Professional Documents
Culture Documents
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Section Page
INTRODUCTION............................................................................................................ 5
Purpose ............................................................................................................... 5
Advantages.......................................................................................................... 6
Importance .......................................................................................................... 7
Scope .................................................................................................................. 7
GLOSSARY ................................................................................................................. 32
BIBLIOGRAPHY........................................................................................................... 38
List of Figures
List of Tables
Table 5. Weld Acceptance Criteria for Large Low Pressure Storage Tanks................. 29
Table 6. Weld Acceptance Criteria for Large Low Pressure Storage Tanks................ 30
INTRODUCTION
This Module provides information on the requirements for
performance of nondestructive testing (NDT) on various Saudi
Aramco systems. The emphasis of the information is placed on
why NDT is performed and on how to locate the NDT
requirements that are in the various codes and standards.
Purpose
The purpose of nondestructive testing (NDT) is to prevent the
premature failure of components or weldments. The purpose is
also to improve the reliability and the safety of production and
maintenance operations at Saudi Aramco. NDT is used to
check and monitor the condition of equipment used in all
aspects of oil extraction and refining. NDT is used during
fabrication, construction, and maintenance repair activities.
You should already be familiar with the terms NDT, NDE, VT,
PT, MT, UT, RT, and ET. The Instructor will review these terms
briefly.
Advantages
NDT improves reliability through the detection of potential
problems that could result in premature system or component
failures. Nondestructive tests are performed before the first
installation, after repairs, and at regularly scheduled intervals
throughout the life of critical components. The continuous
performance of NDT at regularly scheduled intervals provides
an added level of confidence in the continued reliability of the
component or system on which the NDT is performed.
Importance
Nondestructive Testing (NDT) is an important tool that allows
the user to find potential problems that could result in an
unexpected failure of piping, vessels, or other components
during normal operation. When a problem is found, it can be
fixed before a situation develops that results in personnel injury,
equipment or production loss, or damage to the environment.
Scope
It is not in the context of this module nor is it stated in the
objectives that you will be able to perform or practice NDT
activities either during this course or upon its completion. This
is a basic course on identification of procedures and
discontinuities, identifying the standards required, and locating
the requirements and criteria for NDT. Application of techniques
and performance of NDT is outside the scope of this module.
• Inherent
• Primary Process
• Secondary Process
Inherent
Discontinuities
Inherent discontinuities result from the original melt, casting, or
solidification of the ingot of primary metal or alloy and are given
names, such as stringer, seam, lamination, etc. Table 1 lists
the location of examples in of inherent discontinuities found in
the ASNT Manual on the pages indicated.
Primary Process
Discontinuities
Primary process discontinuities are formed during the rough
shaping and forming of metals during primary processing such
as forging, casting, rolling and drawing. Table 2 lists the
location of examples of primary process discontinuity found in
the ASNT Manual on the pages indicated.
Secondary
Process
Discontinuities
Secondary process discontinuities are associated with final
finishing operations such as machining and heat treatments.
Table 3 lists the location of examples of secondary process
discontinuities found in the ASNT Manual on the pages
indicated.
Note: For more information on each class of base metal discontinuity, refer to pages
14:4 through 14:9 of the supplemental text, “ASNT Manual.”
Cracks in Welds
Cracks in welds is usually caused by shrinkage due to rapid
cooling or severe restraint of parts while welding or heat
treating.
Cracks in welds are best detected by RT, UT, MT, PT, or VT.
SUBSURFACE
LONGITUDINAL
Slag Inclusions
Slag inclusion is usually caused by poor welding technique,
welding with inadequate heat input, or improper bead placement
Lack of Fusion
Lack of fusion is usually caused by welding with inadequate
heat or poor technique in which all metal surfaces are not
melted.
Incomplete Root
Penetration
Incomplete root penetration is usually caused by inadequate
heat or improper weld joint fit-up.
Weld Undercut
Weld undercut is caused by poor welding technique, excessive
heat, or traveling too fast. This discontinuity is located on the
surface at the weld toe.
Cold Lap
Figure 6 shows a discontinuity called cold lap. Cold lap occurs
when the weld metal freezes too quickly and does not fuse with
the surface of the base metal. Cold lap is most typically found
on the cover pass at the toe of the weld.
TOE
COLD LAP TOE
(GAP)
Root Concavity
Figure 7 shows a discontinuity called root concavity. Root
concavity occurs in weld joints that are welded from one side
only, an example of which would be pipe. The following are
typical causes of root concavity:
CONCAVITY
Crater Pit
Crater pits result from the rapid breaking of the electric arc so
that the weld puddle freezes too quickly and shrinks, which
leaves a small void.
