PROCEDURE FOR RADIGRAPHIC TESTING

Document No: STD-INSP-0024

A 22-07-2022 FIRST ISSUE

Prepared Reviewed Approved
Rev Date Details AI/TPI/CLIENT
By By By QM
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PROCEDURE FOR RADIGRAPHIC TESTING

1. Scope:

1.1 This procedure covers the technique and acceptance standard for radiographic
examination of the weld in steel with thickness up to 200mm.

1.2 This procedure establishes the requirements for radiographic examination of weld
joints using Gamma Radiation (Ir192 / Se75) or X Ray machines and is intended
for application as required in accordance with requirements of the reference
codes or standards.

1.3 This procedure shall be applicable for examination of weld joints of steel,
stainless steel, alloy steel, copper, copper alloys, nickel and nickel alloys.

1.4 This procedure shall be applicable for thickness from 3mm to 70mm.The
minimum and maximum thickness range can be waived if the technique
demonstrates the required sensitivity is achieved

2. Responsibility:

2.1 Quality Manager

2.2 Inspection Engineer

3. Reference:

2.1 ASME Sec. V, Art-2

2.2 ASME Section VIII Div. 1 & 2

2.3 ASME Section 1

2.4 ASME B 31.1

2.5 ASTM E-94

2.6 ASNT CP-189

(Latest Edition and Addenda on the day of use of this procedure)

4. Personnel Qualification:

3.1 Personnel performing and/or evaluating Radiography Testing shall be qualified

and certified to at least Level-II as per written practice of company complying
with ASME Sec. V Article 2 &ASNT CP-189.

3.2 Interpretation of Radiographs shall be carried out by NDE Level II (RT) or NDE
Level Ill (RT) which is in line with ASNT-TC-1A

3.3 Vision test of NDE personnel shall be carried out and certified on yearly basis.

5. PROCEDRURE:
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4.1 Surface Preparation

4.1.1 Any surface irregularity that may interfere with the interpretation of the
Radiographs shall be removed, so that, these irregularities cannot mask or be
confused with the image of the discontinuities.

4.1.2 The weld ripples or weld surface irregularities on both the inside (Where
accessible) and outside shall be removed by suitable process to such degree
that the images of surface irregularities cannot mask or be confused with image
of any discontinuity on the resulting radiograph.

4.1.3 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.

4.2 Radiation Energy

4.2.1 Radiography Testing shall be done using Gamma radiations with Iridium 192
source.

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

4.3 Radiographic Film

4.3.1 Radiography Testing shall be carried out by industrial radiography films.

4.3.2 For Gamma radiation with Iridium - 192 sources, Kodak make MX 125 or Agfa
make 04 very fine grain very high contrast films shall be used for nominal wall
thickness up to 9 mm. For nominal wall thickness of weld members more than
9 mm Kodak make AA 400 or Agfa make 07 fine grained high contrast films
shall be used for Radiography Testing.

4.3.3 All films to be used for radiography shall be visibly in good condition and within
the period of usefulness as indicated by the manufacturer's prescribed expiry
date marked on each individual carton.

4.3.4 Unexposed films shall be stored in a manner, so that they are protected from
the effects of Light, Pressure, Heat, excessive Humidity, Fumes or penetrating
radiation.

4.3.5 Use type- I, type- II films for X-ray. Use of type-I films for gamma radiation is
recommended, type-II films can be used with gamma radiation if sensitivity
contrast requirement

4.4 Intensifying Screens

Only lead intensifying screens shall are used.
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4.5 Identification of Radiographs

5.1.1 A system of radiographic identification shall be used using

lead markers radiographic images to produce a permanent and
traceable record of individual part or Welds and,

- Manufacturer Name
- Project No.
- Seam No.
- Weld.er Number.
- Date of Test

5.1.2 For panoramic exposure of Cir. seam having outer diameter more than
1meter, where multiple films are exposed during single exposure,
Complete identification by lead marker images are not practical on all
films. In such cases following unified coded identification system shall
be followed.

