INSPECTION

TRENDS
FEBRUARY 2023

THE MAGAZINE FOR MATERIALS INSPECTION AND TESTING PERSONNEL

ACFM Inspection
of Storage Tanks

Bridge Inspection

Quality Assurance vs.

Quality Control
IN THIS ISSUE: TIPS FOR READING CODES AND STANDARDS ■ INTERNATIONAL CWI PROFILE
[ FEBRUARY 2023 | VOLUME 26 | NUMBER 1 ]

[ FEATURES ] [ DEPARTMENTS ]
04 Editorial

05 News Bulletin

12 The Role of the CWI or SCWI in Fracture 07 Product & Print Showcase
Critical Applications
08 The Answer Is
Fracture critical materials, welds, and applications; related
special testing; and personnel qualification and certification 11 International CWI
are discussed
23 Classifieds
C. E. Pepper, H. J. Wolf, and A. D. Blakeney
23 Advertiser Index

16 Quality Assurance vs. Quality Control

The differences and similarities between these two terms are INSPECTION TRENDS (ISSN 1523-7168 Print) (ISSN 2689-0631

explained Online) is published quarterly by the American Welding Society.

Editorial and advertising offices are located at 8669 NW 36 St.,
D. Peterson #130, Miami, FL 33166; telephone (305) 443-9353. Printed by LSC
Communications, Liberty, MO. Periodicals postage paid in Miami,
Fla., and additional mailing offices. POSTMASTER: Send address
changes to Inspection Trends c/o American Welding Society, 8669
NW 36 St., #130, Miami, FL 33166. Readers of Inspection Trends
may make copies of articles for personal, archival, educational, or
research purposes, and which are not for sale or resale. Permission

18
is granted to quote from articles, provided customary acknowledg-

Alternating Current Field Measurement ment of authors and sources is made. Starred (*) items excluded
from copyright.

Inspection of Storage Tanks AWS MISSION STATEMENT: The mission of the American Welding

How the Alternating Current Field Measurement (ACFM®)

Society is to advance the science, technology, and application of
welding and allied joining processes worldwide, including brazing,

technology can improve tank inspection efficiency soldering, and thermal spraying.

C. Tremblay

Cover credit: iStock.

12 18
 EDITORIAL

Dear Readers, PUBLISHER: Annette Alonso

[email protected]

Welcome to a new year of Inspection EDITOR: Carlos Guzman

Trends. If you are reading this on paper, [email protected]
you’ve realized Inspection Trends is now
published as part of the Welding Journal.
[ EDITORIAL ]
Facing the increasing costs of mailing,
printing, and paper because of world- MANAGING EDITOR: Kristin Campbell
wide supply shortages, we’ve decided [email protected]
not to keep printing Inspection Trends SENIOR EDITOR: Cindy Weihl
as a stand-alone magazine. However, [email protected]
the digital version will remain a stand-
BY CARLOS GUZMAN alone publication, and all AWS Certified
ASSOCIATE EDITOR: Katie Pacheco
Welding Inspectors (CWIs) and Senior [email protected]
CWIs will continue to receive Inspection ASSOCIATE EDITOR: Alexandra Quiñones
Trends in digital format. An upside of this new configuration is that all [email protected]
AWS members will now have access and be exposed to more welding EDUCATION EDITOR: Roline Pascal
inspection content. Furthermore, we are working on a new online format [email protected]
to deliver all AWS periodicals in a manner that will be easier to access
and read. Stay tuned.
[ DESIGN & PRODUCTION ]
On a separate note, I want to congratulate our long-time contributor,
Calvin E. Pepper, on receiving his CWI Lifetime Achievement Award at MANAGING EDITOR, DIGITAL & DESIGN:
FABTECH 2022 in Atlanta, Ga. (Read more about it in this issue’s News Carlos Guzman
Bulletin section.) Pepper has been a constant contributor to the Welding [email protected]
Journal and Inspection Trends for many years, and this well-deserved PRODUCTION MANAGER: Zaida Chavez
award reiterates his high level of expertise and professionalism as well [email protected]
as his commitment to AWS and giving back to the welding community.
ASSISTANT PRODUCTION MANAGER:
Additionally, we have more exciting news to share. After a long delay Brenda Flores
due to the pandemic, the Inspection Expo & Conference (IEC) will take [email protected]
place in Austin, Tex., on November 8–10. The IEC allows inspection
professionals to network with industry experts, attend expert panel
presentations and breakout sessions, and make connections that can [ ADVERTISING ]
boost their career and keep their inspection business on the cutting
MEDIA SALES EXECUTIVES:
edge while earning up to 22 professional development hours. Learn
about quality assurance/quality control roles, corrosion and inspection Lea Owen
plan development, remote inspections, documentation, auditing, steel [email protected]
structural bolting, and advanced ultrasonic testing, among other vital Scott Beller
topics. Visit aws.org/conferences for more information. [email protected]

SUBSCRIPTIONS REPRESENTATIVE:
Call for Volunteers Marandi Gills
[email protected]
The Certification Department is looking for volunteers to serve in the
AWS Qualification & Certification (QC) subcommittees. This is an oppor- AMERICAN WELDING SOCIETY
tunity for industry leaders and subject-matter experts to play an integral 8669 NW 36 St., #130, Miami, FL 33166-6672
role in the future of welding by providing knowledge and expertise to (800/305) 443-9353
AWS certification programs and other publications. Anyone with a range
of knowledge and experience in the welding industry is encouraged to COPYRIGHT
apply. As a QC subcommittee member, you will be able to review and con- Copyright © 2023 by American Welding Society in both printed and
electronic formats. The Society is not responsible for any statements
tribute to new standards and revisions of existing standards, be invited made or opinion expressed herein. Data and information developed
by the authors of specific articles are for informational purposes only
to join the QC committee biannual meetings, and network with leading and are not intended for use without independent, substantiating
experts in the industry. For more information and to apply, visit aws.org/ investigation on the part of potential users.

certification/page/certification-committees. IT AWS DIVERSITY, EQUITY, AND INCLUSION STATEMENT

AWS values diversity, advocates equitable and inclusive practices,
and engages its members and stakeholders in establishing a culture
CARLOS GUZMAN ([email protected]) is managing editor, digital and design, in the welding community that welcomes, learns from, and celebrates
differences among people. AWS recognizes that a commitment to
and editor of Inspection Trends and Welding Journal en Español. diversity, equity, and inclusion is essential to achieving excellence
for the Association, its members, and employees.

4 | INSPECTION TRENDS
 NEWS BULLETIN

Calvin E. Pepper Earns the CWI

Lifetime Achievement Award
Calvin E. Pepper received the AWS Certified Welding
Inspector (CWI) Lifetime Achievement Award at the AWS
103rd Annual Business Meeting during FABTECH, Atlanta, Ga.
He was inducted with a plaque and medallion.
Pepper was recognized for his work in promoting welding
inspection in the industrial sector as well as in education at
the secondary, technical college, and university level. He has
taught at many local colleges and universities and initiated
welding technology and inspection courses at each of the
institutions.
He developed a device for the inspection of flow restric-
tions in lead transfer pipelines for a tetraethyl lead process
unit at the ExxonMobil refinery in Baton Rouge, La.; expanded
underwater welding inspection techniques for underwater
pipelines used in offshore crude and gas gathering systems;
and formulated a technique for inspecting joints in fiber-
glass and solid polymer piping systems. He has also been
a consultant to the U.S. Department of Energy and various Calvin E. Pepper displayed his CWI Lifetime Achievement
energy companies for underwater welding and inspection Award at the AWS 103rd Annual Business Meeting.
techniques and procedures.
Additionally, Pepper has been a member of the AWS Qual-
ification and Certification Committee for 35 years, including
eight years as chair. He has also been a member of the Welding
Handbook Committee for 22 years, serving as committee and
chapter chair. He was an AWS director-at-large from 1996 to
1999 and currently serves as District 9 director. He has been
awarded two AWS Lifetime Memberships.

