Non-Destructive Testing (NDT) Procedure

1. Radiographic Testing – 10% of total welds

a) T-Joints
b) Horizontal Welds
c) Vertical Welds

Radiographic Testing or RT is a non-destructive test that uses x-rays and gamma-

rays to produce a radiograph of the test specimen that shows changes in thickness,
defects or flaws, and assembly details to ensure optimum quality. Radiographic
Examination is required for shell butt welds, annular- plate butt-welds and flush-type
connection with butt welds. Radiographic examination is not required for the following:
roof-plate welds, bottom-plate welds, welds joining the top angle to either the roof or shell,
welds joining the shell plate to the bottom plate, welds in nozzle and manway necks made
from plate, or appurtenance welds to the tank.

Radiographic Testing Procedure:

1. Surface Preparation: Surface irregularities must be removed so that they
cannot mask or confuse the image as defect. The finished surface of all
butt welded joints should be flushed with the base material.
2. Selecting the right radiation source and radiographic film: Depending on
radiographic sensitivity and material thickness radiation source (x-ray or
gamma-ray) must be decided. Fine grain high-definition radiographic
films can be used.
3. Selection of Penetrameter: As per SE 142 or SE 1025 (for whole type)
and SE-747 (for wire type), ASME V & ASME Sec VIII Div I, whole type
or wire type penetrameter need to be selected.
4. Radiographic testing technique: Single or Double wall exposure
technique is used. Source to object and object to source distance must
be established beforehand.
5. Defect inspection and removal: The radiograph to be studied for
probable defects and repaired if defect is observed.
6. Recording: All data need to be properly recorded.
 Sample Radiographic Testing Procedure

Radiographic Test Requirement for Vertical Weld:

a. For butt-welded joints in which the thinner shell plate is less than or equal to 10
mm (3/8 in.) thick, one spot radiograph shall be taken in the first 3 m (10 ft) of
completed vertical joint of each type and thickness welded by each welder or
welding operator. The spot radiographs taken in the vertical joints of the lowest
course may be used to meet the requirements of Note 3 in Figure 1 for
individual joints. Thereafter, without regard to the number of welders or welding
operators, one additional spot radiograph shall be taken in each additional 30
m (100 ft) (approximately) and any remaining major fraction of vertical joint of
the same type and thickness. At least 25 % of the selected spots shall be at
junctions of vertical and horizontal joints, with a minimum of two such
intersections per tank. In addition to the foregoing requirements, one random
spot radiograph shall be taken in each vertical joint in the lowest course (see
the top panel of Figure 1).
b. For butt-welded joints in which the thinner shell plate is greater than 10 mm
(3/8 in.) but less than or equal to 25 mm (1 in.) in thickness, spot radiographs
shall be taken according to Item a. In addition, all junctions of vertical and
horizontal joints in plates in this thickness range shall be radiographed; each
film shall clearly show not less than 75 mm (3 in.) of vertical weld and 50 mm
(2 in.) of weld length on each side of the vertical intersection. In the lowest
course, two spot radiographs shall be taken in each vertical joint: one of the
radiographs shall be as close to the bottom as is practicable, and the other shall
be taken at random (see the center panel of Figure 1).
c. The butt-weld around the periphery of an insert plate that extends less than the
adjacent shell course height and that contains shell openings (i.e. nozzle,
manway, flush-type cleanout, flush type shell-connection) and their reinforcing
elements shall be completely radiographed.
 d. The butt-weld around the periphery of an insert plate which extends to match
the adjacent shell course height shall have the vertical and the horizontal butt
joints and the intersections of vertical and horizontal weld joints radiographed
using the same rules that apply to the weld joints in adjacent shell plates in the
same shell course.

Radiographic Test Requirement for Horizontal Weld:

One spot radiograph shall be taken in the first 3 m (10 ft) of completed horizontal
butt joint of the same type and thickness (based on the thickness of the thinner plate at
the joint) without regard to the number of welders or welding operators. Thereafter, one
radiograph shall be taken in each additional 60 m (200 ft) (approximately) and any
remaining major fraction of horizontal joint of the same type and thickness. These
radiographs are in addition to the radiographs of junctions of vertical joints

