february 2019 / vol. 22 / no. 1 inspection trendsinspection trends the magazine for materials...

Inspection Trends

THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL

FEBRUARY 2019 / VOL. 22 / NO. 1

▪Applications ofSymbols for NDE

PUBLISHED BY THE AMERICAN WELDING SOCIETY TO ADVANCE THE SCIENCE, TECHNOLOGY, AND APPLICATION OF WELDINGAND ALLIED JOINING AND CUTTING PROCESSES WORLDWIDE, INCLUDING BRAZING, SOLDERING, AND THERMAL SPRAYING

▪Pipeline Hot Tappingand CWIs

▪SOPs for WorkforceDevelopment and

Quality Control

Features

Applications of Symbols for Nondestructive Examinationby J. P. Christein and Richard D. Campbell / The ninth in a series ofarticles about the proper use and requirements of welding symbols,this feature addresses symbols for nondestructive examination / 12

Pipeline Hot Tappingby Jeffry Strahan / Learn about this pipeline modification andrepair method and how the expertise of an experienced CWI makesit safer / 20

Standard Operating Procedures as a Single Mechanism forWorkforce Development and Quality Control Programs by Lance C. Becker / An efficient tool to provide training, workforcedevelopment, and a framework for technical operations and qualitycontrol / 24

Departments

Editorial........................................4

News Bulletins .............................6

Print and Product ........................8

The Answer Is.............................10

Technology Notes ......................28

Mark Your Calendar ..................30

Certification Calendar ...............32

Classifieds ..................................34

Advertiser Index ........................34

INSPECTION TRENDS (ISSN 1523-7168) ispublished quarterly by the American Welding Society.Editorial and advertising offices are located at 8669 NW36 St., #130, Miami, FL 33166; telephone (305) 443-9353. Printed by R. R. Donnelley & Sons Co., Senatobia,Miss. Subscriptions $30.00 per year for noncertified,nonmembers in the United States and its possessions;$50.00 per year in foreign countries; $20.00 per year fornoncertified members and students; $10.00 single issuefor nonmembers; and $7.00 single issue for members.American Welding Society is located at 8669 NW 36 St.,#130, Miami, FL 33166; telephone (305) 443-9353.Periodicals postage paid in Miami, Fla., and additionalmailing offices.

POSTMASTER: Send address changes to Inspection Trends c/o American Welding Society, 8669NW 36 St., #130, Miami, FL 33166.

Readers of Inspection Trends may make copies of articlesfor personal, archival, educational, or research purposes, and which are not for sale or resale. Permis-sion is granted to quote from articles, provided custom-ary acknowledgment of authors and sources is made.Starred (*) items excluded from copyright.

AWS MISSION STATEMENTThe mission of the American Welding Society is to advancethe science, technology, and application of welding andallied joining processes worldwide, including brazing,soldering, and thermal spraying.

AWS DIVERSITY AND INCLUSIONSTATEMENTAWS values diversity, advocates equitable and inclusivepractices, and engages its members and stakeholders in establishing a culture in the welding community thatwelcomes, learns from, and celebrates differences amongpeople.

AWS recognizes that a commitment to diversity, equity,and inclusion is essential to achieving excellence for theAssociation, its members, and employees.

February 2019 / Inspection Trends 3

Inspection Trends

THE MAGAZINE FOR MATERIALS INSPECTIONS AND TESTING PERSONNEL

February 2019 / Vol. 22 / No. 1

Cover photo: Welder and CWI Jeff Strahanperforms an API 1104 branch test for qualifi-cation on pipeline welding. (Photo by SamSievert.)

Editorial

Inspection Trends / February 20194

As some of you may know, the AmericanWelding Society (AWS) commemorates its 100th

anniversary this year. Our industry and the Soci-ety have come a long way since 1919, from theevolution of the welding processes and the de-velopment of welding standards, to the creationof the Certified Welding Inspector (CWI) pro-gram in 1976 and the publication of the first In-spection Trends in 1998.

Today, AWS serves more than 70,000 mem-bers, has 22 Districts and 250 Sections, publishes more than 300 techni-cal books, has certified more than 97,000 welding inspectors, and offers 8welding-related certifications and 12 endorsements. In continuing withthe modernization of our certification program, 2019 will see a furthertransition toward computer-based testing by our partner, Prometric. Al-though many of the CWI endorsements are already offered using this test-ing method, this will be the first year a portion of the CWI exam will beconducted using computer-based testing. Please visit aws.org/certificationfor updated information.

This year, we will bring you four issues filled with welding inspectionarticles we hope you find informative and interesting. Authors J. P. Chris-tein and Richard Campbell will continue to produce their series on appli-cations of welding symbols, including topics such as symbols for nonde-structive examination (NDE), brazing, and a comparison between AWSA2.4, Standard Symbols for Welding, Brazing, and Nondestructive Examina-tion, and ISO 2553, Welding and allied processes — Symbolic representationon drawings — Welded joints.

Other topics that will be covered throughout the year are NDE educa-tion and training, software for NDE projects management, radiographicexamination, metallurgy for CWIs, demagnetization, eddy current test-ing, magnetic particle testing (MT), and code interpretation and accept-ance criteria. As always, please don’t hesitate to contact me [email protected] and let me know what topics you would like to see cov-ered in the future. Inspection Trends indeed is written by welding inspec-tors for welding inspectors.

Beside the continuation of the series on the application of weldingsymbols, this issue brings two attention-grabbing topics: the roles ofCWIs in pipeline hot tapping, and using standard operating procedures asa single mechanism for workforce development programs and quality con-trol programs. Hot tapping is a demanding pipeline modification and re-pair method that requires the expertise of an experienced CWI; this arti-cle will give inspectors unfamiliar with the process a detailed look of whatit entails. Last but not least, our third feature explains how standard oper-ating procedures (SOPs) can provide a basis for training while creatingstandards for quality control.

In case your AWS membership has expired, or if you are not yet amember, I would like to invite you to renew or become an AWS memberand celebrate this 100th anniversary with us. With your membership, youwill receive the Welding Journal, our monthly publication, which will bepacked with special content, from the historical milestones of the Societyto its myriad expanding activities, and a look into the future of the weld-ing industry.

Carlos GuzmanEditor of InspectionTrends

PublisherMary Ruth Johnsen, [email protected]

Editorial

EditorCarlos Guzman, [email protected]

Senior EditorCindy Weihl, [email protected]

Features EditorKristin Campbell, [email protected]

Design and Production

Production EditorZaida Chavez, [email protected]

Senior Production CoordinatorBrenda Flores, [email protected]

Manager of International Periodicalsand Electronic MediaCarlos Guzman, [email protected]

Advertising

Media Sales ExecutivesJeff Rhodes, [email protected] Daniele, kim.daniele@mci-group

Subscriptions RepresentativeSonia Aleman, [email protected]

American Welding Society8669 NW 36th St., #130Miami, FL 33166-6672(800/305) 443-9353

Copyright

Copyright © 2019 by American Welding Society in bothprinted and electronic formats. The Society is not responsi-ble for any statement made or opinion expressed herein.Data and information developed by the authors of specificarticles are for informational purposes only and are notintended for use without independent, substantiating investigation on the part of potential users.

Celebrate 100 Years with Us

American Institute of NondestructiveTesting Expands CWI Exam Prep Courseto Houston, Texas

The American Institute of Nondestructive Testing(AINDT) now offers its Certified Welding Inspector (CWI)exam prep courses in Houston, Tex.

“Our instructors have decades of welding inspectionexperience and are deftly involved with the AmericanWelding Society (AWS), providing the most up-to-datetraining for the ever-evolving CWI exam,” said AINDT CEODon Booth. “We not only prepare our students for takingthe CWI exam but also provide them with real-lifeexperiences from industry experts.”

The AINDT CWI exam prep course begins with a 40-honline course that students can move through at their ownpace. Part A, the online portion, covers the fundamentals ofwelding technology as established by AWS; part B consistsof extensive practical hands-on techniques and will be heldat the Houston Marriott North in Houston, Tex.; and part Cprovides in-depth training to the welding code portion ofthe exam.

According to Booth, AINDT will be adding additional

locations across the country for the CWI exam prep coursein the third quarter of 2019 and early 2020.

For more information about available training courses,contact Jeff LeTourneau at [email protected], visittrainingndt.com, or call (855) 313-0325.

War2In Inspection Training ProgramRelocates to Bellemont

Warrior to Inspector (War2In), Flagstaff, Ariz., atraining program that certifies veterans and others in thefield of nondestructive examination (NDE), is relocatingfrom the moonshot at NACET facility to its own facility innearby Bellemont.

War2In was the first moonshot client to occupy itsbusiness accelerator at the Northern Arizona Center forEntrepreneurship and Technology (NACET) when it openedin October 2015.

“In about three years, we outgrew our space in theaccelerator,” said Kenny Greene, War2In’s founder and oneof its two instructors. “It’s perfect evidence of how wellNACET is working; it’s a good program and a goodprocess.”

News Bulletins


The school’s new 6000-sq-ft Bellemont facility willquadruple the indoor space War2In currently uses. Theadditional space will help accommodate an anticipatedincrease in students.