Arc Strike
Arc strikes are caused by dragging the electrode over the
surface of the base metal in an effort to initiate an arc for
welding. It is located on the surface of the weld or base metal
Weld Porosity
Weld porosity is caused by inadequate flux or shielding gas
coverage, which allows oxygen to contaminate the molten weld
metal prior to solidification.
Nonrelevant
Indications
NDT can produce or reveal indications that are not caused by
actual discontinuities and these indications are known as
nonrelevant indications. Examples of nonrelevant indications
include scratches or water spots on radiographic film and liquid
penetrant indications that result from the inability to adequately
remove all of the surface penetrant. Such indications can be
determined to be nonrelevant by the NDT technician based on
the method of NDT, the configuration of the component being
examined, and the appearance of the indication. For more
information on nonrelevant indications, refer to pages 14-2 and
14-3 of ASNT.
Defects
A defect in a component or a weld is a discontinuity or flaw that
would probably result in an early failure of the component or
weld. Because all discontinuities are not defects, acceptance
criteria must be established to identify which discontinuities are
acceptable. Past experience has helped to establish the criteria
for an acceptable discontinuity. These criteria are known as
acceptance criteria. They can be found in the applicable
fabrication and construction codes and standards. The
discontinuities must be compared to the acceptance criteria to
determine whether they actually are defects.
ASNT SNT-TC-1A
ASNT SNT-TC-1A, Recommended Practice for Personnel
Qualification and Certification in Nondestructive Testing,
provides requirements for the qualification and certification of
NDT personnel.
• API 510
• API 620
• API 650
• API RP-2A
API 510
API 510, Pressure Vessel Inspection Code, provides
requirements for the maintenance inspection, repair, alteration,
and rerating procedures for pressure vessels that are used by
the petroleum and chemical process industries. Refer to
Addendum A10 for a more detailed explanation of the scope of
API 510.
API 620
API 620, Design and Construction of Large, Welded, Low-
Pressure Storage Tanks, pertains to the design and
construction of large, low pressure, above ground storage tanks.
Typical applications include the storage of gases or vapors that
results from refining operations. Refer to Addendum A11 for a
more detailed explanation of the scope of API 620.
API 650
API 650, Welded Steel Tanks for Oil Storage, provides material,
design, fabrication, and testing requirements for above ground
atmospheric tanks. Typical applications include the storage of
crude and other liquid petroleum products. Refer to Addendum
A12 for a more detailed explanation of the scope of API 650.
API RP-2A
API RP-2A, Recommended Practice for Planning, Designing,
and Constructing Fixed Off-Shore Platforms, provides a guide
for the design and construction of drilling platforms. Refer to
Addendum 13 for a more detailed explanation of the scope of
API RP-2A.
SAEP-1145
SAEP-1145, Liquid Penetrant Examination of Welds and
Components, is used by Saudi Aramco personnel in the
performance of liquid penetrant examinations to define the
minimum requirements and to establish applicable acceptance
criteria. Refer to Addendum A14 for a more detailed
explanation of the scope of SAEP-1145.
SAEP-1144
SAEP- 1144, Magnetic Particle Examination of Welds and
Components, is used by Saudi Aramco personnel in the
performance of magnetic particle examinations to define the
minimum requirements and to establish applicable acceptance
criteria. Refer to Addendum A15 for a more detailed
explanation of the scope of SAEP- 1144.
SAEP-1140
SAEP-1140, Qualification and Testing of Saudi Aramco
Nondestruct Testing Personnel, specifies the requirements for
personnel assigned to Saudi Aramco to be certified for
nondestructive testing. It specifies both the training and the
testing necessary and the standards against which they are to
be certified, mainly ASNT SNT-TC-1A.. Refer to Addendum
A16 for a more detailed explanation of the scope SAEP-1140.
SAEP-1142
SAEP-1142, Qualification and Testing of Non-Saudi Aramco
Nondestruct Testing Personnel, specifies the requirements for
personnel who are not assigned to Saudi Aramco to be certified
for nondestructive testing. These NDT technicians are
personnel such as contractor NDT personnel. This standard
specifies both the training and the testing necessary and the
standards against which they are to be certified, mainly ASNT
SNT-TC-1A. .. Refer to Addendum A17 for a more detailed
explanation of the scope SAEP-1140
SAEP-1147
SAEP-1147, Ultrasonic Examination will be a new SAEP that is
currently being prepared. It will be based upon the industry
standards and codes with special emphasis on Saudi Aramco
Procedures. When completed, SAEP-1146 will become
Addendum 18.
• Power Piping
• Chemical Piping
• Liquid Petroleum and Anhydrous Ammonia Piping
• Gas Transmission Piping
• Power Boilers
• Heating Boilers
• Pressure Vessels
• Buildings and Structures
• Large Low Pressure Storage Tanks
• Above Ground Atmospheric Storage Tanks
• Drilling Platforms
Power Piping
The NDT requirements for power piping welds are described in
ASME B31.1, Chapter VI, Table 136.4. The table shows the
various NDT requirements for pressure welds or for welds to
pressure retaining components based on piping service
conditions. The table also shows that the specific requirements
for NDT depend on the design temperature and pressure ratings
of a given system.
