NON-DESTRUCTIVE TESTS PROCEDURE

PROJECT TITLE:
REPAIR OF SOKU PWD DISPOSAL LOOP LINE TO ACE LINE WORKS

CONTRACT NO. CW213623

DOCUMENT NUMBER: CW213623-SOKAIJ-QA-5733-00002

Action Prepared By Reviewed By Approved By

Name Bassey Emmanuel Okoro Sunny Eric k. Ehimen
Designation Project Engineer/QA-QC Site Engineer Project Manager
Sign/Date AUGUST 2023

CLIENT (SPDC)
Action Reviewed by Agreed By Approved By
Name Omon Ehizoyanyan Adeshina Chukwunalu
Designation QA/QC Coordinator Project Engineer Contract Holder
Sign/Date

1. Scope
This procedure provides the general requirements, methods, techniques, and acceptance standards
for the radiographic examination of butt welds in plate, formed products and tubular products for
wall thickness range 2.5 mm to 70mm.

2. Reference Documents:
API 1104 Ed.2021
 ASME B31.3
ASME SECTION V
RELEVANT DEP
Written Practice: TGRL/WP/001 Rev.01 as per SNT–TC–1A (Ed.2016)

3. Personal Qualification

3.1. Personnel performing examination to this procedure shall be qualified and certified according to
Written Practice for Training, Qualification and Certification of NDE Personnel as per
TGRL/WP/001 Rev.01

3.2. Personnel performing radiography - RT Level I/II

Personnel evaluating radiographs - RT Level II/III

3.3. Radiation safety officer:

The Radiation Safety Officer (RSO) will be responsible for overseeing the Radiation Protection
Program and the requirements of the radioactive materials license. The responsibilities of the
RSO are outlined in Section 1.3.2 in the Radiation Protection procedure. The individuals in these
categories are people of 18 years and above who have participated in some training course on
radiation protection.

4. SAFETY
4.1. and NDT subcontractor Inspectors and Technicians shall ensure environmental conditions are
suitable for the use of inspection, measuring and testing equipment used during radiographic
testing. Equipment shall be safeguarded against damage and malfunction by regular checks and
calibration. Thermo-Illumine scent Dosimeter Badges shall be worn at all time while carrying out
the task.

4.2. For handling or radiation emergency and investigation and medical surveillance see the
following procedures:
i. Local Rules for Site and installation Radiography
ii. Radiation protection procedure.
iii. Safety manual.

5. Surface Preparation

1) Surface shall satisfy the requirements of the applicable materials specification with additional
Conditioning, if necessary, by any suitable process to a degree that surface irregularities cannot
mask or be confused with discontinuities.
 2) Weld ripples or weld surface irregularities on both the inside (where accessible) and outside shall
be removed by any suitable process to such a degree that the resulting Radiographic image cannot
mask or be confused with the image of a discontinuity.
3) The Finished surface of all butt-welded joints may be flush with the base material or may have
reasonably uniform crowns with reinforcement not to exceed that specified in the referencing code
section.

6. Radiography Equipment, Radiation Energy and Focal Spot Sizes

5.1. Equipment
The radiographic examination covered by this procedure shall be performed with the following
equipment:
 Gamma Ray Projector and related accessories using Iridium 192 radioisotope.
 X-Ray generator having maximum of 250kV.
 Manual Processing Dark–room equipment and accessories
 Suitable viewing apparatus for Radiographic Interpretation
 Calibrated Optical Densitometer

5.2. Radiation Energy

The radiation energy employed for any radiographic technique shall achieve the density and IQI
image requirements of this procedure.

5.3. Verification/Determination of source size or focal spot.

For Ir-192 isotope, the size provided by supplier of the source will be taken as the source size;
for X-Ray equipment, the focal size provided by manufacturer will be taken as The Focal spot
size.

7. Image Quality Indicator (IQI)

7.1 IQI Selection

 7.1.1 The ASTM standard hole or wire type IQI shall be used as per Apendix-1 for hole type
and Apendix-2 for Wire type (IQI Designation, Thickness and Diameters).

7.1.2 Selection shall be based on Apendix-3 for hole type and Wire type.

7.1.3 The thickness based on which IQI is selected is the nominal single wall thickness plus
any estimated weld reinforcement not to exceed maximum permitted by referencing,
Code section, as stipulated in Apendix-1. Backing rings / strips shall not be considered
as a part of thickness during IQI selection.

7.1.4 For weld without reinforcement, IQI is selected based on nominal single wall thickness.

7.2 IQI Placement

7.2.1 The IQI (s) shall be placed on the source side of the part being examined. Where
inaccessibility prevents hand placing the IQI on the source side, it shall be placed on the
Film side in contact with the part being examined. A lead letter "F" at least as high as
the IQI, shall be placed adjacent to or on the IQI(s), but shall not mask the essential hole
where a hole type IQI’s are used.

7.2.2 For double wall double image or single wall single image technique, except panoramic
exposure, IQI shall be placed on the source side. For double wall single image and
panoramic technique IQI to be placed on the film side.