ASNT Announces Winners for First

UT Competition
The winner of the American Society for Nondestructive
Testing’s (ASNT’s) first Ultrasonic Testing (UT) Competition
was Aaron Guidry of Versa Integrity Group, Sulphur, La. He
took home the top prize of $500. Guidry is certified through
ASNT’s Industry Section Qualification for Oil & Gas (ISQ –
O&G) program in ultrasonic thickness testing and ultrasonic
shear wave testing. Tim Everhart of MISTRAS Group, Heath,
Ohio, placed second, winning a prize of $250.
The competition was held November 1, 2022, during ASNT
2022: The Annual Conference in the exhibit hall of the event.
Six Level II personnel from five different states and Peru had
30 minutes at each of five stations to standardize the equip-
ment, conduct the test, and evaluate the sample.
Each sample offered a different challenge for competi-
tors: carbon steel corrosion, carbon steel single-V plate weld,
carbon steel pipe weld, and carbon steel double-V plate as
well as a mystery sample in the shape of Texas. Naming each
sample after a different horror movie added to the fun of
the event.

FEBRUARY 2023 | 5
 program manager. “The competition was amazingly close,
and the entire group finished within ten points of each other.
If I were starting a UT department, I would hire all of them.”
­— Courtesy of ASNT.

InterTest and Cavitar Partner in Weld

Inspection Divisions
InterTest Inc., Columbia, N.J., a remote visual inspection
and nondestructive examination equipment provider, and
Cavitar Ltd., Tampere, Finland, a manufacturer of diode
laser illumination technology, are partnering to bolster
Six ASNT Level II personnel tried their hand at their weld-viewing technology divisions. The agreement
difficult corrosion and weld samples during ASNT’s will increase Cavitar Welding Camera production and bring
first UT Competition. Aaron Guidry (third from right) its technology to InterTest’s customer base of weld quality
and Tim Everhart (second from left) were declared assurance and inspection groups within North American
the winners. manufacturing, aerospace, and automotive industries.
“[Cavitar] technology, along with our distribution chan-
nels, experience, and support, will allow customers to view
The point system for scoring was based on the accuracy
more welding applications and increase their productivity by
of the flaw reporting, and the winner was determined by a
reducing manufacturing scrap and human risk,” said Thomas
group of ASNT Level III subject matter experts.
Daly, president and owner of InterTest.
“These six Level IIs were brave enough to try their hand at
The camera uses proprietary bandpass filtering and laser
some very difficult corrosion and weld samples supplied by
illumination, allowing users to see through the bright weld-
Materials Research & Technology,” said Brian Frye, ASNT ISQ
ing arc in real time. It produces a clear image of the welding
torch, weld pool, and base metals so operators can monitor,
record, and adjust their welding process from a distance,
reducing human safety risk and scrap on long automated
production runs.

EinSource Cofounder Receives

NDE Award
Ripi Singh, cofounder and chief innovation officer of
EinSource, Ellington, Conn., earned the American Society
for Nondestructive Testing (ASNT) Robert C. McMaster Gold
Medal Award for outstanding contributions to the nonde-
structive examination (NDE) profession. The award was
presented at the annual ASNT Conference, which was held
in Nashville, Tenn., October 31–November 3, 2022.
“I’m grateful to the ASNT for recognizing our efforts to
digitally transform the inspection industry,” Singh said. “And
I’m equally grateful to my partner and coauthor of the book
The World of NDE 4.0: Let the Journey Begin, Dr. Johannes
Vrana. The award could have gone to either of us. I happened
to be the fortunate one this year. I was happy to share the
credit with him in Nashville.”
Singh is a U.S. delegate to ISO 56000 on Innovation Man-
agement Guidance; chair of NDE 4.0 for ASNT; a member of
the Connecticut Academy of Science and Engineering; guest
editor for Springer on NDE 4.0; and a member of industrial
advisory boards at the University of New Haven, the Univer-
sity of Hartford, Tsinghua University, and the International
Association of Innovation Professionals. IT

6 | INSPECTION TRENDS
 PRODUCT & PRINT SHOWCASE

Portable Eddy Current Flaw Detector

Facilitates Standard and Complex
Inspections

scope when it is used in tight spaces. The sealed tip keeps out oil.
Channels on the oil-clearing tip adaptor use capillary action to draw
oil away from the lens, keeping images clear. The scope’s smooth,
oil-resistant coating provides for fast, simple cleaning. It’s designed
to meet IP65 standards and built to pass the U.S. Department of
Defense testing.
Evident
evidentscientific.com

Designed for use by nondestructive examination (NDE) profession-

als, the EddyView® II portable eddy current flaw detector recognizes
standard eddy current measurements and complex inspections,
including use of eddy current array probes up to 32 elements as
well as large-scale automated and robotic production applications.
It features an 8-in. touch screen display with gesture adjustments
for gain and rotation, drives conventional or array probes, an inde-
pendent channel that monitors probe-to-part coupling (lift-off),
and signal performance with very low signal-to-noise ratio. It also
includes multifrequency probe drive and signal mixing, digital con-
ductivity and nonconductive coating thickness, and compatibility
with the ECS-1S and JF-15 rotating bolt hole scanners. The unit can
be connected to the internet for remote diagnostics, calibration,
and exporting raw eddy current data for postprocessing flexibility.
For use in demanding and often dirty NDE environments, the flaw
detector’s rugged housing is designed to meet the standards of
an IP65 rating.
UniWest
uniwest.com

Compact Videoscope Designed for

Inspections in Tight Areas
The IPLEX™ G Lite-W videoscope lets users visually inspect inside
a wind turbine gearbox without disassembling it. Weighing 1.16 kg
(2.56 lb) with a scope diameter of 4 mm (0.157 in.), the instrument
is easy to carry to the top of wind tower nacelles, and its ergonomic
design enables users to control it while wearing gloves in tight con-
fines. The videoscope’s optics balance the need to view areas of the
wind turbine gearbox up close, spot defects in large spaces, and is
small enough to fit into the space between a turbine’s bearings.
The insertion tube’s durable articulation mechanism protects the

FEBRUARY 2023 | 7
 THE ANSWER IS
BY ALBERT J. MOORE JR.

