Pipeline Welding Inspection

This section discusses the requirements and procedures for inspection of pipeline
girth welds. Normally, the Company’s arrangements for pipeline welding inspection
are independent of the pipeline contractor’s organization. The contracts for
welding inspection and nondestructive examination (radiography) are based on
applicable codes, regulations, and Company requirements. However, the Company’s
quality assurance responsibilities must be carefully coordinated with the pipeline
contractor to avoid lessening his sense of responsibility for the quality of the pipeline
welding. The Company’s responsibilities include:
• Preparation of clearly written specifications for the inspection and nondestructive
examination (NDE) of the pipeline welds
• Providing qualified welding inspectors
• Assuring that welding procedures and welders are properly qualified
• Documenting or assuring documentation of all inspection results and providing
quality control feedback to the pipeline contractor
• Spot visual examination of pipeline fit-up before welding, the welding in progress,
and the completed welds
• Providing radiographic inspection through an inspection organization whose
personnel are qualified to the American Society of Nondestructive Testing
(ASNT) Recommended Practice No. SNT-TC-1A

Visual Examination
Visual examination before, during, and after welding is one of the welding
inspector’s most important jobs. Visual examination includes both the pipe and the
welds. Documentation of visual examinations can vary from a minimum of daily
field notes to formal checklists, depending upon the size of the job. The frequency
of visual examinations can vary from 100% surveillance to selective spot checking,
depending upon the location of the pipeline (i.e., urban, rural, crossing, etc.) and the
risks to pipeline operations. The following is a list of the visual examinations which
should be made or verified by the welding inspector:
• The pipe is in good condition and free of defects
• Cold bends have been made properly without damaging the pipe or coating, and
the pipe is free of wrinkles, flat spots, and excessive out-of-roundness
• Each joint of pipe has been swabbed clean of trash and debris before it is placed
in the line
• Bevels and lands are satisfactory for welding and are:
– Free of material defects (e.g., laminations)
– Properly cleaned and free of weld contaminants such as rust, grease, and
other foreign material
– Dimensionally correct and within tolerances
• The pipe is free of handling damage, or has been repaired
• The pipe is properly supported by studs for welding
• The welding is performed as required by the procedure and has been checked
for:
– Pipe fit-up and alignment. Offset and gap dimensions are within tolerances
– Correct preheat

– Sound stringer pass without cracks, undercut, or excessive porosity. Proper

grinding for the hot pass
– Adherence to the maximum time permitted between the stringer and hot
pass
– Interpass cleaning (power wire bushing) and grinding starts and stops as
needed
– Fit-up clamps used as specified in the procedures
– Electrodes are properly stored with rod ovens controlled to the correct
temperature and bake out ovens (if used) are controlled to the correct
temperature and time. Verify that the maximum number of bake out cycles
has not been exceeded.
– Correct types (AWS classification) and diameters of electrodes. Electrodes
are in good condition for welding (i.e., free of damage and contamination)
– Correct welding polarity. (Generally DC+, but DC- is sometimes used for
the root pass with certain electrodes, such as Lincoln 5P and HYP)
– Shielding gases are of correct composition and purity (e.g. 99.995%
Argon, 75% Argon, and 25% CO2)
– Staggered starts and stops to avoid alignment with other passes
– No cracks, undercut, or excessive porosity in any bead
– Minimum number of passes as specified in the procedure for the thickness
(but not less than three)
– Correct reinforcement and width of the cap pass and no excessive undercut
of the pipe
– Welder identification marked in a manner not injurious to the pipe but
permanent enough for pickup by the X-ray crew
– Weather, wind, and dust conditions not adverse to good welding practice
• Defect repairs do not exceed more than one repair at any given location in a
pipe weld, and the welder contributing to the defect is identified

Radiography of Field Welds

The use and frequency of radiographic inspection is established by the Company.
Radiography is performed to the acceptability standards in Section 9.0 of
API STD 1104 and additional requirements of the Company (see PPL-SC-1564).

Radiographic Procedure
Before any radiography can be performed on a pipeline, a detailed procedure for the
production of radiographs must be prepared, recorded, and demonstrated by the
radiographic contractor to produce acceptable radiographs, in accordance with
Section 11.0 of API STD 1104. API STD 1104 requires demonstration on test shots
that the radiographic procedure produces acceptable radiographs. A written procedure
is required that includes at least the following:
• Radiation source. Covers type of radiation source, effective source or focal
spot size, and voltage rating of X-ray equipment.

• Intensifying screens. Describes the type and placement of screens, and lead
screen thickness. Lead screens are preferred for pipeline
work. An exception is offshore construction from a lay barge, where remoteoperated,
battery-powered, crawler-mounted internal X-ray heads are
frequently used. These generally employ fluorescent screens to minimize exposure
times and battery recharging frequency. Intermediate speed fluorescent
intensifying screens (e.g., Du Pont Conex NDT 5) with fine grain medium
speed film have proved satisfactory for this application. Fluorescent screens are
very sensitive to dirt, dust, and scratches, and must be kept immaculately clean
and replaced more frequently than lead screens.
• Film. Film brand rather than film type should be specified, along with the
number of films per cassette. Where more than one film per cassette is specified,
how they will be viewed should be stated (e.g., single film viewing or
double film viewing). In the past film type designations (Type 1 or 2) have been
accepted in lieu of brand names. However, because of significant variations in
the grain size and speed of films meeting the same type, this designation should
not be used to obtain equivalent radiographic quality by substitutions made
solely on the basis of film type.
• Exposure Geometry. Exposure geometry refers to the relative placement of the
source of radiation, pipe weld, film, penetrameters and lead markers (for film
intervals and reference). The number of exposures per weld is also stated. Variations
include the following:
– SWE/SWV. Single-wall exposure with single-wall viewing. The radiation
source is positioned for single-wall penetration. A typical setup would be
with the source on the inside and the film on the outside. When the source
is centered inside of the pipe, a single 360-degree exposure of the weld can
be made.
– DWE/SWV. Double-wall exposure with single-wall viewing. The radiation
source is positioned for double wall penetration, but only the weld
from “one” wall (i.e., one side of the pipe) is recorded on the film. A
typical setup is with the source on the outside of the pipe and the film on
the opposite side. A minimum of three 120-degree exposures are required
if the source is positioned within 1/2 inch of the pipe, otherwise four
90-degree exposures are required .
– DWE/DWV. Double-wall exposure with double-wall viewing. The radiation
source is positioned for double wall penetration, with welds on “both”
walls recorded on the film. NPS 3 and smaller pipe requires this technique
with the radiation beam offset so that the source side and film side portions
of the weld do not overlap in the area of the radiograph to be evaluated.
Two or more exposures (N) are required with each shot, separated by
180 degrees divided by N.
• Exposure Conditions. The exposure conditions depend on the exposure
parameters of the radiation source (either X-ray or radioisotope). For X-ray
units, they are measured in milliamperes, peak X-ray voltage (KVP), and exposure
time. For radioisotopes they are measured in curie minutes.

• Processing. The radiographic procedure should specify:

– Automatic or manual processing
– Time and temperature of solutions for development, stop bath (or rinse),
fixation, and washing
– Drying method
• Materials. Type and thickness range of material for which the procedure is
suitable
• Penetrameters. API 1104 now allows both hole and wire type of penetrameter
(11.1.4). Hole type can be either ASTM E 1025 or as shown in Figure 21 of
API 1104. Wire type must be ASTM E 747. The material, identifying number,
and essential hole (if hole type) to meet the required sensitivity level should be
specified. Shim material and thickness should also be given. The minimum
sensitivity level is 2% unless otherwise stated