedto produce the calibration curvesshown in Figs. 7 and 8.Procedure. A datum line markedon the wall was where allmeasurements were taken. In thisinstance, the datum line was at anelevation of approximately 99.5 ft. Thetool detectors were aligned with thisdatum for each of the scans performed.From the datum line, the RFTsystem descended the wall at a speedof approximately 10 ft/min whilegathering data from the crowns of fivetubes simultaneously. Depending onthe frequency and sample rate, this canequate to (up to) 2000 thicknessreadings per foot.Once reaching target height, thecrawler was stopped and the directionreversed. Data were also gathered on26Inspection Trends / April 2011

Fig. 10 — Butt joint weld with possible loss below (east wall62–66).Fig. 11 — Ultrasonic test results of the same tubes evaluatedin Fig. 10 (wall loss detected).the way up and were used to confirmany indications of wall loss detected.Results. The softwaresemiautomatically generated a detailedreport (spreadsheet) for each wall. Inadditon, field notes and a collage of the“color map” of the full-scan data fromeach wall was made — Fig. 9.Confirmations. The inspectionresults were backed up using ultrasonics— Figs. 10, 11.Summary• The VertiScan system proved effectivein identifying general and localthinning near the welds at elevation90.5 ft. Thinning was confirmed byultrasonic thickness readings.• The scaffold gap must be a minimumof 10 in. from the crown of the tubesto allow the system to pass by.• For future inspections, it would helpto have a fourth person doing on-sitedata analysis only. The operation ofthe RFT system when scaffolds arepresent is a three-person job (twopeople if no scaffolds are present).• The system provides the best valuewhen there is no scaffold in the boiler.• Generally, one full water wall can bescanned per shift if just one system isin use.Capabilities. The technique issensitive to all types of wall thinning,including the following:• Hydrogen damage,• Underscale pitting and graphitization,• Flame and soot blower erosion,• Blister and local overheating,• Creep damage (thermal fatigue),• Elephant skin and rhino hide,• Dents and gouges, and• Internal pitting.Works Consulted1. MacLean, W. R. 1951. Apparatusfor magnetically measuring thickness offerrous pipe. U.S. Patent 2573799.2. Schmidt, T. R. 1989. History ofthe remote-field eddy current inspectiontechnique. Materials Evaluation 47(1):pp. 14, 17, 18, 20–22. Columbus, Ohio:American Society for NondestructiveTesting.3. Atherton, D. L., and Czura, W. M.1994. Finite element calculations for eddycurrent interactions with collinear slots.Materials Evaluation 52(1): 96–100.Columbus, Ohio: American Society forNondestructive Testing.4. Hoshikawa, H., Koyama, K.,Koidoand, J., and Ishibashi, Y. 1989.Characteristics of remote-field eddycurrent technique. Materials Evaluation47(1): 93–97. Columbus, Ohio:American Society for NondestructiveTesting.5. Schmidt, T. R. 1984. The remotefield eddy current inspection technique.Materials Evaluation 42(2): 225–230.Columbus, Ohio: American Society forNondestructive Testing.6. Lord, W., Sun, Y.-S., Udpa, S. S.,and Nath, S. 1988. A finite elementstudy of the remote-field eddy currentphenomenon. IEEE Transactions onMagnetics Vol. 24, pp. 435–438. NewYork, N.Y.: Institute of Electrical andElectronics Engineers.7. Mackintosh, D. D., Atherton, D.L., and Puhach, P. A. 1993. Throughtransmissionequations for remote-fieldeddy current inspection of small-boreferromagnetic tubes. MaterialsEvaluation 51(6): 744–748. Columbus,Ohio: American Society forNondestructive Testing.8. Sun, Y.-S., Udpa, L., Udpa, S.,Lord, W., Nath, S., Lua, S. K., and Ng,K. H. 1998. A novel remote-field eddycurrent technique for inspection of thickwalled aluminum plates. MaterialsEvaluation 56(1): 94–97. Columbus,Ohio: American Society forNondestructive Testing.9. Kilgore, R. J., andRamachandran, S. 1989. Remote fieldeddy current testing of small-diametercarbon steel tubes. Materials Evaluation47(1): 32–36. Columbus, Ohio:American Society for NondestructiveTesting.10. Atherton, D. L., Macintosh, D.D., Sullivan, S. P., Dubois, J. M. S., andSchmidt, T. R. 1993. Remote field eddycurrent signal representation. MaterialsEvaluation 51(7): 782–789. Columbus,Ohio: American Society forNondestructive Testing.11. ASTM E 2096-00, StandardPractice for In Situ Examination ofFerromagnetic Heat-Exchanger TubesUsing Remote Field Testing. 2000. WestConshohocken, Pa.: ASTMInternational.ANKIT VAJPAYEE(avajpayee@russelltech.com) iswith Russell NDE Systems, Inc.,Edmonton, Alb., Canada.Inspection Trends / Spring 2011 27