Premium Inspection & Testing GroupAppoints Vice President of Operations

Premium Inspection & Testing Group, Houston, Tex., aprovider of industrial nondestructive examination (NDE),inspection, and calibration services, has appointed StephoneElam to vice president, operations.

Elam is a 20-plus year NDE veteran. Most recently, hewas in a management role in business development for teamindustrial services. Prior to that, he was director ofoperations for Acuren Inspection for 15 years.

“Mr. Elam has built a decades-long leadership career inour industry and understands the unique needs andrequirements of asset owners for top quality [NDE], as wellas the challenges and opportunities on the service providerside...,” said Rodney Bonvillain, CEO of Premium Inspection & Testing Group.

Elam also serves as a regional director for the AmericanSociety for Nondestructive Testing in Region 8 and foundedthe Society’s Acadiana Section, La.


— continued on page 33

XRF Analyzer ProvidesLow Detection Limits

The Niton™ XL2 Plus handheld XRFanalyzer provides operators the abilityto scan a broad range of materials fordiverse applications. It also identifies

pure metals and alloys in manufactur-ing operations, detects tramp ele-ments, and obtains geochemical data.Additional benefits include a 2W x-raytube, silicon drift detector for light ele-ment detection (Mg, Al, Si, P, and S),detector ProGuard protection, microcamera, hot-swap battery, touch

screen and directional keys, password-protected security, and nose conealignment guides. It is IP54 certified(splash/dust proof).

Thermo Fisher Scientificthermofisher.com

System Tracks andInspects Joints in Tube Mills

The SeamMonitor™ tracking and in-spection system for tube mills and weldseamers allows operators to measurethe alignment of the weld joint relativeto the torch tip and the width of theweld joint, as well as monitor the torchtip condition. The system includes anopen-arc weld camera, industrial HMIcontroller, software, and optional op-tics, and interfaces to integrate withother automation devices. The softwareoffers multiple recipe setups and user-level control features, along with a viewof the welding process in real time. Pa-rameters and images can be recorded forprocess monitoring and quality assur-ance based on the setup parameters anddefined warning limits.

Xiris Automation Inc.xiris.com

Print and Product Showcase


Motorized ScannerFeatures SteeringCapabilities

The field-tested, remote-controlledSteerROVER™ scanner performs cir-cumferential weld inspection and corro-sion mapping. It inspects at heightswithout expensive scaffolding, is easyto control and versatile, and performslongitudinal inspection of welds onpipes as small as 12-in. outer diameter.The steerable scanner is comprised oftwo pods with independent motors andfour magnetic wheels, touch screenhandheld remote control with two joy-sticks, two automatic raster scan pat-terns, and emergency-stop buttons.The product can be ordered with twochoices of motorized raster arms forcorrosion inspection or a probe holderrack for weld inspection with fourprobes (users can increase to six probeswith optional probe holders). A divisi-ble cable conduit umbilical offers cableprotection and flexible configurations.Ultrasonic data can be acquired and col-lected using a compatible instrument,such as the OmniScan® MX2 flaw de-tector or the FOCUS PX™ phased arraydata acquisition unit.

Olympus

olympus-ims.com

Overhead Lamp Meant forWash Station Work

The EDGE™ 4 overhead lamp is de-signed with long-lasting LEDs forwash station applications. It providesa wide area of coverage without ahigh intensity. Its large beam profileallows the lamp to light the entiresample or booth, while also minimiz-ing UV exposure with its movablebeam path. The IP65 rating enablesthis unit to withstand water and dust,a necessity in harsh wash station con-ditions. Heat sinks keep the lampcool without the need for a fan, so no

dust or water can enter. Four UV-ALEDs provide a wide, uniform beamthat is consistent and reliable.

Spectroline®spectroline.com


A: You didn’t provide any informationregarding the type of defects being ob-served. However, you included a cou-ple of clues that point in the directionof possible causes of your problems.

Clue 1: Monitoring the welding pa-rameters using the meters on the pow-er supply. The meters on the weldingmachines are reasonably accurate ifthe welding leads are short (20 ft orless). However, as the welding leadsget longer, the voltage meter is nolonger an accurate means of checkingthe voltage drop across the arc.

Clue 2: The welders were producingacceptable welds when the connec-tions were located near the power sup-plies. The quality degraded when thedistance increased between the con-nections and the power supplies.

There is a reasonable explanation forthe cause of your problems. The powersupply is a constant-voltage powersupply. The welding machine self-regu-lates to maintain the voltage set by thewelder regardless of the resistance of-fered by the welding circuit. When thewelding machine is located close to thewire feeder, the resistance of the weld-ing circuit is relatively low, and thewelding current and voltage as indicat-

ed by the meters on the welding ma-chine are “accurate enough” for settingand monitoring the welding opera-tions. As welding leads are added tothe circuit and as more structural steelis added to the circuit, the resistanceof the circuit increases. Ohm’s law pre-dicts the amperage decreases in inverseproportion to the increase in resistancein the circuit. The formula for Ohm’slaw is as follows :

The circuit is in series, so the resist-ance is simply the sum of the individ-ual components. Figure 1 shows thecomponents that have to be consid-ered. They include the welding leadsand the structural steel framing thatare part of the circuit. The equationshows that as resistance increases, am-perage decreases.

Assuming the voltage provided bythe welding machine is constant (it is aconstant-voltage power supply), thevoltage drop in each component is in-versely proportional to the resistance ofthe component. The sum of the voltagedrop in each component is equal to thevoltage indicated by the voltmeter onthe welding machine.

Per Ohm’s law

As the sum of the resistance increases,the amperage decreases, unless thevoltage increases. Thus, there is an ad-ditional consideration: the voltagedrop across each component in thewelding circuit. The voltage dropacross the arc must fall within a smallrange as specified by the manufactur-er, so it is “fixed.” The greater the re-sistance of the other components, thelarger the voltage drop. Therefore, asmore welding lead is added, the resist-ance increases, and the voltage dropincreases. The welding machine mustbe capable of supplying sufficient volt-age to accommodate the total voltagedrop in the welding circuit. The weld-ing machine voltage output is limitedto about 80 V to mitigate the possibili-ty of electrocuting the welder, but thatis static voltage. We need to know thedynamic voltage (voltage while underload, i.e., while welding) of the powersupply. The dynamic voltage must begreater than the sum of the voltagedrops of each component in the circuit.

Amperage = VoltageResistance

Amperage = VoltageR1 + R2 + R3 + R4

The Answer Is


By A. Moore

Q: I have a problem with welding inthe field. We are welding with fluxcore on a high-rise, steel-framedbuilding. The welders are havingproblems maintaining the arc whenthe wire feeder and welding are lo-cated at a distance from the weld-ing machines. The welding ma-chines are located in the basementof the building. We had no difficultywelding on the first few floors, butnow that we’re several storiesabove the basement, the weldersare complaining, and the rejectionrate has increased to an unaccept-able level. The welders were quali-fied using the same welding proce-dure specification (WPS) they areusing to weld the field connections.I’ve checked the welding parame-ters, for example, voltage and am-perage, shown by the meters on thewelding machines, and they arewithin the limits of the WPS. Do youhave any suggestions or recom-mendations?

Fig. 1 — The total resistance in the welding circuit is the sum of the resistance, i.e., R1, R2,R3, and R4.

The formula for the approximate dy-namic voltage is

Voltage = 20 + (0.04 × Amperage)

where the amperage is the rated am-perage listed by the nameplate on thewelding machine.

The values shown in the followingexample are not actual values. They areintended to illustrate the principles atwork:

Voltage drop in the work leadequals 4 V Voltage drop through the structuralsteel frame equals 3 V due to the re-sistance of the structural steel that ispart of the circuit Arc voltage equals 29 V based onthe electrode requirements Voltage drop in the electrode leadequals 6 V due to the resistance of thewelding lead Welding amperage equals 375 Abased on the electrode requirements

The minimum required amperage ofthe power supply is the greater of 375 A or:

39 = 20 + (0.04 × Amperage)

Amperage = (39 – 20) ÷ 0.04 = 475

Therefore, we need to have a powersupply rated to provide 475 A to pro-vide a dynamic voltage of 39 V.

The amperage is the same regardlessof where in the circuit it is measured.That isn’t the case for voltage becausethere is a voltage drop across each com-ponent. Since the welder is only con-cerned with the voltage drop across thearc, it is best to measure the voltageclose to the arc. The voltmeter on thewelding machine may be adequate whenthe welding leads are short; however,the voltmeter on the machine is not ad-equate if the welding leads are “long.” Itis best to use a multimeter located closeto the welding arc. Typical practice is tolocate the multimeter between the wirefeeder and the member being welded asshown in Fig. 1 when measuring the arcvoltage. The voltage reading taken whenthe multimeter is positioned as shownby Fig. 1 is accurate enough for mostwork.