Chemical Piping
Table 341.3.2A of ASME B31.3 located on page A26 of the
Addendum A2 shows the acceptance criteria for welds and is
based on the applicable service conditions. An understanding
of the service condition (normal fluid, severe cyclic, or category
D) is critical to determining the appropriate NDT requirements.
Power Boilers
The NDT requirements for the fabrication of power boilers are
described in ASME Section I, Part PW. Paragraphs PW-11 and
PW-41 address NDT requirements that are based on
component diameter, wall thickness, and component exposure
to radiant heat or furnace gases. Paragraph PW-11 is located
on page A62 of Addendum A5 and Paragraph PW-41 is located
on page A63.
Heating Boilers
ASME Section IV does not require specific NDT beyond a visual
examination. The weld acceptance criteria is provided in
Paragraph HW-820 located on page A71 of Addendum A6.
Pressure Vessels
The NDT requirements for pressure vessel welds are described
in ASME Section VIII, Division 1, paragraph UW-11. located on
page A84 of Addendum A8. The NDT requirements may be
based on the type of weld, the weld category, or the diameter or
the thickness of the weld.
Table 4.
VT 8.15.1 A114
RT 8.15.3 A114
PT 8.15.5 A115
HT 8.15.5 A115
Table 5. Weld Acceptance Criteria for Large Low Pressure Storage Tanks
UT 5.19 A126
(2) Refer to ASME Section VIII, paragraph UW-51(b), Page A86 in Addendum A8
for the actual acceptance criteria.
(3) Refer to ASME Section VIII, Appendix 6, Page A104 and A105 in Addendum
A8 for the actual acceptance criteria.
(4) Refer to ASME Section VIII, Appendix 8, Page A109 and A110 in Addendum
A8 for the actual acceptance criteria.
Table 6. Weld Acceptance Criteria for Large Low Pressure Storage Tanks
UT 6.3.4(Note 1 A138
(3) Refer to ASME Section VIII, Appendix 6, Page A104 and A105 in Addendum
A8 for the actual acceptance criteria.
(4) Refer to ASME Section VIII, Appendix 8, Page A109 and A110 in Addendum
A8 for the actual acceptance criteria.
Drilling Platforms
NDT requirements for drilling platforms are described in
API RP-2A, Section 13 located on pages A141 through A143 of
Addendum A13. The Weld acceptance criteria is located in
paragraph 13.4.3b of API RP-2A, Section 13. This paragraph
references AWS D1.1 for the actual acceptance criteria. AWS
D1.1 is located on pages A113 through A117 of Addendum 9.
GLOSSARY
primary process A discontinuity that occurs during the rough shaping and
forming of metals. This refers to processes such as
forging, casting, rolling, and drawing.
Arc Strike Caused by dragging the electrode over the base metal in
an effort to initiate an arc for welding.
Cold Lap Occurs when the weld metal freezes too quickly and does no
found on the cover pass at the toe of the weld.
Cold Shuts Caused by localized cooling of one part of the casting to suc
additional molten metal comes in contact with that area.
Cracks in Welds Can be either longitudinal (aligned with the weld bead) or tra
occur from stresses that are developed during the welding p
Crater Pit Is generally associated with Gas Tungsten Arc Welding (GTA
electric arc so that the weld puddle freezes too quickly and s
Forging Lap Occurs during a forging process when some of the metal is f
part.
Grinding Cracks Are caused by a localized heating of the surface during the g
a cut, or too rapid of a feed rate.
Incomplete Root Occurs when the weld metal does not completely penetrate
Lack of Fusion Occurs when the molten weld metal does not fuse completel
Quench Cracks Occur during the cooling cycle and are usually found at
sharp changes of section or points of high stress
concentration.
Root Concavity Occurs in weld joints welded from one side only, like pipe.
Either too much heat resulting in shrinkage, too wide of a
root opening, or insufficient weld metal deposited are
typical causes.
Weld Undercut Is an area where the actual weld is less than the specific
contour. Undercutting results in a depression in the area
where the weld metal contacts the base metal.
ASME Code B31.1 Power Piping, pertains to power and auxiliary piping.
ASME Section IV, Heating Boilers, pertains to heating boilers that do not
exceed 15 psi for steam service or do not exceed 160 psi
and 250oF for hot water service.
API 650 Welded Steel Tanks for Oil Storage, provides material,
design, fabrication, and testing requirements for above
ground atmospheric tanks.
primary process A discontinuity that occurs during the rough shaping and
forming of metals. This refers to processes such as
forging, casting, rolling, and drawing.
BIBLIOGRAPHY