By Albert J. Moore Jr.FeatureTips for Qualifying WeldersAn experienced inspector offers help in developing a systematic method for administeringwelder qualification testsAnswering questions about welderqualification and how a welder getsqualified is like shoveling sand into theocean. No matter how hard you work,there is still more sand to toss into thesea just like there are always morequestions to answer about qualifyingwelders.Since most employers haveinstituted welder performancequalification testing programs to ensureonly skilled welders are employed forall critical welding tasks, I am going towalk you through the process ofqualifying a welder and show you acompleted welder performance testrecord — Fig. 1. I have also provided achecklist to help ensure welders arequalified properly (see page 29).QualificationWelder qualification involveswelders doing those activitiesnecessary to demonstrate they havemet the qualification requirements.Welding standards typically requirewelders to demonstrate they have theskills needed to deposit a sound weldthat meets the acceptance criteria of thestandard. The particular performancetest the welders take is dependent onthe type of work they will be doing. Ifthe welders will be fabricating pressurevessels or pressure piping, they wouldbe qualified under the auspices of anASME code. If they will be fabricatingstructural members, they will have tomeet the requirements of an AWSstructural welding code. If they arewelding on equipment or componentsdestined for a naval combat vessel,they will have to meet the requirements28Inspection Trends / April 2011stipulated in NAVSEA S9074-AQ-GIB-010/248.The qualification process requireswelding of test coupons that aresubjected to either destructive orvolumetric nondestructive testing orboth. The applicable welding standardmust be reviewed to determine whattests are required.CertificationOnce a welder has met thequalification requirements, someonehas to attest to the fact the welder metthe qualification requirements of theapplicable welding standard. Simplyput, someone has to take theresponsibility for signing aperformance test record that states thewelder met the qualificationrequirement of the welding standard.That’s right, the “certification” isthe signature of the welder’s employer(or that of the employer’srepresentative) who is authorized tosign the performance test report.The Qualification ProcessMany CWIs and SCWIs begantheir careers as welders. Some weregood welders, some were very goodwelders; the vast majority of them werethe best welders in their shop.Seriously, just ask any welder and he orshe will tell you they can weldanything but a broken heart or thecrack of dawn.In our previous lives, many CWIsand SCWIs went through the samequalification process as the weldersbeing tested. I am no different fromany other welder who has burnedelectrodes to make a living. I havetaken so many different tests I cannoteven tell you how many I have taken.Each qualification test was overseen bya different inspector and no two testswere ever administered the same way.As a result, I, like many other welders,questioned the process.Because of my own experience, Ihave given a lot of thought to how awelder should be tested. Every welderenters the test booth with two questionsin mind: “What do you want me to do?What results are you looking for?”With that in mind, I havedeveloped a methodology forqualifying welders. I have honed thissystem over the years, and it seems towork without serious complaints fromthe welders. I am going to walk youthrough my program. If you like it,adopt it as a whole. If you like onlysome of it, adopt the parts that work foryou.Step 1: Determining WhatQualification Test Is RequiredMany clients, whether they are aone-person operation or a largefabricator, have a limitedunderstanding of what is required to“certify” the welder. That is why theycall on a professional to help themthrough the process.The first step involves gatheringinformation. When I am called in, Ibegin by asking the client whatwelding standard the customer hasinvoked. It is amazing how manyclients cannot answer the question.— text continued on page 31

Welder Performance Test RecordWelder: Willie Pazz Employee ID: 212223Witness: Albert J. Moore Jr. Date: 31-Feb-2011Process: SMAW Mode of Transfer: NAMA X SA -- ME -- AU --Procedure: SMA-1F4G10````` Weld Type: GrooveTest VariableVariable Actual (used for test) Qualified ForJoint Type Butt Joint Grooves and FilletsBase MetalCarbon SteelSpecification:A106All P1Alloy: Grade BGroup, P, or S Number: P1 Grp 1Thickness/Diameter: 5/8 inch / 5 inch 2 7/8 and largerBacking: No w/ or w/o BackingFiller Metal Root Fill Root FillSpecification SFA 5.1 SFA 5.1Classification E6010 E7018Diameter 1/8 in. 1/8 in.SFA 5.1SFA 5.1 andSFA 5.5F Number 3 4 1, 2, and 3 1 through 4Deposit Thickness: in. 3/8 in. inch max. inch max.Welding ParametersVoltage: 24-25 22-24Wire Feed Speed: NA NAAmperage: 110-120 125-135Travel Speed: 3 ipm 4 ipmNumber of Electrodes Single SingleWelded from One Side or Both One Side Single or Double WeldedPosition & Progression 6G, Vertical Uphill All Positions, UphillShielding Gas None NoneBacking or Trailing Gas None NoneCurrent / Polarity DCEP DCEP, DCEN, or ACTest ResultsVisual (ASME B31.3 Normal Service)Profile Porosity Convexity Undercutaccept accept accept acceptCracks Fusion Penetration Inclusionsaccept accept accept acceptBend TestType of Bend Test: Guided Bends, Side Bends4 Side Bends: accept, open defects 3/8 inch, none > 1/8 inchBend Diameter: 1 inch Dia.Sample Thickness / Width: 5/8 x 3/8 inchTest Temperature: 72°FTested By: Albert J. Moore Jr. Date: 32-Feb-2011We, the undersigned, certify that the tests administered above were prepared, welded, and tested inaccordance with the applicable paragraphs of ASME Section IX-2010 and B31.3-2010.Test Witness: Albert J. Moore Jr. Date: 32-Feb-2011Employer:John Grunsalot Date: 34-Feb-2011Wakum Crakum WeldingFig. 1 — An example of a completed welder performance test record. (The entries in red are completed when the test is requestedand serve as the Test Request. Entries in green are completed at the time the test is administered and test results are known.)Inspection Trends / Spring 2011 29

