Out in the field, inspection crews often need to identify the seam welds used in pipeline fabrication to improve the accuracy of their structural integrity assessments. However, challenges may arise if unreliable tools are utilized during this process. If a weld is initially misidentified and non-destructive evaluation (NDE) proceeds, the resulting data could be severely skewed, leading to pipeline safety concerns or de-rating.
By Matthew Prozesky, Software Engineer
The Seam ID accessory for the PLX-Portable has been engineered to provide users with fast and accurate weld characterization data. This process has four key features:
Pipe prep to results in 30 minutes
Designed to be as quick and intuitive as possible, the Seam ID software walks users through a step-by-step workflow that takes no more than 30 minutes to complete. For easily identifiable welds such as flash welds, submerged arc welds (SAW), and lap welds, the software requires a photograph to be uploaded, after which the user can proceed with material verification using the PLX-Portable.
Electric Resistance Welds (ERW) require further surface preparation. If the presence of an ERW weld is suspected, users are guided through the preparation and etching process.
Once testing is complete, definitive seam type data is delivered immediately at the test site. The final report contains a clear and ranked probability of weld type (Figure 1).
One-day user training
Efficiency is a theme that's factored into every part of the Seam ID offering, including training. To enable fast crew mobilization, techs can be trained to become Certified Users in just one day. This hands-on training program ensures technicians leave the course confident and ready to deploy Seam ID in the field. Through a combination of practical and theoretical teaching, users learn how to properly prepare the surface of a weld, as well as key characteristics to look out for when identifying weld type.
The in-person training is supplemented by reminders and on-demand refresher videos embedded within the Seam ID software. This information is accessible without an internet connection, meaning crews won’t have to worry about unplanned downtime at the dig site if questions arise.
No mechanical interrogation
Because the system is intended for use on live pipe, the Seam ID testing process was designed with pipeline safety as the top priority. From inception, our team worked to avoid any disturbance of the seam. As a result, the process does not require indentation or scratching of the weld, avoiding any risk associated with mechanical interrogation.
Instead, the software guides users through surface preparation and etching, which uncovers key visual characteristics of the weld, including electrode marks, heat affected zones, and bond lines (Figure 3). These visual cues are then photographed and uploaded into the Seam ID software, where the images are stored as part of the job record.
By collecting numerous data points, the Seam ID software provides clear and conclusive weld identification every time.
Smaller prepared area, less room for error
Rather than a one-size-fits-all approach, the Seam ID process instead prompts users to prepare the minimum area required per pipe diameter. This size-dependent method of surface area preparation further streamlines the weld classification process, saving in-field technicians valuable time.
Further, the relatively small size of prepped area required by the Seam ID process reduces the risk of irregular surface preparation caused by such factors as technician variability. This, in turn, contributes to the accurate and repeatable results provided by the software.
Conclusion
Throughout the development of the Seam ID system, our team always referred back to three guiding principles: speed, accuracy, and safety.
From one-day Certified User training to immediate in-ditch results in just 30 minutes, the system is designed to make the testing process fast and intuitive. The guided software and minimal surface preparation requirements help to ensure that each weld identification is as accurate as possible, providing inspection crews and pipeline operators with peace of mind. Critical seam data is collected without indenting or scratching the welds, reducing safety risks associated with mechanical interrogation and contributing to the ongoing integrity of pipelines.
Every feature of Seam ID has been shaped around the realities of pipeline inspection work. By delivering dependable seam identification directly at the dig site, Seam ID helps operators safeguard data quality, streamline inspections, and maintain the integrity of critical pipeline assets.