Q I’ve been studying in

preparation for the
AWS Certified Welding
Inspector examination, and I
am struggling with the code.
I am having a difficult time
trying to find answers to the
practice questions. I feel like
I’m chasing my tail or trying
to run down a football that
bounces one way and then
another. Is there a secret or a
secret decoder ring needed to
decipher a code? Thanks for
any help you can offer.
Fig. 1 — Table 6.10 has been partially populated with the footnotes

A
highlighted to reduce the possibility of overlooking them. Make sure you
The first thing to recognize is the read the footnotes where they are listed.
code is not read like a novel or
epic poem, where you read from
the front to the back. Don’t try to mem- for the final destination and follow from In the D1.1 standard, there are two
orize the code. Rather, all codes and point to point until you get to where you starting points for the novice user:
standards follow the same basic rules. want to go. Using the standard is more the table of contents (TOC) and index.
The hard part for someone new using a like the map function on your cellphone. The TOC, located in the front, lists the
standard is figuring out the rules. To find your final destination, you input main subjects along with the main sub-
the address and the map leads you by clauses. The index is located in the back
Rule 1. The number one rule is this: providing the route from one point to of the code. In this case, start with the
The numbering system used follows a another in sequence. If you stray from TOC. There are 11 main clauses. Look
certain hierarchy. See below: the directions provided, the program at the question, and look for a clause
recalculates and redirects you back on that might include the information
1. Header the correct path. But that isn’t going to you are searching for. Our question is
1.1. Subclause is subordinate to 1 happen when you don’t follow the map about welder performance qualifica-
provided by the standard. tion. There is a clause listed in the TOC
1.2. Subclause is subordinate to 1
Rule 3. The code is used to find titled Qualification. It is Clause 6. That’s
1.2.1. Subclause is subordinate to 1.2
answers to specific questions. Learn where you begin your search to find an
1.2.2. Subclause is subordinate to 1.2
how the code or standard is organized. answer to the question.
1.2.2.1. Subclause is subordinate to 1.2.2
Let’s use a real-world example with Start with Clause 6 and continue on
1.2.2.2. Subclause is subordinate to 1.2.2
AWS D1.1/D1.1M:2020, Structural to subclause 6.1. The subclause shows
Welding Code — Steel. We need to know Clause 6 is divided into four parts: Part
Each subclause, subordinate to which welder performance test should A — General Requirements, Part B —
those before it, provides more-detailed be administered to the welder, and we Welding Procedure Specification (WPS)
information — either additional details, need to know some basic information Qualification, Part C — Performance
exceptions, or exemptions to the infor- to find a meaningful answer. First, the Qualification, and Part D — Requirements
mation contained in the clause higher welder will be depositing groove welds for CVN Toughness Testing.
in the hierarchy. Often, the subclause and fillet welds in a high-strength, low Back to the map analogy. You’re in
(lower in the hierarchy) will direct the alloy using the gas-shielded flux cored your driveway, and before you back
user to a clause in a different section of arc welding (FCAW-G) process. The into the street, you need to determine
the standard. The reference may be an thickness is unlimited, and the work whether to turn left or right or proceed
additional test, table, or figure. will be in all positions. The application straight back. You decide to turn right.
Rule 2. Another rule is that you use is nontubular structural shapes, e.g., not In our case, you are directed by Sub-
the code in a fashion similar to how you pipe (tubular). clause 6.1 to go to Part C — Performance
would use a map. With a map, you look

8 | INSPECTION TRENDS
 [ THE ANSWER IS ]

Fig. 2 — Table 6.10: The red text is the return address added by the reader to return to Clause 6.16.1 quickly
and easily.

Qualification. Parts A, B, and D don’t the welder takes a fillet weld test, the 6.16.2.1 addresses the qualified thick-
address welder performance testing, welder is limited to fillet welds. We con- ness range of the welder performance
so you don’t have to read them. clude that the welder should be tested qualification. Clause 6.16.2.1 directs
Once you get to Part C, the first sub- using a grooved plate assembly. the reader to Table 6.11. Write the for-
clause you will encounter is Clause 6.16 The next column to the right lists warding address for Table 6.11 (page
— General. Next we see Clause 6.16.1 the test positions. 1G is flat, 2G is hor- 156) in the margin adjacent to Clause
Production Welding Positions Qualified; izontal, 3G is vertical, and 4G is the 6.16.2.1. When you find Table 6.11, you
our question has included the require- overhead position. The alphanumeric will note the table header lists Clause
ment that the welder will be welding designations — 1G, 2G, 3G, and 4G — are 6.16.2.1. That notation tells the reader
in all positions. Then you’ll see Clause test positions. Production positions are where Table 6.11 was referenced. You
6.16.1.1. We know that the subclause is flat, horizontal, vertical, or overhead. can write a return address for Clause
subordinate to 6.16.1, and it is providing The welder can be tested in the 3G and 6.16.2.1 (page 132) in the margin adja-
more-detailed information on welding 4G positions to qualify the welder for cent to the table.
positions. Clause 6.16.1.1 will direct you all positions on structural shapes other From Table 6.11, if the thickness of the
to Table 6.10 — Fig. 1. than HSS. test plate is 1 in. or thicker, the qualified
The table is divided into four main col- This is probably a good time to men- thickness range is 1/8 in. to unlimited
umns; the far left is the weld type and tion forwarding and return addresses. If thickness. One must read all relevant
test positions. The three columns to the a clause includes a reference to another footnotes listed by the table or figure.
right list the product form and the posi- clause, table, or figure, it is good practice The only relevant footnote in Table 6.11
tions in which the production welds will to write the page where the reference appears to be footnote d. The footnote
be made. The product forms listed are is found. The page number is written in states the 1 in. or thicker test assembly
structural shapes (other than tubular, the margin next to the clause containing qualifies the welder to weld fillets and
pipe), and moving farther to the right, the reference. I call these notations in partial joint penetration (PJP) groove
the table addresses pipe and box tubes. the margin forwarding addresses. The welds of any size. What about footnotes
Pipe and box tubing are often referred table or the figure also includes a ref- a, b, and c? They are applicable when
to as hollow structural shapes (HSS). erence back to the clause that sent you evaluating the test assembly (i.e., visual
It is easy to overlook the footnotes, to that table or figure. The page number examination, using radiographic testing
so I highlight them or rewrite them in where the clause is located is written [RT] as an alternate to bend testing, and
large text. in the margin adjacent to the table or when side bends are substituted for face
the figure. I call this the return address and root bends). They are applicable to
The question stated groove welds and
— Fig. 2. Navigating the code is easier our question. From Table 6.11, Figs. 6.16,
fillets are to be welded in all positions on
and quicker when the user adds the for- 6.17, or 6.19 may be applicable. You must
nontubular connections, e.g., structural
warding and return address. now follow the map and see if one of
shapes other than hollow structural
You are not done yet. You now know the figures is germane to the question.
shapes (pipes and tubulars).
you can test the welder using a grooved Figure 6.16 is used for manual and semi-
The far-left column in the table lists automatic welding processes (welder
“plate.” This means the welder is tested plate assembly. But what are the details
of the test assembly? You need to go qualification), Fig. 6.17 is for mecha-
using a plate assembly rather than an nized or automatic welding (welding
assembly consisting of pipe or tube. The back to Clause 6.16.1.1 to resume your
reading. operator), and Fig. 6.19 is used for
table indicates that if a grooved plate welder qualification in the horizontal
is used, the welder is qualified for both You will stumble upon Clause 6.16.2,
(2G) test position. We now know that
grooves and fillets (see footnote g). If where the subject of the thickness of
the production weld is discussed. Clause