5.1.2.1 Complete identification system shall be appeared on first film with

lead marker images as mentioned in RT Report.
5.1.2.2 On all other films, unified code No. i.e. (Project No., seam No.,
Manufacturer Name Date) shall be identified with lead marker
images.
5.1.2.3 Radiographs after weld repair shall be identified by the additional
symbol R1for first repair and be numbered R2, R3 for subsequent
addition of repair thereafter for same location.
5.1.2.4 Radiographs after weld dress up (not repaired by welding) shall be
identified by the additional symbol MRS1 for first dress up and be
numbered MRS 2, MRS 3 for subsequent addition of weld dress up
thereafter for location.
5.1.2.5 Re-taking of radiograph due to poor quality, due to confusing artifacts
and for any other reasons shall be identified by the symbol RT1for
first re-take and be numbered RT2, RT3 for subsequent addition of
re-taking thereafter.
5.1.2.6 If lead markers are used for identification and they formed as
radiographic images, corrections can be made in case of any
mistakes, using other permanent markers provided these mistakes
are justified documented and reported to TPI for acceptance.

4.6 Back Scatter Radiation

4.6.1 As a check on Back Scattered Radiation, a lead letter 'B' with minimum
dimension of 13mm in height and 1.5mm in thickness shall be attached to the
back of each film holder. The letter B shall be put in such a way that its image
shall not overlap with weld image.
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4.6.2 If a light image of the letter ‘B’ be clearly appear on dark background on the
Radiograph, corrective measures shall be taken, and the area shall be re-
radiographed till satisfactory results are obtained.

4.6.3 A dark image of the “B" on a lighter background is not a cause for rejection.
However, if this dark image appears on weld image or hole type IQI image, the
radiograph shall be retaken such that the dark image of letter 'B' should not fall
on weld image or hole type IQI image.

4.7 Radiographic Techniques

4.7.1 A single wall exposure - single wall viewing technique shall be used for
radiography wherever practical.

4.7.2 Where it is not practical to use a single wall exposure - single wall viewing
technique a double wall exposure- single wall viewing technique shall be used.
For complete coverage for double wall exposure - single wall viewing technique
for circumferential welds, a minimum of three exposures at 120° to each other
shall be made.

4.7.3 In place of double wall exposure, single wall viewing technique, the double wall
exposure - double wall viewing technique can also be used for
circumferential weld joints having nominal diameter up to 89 mm by
offsetting the radiation source at an angle sufficient to separate the image of
source side and film side portion of weld. For complete coverage for double wall
exposure - double wall viewing technique, minimum of two exposures at goo to
each other shall be made. For double wall exposure- double wall viewing
technique IQI placement shall be on Source side only.

4.7.4 In option to serial number 9.3, the double wall exposure double wall viewing
technique having super imposed image of both walls can be used for pipe
nominal diameter 89 mm or bellow. A minimum 3 exposures at 120° to each
shall be performed for the same.

4.8 Location Markers

4.8.1 Location Markers {see Fig. T-275) which are to be appear as radiographic
images on the film shall be placed on the part, not on the exposure holder /
cassette. There locations shall be permanently marked on the surface of
the part being radiographed when permitted, or on a map, in a manner
permitting the area of interest on a radiograph to be accurately traceable to
its location on the part, for the required retention period of the radiograph.
Evidence shall also be provided on the radiograph that required coverage of the
region being examined has been obtained. Segment for location marker shall be
0-1, 1-2, 2-3, or A-B, B-C, C-D ... etc.
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4.8.2 Single side viewing:

a) Source-Side Markers. - Location markers shall be placed on the source
side when radiographing the following:
- Flat components or longitudinal joints in cylindrical or conical
components;
- Curved or spherical components whose concave side is toward the
source and
- When the "source-to-material" distance is less than the inside radius of
the
- Component;
- Curved or spherical components whose convex side is toward the
source.
b) Film-Side Markers
- Location markers shall be placed on the film side when radiographing
either curved or spherical components whose concave side is toward the
source and when the "source-to-material" distance is greater than the
inside radius.
- As an alternative to source-side placement in T-275.1{a) (1), location
markers may be placed on the film side when the radiograph shows
coverage beyond the location markers to the extent demonstrated by
Fig. T-275.1(b) (2), sketch (e).
c) Either Side Markers.
- Location markers may be placed on either the source side or film side
when radiographing either curved or spherical components whose
concave side is toward the source and the "source-to-material" distance
equals the inside radius of the component.