Checklist for a Systematic Approach to Welder QualificationA successful welder qualification program requires careful consideration of the intended goals of testing the welder.The process should be formalized and systematic. The steps should be well defined and a process followed to ensure theproper test is administered to the welder.The following is a brief outline of the system I employ when qualifying welders. You can use it as a checklist.Organize1. Determine what welding standard is applicable.2. Verify a copy of the applicable welding standard(s) is available to the inspector.3. Determine what performance tests are required, i.e., grooved plate test, fillet break test, pipe test, etc.4. Determine what test positions are appropriate.5. Determine what evaluation tests are required, i.e., guided bend tests, fillet break test, NDE, etc.6. Determine the size of the test pieces required.7. Determine what base metals and thicknesses are to be welded.8. Determine what welding process will be used.9. Develop an appropriate WPS for the test to be administered.10. Determine what testing equipment is required, i.e., diameter of the bending mandrels, wraparound vs. a plunger anddie-type guided bend tester, appropriate press for fillet break test, etc.11. Complete a welder qualification test request identifying the welder, applicable welding standard, test to be taken,method of evaluation, etc. This may simply entail entering the basic information on the Welder Performance Test Record. Itdoes not have to be a separate document if the test record contains all the required information.Administering the Performance Test12. Check the welder’s identification. I take the welder’s photograph before testing starts and attach it to the test report.13. Enter all applicable information and the photograph onto the Welder Performance Test Record.14. Review WPS, test rules, and acceptance criteria with the welder.15. Verify the proper materials are being used, including the following:a. Base metal material specification (certified material test report)b. Filler metalc. Proper storage considerations for low-hydrogen shielded metal arc welding covered electrodes.16. Verify test assembly is properly fitted and tack welded.17. Verify the test assembly is in the proper test position (check with a spirit level).18. Verify proper preheat is utilized if it is required.19. Check root bead for profile, defects, proper interpass cleaning, preheat maintenance, etc.20. Check welding parameters while the welder is welding.21. Verify proper interpass cleaning is performed, and when prohibited, that power tools are not used.22. Perform visual examination of the completed weld.23. Verify the appropriate identification is applied to the test coupon and the top of the test coupon is marked beforeremoving it from the test position.Evaluation24. Check the test coupon for proper markings. The type of markings required is not the same for every situation. Thefollowing information is usually considered to be the minimum required:a. Welder’s identificationb. Test positionc. WPS.25. Perform the final visual evaluation in accordance with the appropriate welding standard or per customerrequirements. In many cases, the client has established criteria that are more stringent than that required by the weldingstandard. For example, ASME Section IX visual criteria can be described as spartan at best. Many clients require the testpiece to pass the visual criteria applicable to the appropriate construction code such as Section I, B31.3 high pressure, etc.26. Lay out the test piece for cutting test specimens that will be subjected to guided bend testing or the fillet break test.27. Mark each test specimen with appropriate identification before testing.28. Subject the test specimens to the appropriate destructive or nondestructive tests as required by the applicablewelding standard.29. Record the test results on the Welder Performance Test Record.30. Return the test specimens to the client when requested to do so or retain the specimens for future review. I typicallykeep the test specimens for 30 days before I discard them.31. Inform the client of the test results.30Inspection Trends / April 2011

— continued from page 28If the client does not know whatwelding standard is applicable, I musthelp them determine what weldingstandard is appropriate. I begin byasking a few basic questions:1. What are you welding(structural steel, pressure vessels,pressure piping, machinery, railroadequipment, shipboard equipment, etc.)?2. Who are your customers?3. Did the customer issue apurchase order?4. Did the purchase orderreference a welding standard, code, orspecification?5. Do you have a copy of thepurchase order and welding standard?6. Did the customer issue adrawing for the part or componentsbeing welded?Their response to the questionstypically pushes us toward arecognized welding standard or onethat was developed by the customer (acommon practice in the aerospace andpetrochemical industries). A littleinformation mining usually results infinding a reference to a weldingstandard in the purchase order orproject specifications. On rareoccasions, I have recommended arecognized welding standard based onthe type of product if one was notimposed by a customer.The next question is what basemetal are you welding? They areusually welding a ferrous metal.Nonferrous metals only account forabout 5% of the tonnage of metalmodern industry uses; that means thereis a 95% chance the client is welding aferrous metal.A follow-up question: Are youwelding grooves or fillets or someother type of weld? The usual responseis “we weld mostly fillet welds.” Thisis reasonable because fillet weldsaccount for the majority of the weldsmade in manufacturing or fabricationoperations.Next question: “Do you weld anygrooved joints?”The typical response is “Yes, butmost of our welds are fillets.”My advice is “That’s fine, but ifyou make even a single groove weld,you have to use a test that utilizes agrooved weld preparation. In general,groove weld qualification qualifies thewelder for both grooves and filletwelds, but a welder qualified by takinga fillet weld test is only qualified forfillet welds.”A common response to a questionabout welding positions is, “Well, mostof the work is done in the flatposition.”“So, the welder never has to weldin the vertical or overhead positions?”is my next query. That question causesthe client to wince a little, but ameeting of the minds comes about andthe test positions are agreed to.Another question is “Are youwelding structural shapes, plate, orpipe?”Finally, as I near the end of theinformation-gathering process, I ask,“Do you have a WPS that describeshow the weld is made?” That questionis merely a courtesy, since I know fullwell the next words I am likely to hearare, “A what?”The Welding ProcedureSpecification (WPS)Contrary to the belief held bysome people, welders are not psychicnor can they read minds. Tossing acouple of test coupons on the weldingbench with a simple command of“weld these” isn’t sufficientinformation for the welder tounderstand what is expected.The welder needs specificinstructions on how the test couponsare to be assembled and welded.Does the welder have to weld thetest coupons in accordance with aparticular welding procedurespecification?I say yes if for no other reasonthan I do not want any surprises whenthe welder settles in to take the weldingperformance test. And, yes, I do write aspecific WPS for the welderqualification test.The WPS tells the welder thewelding process, base metal, fillermetal, filler metal diameters, jointdetails including the root opening, andwhether backing is required.I do not simply hand the welder aFig. 2 — Welder breaking the fillet weldto assess the weld for internal defectssuch as incomplete fusion to the root,slag inclusions, piping porosity, etc.generic WPS that states it is applicableto all grooves and all fillets. Thespecific WPS used for welderqualification depicts the joint and thejoint details the welder is to use, andlists the welding process and ranges forvarious welding parameters.It isn’t enough to hand the WPS tothe welder. I review the WPS with thewelder item by item so there are noquestions of how the test coupons areto be welded.Test RulesI have already said I do not likesurprises while taking or administering awelder qualification test. I remember aninspector telling one of my friends, “Youcan’t weave on this test” as he rejectedmy friend’s test piece. Fortunately, I hadnot started welding yet.I have developed a set of test rulesto ensure that surprises do not happenwhen I am giving a qualification test. Ihand a printed copy of the test rules tothe welder, then review them and answerany questions he or she may have.What do I include in the test rules?The first thing listed is the requiredpersonal protective equipment theInspection Trends / Spring 2011 31