FEBRUARY 2023 | 9
 only Figs. 6.16 and 6.19 are applicable administer two plate tests that utilize the ground isn’t too far off. One must
to our question. groove welds. One test is in the hori- learn to follow the map provided by the
We also see from the figures that zontal position having the geometry code. Even when you get comfortable
Clause 6.21.1 may be applicable. A quick depicted in Fig. 6.19, and the second using the code, don’t try to skip a step.
look tells us that Clause 6.21.1 simply test is a groove weld in the overhead That clause you skip may contain some
reiterates which figures apply to the position with the geometry depicted important information. I hope this exer-
welder performance qualification. in Fig. 6.16. cise clears up some of the mystery of
Using the return address listed by To recap, you start with Clause 6, Part using the code to answer a question. No
Table 6.11, go back to Clause 6.16.2.1. C; go to Clause 6.16; then Clause 6.16.1; magic decoder ring is required. IT
You did write the return address in the then on to Clause 6.16.1.1; then proceed
to Table 6.10; then Figs. 6.16 and 6.19; The Society is not responsible for any statements
margin adjacent to Table 6.11, right? made or opinions expressed herein. Data and infor-
Continue reading the clauses and back to 6.16.1.1; then to Clause 6.16.2.1. mation developed by the authors are for specific
you will see that Clause 6.16.3 states The next couple of clauses, 6.16.3 informational purposes only and are not intended
a welder or welding operator may be and 6.17, have nothing to do with our for use without independent, substantiating inves-
question. tigation on the part of potential users.
qualified by welding a successful WPS
qualification test assembly within the The point-to-point map you followed
looks like the following: ALBERT J. MOORE JR. (amoore999
constraints of Table 6.10, thereby, meet- @comcast.net) is president and owner of
ing the conditions of Clauses 6.16.1 and NAVSEA Solutions/Marion Testing &
6.16.2. There’s nothing in the question Clause 6, Part C → 6.16 → 6.16.1 → Inspection, Burlington, Conn. He is an AWS
alluding to welding up a coupon to qual- 6.16.1.1 → Table 6.10 → Fig. 6.16 and 6.19 Senior Certified Welding Inspector, an NDT
ify the WPS, so this clause doesn’t apply. → 6.16.1.1 → 6.16.2.1 Examiner per NAVSEA TP271, and an ASNT
Continuing to read, you will come SNT-TC-1 Level III. He is also a member
across Clause 6.17, a clause that is of the AWS Qualification & Certification
You have all the information needed Committee and the B1 Committee on
addressing something not germane to to answer the original question. Methods of Inspection.
the question.
Your description that it feels like
I believe you have all the information you are chasing a football bouncing on
you need to test the welder. You will

10 | INSPECTION TRENDS
 INTERNATIONAL CWI
HIGHLIGHTING THE CAREERS OF CWIs WORLDWIDE

An Inspiring Story about Becoming a SCWI and

CWEng in Taiwan
After majoring in mathematics at Inspection Trends asked Chang
an American college, Michael Chang to elaborate more about his weld-
returned to Taiwan to work for his ing inspection career and his current
family business, Froch Enterprise Co. position:
Ltd., claimed to be the largest stain-
less tubing manufacturer in Taiwan. 1. Why did you decide to
Serving as a process engineer, he was become an AWS CWI in 2006
given the responsibility of overseeing and then a SCWI in 2014?
the automatic pipe manufacturing pro- When I joined Froch Enterprise, my
cess, including welding, inspection, and job was to help the factory in many
quality control. areas, including quality. Also, I was
To get ready for this job, Chang assigned to supervise the construction
started learning the gas tungsten and of new plants, which was usually related
gas metal arc welding processes from to various welding of steel structures. Michael Chang is an AWS SCWI and
the company’s senior welders and Consequently, I knew I needed more CWEng in Taiwan.
studying welding basics on his own than just experience and verbal lessons
during off-duty hours. After gaining from onsite workers. I turned to AWS
some experience, he enrolled in the the world’s leading brands in stainless
Taiwan to pursue my certification.
AWS Certified Welding Inspector (CWI) steel tubes and pipes with distribution
training courses in Taiwan and passed 2. What inspection processes in more than 130 countries. Welding a
the test, obtaining the credentials in do you use at Froch Enterprise? pipe is like making a piece of jewelry:
2006. Afterward, he was promoted to It requires knowledge, craftsman-
Various nondestructive examination ship, and mindfulness. Running such a
manager of the R&D department, where
methods, such as eddy current and radi- business requires not only the leader-
he was responsible for enhancing the
ography, are performed throughout the ship of professional management but
company’s welding technology and
inspection procedures. Understanding also unconditional devotion and per-
welder training program.
the theories and operations of differ- sistence. As a second-generation family
Chang continued his AWS certifi- ent tests allows us to deliver qualified member, I understand the importance
cation journey to become a Certified products to customers. of passing it on to the next generation.
Welding Engineer (CWEng) in 2013, and
It is our responsibility to make sure the
in 2014, he passed the Senior Certified 3. How has being an AWS CWI
legacy is inherited and continues for the
Welding Inspector (SCWI) test. He was and SCWI been beneficial to next 50 years and beyond.
promoted to the position of vice pres- your professional career?
ident in charge of the engineering and 5. What words of encourage-
With the SCWI credential, it is easier
manufacturing work in the company.
to communicate with colleagues, espe-
ment do you have for individuals
Becoming a CWI has turned Chang into in your country thinking about
a remarkable success in his profession cially those who have been welding for
a long time and are experienced. Being becoming an AWS CWI?
and a reputable leader in stainless steel
welding in Taiwan. a SCWI also allows me to give welders Back in school, I had studied business-
better guidance so they can improve related majors and hadn’t been in
Chang has served as vice chair of the
their skills, resulting in the entire pro- contact with welding before. Instead
AWS Taiwan Section for many years. He
duction team’s growth. of sitting in an office or working on Wall
is a strong and frequent advocate of the
AWS certification programs in Taiwan. 4. Why are you an advocate of Street, my first job after graduation was
operating a semiautomatic pipe weld-
He has been a frequent speaker on var- AWS certification programs in
ious occasions, inspiring the welding ing system. Without any knowledge of
Taiwan? welding, it took me quite some time to
interest of young professionals, using
his own experience as examples. In Froch Enterprise is a family-owned figure it out, but I’ve come so far, and
addition, he has co-sponsored many entity. It was founded by my father, now I’m a SCWI and CWEng. For those
AWS Taiwan Section activities, including Ping-Yao Chang, who built this com- who have just started welding, stay
meetings, conferences, and seminars. pany in a small workshop. In the last focused, be open-minded, and I believe
50 years, it has grown to be one of you will have better opportunities. IT