7.3 IQI Location for Welds

7.3.1 For Hole type IQI

 Hole type IQI(s) may be placed adjacent to or on the weld. The identification number(s)
and the lead letter “F” when used shall not be in the area of interest. For the condition
described in (a) and (b) below, the identification number and the lead letter “F” may be
placed in the area of interest.
 When geometric condition makes it impractical to place the IQI as per Para. 6.2
 When the weld metal is not radiographically similar to the base metal.

7.3.2 Shims Under Hole IQ'I’s

For welds, a shim of material radiographically similar to the weld metal shall be placed
between the part and the IQI, if needed, so that the radiographic density through the area
 of interest is no more than minus 15 % from (lighter than) the radiographic density through
IQI.
The shim dimensions shall exceed the IQI dimensions such that outline of at least three
sides of the IQI image shall be visible in the radiograph.

7.3.3 For Wire type IQI

IQI(s) shall be placed on the weld so that the length of the wires is perpendicular to the
length of the weld. The identification number(s) and the lead letter “F” when used shall not
be in the area of interest. Except for the condition as described in 6.3.1.1 and 6.3.1.2 above.

7.4 Alternative location for IQI (s)

When configuration or size prevents placing the hole type IQI(s) on the part or weld, it may
be placed on a separate block (shim stock) of material radiographically similar to the weld
metal. The block dimensions shall exceed the IQI dimensions such that the outline of at least
three (3) sides of the IQI image shall be visible on the radiograph.

7.5 Number of IQI(s)

At least one (1) IQI image shall appear on each radiograph with the following exceptions: For
cylindrical vessels where the source is placed on the axis or center and the complete
circumference is radiographer with a single exposure, at least three (3) uniformly placed IQI
shall be used spaced approximately 120o apart. Where sections of longitudinal weld
adjoining the circumferential weld is radiographer simultaneously with the circumferential
weld, an additional IQI shall be placed on each longitudinal weld at the end of each section
most remote from the junction with the circumferential weld being radio graphed.
 7.5.1 When a section of circumference, the length of which is greater than 120 deg. but
less than 240 deg. is radio graphed using one film holder or when a section or
sections of the circumference, where the length between the ends of the outermost
section spans less than 240 deg. radiographed using more than one film holders at
least three IQI’s with one placed at each end of film and one at the center of the film
are required in the above cases.

7.5.2 For segments of a flat or curved (i.e., ellipsoidal, tori spherical, tori conical, elliptical,
etc.) component where the source is placed perpendicular to the center of a length
of weld for a single exposure when using more than three film holders, at least three
IQI’s, one placed at each end of the radiograph span and one in the approximate
center of the span, are required.

7.5.3 Multiple IQI’s on a single radiograph are required under the following condition:

7.5.4 If the density of the radiograph anywhere through the area of interest varies by
more than - 15% or + 30% from the density through the body of the hole type IQI or
adjacent to the designated wire of a wire type IQI, then an additional pentameter
shall be used for each exceptional area (s). When two (2) IQI’s are used, one shall
represent the lightest area of interest and the other, the darkest area of interest; the
intervening densities on the radiograph shall be considered as having acceptable
density.

7.6 IQI Sensitivity

The radiographic examination shall be performed with a technique of sufficient sensitivity to
display the hole IQI image i.e. The 2 -T hole, or the designated wire of a wire IQI.
Radiographs shall also display the IQI’s identification numbers and letters.

7.7 Equivalent Hole -Type Sensitivity.

A thinner or thicker hole type IQI than the required IQI may be substituted, provided an
equivalent or better IQI sensitivity, as listed in the attachment 2, table 7 is achieved and all
other requirements for radiography are met. Equivalent IQI sensitivity is shown in any row
of the table 7, which contains the required IQI and hole. Better IQI sensitivity is shown in any
row of attachment 1 which is above the equivalent sensitivity row. If the required IQI and
hole are not represented in the attachment, the next thinner IQI row from the attachment
2, table 7 may be used to establish equivalent IQI sensitivity.

8. Location Markers and its placement

Location markers, which are to appear on the film as radiographic images, shall be placed on
the part and not on the film holder / cassette. Their location shall be permanently marked
 on the surface of the part being radiographed or on a map when permanent marking is
inaccessible, in a manner permitting the area of interest on the radiograph to be accurately
traceable for its location on the part during the retention period of the radiograph. The
evidence shall also be provided on the radiograph that the required coverage of the area
being examined has been obtained. Location markers shall be placed as per attached
sheet. (Location Marker Sketches)

8.1 For Single-Wall Viewing

8.1.1 Source-Side Markers

Location markers shall be placed on the source side when radiographing the following:

8.1.2
Flat components or longitudinal joints in cylindrical or conical components.
Curved or spherical components whose concave side is toward the source and when
source-to-material distance is less than the inside radius of the component. (Curved or
spherical components whose convex side is toward the source.