welder is expected to provide and usewhile testing.Then, specific hold points areidentified. The first hold point is aconfirmation the person being tested isthe welder identified by the employer, areview of the WPS, the test rules, andthat the proper test is beingadministered. The first tack weld isn’tmade until the paperwork is in order.The next hold point is assembly andtack welding of the test coupons. Alldimensions are checked to verify theyare in accordance with the sketchincluded in the WPS. If preheating isrequired, it is checked at this time.Once welding has begun, the nexthold point is a visual examination of thecompleted root bead to verify interpasscleaning has been performed and theproper bead profile has been produced.The next hold point is the completedtest while the test coupon is still in the testposition. Only after the coupon has beenchecked is the welder permitted toremove it from the test position.I also check the welding parameterswhile the welder is welding, but thisfunction is not identified as a hold point.The test rules include someinstructions regarding interpasscleaning. Structural tests on plate cannotutilize power tools. Hand toolsincluding cold chisels, wire brushes,slag picks, files, etc., are allowed. Pipetests allow the use of power tools forinterpass cleaning and limited grinding.Welders who will be qualifying to AWSD1.5, Bridge Welding Code, are notpermitted to use power tools or handtools for improving the weld beadprofile or interpass cleaning. Allcleaning must be performed in the testposition.Relax. Some of you are squirmingin your chairs as you read this. I knowwhat you are thinking: “There is nothingin AWS D1.1, Structural Welding Code— Steel, that prohibits the use of powertools for grinding or improving theprofile of the weld bead.”I agree. However, I amadministering the qualification test, andit is my signature on the test report. Theclient, i.e., the welder’s employer, willsign the certifying statement, but I seelittle value in “certifying” a structuralwelder who has to remove 50% of theweld deposited because the welds are atbest marginal. I realize that’s my ownphilosophy, but that is why my clientsretain my services. They pay me to bethe bad guy and to do the dirty work.Acceptance CriteriaEvery welding standard has visualacceptance criteria that are unique tothat standard. The testing regimen variesfrom one welding standard to another. Ibelieve in offering a fair and levelplaying field to every welder I test. Ihave formalized the written acceptancecriteria for each specific qualificationtest I administer. The acceptance criteriafor AWS D1.1 are different from thoseof ASME Section IX or AWS D17.1.The welder is provided with a copy ofthe acceptance criteria that will beapplied when his or her test coupon isevaluated. There are no secrets.EvaluationWhen time permits and it is feasible,the welder is present when the testcoupons are evaluated. The evaluationincludes the visual examination;preparation of the coupons, i.e., grindingthe face reinforcement of the groove test;and the bending of the test coupons orbreaking of the fillet welds. Whenpossible, I let the welder do the grindingand provide the motive force needed tobend the test coupons or break the filletweld — Fig. 2.Once again, personal philosophyplays a part in allowing welders to bepart of the test piece evaluation. It givesthe welders a sense that the cards are notstacked against them. The welders seehow the tests are performed and how thetest pieces are evaluated. It is just onemore learning experience for thewelders, and it serves as an importantteaching aid should the coupons fail forsome reason. They have a firsthandopportunity to see how a welddiscontinuity affects the test results.Test ResultsLet’s face it, welders are not perfect.Occasionally, they do fail to pass therequired tests. So what happens if thewelder fails to meet the visual acceptancecriteria or the guided bend test?The easy answer is to send thewelder packing, but that is not the onlyresponse when a welder fails thequalification test. Welding standardsusually have provisions that allow thewelder to be retested immediately orafter additional training.Many welding standards require thewelder to pass two additional tests if heor she is administered an immediateretest or a single retest if additionaltraining is received. The duration of thetraining is left to the discretion of theemployer or the inspector.To ensure the welder qualificationprocess does not become an exercise instatistics, I require the welder to providetwo welded coupons that meet the visualcriteria before allowing the welder toweld two new test coupons. Bothwelded coupons are required to pass therequisite tests. If one of the two testcoupons fails, it is back to the trainingbooth.The welder qualification programestablished for each client may differsomewhat depending on the specificrequirements of the welding standardused. However, the similarities betweenvarious standards outweigh thedifferences. Regardless of the weldingstandard used, a systematic approach towelder qualification will mitigateopportunities for mistakes andmisunderstandings between the welderand the individual administering thewelder qualification test.ALBERT J. MOORE JR.(AMoore999@comcast.net) is vice president,Marion Testing & Inspection, Canton,Conn. He is an AWS Senior CertifiedWelding Inspector and an ASNT ACCPNDT Level III. He is also a member of theAWS Certification Committee and theCommittee on Methods of Inspection ofWelds.An Important Eventon Its Way?Send information on upcoming eventsto Inspection Trends, 550 NW LeJeuneRd., Miami, FL 33126. Items can alsobe sent via FAX to (305) 443-7404 orby e-mail to mjohnsen@aws.org.32Inspection Trends / April 2011