FEBRUARY 2023 | 11
 FEATURE

The Role of the CWI or SCWI in

Fracture Critical Applications

When identified in contract documents, the requirements

Fracture critical materials, welds, for inspection and testing of fracture critical materials and
and applications; related special welds may be significantly different from standard proce-
dures and production welds typically encountered by the
testing; and personnel qualification Certified Welding Inspector (CWI) or Senior Certified Welding
and certification are discussed Inspector (SCWI).
A fracture critical member (FCM) is defined within
BY CALVIN E. PEPPER, HANNAH J. WOLF, AND the American Association of State Highway and Trans-
ANTHONY D. BLAKENEY portation Officials (AASHTO)/AWS D1.5M/D1.5:2020,
Bridge Welding Code , sec tion 12 . A A SHTO/AWS
Fracture Control Plan (FCP) for Nonredundant Members, sub-
section 12.2, Definitions, states, “12.2.2 Fracture Critical
Member (FCM). AASHTO LRFD Bridge Design Specifications
define an FCM as a steel primary member or portion thereof
subject to tension whose failure would probably cause a por-
tion of or the entire bridge to collapse.”
For many certified inspectors, bridge welding was not a
part of their original career choice, and they prefer to work
with standard structural fabrication and erection described
in AWS D1.1/D1.1M:2020, Structural Welding Code — Steel,
or other industry standards for piping, equipment, or tanks.
However, recent initiatives by the U.S. Congress to improve
the nation’s infrastructure have placed inspectors from dif-

12 | INSPECTION TRENDS
ferent industries in positions where they need to become
familiar with the codes and other standards relating to
bridges.
This article is intended to identify and discuss the topics
related to fracture critical materials and welds during the
quality and inspection procedure development phase, as
follows:

The source and rationale for fracture critical

materials and welds

■ How does the inspector know that a procedure, materials,

and welds are fracture critical?
■ What codes and standards are used to govern fracture
critical?
■ What is the FCP?
■ What is the relationship between the inspector and the
engineer of record?

Special testing requirements for welding

procedure specifications (WPSs) used to produce
fracture critical welds There are more than 617,000 bridges across the
United States. Currently, 42% of all bridges are
at least 50 years old, and 46,154, or 7.5%, of the
■ Are prequalified welding procedure specifications nation’s bridges are considered in poor condition and
(PWPSs) allowed for fracture critical welds? structurally deficient. Every day, 178 million trips are
■ What welding processes are allowed? taken across these structurally deficient bridges. In
■ What materials are allowed? recent years, as the average age of America’s bridges
■ What special considerations are there for filler metals or has increased to 44 years, the number of structurally
base metals? deficient bridges has declined; however, the rate of
■ What is the reference for removal (location) of improvements has slowed. (Source: U.S. Department
supplemental Charpy V-Notch (CVN) test specimens? of Transportation, Federal Highway Administration,
InfoBridge™: Data: infobridge.fhwa.dot.gov/data/
dashboard.)
Personnel qualification and certification required
for fracture critical applications
Bridge Inspection Standards (NBIS), the Federal Highway
■ What are the personnel requirements within the Administration (FHWA) manuals, and AASHTO Bridge Design
governing documents? Specifications (LRFD) all have information the inspector will
■ Are specific CWI/SCWI endorsements required for need when going into a bridge project where the engineer
fracture critical? has identified a FCM. Furthermore, any company wishing to
perform construction or fabrication of bridges with FCMs
The inspector should note that the relevant section in must be certified under the American Institute of Steel Con-
D1.5M/D1.5 regarding the special requirements for FCM struction (AISC) Quality Certification Program, Category III,
is section 12, AASHTO/AWS Fracture Control Plan (FCP) Major Steel Bridges with Fracture Critical Rating.
for Nonredundant Members. This approach to identifying
fracture critical members and weldments focuses on the
requirement for an FCP, which will be used whenever the
Identifying the Presence of FCMs
engineer of record identifies structural members as fracture Identifying the presence of FCMs must begin during
critical. Bridge structures that do not contain fracture critical the prebid phase to alert all bidders of the need to include
members rely on the content of all sections of D1.5M/D1.5, requirements contained in section 12 of D1.5M/D1.5. This
except section 12. addition to the scope of the project has a significant impact on
In addition to AWS D1.5M/D1.5, standards such as the value of fabrication contracts. Additionally, the presence
AASHTO’s Manual for Bridge Evaluation (MBE), National of FCMs and fracture critical welds requires that the list of

FEBRUARY 2023 | 13
 A recent estimate of the nation’s backlog
of bridge repair needs is $125 billion. We
need to increase annual spending on bridge
rehabilitation from $14.4 billion to $22.7 are rarely manufactured, tested, and accompanied by this
billion, or by 58%, if we are to improve the level of documentation. Regardless of whether they’re from
conditions of bridges. At the current rate of a mill order or a smaller quantity, all base metal surfaces and
investment, it will take until 2071 to make all edges must be inspected for discontinuities upon arrival at
of the repairs that are currently necessary,
the fabricator or construction site.
and the additional deterioration over the next
50 years will become overwhelming. (Source:
U.S. Department of Transportation, Federal Welding Processes and Consumables
Highway Administration, InfoBridge™: Data:
infobridge.fhwa.dot.gov/data/dashboard.) According to subsection 12.5, Welding Processes, the fol-
lowing processes listed in 12.5.1 may be used to construct or
repair FCMs: shielded metal arc welding (SMAW), submerged
arc welding (SAW), flux cored arc welding (FCAW), and gas
metal arc welding (GMAW) with metal cored electrodes.
Conversely, in 12.5.2, Prohibited Processes and Procedure
Restrictions, electroslag welding (ESW) and electrogas weld-
ing (EGW) are prohibited for welding FCMs. When GMAW is
used (except as allowed in 12.5.1), qualification tests, pro-
cedure control, and nondestructive examination (NDE) shall
be as specified by the engineer. Subsection 12.5.3, Preferred
contractors be restricted to those with specific experience Processes and Procedures, further stipulates that the engi-
in fabricating steel with FCMs, as defined by the engineer. neer may designate specific processes or process controls for
specific bridge welds. All special provisions shall be specified
The FCP referenced earlier contains the requirements of
in the contract documents. Other restrictions, if any, on the
section 12 of AASHTO/AWS D1.5M/D1.5 and those additional
use of welding processes or procedures shall be described
requirements specified by the engineer of record. The FCP
in the contract documents.
is a document clearly spelling out for both production and
quality personnel the requirements that will apply to that Prequalified Welding Procedures are allowed to be used
specific project and that have been reviewed and approved for welds in FCMs but only for SMAW using E7016, E7018,
by the engineer. Because different engineers of record may E7018-1, and E8018-X electrodes, including those with the C
supplement Section 12 differently, it should be expected that alloy and M classification as well as the R supplemental des-
some differences will occur between projects. The inspector ignator. All other groove weld WPSs using approved welding
must be familiar with the requirements of the FCP as it applies processes (SAW, FCAW, and GMAW) require testing — includ-
to the project at hand. ing CVN — to have been generated within a year of the start
of production welding of FCMs.
FCMs require mill orders of base metals to be manu-
factured of killed carbon steel and fine-grain base metals Filler metals and fluxes used in FCMs, except for SMAW
normalized, quenched, and tempered as specified with electrodes, are required to be tested and documented for
accompanying CVN results at the temperature specified by diffusible hydrogen to meet optional designator H4, H8, or
the engineer, all of which must be included in the contract H16 (for ≤ 50 ksi – 345 MPa) or designator H4 or H8 (for ≥
documents. These requirements are typically specified for 50 ksi – 345 MPa). Handling, storage, and drying of filler
orders for structural shapes large enough to consume an metals generally follow the manufacturer’s recommenda-
entire heat (ladle) at a steel mill, finished and tested to the tions; however, these may be modified by the engineer.
buyer’s specifications, and used to fill only that order. Find- According to 6.1.3.2, Heat or Lot Testing, all welding con-
ing small quantities or partial heats meeting these special sumables shall be heat or lot tested by the manufacturer
requirements and documentation would be very difficult for to determine conformance with the applicable AWS A5.XX
purchasing and inspection, as noncritical structural shapes specification. The engineer must also be given certified copies
of the test results. The heat and lot information shall be as
defined in the latest edition of AWS A5.01, Welding and Braz-
ing Consumables — Procurement of Filler Metals and Fluxes.
Recent events have placed The consumables shall also be tested by welding as specified
inspectors from other industries in the appropriate AWS filler metal specifications. All tests
required by AWS A5.01, Schedule J, shall be performed and
in positions where they need to reported. Also specified by 6.1.3.2, materials of the same
become familiar with the codes and specification, classification, brand, product trade name, and
other standards relating to bridges. manufacturer (but not necessarily the same heat or lot) to