8.1.3 Film Side Markers

Location markers shall be placed on the film side when radio graphing the following:
a) Curved or spherical components whose concave side is toward the source and when
the source-to-material distance is greater than the inside radius.
b) As an alternative to source-side placement of location markers as per clause. 6.1.1.1,
6.1.1.2 & 6.1.1.3 location markers may be placed on the film side.

8.1.4 Either Side markers

Location markers may be placed on either the source side or film side when radiographing
curved or spherical components whose concave side is toward the source and the source-
to-material distance equals the inside radius of the component.

8.1.5 For Double - Wall Viewing

At least one (1) location marker shall be placed adjacent to the weld or on the material in
the area of interest for each radiograph.

8.1.6 Mapping
When inaccessibility or other limitations prevent the placement of markers as stipulated
in clause 7.1 and 7.2 above, a dimensional map of the geometric arrangement including
marker locations, shall accompany the radiographs to show that full coverage has been
obtained. It shall be provided with radiograph review form as well.
9. Screens and film holders
Intensifying screens consisting of lead foil (0.1mm thick) shall be used as both front and back
of the film in direct contact with film. Screens shall be free of dirt, oxide, coatings, wrinkles,
pitting and other defects. Fluorescent screens are not under the scope of this work
instruction.
Film holders / Cassettes are of PVC double envelope type. Cassette containing film shall be
in intimate contact to the object being radiographed.

10. Excessive Back scatter

To determine the effect of back scattered radiation a lead letter “B” of a minimum 0.5”
(13mm). High and a minimum of 0.063 in. (1.5mm) thickness fastened to the back of the
film holder / cassette. If the image of the lead letter “B” appears lighter on a darker
background of the radiograph, back-scattered protection is insufficient, and the radiograph
shall be considered unacceptable. A dark image of the lead letter “B” on a lighter
background is acceptable.

11. Film Selection

Film selection shall be in accordance with the manufacturer’s certification for film systems.
The film Manufacturer shall determine the class for the family of film. According to their
recommendation, Type II (medium grain & medium speed) or Type I (fine grain & slow
speed) depending on the nature of job and quality level requirement.
12. Film Identifications

12.1 Location markers which are to appear as radiographic images on the radiograph shall be placed on
the part and not on the film holder / cassette and their location shall be marked permanently
(where accessible) on the surface of the part being radiographed.

12.2 Each radiograph shall be permanently identified providing the following information:

12.3 Company’s name

12.4 Job no (MSN), if required and job identification

12.5 Weld seam identification number and segment/ location number

12.6 Date of radiography

12.7 Any weld / weld segment that has been repaired shall be marked as R1, R2 etc. for 1st and 2nd
repair etc. respectively on the radiograph.

13. Geometric Unsharpness (Ug)

The geometric un sharpness (Ug) of the radiograph shall be determined in accordance with
the following formula:
Ug = F. d / D
Where Ug = Geometric Un-sharpness
F= Source size i.e., the maximum projected dimension of the radiating source (or Effective
focal spot) in the plane perpendicular to the distance D from the weld or object being
radiographed (mm.).

D=Distance from source of radiation to weld or object being radiographed (mm.)

d= Distance from source side of weld or object being radiographed to the film (mm).
D and d shall be measured to the approximate center of the area of interest.

13.1 Geometric Un-sharpness Limitation:Following criteria of maximum geometrical un-sharpness shall

be used to calculate minimum source to object distance, however, actual measurement of
Geometric Un sharpness of the Radiograph is not required.
 Material Thickness Ug maximum

In. mm. In. mm.

Under 2 Under 50 0.020 0.51

2 through 3 50 through 75 0.030 0.76

over 3 through 4 75 through 100 0.040 1.02

over 4 over 100 0.070 1.78

Note: Material thickness is the thickness on which the IQI is based.

However, is no case geometrical un sharpness shall be greater than 1.78mm.

14. Radiographic Density

14.1 Density Limitations

14.1.1 Either a densitometer or a step wedge comparison film shall be used for reading film density.
The density of the step wedge comparison film and densitometer calibration shall be verified
by comparison with a calibrated step wedge film traceable to National Standards step tablet
having at least 5 steps with neutral densities from 1.0 through 4.0. In case of difference of
reading between step wedge comparison film and densitometer affecting acceptability of the
radiograph, then the densitometer reading shall govern. A tolerance of + 0.05 in density is
allowed for variations between densitometer readings.

14.1.2 The transmitted film density through the radiographic image of the body of the appropriate
hole type IQI or adjacent to the designated wire of the wire IQI and the area of interest shall
be 1.8 minimum for single film viewing for radiographs made with gamma ray source The
maximum allowable density shall be 4 for gamma ray source. A tolerance of 0.05 in density is
allowed for variations between densitometer readings.

14.1.3 Densitometer shall be calibrated against national standard step tablet or step wedge
Calibration film traceable to national standard step tablet, at a density closest 1.0, 2.0, 3.0 &
4.0, Every 90 days. The record of such calibration will be documented.