NDE professionals and current AWS CWIs:The AWS Certified Radiographic Interpreter training and certification program assures employers and practitionersalike that the principles of radiographic interpretation are reliably applied to the examination of welds. If your jobresponsibilities include reading and interpretation of weld radiographs, this program is for you. You’ll learn proper filmexposure, correct selection of penetrameters, characterization of indications, and use of acceptance criteria asexpressed in the AWS, API, and ASME codes.NEW! If you are a CWI, certification as an Radiographic Interpreter (CRI) can now exemptyou from your next 9-Year CWI Recertification Exam.For more information on the course, qualification requirements,certification exams, and test locations, visit our website atwww.aws.org/certification/CRI or call 1-800-443-9353 ext 273.Founded in 1919 to advance the science, technologyand application of welding and allied processes includingjoining, brazing, soldering, cutting and thermal spraying.

By K. Erickson and C. MankenbergThe Answer IsThe Society is not responsible for any statements made or opinion expressed herein. Data and information developed by the authors are for specificinformational purposes only and are not intended for use without independent, substantiating investigation on the part of potential users.Q: Is there any national requirementto perform both radiography andbend testing on welder qualificationtests?A: Not that I am aware of, althoughcertain employers and projects mayrequire that all welders pass both a NDEvolumetric test such as radiography orultrasonic testing along with amechanical test such as bend testingprior to certification being issued and/oras a condition of employment. In thesecases, the NDE inspection would first beperformed followed by the mechanicaltesting phase. In any case, the minimumrequirements for welder qualificationand testing are detailed within eachgoverning national specification forwelding.Q: I have accepted employment witha small midwest structural companythat wants me to develop an AWScompliantwelding program. Whatcan you suggest to help me in thiseffort?A: Welding programs will generallychange over time as a company growsand/or changes its direction to suit itscustomers’ needs. So, when developingan initial program, look atencompassing the company’s currentneeds while being able to expand theprogram with minimal effort and cost.Following are some suggestions onhow to do so.• Develop a general welding procedurethat will provide direction andguidance for both shop and fieldwelding applications relative to suchitems asa) Purpose and applicationb) Responsibilities and referencesc) Material selection andidentificationd) Weld details, welding symbols, etc.e) Filler metal control and issuancef) Equipment maintenanceg) Welding safetyh) Welding fit-ups, weld outs, andfinal weldingi) Inspection34For info go to www.aws.org/ad-indexInspection Trends / April 2011For info go to www.aws.org/ad-index

j) Reporting and documentationk) Repairs and reworksl) Nonconformances and defectiveweldingm) Other related items of interest.• Utilize as many prequalified proceduresas possible to minimize the need todevelop new Procedure QualificationRecords (PQRs) and WeldingProcedure Specifications (WPSs).When developing a new PQR, researchyour present and possible future needsto encompass as many applications aspossible to minimize the number ofPQRs for which many WPSs can becreated.• Create a unique welding PQR and WPSidentification system so that each WPScan easily be recognized for thewelding application it covers, such asJW101SCJPB1.875-A1-2011, whereJW = Jay’s Welding or company ID101 = P1 material to P1 materialS = SMAWCJP = complete joint penetrationB = backing required (omission of“B” indicates open butt joint relative toCJP weldments)1.875 = thickness value to 1.875 in.PQR-A1 (use numbers for yourWPSs and letters for your PQRs)2011 = year the document wascreated.By using this or a similar format, youcan easily identify the contents of eachWPS by its title number. Spend the timeup front to research and create how youor the company wants the weldingprogram to be organized. The programshould stand alone while also being easilyreviewed and interpreted by potentialcustomers and auditors to maximize yourcontract and future marketingconsiderations.Inspection Trends encouragesquestion and answer submissions. Pleasemail to the editor (mjohnsen@aws.org).KENNETH ERICKSON is manager of qualityat National Inspection & Consultants,Inc., Ft. Myers, Fla. He is an AWS SeniorCertified Welding Inspector, an ASNT NationalNDT Level III Inspector in four methods,and provides expert witness reviewand analysis for legal considerations.CLIFFORD (KIP) MANKENBERG is aconstruction supervisor for Shell InternationalExploration & Production, Houston,Tex. He is an AWS Senior Certified WeldingInspector and an ASNT National NDTLevel III Inspector in five methods.Errata D17.1:2001Specification for Fusion Welding forAerospace ApplicationsThe following errata have been identifiedand will be incorporated into the nextreprinting of this document.Page iii. Personnel. Add M. WebberRaytheon Co. after J. Waugh LockheedMartin AeronauticsPage 9. Table 4.3, Revise Footnote (1)to read: A groove weld does not qualify forfillet welds in base metal ≤ 0.063 in. inthickness.Page 71. Under B3. Procedure revisedto read as follows: Managing Director ofTechnical ServicesPage 7. Clauses 4.3.7.6 and 4.3.7.7should be subordinate to Clause 4.3.7.5and revised as follows:4.3.7.5 Special Applications. Whennone of the test welds described above areapplicable to a given production weld, aspecial welder or welding operator qualificationlimited to the specific applicationmay be achieved with a test weld consistingof the given production weld or a testweld representative of the given productionweld.(1) Qualification Limitations. Thequalification is limited to the welding conditionsof the test weld with regard towelding process, base metal composition,base metal thickness, welding position,base metal form, type of weld, and theother welding conditions of 4.3.6.(2) Acceptance Criteria. The requiredinspection, examination, and acceptancecriteria shall be consistent with4.3.8 or with production part criteria.CAN WE TALK?The Inspection Trends staff encourages an exchange of ideas with you, our readers. Ifyou’d like to ask a question, share an idea or voice an opinion, you can call, write, e-mail orfax. Staff e-mail addresses are listed below, along with a guide to help you interact with theright person.PublisherAndrew Cullisoncullison@aws.org, Extension 249General Management,Reprint Permission,Copyright IssuesEditorMary Ruth Johnsenmjohnsen@aws.org, Extension 238Feature ArticlesProduction ManagerZaida Chavezzaida@aws.org, Extension 265Design and ProductionAdvertising Sales DirectorRob Saltzsteinsalty@aws.org, Extension 243Advertising SalesAdvertising Production ManagerFrank Wilsonfwilson@aws.org; Extension 465Advertising ProductionAdvertising Sales RepresentativeLea Garrigan Badwygarrigan@aws.org, Extension 220Production and PromotionWelding Journal Dept.550 N.W. LeJeune Rd.Miami, FL 33126(800) 443-9353; FAX (305) 443-7404Inspection Trends / Spring 2011 35