14 | INSPECTION TRENDS
be combined during production welding shall be used for
heat and lot testing.
Additional consumable requirements are given in 6.1.3.1,
Consumable Manufacturer Quality Assurance Program, which
states: “Welding consumables shall be produced under con-
tinuing quality assurance programs audited and approved by
one or more of the following agencies: (1) American Bureau
of Shipping (ABS), (2) Lloyd’s Register of Shipping, and (3)
American Society of Mechanical Engineers (ASME).”

Examination and Quality

Quality functions are shared by the engineer and the con-
tractor’s or fabricator’s inspector. The engineer is responsible
for quality assurance (QA), and the inspector is responsible
for quality control (QC). The engineer may contract for QA
surveillance and audits; however, the final responsibility for
the quality of the finished product rests with the contractor AWS D1.5M/D1.5 covers the welding
or fabricator. The FCP includes a designation for lead inspec- requirements for welded bridges made from
tors, who are required to have a minimum of three years of carbon and alloy construction steels and
experience specifically in steel bridge construction or fab- designed to AASHTO or American Railway
rication in addition to being a current or former AWS CWI, Engineering and Maintenance-of-Way
Association (AREMA) requirements.
or an engineer or technician acceptable to the engineer of
record (AWS D1.5M/D1.5, sections 8.1.3, Inspection Personnel
Qualification, and 12.16.1.1, Inspectors). This lead inspector
has the final determination for the acceptability of FCMs and
welds associated with FCMs.
AASHTO/AWS D1.5M/D1.5 and the NBIS for a thorough under-
The lead inspector must ensure that any NDE technicians
standing of the requirements for materials, procedures, as
assigned to test FCMs are currently certified Level II or III in
well as the roles and responsibilities of all personnel involved
the appropriate method per the American Society for Nonde-
in bridge design, fabrication, and construction.
structive Testing (ASNT) Recommended Practice SNT-TC-1A.
The engineer may accept alternative qualifications for NDE For new applicants to the AWS CWI program, we highly
personnel that are deemed equivalent. recommend certification with AASHTO/AWS D1.5M/D1.5
(current edition) as the code of choice. IT
One of the many unique requirements contained within
section 8 of AWS D1.5M/D1.5 is that radiographic examination
of welds in FCMs must use hole-type penetrameter (IQI) to
capture the quality-level hole size specified in the contract.
Wire-type IQI is not allowed for this application. This, and
many more such special requirements, is found throughout CALVIN E. PEPPER ([email protected]) is an AWS
section 8 and explains the challenges to inspectors ensuring CWI (past SCWI), ASNT VT Level II, CQA (ASQ), MS nuclear
that all requirements are met every time FCMs are identified. engineer, and Certified Galvanizing Inspector (AGA). He serves
on the AWS Q&C and Welding Handbook Committees, is an
AWS Life Member, is District 9 Director, and a CWI Lifetime
Conclusion Achievement Award recipient.
Even with a high-level review of requirements outlined in HANNAH J. WOLF ([email protected]) was a 2020
section 12 of AASHTO/AWS D1.5M/D1.5, inspectors seeking AWS Future Leader. She has spent the past five years teaching
to expand their work experience into infrastructure — the next generation of welders at the technical college level.
specifically bridge construction and fabrication — will be
faced with a large volume of knowledge to master. The three- ANTHONY D. BLAKENEY ([email protected]) is an AWS
year experience requirement for a lead inspector can be met CWI and CWE, a CSIT, and an instructor of Industrial Technol-
by working on bridge fabrication under the supervision of ogy at Southeastern Louisiana University. He serves on the
a lead inspector. Once the experience requirement is met Welding Handbook Volume 2, Chapter 1, Committee and has
held positions with District 9, including Baton Rouge secretary,
and documented by the employer, the inspector can then
second vice chair, first vice chair, Student Section advisor, and
consider a lead inspector role. is the second vice chair of the New Orleans Section. He is an
For current CWIs interested in bridge inspection, the AWS Silver Member and was a 2019 AWS Counselor.
authors recommend a code review course focusing on

FEBRUARY 2023 | 15
 FEATURE

Quality Assurance vs.

Quality Control
Quality assurance (QA) and quality control (QC) are often
The differences and similarities considered the same; however, they are distinctly different,
between these two terms are and the inspectors performing these functions usually have
different duties and responsibilities.
explained
Definitions
BY DARYL PETERSON
QA provides general guidelines used in the comprehen-
sive quality system. The core of QA is to provide confidence
that the quality requirements will be fulfilled. Verification is
the main focus of QA and is typically accomplished through
auditing. The extent of auditing may be defined for the proj-
ect or may be at the QA inspector’s discretion. When the QA
inspector’s audit finds systemic discrepancies, expanding
the score of the audit would be appropriate. The focus of
QA is to ensure the QC functions are correctly carried out.
QC is specifically related to products or services. QC is
focused on fulfilling the contract-specified quality require-
ments and is primarily accomplished through inspections.