14.1.4 The periodic calibration verification checks shall be performed at least the beginning of each
shift, after 8 hours of continuous use or after change operation, which comes first.
14.2 Density Variation

14.2.1 The transmitted film density of the radiograph anywhere through the area of interest shall
not vary by more than -15% or + 30% from the density through the body of the hole type IQI
or adjacent to the designated wire of a wire type IQI representing that area of interest.

14.2.2 When shims are used, the + 30% density restriction may be exceeded, provided the required
IQI sensitivity is displayed, and the density limitation of 13.1.2 are not exceeded.

14.2.3 When calculating the allowable variation in density, the calculation may be rounded off to
nearest  0.1.

15. Radiographic Technique

15.1 Direction of Radiation

The direction of the central beam of radiation shall be centered on the area of interest, as far as
practicable.

15.2 Single Wall Technique

A single wall exposure technique shall be used whenever practical. In the single-wall technique,
the radiation beam passes through only one wall of the weld / material, which is viewed for
acceptance of the radiograph as per shooting sketches attached. When it is not practical to use a
single wall technique, a double-wall technique shall be used as detailed below. An adequate
number of exposures shall be made to demonstrate that the required coverage has been obtained.

15.3 Double Wall Technique

When it is not practical to use a single wall technique, one of the following double-wall techniques
shall be used:

15.4 Double Wall Single Image Viewing Technique:

For circumferential welds in components more than 3 1/2 in. (89 mm.), this technique may
be used in which the radiation passes through two walls and only the weld on the film side
wall is imaged and viewed for acceptance on the radiograph as per shooting sketch
attached. When complete coverage is required for this type of circumferential welds in
components, a minimum of three (3) exposures 120 o to each other shall be made.
15.5 Double Wall Double Image Viewing Technique
A) For circumferential weld in components less than or equal to 3 1/2 in. (88.9 mm.), this
technique is used in which the radiation passes through two walls and the weld of both
the walls is imaged on the film giving an elliptical image and viewed for acceptance on
the radiograph as per shooting sketch attached. The radiation beam set offset from the
plane of the weld at angle sufficient to separate the images of the source side and film
side portions of the weld so that there is no overlap of the areas to be interpreted.
When complete coverage is required for this type of circumferential welds a minimum
of two (2) exposures is taken 90o to each other.

B) For Double-wall viewing, only source side IQI shall be used. Care should be exercised to
ensure that the required geometric un sharpness is not exceeded. If the geometric un-
sharpness requirement is not met; then single wall should be used.

C) In case of extreme difficulty to employ double wall double image technique the weld
may be radiographed with the radiation beam positioned in such a way that the images
of both walls are superimposed as per shooting sketch attached. In this case when
complete coverage is required a minimum of three (3) exposures is taken at either 60 o
or 120 o to each other for each joint.

16. Processing of Radiograph

16.1 Radiographs shall be developed manually.

16.2 Processing chemicals shall be used within the manufacturer’s recommended

16.3 Shelf life or product expiry date specified.

16.4 Developing shall be done for a period between 5 and 8 minutes at a temperature of 20 degrees C.
At higher temperatures (not exceeding 24 degrees C) the developing time may be curtailed as
determined by visually observing the extent of film development during the process. For lower
temperatures (not to go below 18 degrees C), the development time may be required to be
increased as appropriate.

16.5 Fixing time shall normally be at least twice the developing time (not to exceed 15 minutes in fresh
fixer).

16.6 Washing after developing and fixing shall be done in running water as appropriate.

16.7 After washing, the films shall be put to dry. A film drying cabinet incorporating circulating heated air
may be used to assist in drying.
17. Viewing Radiographs

17.1 Illuminator used for viewing & interpretation of radiographs shall have sufficient illumination
output and a rheostat control to provide variable light intensity to suitably evaluate the
radiographic sensitivity with respect to the designated hole or wire of the hole type or wire type IQI
respectively.

17.2 Viewing room may not be completely dark but can have subdued background light of an intensity
that will not create troublesome reflections, shadows, or glare on the radiograph to the evaluator.

17.3 The light from around the outer edge of the radiograph or coming through low density portion of
the radiograph shall not interfere with interpretation.

18. Evaluating Radiographs

18.1 Artifacts:
Radiographs may have some mechanical, chemical or other blemishes but these shall not mask
or be confused with the image of any discontinuity in the area of interest of the object being
radiographed. Such blemishes include but not limited to the following:

18.1.1 Fogging

18.1.2 Mechanical defects such as scratches, finger marks, crimps, dirtiness, static marks,
smudges, or tears etc.

18.1.3 Processing defects such as streaks, water marks, frilling, puckering, chemical stains.

18.1.4 False indications due to defective screens

18.2
If the white image of the lead symbol `B' attached back of the cassette, appears on a darker
background of the radiograph, protection from back scatter is insufficient and the radiograph shall
be considered unacceptable. A dark image of the lead symbol `B' on a lighter background is
accepted.