Assume the welding circuit includesthe cable between the wire feeder andthe gun, electrode lead, the structuralsteel framing and work lead. In Fig. 1,these components each have resistance

value indicated by R1, R2, R3, and R4.The resistance of each is a variable thatdepends on the length, and in the caseof the welding leads, the diameter andmaterial (aluminum or copper). If thelength of the welding lead is increasedand if linear distance of the structuralsteel framing is increased, the resistanceincreases. An increase in the distancebetween the welding machine increasesthe resistance in the circuit and resultsin more voltage drop. To maintain the

required arc voltage and welding cur-rent, the welder must increase the volt-age at the welding machine. The valueof R3 is not a variable because it doesn’tchange. The voltage measured at thewelding machine represents the voltagedrop of the work lead, the structuralsteel frame, the welding arc, the lead


— continued on page 33

This is the ninth in a series of arti-cles about improving the communica-tion of welding symbols. The previouseight issues of Inspection Trends haveaddressed groove weld symbols; filletweld symbols; spot, seam, and projec-tion weld symbols; plug and slot weldsymbols; edge weld symbols; stud,back, backing, and surfacing weldsymbols; supplementary welding sym-bols; and welding symbols to supportT- and corner joints as well as sealwelds. This article addresses applica-tions of symbols for nondestructiveexamination (NDE).

Welding symbols provide a systemfor placing welding information ondrawings, procedures, and data sheetsfor the purpose of relaying informa-tion to fitters, welders, fabricators,and inspectors. Welding symbolsquickly indicate the type of weld jointneeded to satisfy the requirements forthe intended service conditions.

There are a number of standardsthroughout the world that relate towelding symbols; however, AWS A2.4,Standard Symbols for Welding, Brazing,and Nondestructive Examination, is thestandard most widely used. The dataand definitions in this article are refer-enced from AWS A2.4:2012 and AWSA3.0M/A3.0:2010, Standard WeldingTerms and Definitions.

While welding symbols are widelyapplied on structural, civil, and architec-tural drawings and blueprints, symbolsfor NDE are not utilized to the same ex-tent. However, they are powerful andhave great potential for users.

Basics of Symbols for NDE

In the AWS system, the same basicprinciples of welding symbols apply tosymbols for NDE applications. Some

elements, however, have slightly dif-ferent meanings. Even though a sym-bol for NDE may consist of several ele-ments, only the reference line and anarrow are required elements — Fig. 1. The reference line is always drawn hor-izontally. The arrow connects the ref-erence line to the weld, surface, part,or component to be examined (notingthat NDE may be performed on more

than just the weld). The side of themember to which the arrow points isconsidered the arrow side and the sideopposite the arrow side of the part isconsidered the other side.

In the next edition of AWS A2.4,the planned direction for NDE sym-bols is to refer to them as symbols fornondestructive examination rather thannondestructive examination symbols;

Feature By J. P. Christein and Richard D. Campbell

Applications of Symbols for NondestructiveExaminationTheir use and proper applications are described

Fig. 1 — Reference line and arrow.

Table 1 — NDE method letter designations.

ARROW

REFERENCE LINE


however, since the 2012 Edition stilluses NDE symbols, that is usedthroughout this article.

Unique to NDE symbols, the methodof NDE is used on the symbol to identi-fy the operation, which is different thanthe welding symbol that may contain aweld symbol, which is a depiction of thespecific type of weld (for example, fillet,groove, plug, or slot).

Symbols for NDE

Symbols for NDE were established in1950 with the release of MIL-STD-23,Nondestructive Testing Symbols by theMunitions Board Standards Agency ofthe Department of Defense. MIL-STD-23 was later adopted by AWS, producingAWS A2.2:1958, Nondestructive TestingSymbols. AWS A2.2:1969 was later in-corporated into Part B of A2.4:1976,Symbols for Welding and NondestructiveTesting. These symbols for NDE havebeen a part of AWS A2.4 ever since.

Elements

The NDE symbol consists of severalelements:1. Reference line2. Arrow3. Examination method (i.e., letterdesignations)4. Extent and number of examinations5. Supplementary symbols6. Tail (specifications, codes, notes, orother references).

Examination Method LetterDesignations

NDE methods are specified on thesymbol by use of the letter designa-tions shown in Table 1. These standardNDE methods are explained in signifi-cant detail in AWS B1.10M/B1.10:2016, Guide for the Nondestructive Ex-amination of Welds.

AWS B1.10M/B1.10:2016 describesthe term nondestructive examination(abbreviated NDE) as a general termused to identify the common examina-tion methods used for evaluation ofwelds and related materials withoutdestroying their usefulness. AWS haschosen nondestructive examination(NDE) as the preferred terminologyfor these inspection methods. In otherstandards, literature, and industry us-age, different expressions are com-

monly used, including nondestructiveevaluation, nondestructive inspection(NDI), and nondestructive testing(NDT). The term most commonly usedin AWS D1 structural welding codes isnondestructive testing (NDT) (Ref.AWS D1.1/D1.1M:2015, StructuralWelding Code — Steel, paragraph 6.11).It must be emphasized that all of theseexpressions are commonly used andmay be considered equivalent. (Ref.AWS A3.0M/A3.0:2010, paragraph 3.)

Supplementary Symbols

Where supplementary symbols areto be used in symbols for nondestruc-tive examination, they are as shown inFig. 2.

Location Significance of theElements

The elements of a nondestructive

Fig. 3 — NDE on the arrow side of the member.

Fig. 2 — Supplementary nondestructive examination symbols.

Fig. 4 — NDE on the other side of the member.


Fig. 5 — NDE on both sides of the member.

examination symbol have standard lo-cations with respect to each other,similar to welding symbols. These aredescribed in the following paragraphs.

Placement of the Arrow

The arrow shall connect the referenceline to the part to be examined. The sideof the part to which the arrow pointsshall be considered the arrow side. Theside opposite the arrow side of the partshall be considered the other side.

Location on the Arrow Side

Examinations to be made on the ar-row side of the part are specified byplacing the letter designation for theselected examination method belowthe reference line, as shown in Fig. 3.

Location on the Other Side

Examinations to be made on theother side of the part are specified byplacing the letter designation for the se-lected examination method above thereference line, as illustrated in Fig. 4.

Location on Both Sides

Examinations to be made on bothsides of the part are specified by plac-ing the letter designation for the se-lected examination method on eachside of the reference line, as shown inFig. 5 and applied in Fig. 6.

Location Centered on theReference Line

When the letter designation has noarrow- or other-side significance, orthere is no preference from which sidethe examination is to be made, the let-ter designation is centered on the ref-erence line, as shown in Fig. 7. This istypically utilized for those NDE meth-ods that are considered volumetric orcan detect subsurface discontinuities(e.g., RT, UT, ET).

Combinations of NDEMethods

More than one nondestructive ex-amination method may be specifiedfor the same part by placing the com-bined letter designations of the select-

ed examination methods in the appro-priate positions relative to the refer-ence line — Fig. 8. Letter designationsfor two or more examination methods,to be placed on the same side of thereference line or centered on the refer-ence line, shall be separated by a plussign.

Multiple Reference Lines toShow a Sequence ofOperations

Two or more reference lines may beused to indicate a sequence of opera-tions in a manner similar to welding

Fig. 9 — Multiple reference lines.

Fig. 6 — Application of NDE symbol to indicate both sides of the member.


Fig. 7 — NDE methods for which there is no side significance.

Fig. 8 — Combinations of NDE methods.

symbols. The first operation is speci-fied on the reference line nearest thearrow, with subsequent operationsspecified sequentially on additionalreference lines — Fig. 9.

Welding and NDE Symbols

Nondestructive examination sym-bols and welding symbols may be com-bined to provide clear instructions forall operations, as illustrated in Fig. 10.

Supplementary NDESymbols

Examine-All-Around Symbol

Examinations required all around aweld, joint, or part are specified byplacing the examine-all-around symbolat the junction of the arrow and refer-ence line, such as in Fig. 11.

Field Examination Symbol

Examinations required to be con-ducted in the field (not in a shop or atthe place of initial construction) arespecified by placing the field examina-tion symbol at the junction of the ar-row and reference line, as illustrated inFig. 12.

Radiation Direction Symbol

The direction of penetrating radia-tion may be specified by use of the ra-diation direction symbol drawn at therequired angle on the drawing, and theangle indicated, in degrees, to ensureno misunderstanding, as shown in Fig.13. This could be applied on a drawingwhen a double-wall-exposure for dou-ble-wall-viewing RT shot is to bemade, such as an elliptical shot on apipe circumferential groove weld, asshown in Fig. 14.

Specifications, Codes, andReferences

In a manner similar to weldingsymbols, information applicable to theexamination specified, such as identifi-cation of an NDE procedure, and thatis not otherwise provided, may beplaced in the tail of the symbol fornondestructive examination — Fig. 15.

Fig. 11 — Examine-all-around with magnetic particle examination from the arrow side.

Fig. 10 — Welding and nondestructive examination symbols.


Fig. 12 — Field examine symbols in combination with weld symbols.

Fig. 13 — Radiation direction.


Extent, Location, andOrientation of NDESymbols

Specifying the Length of theWeld or Section to beExamined

To specify the examination of weldsor parts where only a portion of thelength of the weld or section is to beconsidered, the length dimension isplaced to the right of the letter desig-nation, as illustrated in Fig. 16. Di-mensions on symbols do not includethe unit (U.S. Customary or SI). Di-mensions utilize the same primarysystem of measurement that is stan-dard for the drawing, similar to unitson welding symbols.