Mark Your CalendarAWS Conference on Welding in Shipbuilding. May 10, 11,Seattle, Wash. Contact American Welding Society (800/305)443-9353 or www.aws.org.AWS Weldmex. May 11–13, Cintermex, Monterrey, Mexico.Held in conjunction with FABTECH Mexico and MetalformMexico. Contact American Welding Society (800/305) 443-9353 or www.awsweldmex.com.ASQ 2011 World Conference on Quality and Improvement.May 16–18, David L. Lawrence Convention Center, Pittsburgh,Pa. Contact American Society for Quality, www.asq.org.AWS Conference on Preventing Weld Failures. June 14,15, New Orleans, La. Contact American Welding Society(800/305) 443-9353 or www.aws.org.AWS Conference on Corrosion-Resistant Alloys, the NewChrome-Moly Steels. Aug. 16, 17, Charlotte, N.C. ContactAmerican Welding Society (800/305) 443-9353 or www.aws.org.Materials Testing. Sept. 13–15, International Centre,Telford, UK. Held in conjunction with FABTECH Mexicoand Metalform Mexico. Contact Karen Cambridge, 44-1604-89-3811 or e-mail karen.cambridge@bindt.org;www.materialstesting.org.AWS 14th Annual Aluminum Welding Conference. Sept.20, 21, Ft. Lauderdale, Fla. Contact American WeldingSociety (800/305) 443-9353 or www.aws.org.ASNT Fall Conference and Quality Testing Show. Oct.24–28, Palm Springs Convention Center, Palm Springs,Calif. Contact American Society for Nondestructive Testing,(800) 222-2768 or www.asnt.org.FABTECH. Nov. 13–16, McCormick Place, Chicago, Ill.Contact American Welding Society, (800/305) 443-9353, ext.264; or visit www.fabtechexpo.com or www.aws.org.Educational OpportunitiesNDE Classes. Moraine Valley Community College, PalosHills, Ill., offers NDE classes in PT, MT, UT, RT, RadiationSafety, and Eddy Current, as well as API 510 exam prep andweld inspection. For more information, contact (708) 974-5735; wdcs@morainevalley.edu; morainevalley.edu/NDE.CWI Prep Course and AWS CWI Seminar and Exam. ThePrep Courses prepare candidates for the AWS Certified WeldingInspector (CWI) seminar and examination. Offered July 18–22and Oct. 17–21. The CWI seminar covers how to referenceAWS codes, examine welds, and prepare for the CWI exam onthat following Saturday (proctored by AWS). Offered July24–30, Oct. 23–29. Contact Lincoln Electric’s Welding Schoolat (216) 383-8325 or visit www.lincolnelectric.com.EPRI NDE Training Seminars. EPRI offers NDE technicalskills training in visual examination, ultrasonic examination,ASME Section XI, UT operator training, etc. Contact SherrylStogner, (704) 547-6174, e-mail: sstogner@epri.com.Nondestructive Examination Courses. A course schedule isavailable from Hellier, 277 W. Main St., Ste. 2, Niantic, CT06357, (860) 739-8950, FAX: (860) 739-6732.NDE Training Courses. GE Inspection Technologies offerstraining on topics such as eddy current, digital radiography,and remote visual inspection. For the complete schedule,contact (866) 243-2638; www.geit-info@ge.com;www.ge.com/inspectiontechnologies.Positive Material Identification Seminars. Topics coveredwill include basics of X-ray fluorescence (XRF) analysis, APRIRP 578, and recommended PMI procedures. For moreinformation or to register, contact Thermo Fisher Scientific,Inc., at www.niton.com/News-and-Events.Preparatory and Visual Weld Inspection Courses. One- andtwo-week courses presented in Pascagoula, Miss., Houston,Tex., and Houma and Sulphur, La. Contact Real EducationalServices, Inc., (800) 489-2890; info@realeducational.com.CWI/CWE Course and Exam. A ten-day program presentedin Troy, Ohio. Contact Hobart Institute of Welding Technology(800) 332-9448; www.welding.org; hiwt@welding.org.T.E.S.T. NDT, Inc., Courses. CWI preparation, NDEcourses, including ultrasonic thickness testing and advancedphased 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; www.testndt.com.NDE Training. NDE training at the company’s St. Louis-areafacility or on-site. Level III services available. For a scheduleof upcoming courses, contact Quality Testing Services, Inc.,2305 Millpark Dr., Maryland Heights, MO 63043; (888) 770-0103; training@qualitytesting.net; www.qualitytesting.net.CWI/CWE Prep Course and Exam and NDT InspectorTraining Courses. An AWS Accredited Testing Facility.Courses held year-round in Allentown, Pa., and at customers’facilities. Contact: Welder Training & Testing Institute (WTTI).Call (800) 223-9884, info@wtti.edu, or visit www.wtti.edu.Welding Inspection, INTEG, Welding Health and Safety,and Welding Supervisor Courses. Contact the CanadianWelding Bureau for schedule at (800) 844-6790, or visitwww.cwbgroup.org.36Inspection Trends / April 2011