18.3
TEL shall be responsible for the review, interpretation, evaluation, and acceptance of the
completed radiographs to assure compliance with this procedure. The radiographic technique
details and the radiograph review form documentation shall accompany the radiographs.
 Acceptance shall be completed prior to presentation of the radiographs and accompanying
documentation to the Inspector.

19. Acceptance Standard (As per API 1104)

19.1 Inadequate Penetration Without High-low (IP)

IP shall be considered a defect should any of the following conditions exist:

a) the length of an individual indication of IP exceeds 1 in. (25 mm)

b) the aggregate length of indications of IP in any continuous 12-in. (300-mm) length of weld ex
ceeds 1 in. (25 mm);

c) the aggregate length of indications of IP exceeds 8 % of the weld length in any weld less than
12 in. (300 mm) in length

19.2 Inadequate Penetration Due to High-low (IPD)

IPD, shall be considered a defect should any of the following conditions exist:

a) the length of an individual indication of IPD exceeds 2 in. (50 mm);

b) the aggregate length of indications of IPD in any continuous 12-in. (300-mm) length of weld e
xceeds 3 in. (75 mm).

19.3 Incomplete Fusion (IF)

IF shall be considered a defect should any of the following conditions exist:

a) the length of an individual indication of IF exceeds 1 in. (25 mm);

b) the aggregate length of indications of IF in any continuous 12-in. (300-mm) length of weld ex
ceeds 1 in. (25 mm);

c) the aggregate length of indications of IF exceeds 8 % of the weld length in any weld less than
12 in. (300 mm) in length.

19.4 Slag Inclusions

When the size of a radiographic indication of slag is measured, the indication’s
maximum dimension shall be considered its length.

19.4.1 Pipe Diameter—2.375 in. (60.3 mm) or Greater

For pipe with a specified OD greater than or equal to 2.375 in. (60.3 mm), slag inclusions shall be c
onsidered a defect should any of the following conditions exist:

a) the length of an ESI indication exceeds 2 in. (50 mm);

b) parallel ESI indications separated by approximately the width of the root bead (wagon tracks) s
hall be considered a single indication unless the width of either of them exceeds 1/32 in. (0.8 mm).
In that event, they shall be considered separate indications;

c) the aggregate length of ESI indications in any continuous 12-in. (300-mm) length of weld exceed
s 2 in. (50 mm);

d) the width of an ESI indication exceeds 1/16 in. (1.6 mm);

e) the aggregate length of ISI indications in any continuous 12-in. (300-mm) length of weld exceed
s 1/2 in. (13 mm);

f) the width of an ISI indication exceeds 1/8 in. (3 mm);

g) more than four ISI indications with the maximum width of 1/8 in. (3 mm) are present in any con
tinuous 12-in. (300 mm) length of weld;

h) the aggregate length of ESI and ISI indications exceeds 8 % of the weld length.

19.4.2 Pipe Diameter—Less than 2.375 in. (60.3 mm)

For pipe with a specified OD less than 2.375 in. (60.3 mm), slag inclusions shall be considered a def
ect should any of the following conditions exist:

a) the length of an ESI indication exceeds three times the thinner of the specified wall thicknesses j
oined;

b) parallel ESI indications separated by approximately the width of the root bead (wagon tracks) s
hall be considered a single indication unless the width of either of them exceeds 1/32 in. (0.8 mm).
In that event, they shall be considered separate indications;

c) the width of an ESI indication exceeds 1/16 in. (1.6 mm);

d) the aggregate length of ISI indications exceeds two times the thinner of the specified wall thickn
esses joined and the width exceeds one-half the thinner of the specified wall thicknesses joined;
 e) the aggregate length of ESI and ISI indications exceeds 8 % of the weld length.

19.5 Porosity
The maximum dimension of the indication shall apply to the criteria given in 18.5.1 or 18.5.2.

19.5.1 Individual or Scattered Porosity

Individual or scattered porosity shall be considered a defect should any of the following conditions
exist:

a) the size of an individual pore exceeds 1/8 in. (3 mm) in diameter or 25 % of the specified wall th
ickness, whichever is less;

b) the size of an individual pore exceeds 25 % of the thinner of the two specified wall thicknesses j
oined, but no more than 1/8 in. (3 mm) in diameter;

c) the distribution of scattered porosity exceeds the concentration permitted by Figure 20 or Fi

gure 21 of API 1104 section 9.3.9.

19.5.2 Hollow Bead (HB) Porosity

HB shall be considered a defect should any of the following conditions exist:
a) the length of an individual indication of HB exceeds 1 in. (25 mm);
b) the aggregate length of indications of HB in any continuous 12-in. (300-mm) length of weld exce
eds 2 in. (50 mm);
c) the aggregate length of all indications of HB exceeds 8 % of the weld length.