Location Shown

To specify the exact location of a sec-tion to be examined as well as thelength, dimension lines are used, asshown in Fig. 17. While the symbolsshown are perfectly acceptable symbolsfor nondestructive examination, theydefy a logic about their application.These symbols for NDE identify the ex-act location where magnetic particle ex-aminations are to be performed; thusthe welder is aware of this prior to welding.

Codes such as ASME B31.3, ProcessPiping Code, specify minimum require-ments for random or spot examination.For Normal Fluid Service piping sys-tems, this code requires a minimum of5% of circumferential groove welds areto be examined fully by random radi-ographic or ultrasonic examination(Ref. ASME B31.3-2016, paragraph341.4.1(b)(1)). One of the purposes inthis requirement is to inform weldersthat a percentage of their welds will beexamined, but the welder is not awareof which welds (or portions of welds)will be examined.

Full-Length Examination

When the full length of a part is tobe examined, no length dimension orpercentage dimension needs to be in-cluded in the nondestructive examina-tion symbol, such as shown in Fig. 18.

Fig. 14 — Elliptical radiographic image of a circumferential groove weld on a pipe.

Fig. 15 — Use of the tail to identify additional information.

Fig. 16 — Length of section to be examined.

Fig. 17 — Exact location to be examined.

Fig. 18 — Full-length penetrant examination required.

Partial Examination

When less than 100% of the lengthof a weld or part is to be examined, thelength to be examined is specified byplacing the appropriate percentage tothe right of the letter designation —Fig. 19.

Number of Examinations

Random Locations

To specify a number of examina-tions to be conducted on a joint orpart at random locations, the numberof required examinations shall beplaced in parentheses either above orbelow the letter designation awayfrom the reference line. Figure 20 il-lustrates the number of examinations,and for the penetrant examination ex-ample shown on the left also identifiesthe length of weld to be examined ateach location.

Specific Locations

Where specific locations are re-quired, separate symbols may be used.Alternatively, additional arrows maybe added to the reference line to iden-tify the examination locations, asshown in Fig. 21.

Examination of Areas

The nondestructive examination ofareas may be specified by one of thefollowing methods.

Plane Areas

To specify the nondestructive ex-amination of an area represented as aplane on the drawing, the area to beexamined is enclosed by straight, bro-ken lines with a circle at each changein direction. The letter designationsfor the nondestructive examinationsrequired are used in conjunction withthese lines, as shown in Fig. 22.When necessary, these enclosuresshall be located by coordinate dimensions.

Areas of Revolution

For nondestructive examination ofareas of revolution, the area is specifiedby the examine-all-around symbol and


Fig. 19 — Partial examination.

Fig. 20 — Number of examinations.

Fig. 21 — Specific locations using multiple arrows.

Fig. 22 — NDE of plane areas.

Fig. 23 —NDE of areas of revolution.

the appropriate dimensions. The illus-tration in Fig. 23 specifies the following:

1. Magnetic particle examination ofthe bore of the flange for a distance of3 in. from the right-hand face, all theway around the circumference.

2. Radiographic examination of adesignated area of revolution.

The symbol in Fig. 24 specifies anarea of revolution subject to an inter-nal proof examination and an externaleddy current examination. As no di-mensions are given, the entire lengthis to be examined.

Acoustic EmissionExamination

Acoustic emission examination(AET) is generally applied to all, or alarge portion, of a component, such as apressure vessel or pipe. The symbol inFig. 25 represents the application ofAET to the component without specificreference to the location of sensors.

Summary

This article provided a review of sym-bols for nondestructive examination.While not used as frequently as weldingsymbols, these symbols are very power-ful and have tremendous applications.This article is part of a series of articlesto provide a foundation of basic weldingsymbol requirements per AWS A2.4.The next article will provide informa-tion on symbols for brazing. Final arti-cles will provide a comparison of weld-ing symbols in AWS A2.4 and ISO 2553,Welding and allied processes — Symbolicrepresentation on drawings — Weldedjoints, and typical/common errors ormisuse of welding symbols.


Fig. 24 — NDE of areas of revolution.

Fig. 25 — Acoustic emission examination.

J. P. CHRISTEIN ([email protected]) ischair of the AWS A2 Committee onDefinitions and Symbols as well as chairof the A2C Subcommittee on Symbols. Heis also a member of the AWS TechnicalActivities Committee.

RICHARD D. CAMPBELL([email protected]) is with BechtelCorp. and has taught AWS CWI seminarsfor more than 21 years. He also developeda seminar on welding symbols that heteaches for AWS at FABTECH shows andin-house seminars. He is also a member ofthe AWS D1 Structural Welding Committee.

AET

Guidelines for Submitting an Inspection Trends Feature Article

Have you ever thought about writing a feature article forconsideration in Inspection Trends? If so, our staff stays on the lookoutfor original, noncommercial, practical, and hands-on stories. Take alook at our editorial calendar — available as part of the AmericanWelding Society’s Media Kit at aws.org/wj — to see what topics willbe highlighted in future issues as well as the editorial deadlines.Potential ideas to focus on could include a case study, recentcompany project, tips for handling a particular inspection-relatedactivity, and so on.

Here’s an easy breakdown of our guidelines:

• The text of the article should be about 1500 to 2000 words andprovided in a Word document.

• Line drawings, graphs, and photos should be sent as high-resolution jpg or tiff files with a resolution of 300 or more dots per inch.

• Plan on about one figure for every 500 words, and providecaptions for every image. Also, if a nice lead photo is available, pleaseinclude it for review.

• The authors’ names, along with the companies they work for andtheir positions, should be listed.

If you’d like to discuss a particular idea or e-mail a submission forevaluation, please contact Editor Carlos Guzman [email protected].

Hot tapping is a method used inpipeline repairs, or for attaching abranch outlet to existing pipelines forthe purpose of additional service capa-bilities, without disrupting service. Inmany cases, the hot tap is done to re-pair lines and systems damaged ordeemed unsafe by inspectors and op-erators due to anomalies discoveredduring an in-line inspection (ILI). Hottapping often creates risky and dan-gerous situations; however, pipelineoperators, contractors, and inspectioncompanies who specialize in themethod have acquired enough experi-ence and expertise over the years toaccomplish the process safely — Fig. 1.American Welding Society (AWS) Cer-tified Welding Inspectors (CWIs) plan-ning to work in hot tapping should betrained by CWIs experienced in theprocess to understand the many im-portant steps and safety aspectsrequired.

Hot Tapping and CWIs

Hot tapping can be done with a va-riety of methods, including split-T fit-tings, reinforced forgings, sleeves, orspecialized fittings. These specializedproducts must meet strict inspectionstandards and undergo rigorous mate-rial and statistical analysis in their de-velopment, from the billet to the finalforging, well before being placed in useby tapping contractors.

AWS CWIs play an instrumentalrole in the visual testing (VT) and non-destructive examination (NDE) ofthese fittings and devices prior to im-plementation in the field. Quality as-surance of the integrity of these fix-

tures is mandatory before being placedin pressurized, production situations.CWIs ensure the safety of the opera-tors and the workers who are contract-ed to complete a hot tapping proce-dure, but their work starts long beforethe welding or even before the excava-tions. The CWI must ensure the fabri-cation of the components of the par-ticular hot tap follow the exact stan-dards needed to ensure quality, safecompletion, and long duration of safeworking conditions. Without the experienced, observing eyes of the inspector, substandard materials andworkmanship can lead to unsafeconditions.

Common accidents can be traced toimproper techniques or material im-perfections. The CWI is an essential el-

ement in the cycles of the productionand implementation of a hot tap andmust be involved early in the processto remove any potential threats tosafety, environment, or production.Often, production companies and finalusers of the hot tap product decline tobring a CWI into the process becauseof the costs associated with having aninspector on site. These costs can beminuscule compared to the costs of re-pair, replacement, or failure.

Duties of the CWI as theEngineer of Record (EOR)Representative

Before beginning work, the inspec-tion crew should be involved in the ex-

Feature By Jeffry Strahan

Pipeline Hot TappingThis necessary pipeline modification and repair method requires the expertise of aCWI at every step to make it safer and meet the standards

Fig. 1 — Hot tapping allows for a pipeline for be repaired or modified without interruptingservice.


amination of the proposed workersand their operator qualification (OQ)status. Workers, including CWIs, musthave current OQs that can be demon-strated with field verification reports(FVRs). These reports are issued fromthe training and registering agenciesor an individual production company.Those tapping and contracting em-ployees who will be involved in thework must show their respective oper-ator qualifications are up to date andvalid for the work they are going toperform. Rejection of these docu-ments before the work starts can cre-ate a sizable delay. CWIs work withtheir contracted employers to helpmake this part of the hot tap go quick-ly and smoothly. A good CWI will oftenwork well ahead of the beginning workdate to ensure this sort of interrup-tion does not occur.

A CWI should also be involved inthe qualifying of the materials early onto avoid discrepancies after the partshave been manufactured. One examplecould be an appliance that has beenmanufactured with a material thatdoes not meet the Charpy impact test-ing minimums for high-pressurebranch work where the appliance mustbe installed above ground, in an areasubject to very low temperatures.Some operating companies requirethese low-temperature impact valuesas per their respective safety operatingprocedure (SOP) manuals. If an essen-tial tapping component is manufac-tured with a material that does not

meet those requirements, a substan-tial delay can be incurred. An experi-enced CWI could ensure the require-ment would be met, and if the CWI isbrought into the early productionphase of that process, most delayscould be averted.