Certified Welding Inspector (CWI)LOCATION SEMINAR DATES EXAM DATEDetroit, MI May 15–20 May 21Miami, FL May 15–20 May 21Albuquerque, NM May 15–20 May 21Long Beach, CA Exam only May 28Spokane, WA June 5–10 June 11Oklahoma City, OK June 5–10 June 11Birmingham, AL June 5–10 June 11Hartford, CT June 12–17 June 18Pittsburgh, PA June 12–17 June 18Beaumont, TX June 12–17 June 18Miami, FL June 12–17 June 18Corpus Christi, TX Exam only June 25New Orleans, LA July 10 July 16Phoenix, AZ July 10 July 16Memphis, TN July 10 July 16Miami, FL July 10 July 16Orlando, FL July 17–22 July 23Milwaukee, WI July 17–22 July 23Los Angeles, CA July 17–22 July 23Sacramento, CA July 17–22 July 23Kansas City, MO July 24–29 July 30Cleveland, OH July 24–29 July 30Louisville, KY July 24–29 July 30Denver, CO July 31–Aug. 5 Aug. 6Philadelphia, PA July 31–Aug. 5 Aug. 6San Diego, CA Aug. 7–12 Aug. 13Chicago, IL Aug. 7–12 Aug. 13Miami, FL Aug. 7–12 Aug. 13Charlotte, NC Aug. 14–19 Aug. 20San Antonio, TX Aug. 14–19 Aug. 20Bakersfield, CA Aug. 14–19 Aug. 20Portland, ME Aug. 21–26 Aug. 27Salt Lake City, UT Aug. 21–26 Aug. 27Pittsburgh, PA Aug. 21–26 Aug. 27Seattle, WA Aug. 21–26 Aug. 27Houston, TX Sept. 11–16 Sept. 17Minneapolis, MN Sept. 11–16 Sept. 17St. Louis, MO Sept. 18–23 Sept. 24Miami, FL Sept. 18–23 Sept. 24New Orleans, LA Sept. 18–23 Sept. 24Tulsa, OK Oct. 16–21 Oct. 22Long Beach, CA Oct. 16–21 Oct. 22Newark, NJ Oct. 16–21 Oct. 22Nashville, TN Oct. 16–21 Oct. 22Portland, OR Oct. 23–28 Oct. 29Roanoke, VA Oct. 23–28 Oct. 29Cleveland, OH Oct. 23–28 Oct. 29Detroit, MI Oct. 23–28 Oct. 29Miami, FL Oct. 23–28 Oct. 29Certification ScheduleSeminars, Code Clinics, and ExaminationsApplication deadlines are six weeks before the scheduled seminar or exam. Late applications will be assessed a $250 Fast Track fee.9–Year Recertification Seminar for CWI/SCWIThe exam can be taken at any site listed under Certified WeldingInspector.LOCATION SEMINAR DATES EXAM DATEPittsburgh, PA June 6–10 No examSan Diego, CA July 11–16 No examMiami, FL July 17–23 No examOrlando, FL Aug. 22–27 No examDenver, CO Sept. 19–24 No examDallas, TX Oct. 17–22 No examCertified Welding Supervisor (CWS)LOCATION SEMINAR DATES EXAM DATEMinneapolis, MN July 18–22 July 23Miami, FL Sept. 12–16 Sept. 17Norfolk, VA Oct. 17–21 Oct. 22CWS exams are also given at all CWI exam sites.Certified Radiographic Interpreter (CRI)LOCATION SEMINAR DATES EXAM DATELas Vegas, NV May 16–20 May 21Miami, FL June 6–10 June 11Dallas, TX July 18–22 July 23Chicago, IL Sept. 12–16 Sept. 17Pittsburgh, PA Oct. 17–21 Oct. 22The CRI certification can be a stand-alone credential or can exemptyou from your next 9-Year Recertification.Certified Welding Sales Representative (CWSR)LOCATION SEMINAR DATES EXAM DATEAtlanta, GA June 8–10 June 10Miami, FL Aug. 24–26 Aug. 26Indianapolis, IN Sept. 21–23 Sept. 23CWSR exams will also be given at CWI exam sites.Certified Welding Educator (CWE)Seminar and exam are given at all sites listed under Certified WeldingInspector. Seminar attendees will not attend the Code Clinic portion ofthe seminar (usually the first two days).Senior Certified Welding Inspector (SCWI)Exam can be taken at any site listed under Certified Welding Inspector.No preparatory seminar is offered.Certified Welding Engineer (CWE)Exam can be taken at any site listed under Certified Welding Inspector.No preparatory seminar is offered.Certified Robotic Arc Welding (CRAW)WEEK OF LOCATION CONTACTMay 2 ABB, Inc., Auburn Hills, MI (248) 391–8421May 23 Genesis-Systems, Davenport, IA (563) 445–5688Aug. 1 Wolf Robotics, Ft. Collins, CO (970) 225–7736Aug. 1 ABB, Inc., Auburn Hills, MI (248) 391–8421International CWI Courses and ExamsPlease visit www.aws.org/certification/inter_contact.htmlImportant: This schedule is subject to change without notice. Please verify your event dates with the Certification Dept. and confirm yourcourse status before making your travel plans. For information, visit www.aws.org/certification, or call (800/305) 443–9353, ext. 273, forCertification; or ext. 455 for Seminars. Apply early to avoid paying the $250 Fast Track fee.Inspection Trends / Spring 2011 37