19.5.3 For cluster porosity see Fig 19 and Fig 20 of API 1104

19.6 Cracks
Cracks shall be considered a defect should any of the following conditions exists:
a) the crack, of any size or location in the weld, is not a crater crack or star crack;
b) the crack is a crater crack or star crack with a length that exceeds 5/32 in. (4 mm).

19.7 Undercutting
Undercutting shall be considered a defect when either of the following conditions exists:
a) the aggregate length of indications of EU and IU, in any combination, in any continuous 12-in. (3
00-mm) length of weld exceeds 2 in. (50 mm);
b) the aggregate length of indications of EU and IU, in any combination, exceeds one-sixth of the
weld length.
19.8 Accumulation of Imperfections
Excluding inadequate penetration due to high-low and undercutting, any accumulation of imperfe
ctions shall be considered a defect should any of the following conditions exist:
a) the aggregate length of indications in any continuous 12-in. (300-mm) length of weld exceeds 2
in. (50 mm);
b) the aggregate length of indications exceeds 8 % of the weld length.

20. Examination of Repairs.

Unacceptable discontinuities shall be removed and repaired with the applicable repair weld
procedure. Repair shall be re-examined in accordance with this work instruction.

21. Reporting System.

The radiography technique sheet shall be prepared prior to taking radiograph which shall contain
following information as a minimum:

a) Identification of job/item/part etc.

b) Contract & Unit No. (if applicable)
c) Dimensional map (if used) of marker placement.
d) No. Of exposures
e) X-ray Voltage or Type of Isotope used
f) Source size
g) Ci- min / mA Min
h) Base material type and thickness, weld thickness, and weld reinforcement thickness, as applicable.
i) Source to object distance
j) Distance from source side of object to film
k) Film manufacturer and manufacturer’s type / designation
l) No. of film in each cassette
m) Single or double wall exposure
n) Single or double viewing

Examination results shall be reported in Radiography Evaluation form, which shall contain following
information as a minimum.
1) Listing of each radiograph location.
2) Procedure and rev. no.
3) Evaluation & disposition of the welds examined.
4) Identification of the MGVL personnel performing final acceptance.
5) Date of evaluation

22. RECORDS
The result of radiographic examination shall be recorded in Radiograph Examination Report along
with technique sheet.
23. Appendix-1
24. Appendix-2
25. Appendix-3
26. Appendix-4
LOCATION MARKER SKETCHES
27. Appendix-5
28. APPENDIX 6 (RT TECHNIQUE SHEET)
Equipment No/Job No: W.O. No. Client Stage of Exam

Before/After PWHT

Inspection by Base Material Base Mat. Thickness

Weld Thickness: MM Reinforcement: MM

Applicable Code/Standard Seam No. Part No. Spot No.

X-Ray/Gamma Ray

Radioisotope: - SKETCH

KVp : FOD : mm

SOFD : mm

SOD : mm

Effective Focal Spot/Size of source mm x mm

Exposure time: mA-mnts/Ci – mnts

Intensifying Screen: Lead

IQI : Hole Type/Wire Type

Front: mm Back: mm

IQI Source side/Film side IQI No: ASTM

Shim thk: mm

Film type:(Brand & Designation) Film size: inches

No.of Exposures: No.of Radiographs:

Film viewing: Single/Composite

Exposure: Single wall/ Double wall

No.of walls to be viewed : Single/Double

No.of films per film holder: One/Two

Location Marker: Source side/ Film side

Location Marker Map: Required/Not required

Placement of Back Scatter “B” on back of Cassette Verified : Yes/No

Developing Time : ____________________________ Temp ________________________

Prepared by Level II Approved by Level II/ III Accepted by

Sign & Date: Sign & Date: Sign & Date:

Name: Name : Name :

29. APPENDIX 7 (RT REPORT)
CLIENT DATE

JOB NO. EQUIP NO.

TECHNIQUE SHEET
ACCEPTANCE STD
NO.

PROCEDURE
DRG. NO. & REV.
&REV.NO.

DENSITOMETER READING VERIFIED: YES / NO

PART DESCRIPTION MATERIAL THICKNESS FULL  SPOT  PARTIAL 

RECORDABLE INDICATIONS IF ANY

( )
Sr.
SEAM NO.
Reshoot
Porosity

Accepte
Repair /
Inclusio

surface
Lack of

Others
Fusion

No.

Reject
Check
Crack

Slag

d
SPOT

OTHERS GLOBAL CLIENT

IP-IN-COMPLETE
Name Name
PENETRATION
BU-BURN THROUGH Sign Sign
RC-ROOT CONCAVITY
EP-EXCESS
PENETRATION
Date Date
UC-UNDER CUT
UF-UNDER FLUSH
T-TUNGESTEN
30. Scope:
This procedure shall be applied for performing magnetic particle examination of Ferro magnetic
materials welds and components using wet/dry non-fluorescent Ferro magnetic particle,
continuous AC yoke.