Positive MaterialIdentification

Emphasis on positive material iden-tification (PMI) has become an essen-tial part of the inspector’s duty andgenerally is done at this front load partof the project. More companies are re-quiring certified chemical identifica-tion to ensure the materials specifiedare the materials supplied. This is alsoan integral part of the primary stepsof the inspection process for tappingprojects. Often, tapping parts arrivewith documentation that gives the in-spector a readout of the fabricating fa-cility’s metallurgical makeup of theparts.

A secondary test, usually done on-site, can determine the validity of thesupplier’s submission. These are donewith portable spectroanalyzers thatcan give a reliable readout of thechemical makeup. Although not as ac-curate as an in-lab spectroanalyzer,these portable units are used to verifyand release the tapping apparatus sentby the contractors to fabrication andinstallation. Once again, an experi-enced CWI with a background in met-

allurgy and an understanding of speci-fications and standard operating pro-cedures can be an invaluable asset atthis stage of the process — Fig. 2.

CWI Duties withDocumentation

The next step in this detailedprocess is to be sure the welding proce-dures are accurate and in order. Onceagain, it is helpful to receive the weld-ing documentation well before thecrews and equipment arrive on site, asthis seems to be the area where manydelays arise. When contracted to in-spect a hot tap, the CWI must beginwith getting the welding documenta-tion to check the parameters and per-sonnel. Beginning with the weldingprocedure specification (WPS) and fol-lowing through to the procedure quali-fication record (PQR), the contractedcompany that is hired to do the instal-lation welding must produce these tothe EOR or his or her designated rep-resentative — usually a CWI.

Once these documents have beenexamined and determined to be accu-rate and proper for the operation, theattention then turns to the weldingpersonnel. The welders must be quali-fied to the proper procedures and havethe appropriate welder qualificationrecord (WQR).

Welding rod must also be invento-ried and documented by size, type,brand, date opened, and hours sinceopened, for the welding consumable tobe monitored and verified when used.Welding rod supply companies mustsupply manufacturer technical reports(MTRs) to the contractor and theEOR’s representative for the weldingrod used to be adequately documentedbefore the welding operations. TheseMTRs must be determined by the ac-tual lot number on the cans and not bythe general MTRs given by the localsupplier. The document presented bythe supplier is usually only an elec-trode-type MTR and too general to beconsidered for hot tap work. Thechemistry of the actual lot must be de-termined and documented.

Depending on the diameter of thepipe and the particular company speci-fications, in many cases at least twowelders are needed to be qualified andon site to do the job. Most companiesrequire two welders to work in unisonon a weld on opposite sides of theworkpiece. This is done so that ther-Fig. 2 — Billet markings on tap segments showing material specifications.


mal input is balanced and does notcreate undue stress and heat issueswith the mainline pipe or the hot tapappliance. It is good practice to alwayshave a third qualified welder on site toserve as a backup because the opera-tion requires at least two welders atthe same time.

The welding procedures and thewelders qualified to that procedure arecovered in Appendix B of American Pe-troleum Institute (API) Standard1104, Standard for Welding Pipelinesand Related Facilities. There is also APIRP 2201, Safe Hot Tapping Practices inthe Petroleum and PetrochemicalIndustries, which gives specific guide-lines when conducting a hot tap proce-dure. Depending upon the particulartype of tapping project to be done, thewelders must be tested to API 1104Appendix B “In Service” testing, whichinvolves conducting the welding whilea simulated product media is flowingthrough the test pipe setup — Fig. 3.Most often, this is water or oil flowingat a specified volume-per-time unitthrough the test setup, and is flowingcontinuously to simulate a productthat removes the heat input from thewelding process. The detrimental ef-fect of heat removal in this way canhave severe effects on the integrity ofthe completed weld. If heat input islost too rapidly, the resulting weld willcontain an elevated hardness, whichcan cause weld failures at pressure. Ifthe heat input is too high, the possibil-ity of pipe wall failure can occur andhave catastrophic results. It is forthese reasons that an experienced andattentive CWI should be employed inthe tapping process. CWIs who havebeen trained in welding heat input cal-culations, voltage and amperage man-agement, metallurgy, and visual weldanomaly recognition are needed to thesuccessful completion of any tappingoperation.

Preweld Duties

The first step in a hot tap operationis to locate the exact place on the pipethe tap is to occur. If the tapping is tobe done in a plant setting, the exact lo-cation must be determined, markedappropriately, and prepared. If the tapis to be executed in the field in a re-mote location, survey crews can deter-mine the precise location by GPS coor-dinates and then it be verified andagreed upon by company representa-

tives, NDE personnel, and inspectionparties before the actual work can be-gin. Once this has been done and allparties agree to that location, the crewmust sandblast the exact areas to beworked to “near white” conditions,and made ready for the NDE crew tocomplete its job. Before the sandblast-ing operation, a visual examinationmust be done to the entire surface tobe blasted to locate any anomaly thatmight interfere with the location ofthe tapping work to be done.

NDE personnel must then performultrasonic testing (UT) examining theareas on the pipe where the actualwelding will be done. This is to makesure the welding heat input occurs onpipe wall that can sustain the high en-ergy input, and the pipe wall containsno discontinuity that has not otherwisebeen detected. Pipe defects such as lam-inations, dents or wall thinning, inter-nal porosity, corrosion, or damage canlead to compromises in the process thatmight curtail the tapping being done inthat location. After these essential UTexams are performed, defects can beuncovered that require additional at-tention and a relocation of the tap to anadjacent location to ensure tap integri-ty. Smart pigging and ILI examinationsoften miss some of these problems. Anydiscontinuities within the proposedwelding areas for tapping must ulti-

mately be dealt with promptly andmade inert to the overall pipeline safetyand integrity.

CWI Monitoring of Preheat

Preheating takes place at this point,and the inspector must be satisfied byexamination using temperaturecrayons or temperature pyrometersshowing the appropriate preheat tem-perature has been reached beforewelding may begin. Depending on thegrade of the pipe to be worked, thispreheat is crucial to setting the propermetal temperature before the actualwelding. The preheat process is also in-strumental in driving off any water,water vapor, oil, or grease that mayhave accumulated on the line or fix-ture. The presence of these substancescan severely degrade the wholeprocess, creating defects in the weld orbase pipe material during the weldingprocedure.

Weld Monitoringby the CWI

When the preheat has been metand the welders have been deter-mined to be qualified, the actualwelding can begin. Using precise cal-culation formulas to determine heat


Fig. 3 — Welder testing for in-service welding.

input, the welders begin welding un-der the watchful eyes of the CWI.These calculations use product type,pipe pressure, velocity of productflow, volume of product per time unitfor the diameter of pipe involved, am-perage, voltage, electrode diameter,and pipe wall thickness as input vari-ables, and let the inspector and thewelder know how many inches perminute must be welded for the properamount of heat input to be applied sothat martensite creation is held tozero and enough heat input is gener-ated so the weld material has integri-ty with an absence of discontinuities.The area where the pipe is to be weld-ed is usually marked off in 1-in.marks so the welder and the inspec-tor can monitor and make sure thosecalculated values are met; too muchheat or too little heat can fail thewelding or the overall success of thetap project. While the welding is tak-ing place, the inspector is also contin-uously monitoring the voltage andamperage of the welding equipmentto ensure the target values are beingutilized. It is an intensive operationthat requires continuous attention bythe CWI and the tapping contractorpersonnel. Quite often, the owner oroperator of the pipeline is in continu-ous contact via phone or computer toassist in the monitoring of the pa-

rameters of the process, advising theon-site crew of pressure or velocityfluctuations. These changes can alterthe in./min speed that the weldersmust employ at any given moment.These real-time values are deter-mined and recorded with every weld-ing minute, per welder, per electrode.

NDE of the CompletedWelding

Once the necessary welding iscompleted, the NDE crew conductspenetrant testing (PT) on the girthfillet welds and on the longitudinalwelds of the split-T groove welds.Magnetic particle testing (MT) canalso be used for these fillet weld ex-aminations at the discretion of theEOR — Fig. 4.

In some cases, the EOR requeststhe welds be tested using acousticvolumetric methods to ensure thesoundness of the girth welds. Welddiscontinuities, which may be uncov-ered in the NDE process, most ofteninvolve undercutting, underfill,porosity, or slag inclusion that mustbe addressed. Typically, welding onhot taps is done by highly skilled indi-viduals with many years of experienceand the ability to make multiple,high-quality welds with a minimum

of weld blemishes — Fig. 5. Real-time monitoring occasionally

finds issues that must be corrected inprocess and in-situ. One of the morecritical weld problems that arises isundercut. It is critical that any under-cut is immediately removed by repairand any discrepancies present mustbe analyzed to determine how theypropagated, then removed and repaired.

Future of Hot Tapping

As the welding and pipeline indus-tries move further into the twenty-first century, the demand for hot tap-ping will likely increase to keep upwith the demands of various other in-dustries. The role of CWIs and otherengineering and inspection personnelwill continue to expand along withtechnological research and new equip-ment being pioneered by a host of suppliers.

