Accurate Inspections NACE 2013

NACE RMS 2013 Billy J Fields

• Accurate Inspections, LLC o AWS CWI #03071341 o AWS CWS #0902004S o NACE Level III CCI #7866 o 34 Years Steel Water Pipe Manufacturing & Installation Experience

1

NACE RMS 2013 Discussion Topics • Coating Purpose • Premature Coating Failure • Different Welding Processes & Electrodes

• NACE SP0178 Design, Fabrication, & Surface Finish Practice for Tanks & Vessels to Be Lined for Immersion Services • SP0188 & SP0274 Holiday Testing Standards

NACE RMS 2013 Purpose of Coatings • Safety – Protects structures that support extreme weight

• Appearance – Pealing coatings and rusting steel are typically an eyesore

• Cost – Cost of painting/repainting a structure is expensive, but certainly more economical then replacing

NACE RMS 2013 Purpose of Coatings • First line of defense to stop corrosion of a material, usually a metal. • Acts as a barrier to prevent chemical compounds or corrosion current from contacting the substrate

NACE RMS 2013 • Premature Coating Failure

– Failed at Weld Seams – Laps Not Sealed – Holiday Tested????

NACE RMS 2013 • Premature Coating Failure – Faying Surface Not Sealed – Weld Seams Not Strip Coated – Single Sided Weldments

NACE RMS 2013 • Skip Welds and Lap type joints are difficult to protect

NACE RMS 2013 Premature Coating Failure • Weld Spatter Not Removed

NACE RMS 2013 • NACE SP0178 – Surface weld quality may differ from welding codes – Remove weld spatter – Small amounts of porosity/undercut allowed depending on degree of preparation – Grind rough welds smooth

• ASME/AWS – AWS/ASME have allowances for weld defects that are not allowed by SP0178 – Weld Spatter not necessarily rejectable – Small amounts of undercut allowed – Rough welds not necessarily rejectable

NACE RMS 2013 • NACE SP0178 – For Immersion Service – – – –

No Skip Welds No Laps Round all sharp edges No Arc Strikes

● Most Welding Inspectors are not aware of NACE SP0178

• ASME/AWS – Minimizes distortion from welding process – Laps are part of design – Arc Strikes are not allowed

NACE RMS 2013 • NACE SP0178 – Appendix A, Figure A1

• NACE SP0178 – Appendix A, Figure A2 & A3

NACE RMS 2013 • NACE SP0178 – Appendix A, Figure A5 & A6

• NACE SP0178 – Appendix A, Figure A7 & A8

NACE RMS 2013 • NACE SP0178-2007 Appendix C

NACE RMS 2013 NACE SP0178-2007 Visual Comparator

NACE RMS 2013 • Unacceptable weld & edge defects – Weld Spatter, remove them – Sharp Edges, chamfer with grinder

NACE RMS 2013 • Unacceptable weld & edge defects – Arc Strikes, remove them

NACE RMS 2013 • Unacceptable weld defects

– – – –

Slag Pockets Weld Spatter Cold Laps Stops/Starts not ground

NACE RMS 2013 • Poor Weld Profile

– – – –

Weld Spatter Sharp Edge Undercut Excessive Weld Sag

NACE RMS 2013 • SAW (Submerged Arc Welding) – No weld spatter, typically performed in shops • GTAW (Gas Tungsten Arc Welding) – No weld spatter, typically performed in shops • FCAW (Flux-Core Arc Welding) – Weld spatter but smooth weld profile

• GMAW (Gas Metal Arc Welding) – Lots of weld spatter • SMAW – Lots of weld spatter & typically a rough profile, normally used for field welding – E6010 electrode very rough weld profile – E7018 electrode smoother profile then E6010

NACE RMS 2013 • SAW Weld

• FCAW Weld

NACE RMS 2013 • SMAW E6010 Weld Profile

• SMAW E7018 Weld Profile

NACE RMS 2013 • Strip Coat/Seal the Welds and Beam Edges

NACE RMS 2013 • Holiday Testing – Wet Sponge Testing – Low/High Voltage Testing – Used to Find Voids, cracks, thin spots, or even contaminates in the coating

NACE RMS 2013 • Weld Spatter & Rough welds that failed Holiday Testing

NACE RMS 2013 • Missed Holidays

Missed Holidays

– Use proper Testing procedure • NACE SP0188 • NACE SP0274

– Select proper testing equipment • Wet sponge good up to 20mils DFT • Low/High Voltage set correctly based on average DFT of applied coatings

Missed Holidays

NACE RMS 2013 Thank you for attending Questions ?