31. REFERENCES:
 API 1104, Ed.2021
 ASME Sec-V, Ed.2019
 SNT-TC-1A, Ed.2016
 Written practice – SUNUP/WP/001 Rev.01

32. QUALIFICATION OF PERSONNEL:

Magnetic particle examination shall be performed and interpreted/evaluated by NDE

Personnel qualified to Level II/III, in this method and shall be as per Written Practice
SUNUP/WP/001 Rev.01

33. EXAMINATION MEDIUM:

Magnetic particle examination shall be carried out using wet/dry –visible, color contrast magnetic
particle paint/ink made of finely divided ferromagnetic material of high permeability and low
retentivity (for wet particle 5-20& for dry particle 180). The same family of contrast paint and ink
shall be used.

34. EQUIPMENT:
Magnetization shall be performed using, 220 Volt AC Electromagnetic yokes (Parker and Equivalent
Make) having minimum lifting power of 10 lbs. (4.55 Kg.) at maximum pole spacing of 6.5"(165
mm). This will produce longitudinal magnetic field in examination metal. The magnetizing power of
the yoke shall be verified each day prior to use and also in case if it has been repaired using weight
at max pole spacing. The weight shall be weighed using scale from reputed manufacturer and
 stenciled with applicable nominal weight prior to use and need to be verified only in case of
damage, which could lead to potential loss of material.

35. SURFACE PREPARATION:

The surface to be examined and adjacent surface may be in the as welded, as rolled, as cast or as
forged condition. However, surface preparation by mechanical means may be necessary in some
cases where surface irregularities could mask the indications due to discontinuities. 1" (25.4 mm)
area shall be free from lint, dirt, scale rust, grease, oil, paint weld spatter and any type of coating or
contamination which could interfere with mobility of magnetic particle/mask the indication or
create false indications. Normally, as-weld condition is acceptable, unless weld surface irregularities
are present that could mask indications due to discontinuities. Cleaning of organic compound shall
be accomplished by solvent and other contamination shall be removed by mechanical means (wire
brushing, grinding etc.)

36. PREPARATION OF WET MAGNETIC PARTICLE SUSPENSION:

The wet magnetic particle shall be prepared in water approximately 20 grams of particle with
Conditioning agents (Magna flux make or equivalent) shall be added in 1 liter of water. The
concentration of magnetic particle suspension shall be determined by settling volume through use
of an ASTM Pear shaped centrifuge tube with 1.5mL stem (0.1 mL division) The concentration shall
be between 1.2 to 2.4 mL per 100mL of well mixed sample after settling time of at least ½ hour.
The concentration shall be checked daily or prior to use

37. EXAMINATION PROCEDURE:

Before the magnetic particle examination is conducted, a check of the examination surface shall be
conducted to locate any discontinuity surface openings, which may not attract and hold magnetic
particles because of their width. Longitudinal magnetic field shall be created with the help of AC
Yoke. The yoke legs shall be in full contact with the metal surface. Continuous method shall be
used. The yoke shall be energized after it is properly positioned and de energized before removal.
 The leg spacing shall not be less than 3" (75 mm) and not more than 6.5" (165mm). At each location
two examinations approximately perpendicular to each other shall be carried out. Yoke shall be
placed across the welds at an angle 30-45 degree from the long axis of the weld. Sufficient overlap
shall be made to ensure 100% coverage of the area requiring examination. The ferromagnetic
particles used as examination medium can be either wet or dry.

a) Dry Particles:
The magnetizing current shall remain “on” while the examination medium is being applied.

Accumulations or excess dry particles in examinations shall be removed with a light air stream from
a bulb or syringe or other source of low-pressure dry air. The examination current or power shall be
maintained while removing the excess particles. The Dry magnetic particle examination shall be
carried out below 482 ºF (250ºC).

b) Wet Particles:
The magnetizing current shall be turned on after the particles have been applied. Flow of particles
shall stop with the application of current. Wet particles may be applied before and/or after
magnetizing current is applied. Wet particles may be applied during the application of magnetizing
current if they are not applied directly to the examination area and are allowed to flow over the
examination area or are applied directly to the examination area with low velocities insufficient to
remove accumulated particles. The Wet magnetic particle examination shall be carried out below
122 ºF (50ºC) If an indication is observed, area shall be cleaned and reexamined for conformance.
During reexamination, the yoke legs shall be placed perpendicular to the major direction of
indication (this will give maximum sensitivity and we can determine extent of discontinuity
effectively.)

A minimum light intensity of 100fc (1000 lux) shall be maintained during examination/

evaluation. This can be obtain using 100 W lamp kept at 10" (250 mm) max. from surface. The light
source, technique used, and light level verification is required to be demonstrated one time,
 documented and maintained on file. The span covered under light is 16” (400 mm). Light meter
shall be calibrated at least once a year or whenever meter has been repaired. If meter have not
been in use for one year or more calibration shall be done before being used.

38. EVALUATION:
9.1 All indications shall be evaluated in terms of the acceptance standards of the referencing code
section.