JEFFRY STRAHAN is an instructor atWeber State University. He is an AWSCWI, CRI, CWE, and API 1169 CWI. Hehas a BS and MS from Utah StateUniversity, and extensive experience onhot tap projects.

Fig. 4 — Magnetic particle testing (MT) of completed fillet welds on hot tap split sleeve.Fig. 5 — Completed hot tap ready forbackfill.


An active workforce developmentprogram is the prequel to an effectivequality control (QC) program. Inti-mately linked to bottom-line businessgoals, the two programs coexist toequip employees with the skills tosafely and efficiently deliver compliantproduct output. A formal directive toensure compliance to processes andstandards serves as a guide forwelders, supervisors, and inspectorsthrough the intended steps of produc-tion and inspection.

In the welding and fabrication in-dustry, operation or inspection check-lists are too often a standard approach.Although checklists present criticalsteps and basic requirements, they lackdescriptive direction and thorough ex-planation. Without sufficient details,considerations, and marks of success-ful step or task completion, there is notool or mechanism to actively engage,train, direct, and refresh the employeethrough the task. Rather than provid-ing a mechanism for technical trainingor quality verification, checklist com-pletion becomes merely another rou-tine step in the process.

The Single Mechanism forWorkforce Developmentand Quality Control

By developing and implementingwell-written, detailed procedures, in

addition to or even in place of check-lists, descriptive technical documentsbecome a mechanism for training andworkforce development, while estab-lishing standards for weld and productquality. The standard operating proce-dure (SOP), as industrial and institu-tional operations commonly term thisapproach, is used to provide training,workforce development, and a frame-work for both general and specifictechnical operations. Trained and en-gaged employees actively work a pro-cedure outlining a job setup, productverification, task assessment, or an in-process inspection requirement downto the described detail.

Training and WorkforceDevelopment

In the workforce development book,Developing Technical Training, authorRuth Colvin Clark describes proceduresas clearly defined steps written to resultin the successful completion of a specif-ic job task, also noting that the largestproportion of all workforce trainingand development is procedurally based(Ref. 1). When properly prepared, thesedocuments provide welders, supervi-sors, and inspectors with an unambigu-ous objective-driven instructional setcontaining the technical details of stepsinvolved with proper job setup, qualitychecks, safety precautions, and otherpertinent information. A training and

workforce development program is es-tablished and attained as welders andsupervisors use the SOP to learn towork the details.

Quality Control

Through code compliance and projectspecifications, the welding industry isexperiencing increased demand for theimplementation and streamlining of in-spection directly into welding produc-tion operations and processes. TheAmerican Welding Society (AWS) in-structional book, Welding InspectionTechnology, states that in any effectiveQC program, visual testing (VT) pro-vides the basic element for evaluation ofthe structures or components being fab-ricated (Ref. 2). The VT process, whichincludes many steps before, during, andafter welding, provides an excellent sub-ject for the SOP. See the sidebar for asummary of an SOP for VT.

A general SOP for VT suffices formass-produced or similar product out-put work. However, in custom jobs, asmanufacturing engineers, designers,and QC personnel specify details suchas production materials, joint geometry,interpass temperature requirements,and other welding variables, the prepa-ration of a job-specific SOP for VT canestablish a framework and descriptivedetails for inspection requirements. TheSOP can serve, in either case, as officialpost-project QC documentation.

Feature By Lance C. Becker

Standard Operating Procedures as a Single Mechanism for WorkforceDevelopment and Quality Control Programs

Well-written procedures can provide a foundation for training and development whilealso establishing standards and expectations for quality control


Using the SOP to Meet theDemands of the WeldingIndustry

The demand for the welding indus-try, including job shops, productionplants, contractors, and various otherservices, to implement both a work-force development and a QC/VT pro-gram is undeniably present. Althoughthe basis for this need is wide, the in-dustry is seeing two primary causesfor the surge in demand: costly reworkand code conformance. Well-written,detailed SOPs can serve as the mecha-nism to address these demands.

The SOP to AddressCostly Rework andEstablish CodeCompliance

First, the return-on-investment, orprofit, of a welding project is adverselyaffected by weld discontinuities, de-fects, and other improper output. Ex-pensive rework and costly repairsmust be performed prior to the prod-uct being commissioned and put intoservice. AWS Welding Inspection Tech-nology notes that, through VT, an ef-fective QC program “will result in thediscovery of the vast majority of thosedefects which would be found later us-ing some other more expensive nonde-structive test method.” With an SOPto provide detailed instructions andrequirements for an active VT pro-gram, these costly repairs can be con-trolled. Trained and engaged supervi-sors and welders, with an SOP to workfrom, will observe and correct poten-tial discontinuities and defects beforethe finished products are compro-mised.

Second, the return-on-investmentfor high-end welding projects in indus-trial markets is extremely lucrative.High-end project specifications requirewelding production plants and con-tractors to be compliant to rigorousformal standards. Detail-orientedstandards found in codes created byorganizations such as the AmericanInstitute for Steel Construction(AISC), American Society of Mechani-cal Engineers (ASME), American Pe-troleum Institute (API), and others, re-quire the employment, documenta-tion, and successful third-party audit-ing of detailed workforce development

and QC practices. Although thesecodes present very complex require-ments, the contracts for such projectsare among the most financially re-warding in the welding industry. Stan-dard operating procedure documentsprovide company-specific confor-mance to many of these requirements.

Planning for SOPDevelopment

There is not a mandatory approachto creating SOPs. Plants or contractorswith a sufficient budget may contractthe process out to technical writingspecialists while assigning an in-housesubject matter expert (SME) to con-tribute or oversee. Large operationswith dedicated workforce development

and QC departments may assign com-munications personnel with an SMEto prepare SOP.

Smaller shops may appoint an in-house supervisor or inspector with theassignment of documenting task stepsand writing instructions. A writer oreditor may make these steps and in-structions into procedures. However,whichever approach the company maypursue, be forewarned that the SOP isa direct reflection on the quality of thework you do.

Preparing SOPDocuments

A well-written SOP should read likea set of instructions. Always sequen-tial, the SOP should move from first to


Summary of Operating Procedures for Visual Testing(VT) — Responsibilities before, during, and afterWelding and Fabrication Work

1. VT Responsibilities before Welding and Fabrication Work

Review project drawings and specifications•Check purchase order specifications•Verify job materials•Verify chemical analysis and mechanical properties test reports•Investigate for base metal defects•Check for proper filler metal and condition of storage and filler •metals Check welding equipment•Check weld joint edge geometry•Check weld joint fit•Check weld joint cleanliness•Welder qualification check•Check preheat temperature requirements•

2. VT Responsibilities during Welding and Fabrication Work

Check production welding for compliance with welding •procedureCheck the quality of individual weld passes•Check interpass cleaning•Check Interpass temperature•Complete in-process nondestructive examination (NDE)•

3. VT Responsibilities after Welding and Fabrication Work

Check final weld appearance•Check final weld sizes and lengths•Check dimensional accuracy of completed weldment•Select production test samples•Evaluate test results•Complete final NDE requirements•Maintain records and reports in project quality control •documents


last. An employee should be able tofollow the SOP from the beginning tothe end of the step or task.

Each sentence should reflect a step.Start each sentence/step with an ac-tion verb, directing the action of theSOP user. Write only one action, or in-struction, for each step. After the step,include precise, specific details such astechnical information (dimensions,sizes, arrangements) and any neces-sary explanations (distinguishing cri-teria, locations, placements).

Explanations are extensions of thesteps. They may be presented as sub-steps, numbered or lettered, or appearin italicized text. However, explana-tions should always follow the step towhich they pertain.

Graphics, such as photographs, il-lustrations, or technical drawings, mayaccompany SOPs. Actual photographsof the task or equipment involved inthe task may prove very helpful. In themultimedia mode of presentation,videos of successful step or task com-pletion may accompany the SOP.Use complete sentences, avoid theomission of articles (for example, a,an, and the), and follow standardgrammar.

Presenting SOPTasks/Manuals

Standard operating procedure tasksheets or manuals should be presentedin training rooms or at orientations.The same SOP should be available inworkstations or in close proximity tothe welder or fabricator. An SOP creat-ed for receiving or shipping materialsshould be located in the same way.Posting the SOP in a glass-bound bul-letin board, where employees mustwalk halfway across the plant to access

them, is not the best practice. A competent person should serve as

a controller or director of SOP docu-ments. Responsibilities of this roleshould include the maintenance of acomplete operations manual, whichshould contain every SOP for everyoutlined task. The director of SOP doc-uments must ensure that all copies, in-cluding all workstation task sheets andsupervisor manuals, are updated atevery SOP revision, change, or removal.

For internet or intranet versions ofthe SOP, it is critical that the narra-tives and presentations are precisematches to shop or field paper copies.When online media is the preferred re-source in the shop or field, it should bein close proximity to the welder or fab-ricator. Even the online SOP must bereadily available from pretask analysisthrough completion.

The physical presentation of thetask sheet or manual should bedurable and fit for the conditions ofuse. Often, single page or single taskcopies are laminated to withstandshop conditions. Covers and bindingscan also preserve the life of shop manuals.

Evaluating SOP Contentand Effectiveness

There are many ways to evaluate theSOP content and effectiveness. By in-volving QC personnel, SMEs, welders,and other employees, the process canfoster collaboration and employeebuy-in. Simple usability testing en-gages employees with the SOP. In turn,these employees provide feedback andinput. Other processes involve fieldtests, which may be used to evaluateand revise the SOP.