Figure 1. Radiographic Requirements for Tank Shells

 Notes on the Figure:
Therefore,
1) Vertical spot radiograph must be in accordance with Item a: one in the first 3 m (10
ft) and one in each 30 m (100 ft) thereafter, 25 % of which shall be at intersections.
2) Horizontal spot radiograph must be: one in the first 3 m (10 ft) and one in each 60
m (200 ft) thereafter.
3) Vertical spot radiograph in each vertical seam in the lowest course. Spot
radiographs that satisfy the requirements of Note 1 for the lowest course may be
used to satisfy this requirement.
4) Spot radiographs of all intersections over 10 mm (3/8 in.)
5) Spot radiograph of bottom of each vertical seam in lowest shell course over 10 mm
(3/8 in.)
 2. Magnetic Particle Inspection (MPI) – 100%
a) Annular Plates to Shell Plates 1st course --- 100%
b) Nozzles and Doubler Plates

Magnetic Particle Inspection is a nondestructive inspection method used for

detecting surface breaking and slightly subsurface defects in ferromagnetic materials.
The process puts a magnetic field into the part, either directly or indirectly and the
presence of a surface or subsurface break will allow the magnetic flux to leak. It is viewed
primarily as a surface examination method.
There are many different techniques. The most versatile technique is using a 110v
AC hand held electromagnetic yoke magnet, a white strippable paint as contrast
background and a magnetic "ink" composed of iron powder particles in a liquid carrier
base. The area is magnetized with the yoke magnet. In the event of a surface or slightly
sub surface defect being present, the lines of magnetic force will deform around the
defect. The magnetic ink is applied and the iron powder particles will bridge the gap
caused by the defect and give a visible indication against the white contrast background.
Magnetic Particle Inspection (MPI) provides very good defect resolution and is
used extensively on: Welded fabrications in magnetic material, Castings, Locating
fatigue cracks in items subject to cyclical stress.
MAGNETIC PARTICLE INSPECTION IS PERFORMED BY:
1. Surface Preparation: Prior to the test, the area to be inspected and at least one
inch either side shall be free from any features that may inhibit the test or mask
unacceptable discontinuities. These include but are not limited to, slag, spatter,
oil, scale, rough surface and protective coatings. Surface preparation by grinding,
machining or other methods may be necessary where surface irregularities could
mask indications of unacceptable discontinuities. The temperature of the test
surface shall not exceed 135ºF for magnetic inks and 600ºF for dry powders. (For
dry powders, test surface be clean and dry). For parts to be inspected using
magnetic inks the area to be inspected may, if necessary, be precleaned with a
cloth lightly moistened with cleaner.
2. Inducing a Magnetic Field: This is the most important step in the magnetic particle
inspection procedure. In this step, place the equipment on the area to be tested
and induce a magnetic field. Various types of magnetic particle inspection
equipment are available. Widely used industrial equipment are Permanent
magnet, Electromagnetic Yoke, Current flow probes, Magnetic Flow, Flexible coil,
Threading Bar, Adjacent cable, etc. Magnetization technique can be Longitudinal,
Circular, or Multidirectional Magnetization. Equipment spacing in the inspection
area is normally kept in between 3 inches to 8 inches. An ASME Pie Gauge or
Burmag Castrol strip can be used to verify adequate magnetization of the part.
3. Applying Magnetic Particles on the Test Surface: Both dry and wet magnetic
particles can be either fluorescent or non-fluorescent (visible, color contrast) and
are available in a variety of colors to contrast with the tested material. So
accordingly choose the required particles for the magnetic particle inspection and
apply on the surfaces when the specimen is in magnetized condition.
4. Examine the component surface for defects: Remove the excess particles using
light airflow and inspect the component for defects as per acceptable standards.
5. Repeat the test by changing the magnetic field: Two separate examinations are
carried out on each area to be tested. The second examination is performed with
the lines of flux perpendicular to those used for the first examination in that area.
6. Demagnetization and Cleaning: The presence of Residual magnetism in the
component may interfere with the subsequent usage. Hence, the demagnetization
shall always be performed on the parts once the magnetic particle inspection is
over. The presence of residual magnetism can be verified using a calibrated
Gaussmeter, Magnetic Field Meter, or a hall Probe Gauss meter. Residual
magnetism must not exceed (+/-) 2 gausses. After that, the parts shall be cleaned
to remove all residual magnetic particle materials. If wet fluorescent MPI was
performed, the part shall be scanned with the backlight to assure that the cleaning
is adequate.
Magnetic Particle Inspection Floor to Shell Weld