9.2 Discontinuities on or near the surface are indicated by retention of the examination medium.
However, localized surface irregularities due to machining or grinding marks or other surface
conditions may produce false indication.

9.3 Broad areas of particle accumulation, which might mask indications form discontinuities, are
prohibited and such area shall be cleaned and reexamined.

39. ACCEPTANCE CRITERIA:

The indication which has any dimension is greater than 1/16"(1.5 mm) is relevant indication.

 A linear indication is one having a length greater than three Times of its width.
 A round indication is one of circular or elliptical shape with a length equal to or less than
three times of its width.

39.1 API 1104

The following criteria shall apply when indications are evaluated.

a) Any indication with a maximum dimension of 1/16 in. (1.6 mm) or less shall be classified as nonrelevant.
Any larger indication believed to be nonrelevant shall be regarded as relevant until reexamined by
magnetic particle or another NDT method to determine whether or not an actual imperfection exists. The
surface may be ground or otherwise conditioned before reexamination. After an indication is determined
to be nonrelevant, other nonrelevant indications of the same type need not be reexamined.

b) Relevant indications are those caused by imperfections

Relevant indications shall be considered defects should any of the following conditions exist:

i) indications evaluated as crater cracks or star cracks exceed 5/32 in. (4 mm) in length;

ii) indications evaluated as cracks other than crater cracks or star cracks;

iii) linear indications evaluated as IF and exceed 1 in. (25 mm) in total length in a continuous

12-in. (300-mm) length of weld or 8 % of the weld length.

c) Individual or Scattered Porosity

Individual or scattered porosity shall be considered a defect should any of the following conditions exist:

a) the size of an individual pore exceeds 1/8 in. (3 mm) in diameter or 25 % of the specified wall thickness,
whichever is less;

b) the size of an individual pore exceeds 25 % of the thinner of the specified wall thicknesses joined, but no
more than 1/8 in. (3 mm) in diameter;

c) the distribution of scattered porosity exceeds the concentration permitted by Figure 19 or Figure 20 of
API 1104

d) Cluster Porosity (CP)

CP that occurs in any pass except the finish pass shall be considered a defect should any of the following
conditions exist:

a) the diameter of the cluster exceeds 1/2 in. (13 mm);

b) the aggregate length of CP in any continuous 12 in. (300 mm) length of weld exceeds 1/2 in. (13 mm).

40. repairs:
The unacceptable defects shall be removed and repair when there is a defect thought to be
removed, and prior to making weld repairs, the area shall be examined by suitable method to
ensure it has been removed or reduced to an acceptably Sized imperfection.

Any indication which is believed to be non-relevant shall be regarded as an imperfection

 unless it is shown by reexamination by same method or by the use of other NDE methods

and/ or by surface conditioning that no unacceptable imperfection is present.

41. RE-EXAMINATION OF REPAIR AREAS:

After repairs have been made, the repaired area shall be blended into the surrounding surface so as
to avoid sharp notches, crevices corners and re-examined by magnetic particle method and by all
other approved methods that were originally required for the affected area, except that, when the
depth of the repair is less than the radiographic sensitivity required, radiography may be omitted.

42. POST EXAMINATION CLEANING:

Post examination cleaning shall be carried out as soon as possible, either by blowing compressed air
or by brushing the surface with wire brush

43. DEMAGNITIZATION:
Demagnetization is required only if specified in purchase order, drawings or specification. This shall
be performed with AC yoke, by placing the poles on surface, moving them around the area and
slowly withdrawing the yoke while it is still energized. After demagnetization residual magnetic
field should not exceed 3 Gauss anywhere in the piece absolute value, unless otherwise agreed
upon with purchaser.

44. RECORDS:
The results of magnetic particle examination shall be recorded on the magnetic particle Examination
report as per attach format.

Magnetic Particle Examination Report

PROJECT NAME: REPAIR OF SOKU PWD DISPOSAL LOOP LINE TO ACE LINE
WORKS
CLIENT LOCATION REPORT No.
220 VOLTS
EQUIPMENT MAGNETIC
Procedure & XX/XX/
YOKE DATE
Rev. No. XX
Examination
Wet
Medium
 CAPABLE
SURFACE CALIBRATIO OF
CLEANED
CONDITION N LIFTING
Equipment Tag 4.5Kg
Visible
Type of Particle Technique Spray
Fluorescent
METHOD OF
DRAWING N0 MAGNETIZATIO Continuous Thickness
N
ASME SEC
Acceptance VIII DIV 1 Lighting Type of
Day light
Standard APPENDIX Equipment current
6
INSPECTION
BATCH N0
MEDIUM
BACKGROUND
BATCH N0
CONTRAST
N= Non-Rejectable Indication R= Rejectable Indication
LOCATIO
WEL TYPE OF N
WELDE INDICATIO EXTENT OF REMARK
D INDICATION N R (Length,
R NO N INDICAIONS S
NO. S Dia or
Aligned)

APPROVALS
GLOBAL CLIENT
NAME NAME

SIGN SIGN

DATE DATE