Technical Writing for Success, by Dar-lene Smith-Worthington and Sue Jef-ferson, identifies two field tests toevaluate the clarity, wording, and stepsequence of SOPs (Ref. 3). Concurrenttesting evaluates an SOP while it is be-ing used. During step or task comple-tion, employees are observed perform-ing the instructions. Variables such asaccuracy, speed, recall, and attitudecan be monitored. In retrospectivetesting, the subjects complete the taskfirst and then answer questions aboutthe SOP and the task. Surveys, ques-tionnaires, and other tests are used inthis method.

Conclusion

Developing, implementing, revis-ing, and maintaining SOPs doesn’tcome without a dedicated effort. How-ever, this method for addressing train-ing, workforce development, and QCserves as both an efficient and effec-tive mechanism for the two businessdevelopment needs. The SOP, whenproperly developed, provides detailed,descriptive instructions for welders,supervisors, and inspectors to engagesteps and tasks safely and effectively,while establishing standards for quali-ty verification and inspection.

References

1. Clark, R. C. 2008. DevelopingTechnical Training. New York, N.Y.: Wiley.

2. Welding Inspection Technology.2008. American Welding Society, Mia-mi, Fla.

3. Smith-Worthington, D., and Jef-ferson, S. 2011. Technical Writing forSuccess. Nashville, Tenn.: South-West-ern Publishing.

LANCE C. BECKER([email protected]) is atechnical writing graduate student fromLouisiana Tech University, Ruston, La., anengineer at Illinois Crane Inc., Chicago, Ill.,and an AWS Certified Welding Supervisor(CWS).

The standard operating procedure (SOP) is usedto provide training, workforce development, anda framework for both general and specifictechnical operations. Trained and engagedemployees actively work a procedure outlining ajob setup, product verification, task assessment,or an in-process inspection requirement down tothe described detail.

Technology Notes


Errata

NAVSEA B2.1

The following Erratum has beenidentified and will be incorporated intothe next reprinting of the following doc-uments.

AWS-NAVSEA B2.1-1-311:2018,Standard Welding Procedure Specificationfor Naval Applications (SWPS-N) for GasTungsten Arc Welding of Carbon Steel (S-1), 1⁄8 inch [3 mm] through 1-1⁄2 inch [38mm] Thick, MIL-70S-2, in the As-Weldedor PWHT Condition, Primarily Pipe forNaval Applications. Page 12, Joint 6,note 6: Replace “The provisions of note3” with “The provisions of note 4.”

AWS-NAVSEA B2.1-1-312:2015,Standard Welding Procedure Specificationfor Naval Applications (SWPS-N) forShielded Metal Arc Welding of CarbonSteel (S-1), 1⁄8 inch [3 mm] through 1-1⁄2 inch[38 mm] Thick, MIL-7018-M, in the As-

Welded or PWHT Condition, PrimarilyPipe for Naval Applications. Page 10,Joint 5, note 6: Replace “The provisionsof note 3” with “The provisions of note4.”

AWS-NAVSEA B2.1-1-316:2018,Standard Welding Procedure Specifica-tion for Naval Applications (SWPS-N) forArgon Plus 2% Oxygen Shielded GasMetal Arc Welding (Spray TransferMode) of Carbon Steel (S-1), 1⁄8 inch [3mm] through 1-1⁄2 inch [38 mm] Thick,MIL-70S-3, in the As-Welded or PWHTCondition, Primarily Pipe for Naval Ap-plications. Page 11, Joint 5, note 6: Replace “The provisions of note 3”with “The provisions of note 4.”

AWS-NAVSEA B2.1-1-317:2018,Standard Welding Procedure Specificationfor Naval Applications (SWPS-N) for 75%Argon Plus 25% Carbon Dioxide ShieldedFlux Cored Arc Welding of Carbon Steel (S-1), 1⁄8 inch [3 mm] through 1-1⁄2 inch [38mm] Thick, MIL-70T-1 and MIL-71T-1, inthe As-Welded or PWHTCondition, Prima-

rily Pipe for Naval Applications. Page 11,Joint 5, note 6: Replace “The provisions of note 3” with“The provisions of note 4.”

AWS-NAVSEA B2.1-8-318:2016,Standard Welding Procedure Specificationfor Naval Applications (SWPS-N) for GasTungsten Arc Welding of Austenitic Stain-less Steel (S-8), 1⁄8 inch [3 mm] through 1-1⁄2inch [38 mm] Thick, MIL-3XX, in the As-Welded Condition, Primarily Pipe forNaval Applications. Page 11, Joint 6,note 6: Replace “The provisions of note3” with “The provisions of note 4.”

AWS-NAVSEA B2.1-8-319:2018,Standard Welding Procedure Specificationfor Naval Applications (SWPS-N) forShielded Metal Arc Welding of AusteniticStainless Steel (S-8), 1⁄8 inch [3 mm]through 1-1⁄2 inch [38 mm] Thick, MIL-3XX-XX, in the As-Welded Condition, Pri-marily Pipe for Naval Applications. Page10, Joint 5, note 6: Replace “The provi-sions of note 3” with “The provisions ofnote 4.”

ASNT Research SymposiumApril 1–4. Hyatt Regency Orange County, Garden Grove,Calif. The theme for the 2019 Research Symposium is “Ad-vancing NDE Technologies, Research and Engineering in aChanging World.” It aims to address key research, develop-ment, and innovation of advancing NDE technologies aswell as bridge gaps in NDE research, engineering, and tech-nology transfer. Visit asnt.org.

ASNT NDT of CompositesApril 30–May 2. Motif Seattle, Seattle, Wash. Focusing onthe ever-expanding use of composite materials across sever-al industries, this conference will feature presentations,short courses, and an exhibit floor featuring the latest inproducts and services. This program will provide the oppor-tunity for information exchange on advances in compositeNDT technology, NDT of new product forms, in-processNDT, and NDT of composites used in commercial, military,subsurface, and space applications. Visit asnt.org.

AMPM2019 Additive Manufacturing with Powder Metallurgy June 23–26. Sheraton Grand, Phoenix, Ariz. This eventbrings together industry professionals and decision makersfrom around the world to network and learn from each oth-

er about the latest developments and innovations in metalpowder technology. The conferences address powder metal-lurgy parts and products, metal injection molding, and met-al additive manufacturing. Visit ampm2019.org.

Educational Opportunities

ASME Section IX SeminarLearn how to use ASME Section IX quickly and cost effectively.This three-day ASME-sponsored course is scheduled for thefollowing dates and locations: Portland, Ore., April 8–10, andHouston, Tex., June 10–12. Contact Marion Hess,[email protected], (212) 591-7161, or register at asme.org/prod-ucts/courses/bpv-code-section-ix-welding-brazing-fusing.

The Atlas of Welding Procedure SpecificationsThe AWS Connecticut Section is hosting a three-day semi-nar/workshop on developing welding procedure specifica-tions, procedure qualification records, and welder qualifica-tion records. This event, scheduled for March 25–27 in Sims-bury, Conn., will provide instruction and the rationale fordeveloping qualified and prequalified welding proceduresthat meet AWS and ASME standards. In-class exercises cov-er the process of writing prequalified WPSs and the mechan-ics of qualifying WPSs by testing. The welding documents

Mark Your Calendar


developed are applicable to AWS, ASME, NAVSEA, and oth-er military standards, and commercial welding standards.Contact Albert Moore, workshop leader, for more informa-tion at [email protected].

AWS Online CWI Pre-SeminarThe online CWI Pre-Seminar covers fundamental conceptsand principles frequently used by CWIs. The ten-course pro-gram has been thoughtfully engineered to provide a strongfoundation for those who are preparing to take the CWIexam or as a refresher for accomplished CWIs in need ofprofessional development hours (PDHs). Visit aws.org.

CWI Exam Prep Course American Institute of Nondestructive Testing offers a 40-h on-line CWI exam prep course. Part A covers the fundamentals ofwelding technology; part B consists of extensive practicalhands-on techniques and will be held at the Houston MarriottNorth in Houston, Tex.; and part C provides in-depth trainingto the welding code portion of the exam. Contact Jeff Le-Tourneau, [email protected], (855) 313-0325, or visittrainingndt.com.

CWI/CWS Inspector TrainingWelder Training & Testing Institute is hosting the followingendorsement and CWI/CWS prep course seminars: ASMESection IX/B31.1/B31.3: May 9, 10; Aug. 1, 2; and Nov. 21,22; D1.1/D1.5/API Endorsement: May 16, Aug. 8, and

Dec. 5; CWI: May 13–18, Aug. 5–10, and Dec. 2–7; CWS:March 4–8 and Sept. 16–20. To register, go to wtti.com.

CPCC NDE Continuing Education CoursesCentral Piedmont Community College presents the follow-ing 2019 spring courses: Online: Introduction to NDE, Jan.14–May 10; NDE Visual Testing Level I & II, Jan. 14–May10. Classroom: Level I & II Penetrant Testing, March18–April 1; Ultrasonic Testing Level 2, March 18–April 24.To register, visit cpcc.edu/cce/register-now.