16 | INSPECTION TRENDS
QA and QC in Welding At the owner’s discretion, QA functions may be delegated
to the contractor; however, this may be construed as the fox
How are QA and QC explicitly related to the welding indus- guarding the hen house. This option is better reserved for
try, and who is typically responsible for these roles? AWS contractors with an excellent reputation for quality and with
D1.1:2020, Structural Welding Code — Steel, uses the terms a robust quality system, such as the AWS Certified Welding
contractor’s inspection and verification inspection in Clauses Fabricator (CWF), ISO 9000, and others. Contractors with
8.1.2.1 and 8.1.2.2. certified quality systems are audited by the certification body
The contractor’s inspection is the inspection and testing periodically to ensure there is evidence the contractor is
that shall be performed before assembly, during assembly performing the quality duties in accordance with their doc-
and welding, and after welding to ensure the materials and umented quality system. Typically, the owner’s organization
workmanship meet the requirements of the contract docu- would audit the contractor’s quality system and approve them
ments. Fabrication and erection inspection and testing shall as an approved supplier. This approval may justify delegating
be the responsibility of the contractor unless otherwise spec- some or all the QA functions to the contractor.
ified in the contract documents. As stated in Clause 8.1.2.1,
these are the actual product inspections (i.e., dimensions and Welded Products
weld quality), and these are the contractor’s responsibility
and generally are delegated to the contractor’s inspector. Concerning welded products, QA and QC inspectors typ-
In addition, the contractor must perform welding procedure ically play different roles and have different responsibilities.
specifications (WPSs) and welder qualifications. These duties For instance, a QC inspector (who works for the contractor)
are often delegated to the contractor’s inspector as well. is generally considered highly knowledgeable in welding
and is perhaps an AWS Certified Welding Inspector (CWI).
In addition to the typical inspection duties, the contractor’s
Verification Inspection inspector (QC) may be tasked with directing the contractor’s
The verification inspection is a type of inspection and test- welders on quality and welding matters. This same activity
ing performed in which the results are promptly reported to would be wholly inappropriate for an owner’s inspector (QA).
the owner and contractor to avoid delays in the work. Typical The owner’s inspector’s responsibility is to promptly report
verification inspection (think of auditing for this function) observations (both acceptable and not acceptable) to the
elements are as follows: owner and the contractor’s management or supervision.
This means a QA inspector may bring concerns to the weld-
■ Review of the contractor’s WPSs for suitability for the er’s supervision, thus allowing the contractor to initiate the
work to be performed;
appropriate corrections. In either case, the personality of
■ Review of the contractor’s welder performance the inspector (either QA or QC) plays a key role in the quality
qualification records (WPQRs), or perhaps even witness the
welder’s qualifications demonstrations; system.
■ Review of the material test reports (MTRs);
■ Corroboration that the inspection and test plans (ITPs) or Communication is Vital
travelers are updated and current; and
■ Verification that the nondestructive examination (NDE) The quality professional (QA or QC) must be an excellent
reports and personnel certifications, as well as other communicator. They must be able to speak and understand
quality-related items required by the contract, are properly engineering and welder slang, and they must strive to develop
documented. a professional relationship with all parties concerned. Having
This auditing intends to ensure that the QC functions have worked in both the QA and QC roles, I like them equally. They
been adequately performed and the contractor’s quality both have their unique challenges and rewards. Both roles
system is functioning correctly. The intent is basically to “QC” are grounded in helping to ensure the customer receives the
the QC; however, QA functions do not necessarily exclude the highest quality products and services within or exceeding
QA inspector from verifying some or all of the QC’s respon- the contract requirements. IT
sible inspections.
The extent of actual product inspection may be specified DARYL PETERSON ([email protected]) is quality
manager at Central Maintenance and Welding, Lithia, Fla. He’s
in the contract — in the QA inspector’s work contract — or
an AWS SCWI, ASNT Level III, API 653, and SSPC PCI Level II
may be determined as necessary whenever there is reason inspector.
to question the credibility of the contractor’s inspections.
This function is typically performed by the owner’s QA or
contracted third-party inspector.

FEBRUARY 2023 | 17
 FEATURE
BY CHARLES TREMBLAY

Alternating Current
Field Measurement
Inspection of
STORAGE TANKS
How the Alternating Current Field Measurement (ACFM®) technology
can improve tank inspection efficiency

Storage tanks commonly found in the oil, gas, and pet- through coatings; however, extensive surface cleaning and
rochemical sector are typically constructed from welded removal of any protective epoxy coating can be required to
steel plates. While the primary failure point in storage tanks provide reliable results. When considering post-inspection
is corrosion in the floor plates, inspecting welds for defects cleaning and recoating, MT can be quite expensive and time-
is also critical and mandatory. Detection of through-wall consuming. Alternating Current Field Measurement (ACFM®)
defects at the welds is usually carried out using vacuum can be a cost-efficient and reliable method for inspecting
box technology, although this can be difficult to deploy storage tank welds to supplement corrosion mapping, and
at complicated lap welds or near obstructions. The tradi- successfully detecting cracks with fast scans on coated,
tional technology for inspecting welds for non-through-wall unprepared surfaces.
defects is magnetic particle testing (MT), which is said to work

18 | INSPECTION TRENDS
What is ACFM? as underwater or rope-accessed areas. The birth of ACFM also
created opportunities for better inspections in other appli-
cations, such as fatigue cracking around steel bridge welds,
ACFM is a nondestructive examination (NDE) technology
infrastructure inspections, and storage tanks, to name a few.
developed in response to a specific problem affecting the
structural integrity of industry’s critical assets. It was initially
developed in the 1990s at the University College of London How Does ACFM Work?
(UCL) in response to major oil companies having experienced
fatigue cracking of their offshore structures during the 1980s.
The basis of the ACFM technique lies in the electromagnetic
The NDE options at the time were inefficient and unreliable
induction principle, which states that passing an alternat-
for the task.
ing current in a coil generates a magnetic field around it. In
ACFM enabled fast detection and sizing of surface-break- ACFM probes, the field inducer coil is driven with a constant
ing cracks on complex welded geometries without removing alternating current source and sits relatively high above the
coatings. It proved forgiving enough to provide reliable inspection surface — Fig. 1. It’s designed to generate uniform
inspections even in the most challenging conditions, such fields in the inspection target just below the sensors.

Fig. 1 — The field inducer and the uniform fields generated in the target.

A B

Fig. 2 — Illustration of the interaction between a crack and the induced eddy currents.

FEBRUARY 2023 | 19
 Fig. 3 — The butterfly shape is a combination of the Bx and Bz signals, which provide simple and clear
information that enables efficient and reliable analysis to discriminate between cracks and other features.

Fig. 4A — Newer ACFM probes feature increased crack

detection and sizing performance using micro sensors
A
instead of mini sensors; B — ACFM instruments enable
rapid scanning with the handheld probe, reliable crack
detection and characterization, reduced cleaning
requirements, and a digital data record for backup,
offline, and audit purposes.