North America’s Largest Metal Forming,Fabricating, Welding and Finishing EventIT’S ALL HERE. Discover the mostinnovative technologies, resources andideas. Engage with industry experts.Find solutions to improve productivityand keep your business competitive.REGISTER TODAY!fabtechexpo.comNovember 14-17, 2011 | McCormick Place | Chicago, ILFollow us:Co-Sponsors:

T R E N D S Inspection Trends / Spring 2011 39

Advertiser IndexAmerican Society of Nondestructive Testing . . . . .9, 14www.asnt.org . . . . . . . . . . . . . . . . . . . . . .800-222-2768AWS Certification Services . . . . . . . . . . . . . . . .33, IBCwww.aws.org . . . . . . . . . . . . . . . . . . . . . .800-443-9353Business ProductsAWS Education Services . . . . . . . . . . . . . . . . . . . . . .17www.aws.org . . . . . . . . . . . . . . . . . . . . . .800-443-9353AWS Member Services . . . . . . . . . . . . . . . . . .8, 10, 16www.aws.org . . . . . . . . . . . . . . . . . . . . . .800-443-9353Bruker AXS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15www.bruker.com/hhxrf . . . . . . . . . . . . . .978-663-3660Carestream Health, Inc. . . . . . . . . . . . . . . . . . . . . . . . .7ndt.carestream.com . . . . . . . . . . . . . . . . .800-810-0327FABTECH 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38www.fabtechexpo.com . . . . . . .305-443-9353, ext. 297Fischer Technology . . . . . . . . . . . . . . . . . . . . . . . . . . .11www.Fischer-Technology.com . . . . . . . .800-243-8417G.A.L. Gage Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11www.galgage.com . . . . . . . . . . . . . . . . . .269-465-5750Business CardsGradient Lens Corp. . . . . . . . . . . . . . . . . . . . . . . . . . .12www.gradientlens.com . . . . . . . . . . . . . .800-536-0790InterTest, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13www.intertest.com . . . . . . . . . . . . . . . . . .800-535-3626Iris Inspection Services, Inc. . . . . . . . . . . . . . . . . . . .34www.iris-inspection.com . . . . . . . . . . . . .800-940-1471NDT Seals, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34www.ndtseals.com . . . . . . . . . . . . . . . . . .800-261-6261Olympus NDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IFCwww.olympusNDT.com . . . . . . . . . . . . .781-419-3900Thermo Fisher Scientific/Niton Analyzers . . . . . . .OBCwww.thermo.com/niton . . . . . . . . . . . . . .978-670-7460World Spec Online NDT Training . . . . . . . . . . . . . . .21www.worldspec.org . . . . . . . . . . . . . . . . .877-506-7773IFC = Inside Front CoverIBC = Inside Back CoverOBC = Outside Back CoverVisit Our Interactive Ad Index: www.aws.org/ad-indexConstruction Technical Services16350 Park Ten Place, Suite 238Houston, TX 77084Steven T. SnyderTechnical ManagerAWS-SCWI, ASQ-CQA, ASNT NDT Level III, CSWIP-AUT-PA“Committed To Service”Office: 281-578-6810 Cell: 504-931-9567Email: ctsi7@swbell.netWeb site: www.ctsisite.com40Inspection Trends / April 2011

“C” is for Certified.The “W” stands for Welding.“S” is not just for Supervisor.Studies have shown that having an AWS Certified Welding Supervisor on staff can save thousands ofdollars a year per welder. This certification—which establishes that a CWS has the knowledge toimprove a welding operation’s quality, cost, productivity, and safety—is not just for supervisors. Thetraining has been designed to enhance the value of anyone involved in welding design, quoting,purchasing, detailing, inspecting, instructing, or management.Beneficiaries of the program include CEOs, lead welders, design engineers, CWIs, and others. In fact, wecan train an entire team right at your location, saving you time and money on a program that is proven toimprove profitability.The “S” stands for Supervisor, but for non-supervisors at your company, it can mean “savings,”“superior quality,” “safety,” and more. To find out more about sending employees for six-day CWStraining and certification, or having a program presented at your company, visitwww.aws.org/certification/CWS or call (800) 443-9353 ext 273.

©2010 Thermo Fisher Scientific Inc. All rights reserved.To verify the integrity of your process sytems, takematters into your own hands.The requirement for positive material identification (PMI)in alloys used throughout the physical plant is more criticalthan ever. Simply relying on spot testing of parts andsubassemblies is too risky and unacceptable. While that mayseem like a challenge, it’s now a surprisingly easy task thanksto Thermo Scientific Niton XRF analyzers.vessels www.thermoscientific.com/niton.The all-new Thermo ScientificNiton XL2 GOLDD andNiton XL3t GOLDD+ join ourSpeed, accuracy, value – eitherway, you gain the advantage.Moving science forwardFor Info go to www.aws.org/ad-index