CWB Online/Classroom CoursesCourses in NDE disciplines to meet certifications to Canadi-an General Standards Board or Canadian Nuclear SafetyCommission. The Canadian Welding Bureau; (800) 844-6790; cwbgroup.org; [email protected].

CWI/CWE Course and ExamA ten-day program presented in Troy, Ohio. Contact HobartInstitute of Welding Technology, (800) 332-9448;[email protected]; welding.org.

E-Courses in Destructive and Nondestructive Testingof Welds and Other Welding-Related TopicsOnline video courses taken at one’s own pace offer certifi-cates of completion and continuing education units. HobartInstitute of Welding Technology, (800) 332-9448;welding.org/product-category/online-courses/.


Certification Schedule


Certified Welding Inspector (CWI)

Location Seminar Dates Exam DateOrlando, FL Feb. 17–22 Feb. 23Seattle, WA Feb. 17–22 Feb. 23New Orleans, LA Feb. 24–March 1 March 2San Diego, CA Feb. 24–March 1 March 2Atlanta, GA March 3–8 March 9Salt Lake City, UT March 10–15 March 16Annapolis, MD March 10–15 March 16Houston, TX March 10–15 March 16Chicago, IL March 17–22 March 23Phoenix, AZ March 17–22 March 23Boston, MA March 24–29 March 30Portland, OR March 24–29 March 30Miami, FL March 31–April 5 April 6Minneapolis, MN March 31–April 5 April 6Dallas, TX April 7–12 April 13Las Vegas, NV April 7–12 April 13Bakersfield, CA April 28–May 3 May 4St. Louis, MO April 28–May 3 May 4Baton Rouge, LA May 5–10 May 11Detroit, MI May 5–10 May 11Denver, CO May 19–24 May 25Nashville, TN May 19–24 May 25Birmingham, AL June 2–7 June 8Kansas City, MO June 2–7 June 8Pittsburgh, PA June 9–14 June 15Spokane, WA June 9–14 June 15Beaumont, TX June 16–21 June 22Hartford, CT June 16–21 June 22Newark, NJ June 23–28 June 29Omaha, NE June 23–28 June 29Louisville, KY July 7–12 July 13Phoenix, AZ July 7–12 July 13Norfolk, VA July 14–19 July 20Milwaukee, WI July 21–26 July 27Orlando, FL July 21–26 July 27Cleveland, OH July 28–Aug. 2 Aug. 3Los Angeles, CA July 28–Aug. 2 Aug. 3Denver, CO Aug. 4–9 Aug. 10Philadelphia, PA Aug. 4–9 Aug. 10Chicago, IL Aug. 11–16 Aug. 17San Diego, CA Aug. 11–16 Aug. 17Salt Lake City, UT Aug. 11–16 Aug. 17Charlotte, NC Aug. 18–23 Aug. 24Sacramento, CA Aug. 18–23 Aug. 24Houston, TX Aug. 25–30 Aug. 31Seattle, WA Aug. 25–30 Aug. 31Minneapolis, MN Sept. 8–13 Sept. 14San Francisco, CA Sept. 8–13 Sept. 14Orlando, FL July 21–26 July 27Cleveland, OH July 28–Aug. 2 Aug. 3

9-Year Recertification Seminar for CWI/SCWIFor current CWIs and SCWIs needing to meet education re-quirements without taking the exam. The exam can be takenat any site listed under Certified Welding Inspector.

Location Seminar DatesSan Diego, CA Feb. 17–22New Orleans, LA March 10–15Dallas, TX March 24–29Seattle, WA April 7–12Denver, CO May 5–10Miami, FL May 19–24Pittsburgh, PA June 23–28Charlotte, NC July 21–26Houston, TX Aug. 4–9

Certified Welding Educator (CWE)Seminar and exam are given at all sites listed under CWI. Semi-nar attendees will not attend the Code Clinic portion of theseminar (usually the first two days).

Certified Welding Sales Rep. (CWSR)Prometric testing centers. More information at aws.org/certification/detail/certified-welding-sales-representative.

Certified Welding Supervisor (CWS)Prometric testing centers. More information at aws.org/certification/detail/certified-welding-supervisor.

Certified Radiographic Interpreter (CRI)The CRI certification can be a stand-alone credential or canexempt you from your next 9-Year Recertification. More in-formation at aws.org/certification/detail/certified-radiographic-interpreter.

Location Seminar Dates Exam DateDallas, TX April 1–5 April 6Las Vegas, NV June 3–7 June 8Pittsburgh, PA July 29–Aug. 2 Aug. 3Houston, TX Sept. 30–Oct. 4 Oct. 5

Certified Robotic Arc Welding (CRAW)OTC Daihen Inc., Tipp City, OH; (937) 667-0800, ext. 218Lincoln Electric Co., Cleveland, OH; (216) 383-4723Wolf Robotics, Fort Collins, CO; (970) 225-7667Milwaukee Area Technical College, Milwaukee, WI; (414) 456-5454College of the Canyons, Santa Clarita, CA; (651) 259-7800Ogden-Weber Applied Technology College, Ogden, UT; (800) 627-8448

IMPORTANT: This schedule is subject to change without notice. Please verify your event dates with the Certification Dept. to confirm yourcourse status before making travel plans. Applications are to be received at least six weeks prior to the seminar/exam or exam. Applicationsreceived after that time will be assessed a $250 Fast Track fee. Please verify application deadline dates by visiting our website aws.org/certification/docs/schedules.html. For information on AWS seminars and certification programs, or to register online, visit aws.org/certification or call (800/305) 443-9353, ext. 273, for Certification; or ext. 455 for Seminars.

Note: The 2019 schedule for all certifications is posted online ataws.org/w/a/registrations/prices_schedules.html.

between the gun and wire feeder, andthe electrode lead. Using the values listed by our example, the voltage me-ter on the welding machine should bethe following:

V= 4 + 3 + 29 + 6 = 42

Yet, the multimeter would indicatethe voltage drop at the welding arc is29 V. In total, there is a 13-V drop dueto the resistance of the welding leadsand steel framing.

The erector has a choice: purchasepower supplies with increased ratedamperage that has the capacity to pro-

vide the dynamic voltage that is suffi-cient to accommodate the resistanceof long welding leads and increaseddistance between the welding machineand location where the welder is weld-ing, or move the welding machines upas the height of the building increasesto keep the welding leads relativelyshort.

In consideration of the problem youdescribe in your inquiry, I suspect thedistance between the welding machineand the location where the welding isbeing performed is too great. Boththe amperage and arc voltage are affected.

AWS Taiwan Section Holds CWIConference

The American Welding Society (AWS) Taiwan Section re-cently held its second Certified Welding Inspectors (CWI)conference Oct. 28 and 29, 2018, in Kaohsiung (southernTaiwan). The first CWI conference was held in Taipei (north-ern Taiwan) in 2011. With more than 220 people in atten-dance, the 2018 conference included three keynote speech-es, four plenary speeches, and nine technical presentationsby CWIs and Senior CWIs.

The objective of the conference was to address the opportu-

nities and challenges for AWS CWIs actively participating inTaiwan’s fast-growing offshore wind farm development proj-ects. Taiwan’s strategic energy goal is to achieve a distributionof 20% in renewable energy in 2025, with a targeted offshorewind power of 5.5 GW.

Discussions held on the second day addressed two topics:AWS certifications for Taiwan’s offshore wind farm industry,and the current welding inspector certification system inTaiwan. Additionally, thoughts on integrating the AWS andISO certification systems were discussed for Taiwan’s off-shore wind farm development programs — Chon-LiangTsai, AWS-Taiwan Chairman.

— continued from page 11

— continued from page 7

News Bulletins


More than 200 people attended the AWS-Taiwan CWI Conference, held Oct. 28 and 29 in Kaohsiung, Taiwan, which addressed theopportunities and challenges of AWS CWIs taking part in Taiwan’s offshore windfarm development projects.

The Answer Is

ALBERT J. MOORE JR.([email protected]) is vicepresident, Marion Testing & Inspection,Canton, Conn. He is an AWS SeniorCertified Welding Inspector and an ASNTNDT Level III. He is also a member of theAWS Certification Committee and theCommittee on Methods of Inspection ofWelds.

The Society is not responsible for anystatements made or opinions expressedherein. Data and information developed bythe authors are for specific informationalpurposes only and are not intended for usewithout independent, substantiatinginvestigation on the part of potential users.

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The Atlas of Welding Procedure Specifications

This three-day seminar/workshop on the subject ofdeveloping welding procedure specifications,procedure qualification records, and welderqualification records is being offered once again.The three-day workshop/seminar is scheduled forMarch 25 through March 27, 2019 in Simsbury,Connecticut. The seminar provides a rational basisfor developing welding procedure specificationsthat meet AWS and ASME codes. In-class exercises

cover the process of writing prequalified WPSs andthe mechanics of qualifying WPSs by testing. Thewelding documents developed are applicable toAWS and ASME as well as other standards thatinclude NAVSEA standards, other military standards,and commercial welding standards.

Albert Moore is the point of contact and the instructorfor the workshop. Seating is limited, so register early.The October offering sold out very quickly. If youmissed the October seminar, this is your nextopportunity to attend. For more information contactAlbert Moore at [email protected]