20 | INSPECTION TRENDS
 When scanning the probe over a crack, induced eddy cur- eral millimeters of nonconductive coating. This is a crucial
rents are forced to flow under the crack and around it — Fig. advantage because the costs associated with paint removal,
2. Those disturbances will, in turn, distort the fields above post-MT reblasting, and recoating are typically four or five
the crack where two coils are located. The Bx coil, shown in times more expensive than MT.
red in Fig. 2A, is sensitive to field distortions caused by eddy While the primary failure point in storage tanks is corro-
currents flowing under a crack. It generally results in a single sion in the floor plates, from either the top surface or the
half-sine signal, where the amplitude is proportional to the underside, the welded sections are also a direct source of
crack depth. This is the Bx signal. The Bz coil, shown in green damage mechanisms.
in Fig. 2B, is sensitive to field distortions caused by eddy Tank floor weld inspection can be carried out using stan-
currents curving around the edges of a crack. It generally dard, general purpose, single-sensor probes, or inspection
results in a single sinusoidal signal, where peaks correspond can be sped up using advanced multisensor array probes.
closely to the crack edges. Standard weld or pencil probes can assess all anticipated
The crack length and depth sizing capability of ACFM relies geometries, but overall inspection speed can be improved
on a simultaneous comparison of the Bz and Bx signals with using array probes, where possible.
a mathematical model of the interaction between a crack Compared to MT, standard ACFM inspection with pencil
and the electromagnetic fields. probes is approximately 25% faster and 20% cheaper. For
ACFM doesn’t rely on on-site calibrations for crack sizing. example, if we consider the inspection of both the exter-
Factory calibrations are preloaded into each probe head. Most nal and internal floor-to-shell fillet welds of a 60-m (197-ft)
inspections are made using a carbon steel calibration on a 5 storage tank, the MT fees for blasting, inspecting, reblasting,
kHz probe, but austenitic alloy calibrations are also available and recoating have a median international cost of around
on 50-kHz probes. A calibration remains valid whether a $15,000. The same inspection performed using pencil ACFM
probe is connected to the instrument through a 5, 20, or probes costs about $2500. While the MT takes about four
50 m (16.4, 65.6, or 164 ft) cable. Sizing is possible through to six days for the necessary preparation and post-inspec-
up to 4-mm nonconductive coatings using generic probes. tion work, standard ACFM is typically done in a day. This is
An essential element of ACFM is the butterfly plot, which achieved while providing better Probability of Detection
is obtained by combining the Bx and Bz signals — Fig. 3. The (PoD), depth sizing, and auditable records.
butterfly plot provides a recognizable butterfly shaped signal ACFM’s cost and productivity advantages can be further
unique to cracks, which helps differentiate crack signals from increased by using more-advanced array probes for the fillet
other signals, contributing to the ease of crack detection. weld. These new probes include a clever new way to estimate
Crack detection is generally possible through up to 10-mm crack lengths that improve analysis speed and do not use
(0.4-in.) coatings using generic probes. moving parts.
The same ACFM coil arrangement can be used in various Floor and shell joints, including lap joints, can be assessed
probe geometries to cover most applications and is designed using the high-speed ACFM array probe, which can further
to provide a good balance between noise immunity and cut costs compared to MT — Fig. 4A. While retaining all the
sensitivity to cracks for most welded structure inspections. advantages of ACFM, these probes also feature increased
The simplest single-element probe covers 15 mm (0.6 in.) crack detection and sizing performance using micro sen-
wide in a single pass, and the latest-generation electronics sors instead of the usual mini sensors. The array probe can
enable fast scans while maintaining a good signal-to-noise scan areas up to 90 mm (3.5 in.) wide, utilizing twin-field
ratio (SNR). This makes even the simplest single-element technology for biaxial crack detection and sizing with up to
probes quite productive, as most welds can be covered in 16 individually sprung ACFM sensors. This is less fatiguing
three detection scans. Detection scans count for most of on operators, which translates into highly productive, more
the time spent running an ACFM inspection. ACFM sensors reliable inspections. The array probe also has an embedded
can be assembled in multielement probes to enable wider position encoder to record defect locations and regulate data
scans for more coverage and faster inspections. collection automatically. A single pass scan provides a clear
view of the weld cap, toes, and heat-affected zone (HAZ) with
Storage Tank Welding Inspection rich information, including crack length and depth.
Modern ACFM instrumentation adds fast electronics, pro-
viding clear, high SNR signals even at high scanning speeds.
ACFM was specifically developed to detect and size surface- State-of-the-art software and displays show clear signal
breaking defects on and around rough welds through sev- representation and auditable records — Fig. 4B.

FEBRUARY 2023 | 21
 Fig. 5 — The ACFM fillet weld array probe.

Fillet Weld Inspection It uses two additional Bz coils per sensor for which the relative
distances are known. A sizing scan performed at a reasonably
The latest ACFM technology for floor-to-wall fillet weld constant speed will provide three Bz traces from which time
inspection includes multiple-element probes and the 3BZ measurements will be taken. Combining the known distances
method. These array probes enable single-pass detection and between the Bz coils and the time measured on the Bz signals
sizing of cracks in fillet welds without using an encoder. Their provides an estimation of the average scanning speed. The
rugged monoblock design with no moving parts makes them average scanning speed and the time elapsed between the
suitable for difficult (and dirty) inspection environments, through and the peak of a Bz trace are then used to estimate
such as tanks — Fig. 5. the crack length and depth.
The 3BZ method (Fig. 6) enables crack length and depth
sizing without encoders or marking surfaces, which is an
appreciable advantage in such difficult inspection conditions.
Conclusion
Although ACFM is based on the same basic physics prin-
ciples as several other NDE techniques, it applies them in
a unique way most adapted to the challenges of structural
weld inspection. Among other characteristics, the uniform
fields, the butterfly, and the sizing have been accepted for
weld inspection by major organizations in the oil and gas,
petrochemical, nuclear, and aerospace industries.
ACFM has received approval from several organizations,
such as Det Norske Veritas (DNV), Bureau Veritas, Lloyd’s Reg-
ister, and the American Bureau of Shipping (ABS). Standard
practice guidelines covering ACFM include American Society
for Nondestructive Testing (ASNT) E2261/E2261M-17, Stan-
dard Practice for Examination of Welds Using the Alternating
Current Field Measurement Technique, American Society of
Mechanical Engineers (ASME) Boiler and Pressure Vessel
Code (BPVC) Section V, Nondestructive Examination, and
the French Confederation for Non-destructive Testing (COF-
REND). Training schemes are available under the Certification
Scheme for Personnel (CSWIP), Personnel Certification in
Non-Destructive Testing (PCN), and ASNT. IT

CHARLES TREMBLAY ([email protected]) is product man-

ager, PEC & ACFM®, at Eddyfi Technologies, Quebec, Canada.
Fig. 6 — The 3BZ method.

22 | INSPECTION TRENDS
 CLASSIFIEDS / ADVERTISER INDEX

ASNT 23
asntcertification.org (800) 222-2768

California Welding Institute 10

socalwelding.com (951) 536-3809

Fischer Technology 6
fischer-technology.com (860) 683-0781

Orange County Inspections 7

[email protected] Email contact only

Certification QuikCheck Sonaspection 5

sonaspection.com (704) 262-3384
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FEBRUARY 2023 | 23
Rapid Publication of Cutting-Edge
Welding Research — WJRS Letters
Dear Researchers,

The Welding Journal Research Supplement (WJRS) is seeking manuscripts for rapid
publication of emerging research that is cutting edge and novel. The manuscripts are
relatively short in length and will be called WJRS Letters. They are aimed at allowing authors
to quickly publish new research results on “hot” topic areas of interest to the WJRS.
Editor approval is required for submission of WJRS Letters manuscripts. If you are
interested, please submit an abstract summarizing your proposed manuscript. WJRS
Letters are not intended to be data dumps or options for publications of low-quality
research. Abstracts that do not describe new, cutting-edge research will be declined. If
your abstract is accepted, you’ll be invited to submit a manuscript. Below are more details.

(1) First, provide an abstract < 500 words, which includes author names, emails, and
affiliations, to [email protected]. Note: It was recently discovered that this email was not work-
ing, but it’s been fixed.
A single figure (not multipart) with a caption can also be provided with
the abstract. Complete manuscripts submitted without approval will be
declined immediately. Do not submit abstracts or manuscripts to the WJRS
submission website.

(2) If your abstract is accepted, you’ll be invited to write a manuscript of not more than
2000 words with three to four figures (with captions). All content must fit into five pages
when laid out in the current WJRS format reflected in the template. Also, you will receive
a template for your Letters after abstract approval. Manuscript content must fit into the
template without format changes to be published.

(3) Manuscripts will require succinct and focused communication in the following sections:

• Introduction/Background/Objectives
• Streamlined Procedures
• Results
• Substantive Discussion
• Major Conclusions
• Limited References

If you have questions, please email [email protected]. Thank you for supporting this effort.

Sincerely,

Thomas J. Lienert, PhD, FASM, FAWS

Review Editor