4.8.3 Double-Wall Viewing:

For double wall viewing, at least one location marker shall be placed adjacent to
the weld (or on the material in the area of interest) for each radiograph.

Mapping the Placement of location Markers:

When inaccessibility or other limitations prevent the placement of markers as
stipulated in T-275.1 & T-275.2, a dimensioned map of actual marker placement
shall accompany the radiographs to show that full coverage has been obtained.
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4.9 Source to Film Distance calculation:

Minimum source to film distance / focus to film distance shall be calculated as follows.
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PROCEDURE FOR RADIGRAPHIC TESTING

SFD / FFD (minimum) = SOD (D) + OFD (d)

SFD = (F X D) / Ug

Where
SFD= Force/ Focal spot to film distance (SFD/FFD)
D = Distance from the source of radiation to weld or object being
radio graphed.
F = The maximum projected dimension of the radiation source in the plane
perpendicular to the distance D from the weld or object being radio graphed.
(Value of ‘F’ can be obtained from Gamma Ray Source Certificate).
d = Distance from the source side of weld to the film.
Ug = Geometrical Unsharpness as per paragraph number 12.
D and d shall be measured to the approximate center of the area of interest.

4.10 Geometrical Unsharpness:

4.10.1Radiography shall be performed so that Geometrical Unsharpness of the
radiograph does not exceed the following limits.
(a) Less than 50 mm thickness, allowable maximum value of Unsharpness
is 0.51mm.
(b) For thickness 50 mm inclusive thickness through 75 mm inclusive
thickness, allowable maximum value of Unsharpness is 0.76 mm.
(c) Over 75 mm to 100 mm inclusive thickness, allowable maximum value
of Unsharpness is 1.02 mm.
(d) Greater than 100 mm thickness, allowable maximum value of
Unsharpness is 1.78 mm.
4.10.2Thickness for Unsharpness calculation shall be the thickness on which the IQI is
based. (I.e. nominal single wall thickness plus estimated reinforcement within
maximum allowable limit).

4.11 Image Quality Indicators:

4.11.1The Image Quality Indicators used shall be the hole type or Wire type. Any one
of the IQI shall be visible on radiography film with Essential wire of designated
wire type IQI or essential hole of designated hole type IQI.

4.11.2The Hole type or wire type IQIs can be used for sensitivity monitoring of
radiographs. Shims may be used when required.

4.11.3IQIs shall be selected from either the same alloy material group or grade as
identified in SE - 1025. or from an alloy material group or grade with less
radiation absorption than the material being radiographed.

4.11.4The hole type IQI number or required diameter shall be as per Table T-276 of
Article 2 of ASME Section V (Annexure - 1with this procedure). A thinner or
thicker hole type IQI than the required IQI may be substituted, provided an
equivalent or better IQI. Sensitivity as listed in table T-283 of ASME Sec.V.
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4.11.5The IQI shall be selected based on nominal single wall thickness plus estimated
reinforcement within maximum allowable limit. Backing rings or strips shall not
be considered as part of the thickness in IQI selection. The actual measurement
of the weld reinforcement is not required.

4.11.6When the Weld metal is of an alloy group or grade that has a radiation
attenuation that differs from the base material, the IQI material selection shall
be based on the weld metal and be in accordance with 13.3 on each side of
weld joint.

4.11.7Wire Type IQIs shall be selected from either the same alloy material group or
grade as identified in SE -747. The Wire type IQI shall be placed across the
weld so that the wires are at 90° to the weld seam. Wire type IQI Designation,
Wire Diameter, and wire density shall be as per table T-233.2 of ASME Sec. V
(Annexure -2 with this procedure).

4.11.8The hole type IQI shall be placed adjacent to and parallel to the weld seam.
Generally, hole type IQI should place maximum 3 mm away from weld edge.

4.11.9 Where inaccessibility prevents placement of the IQI on the Source Side, a film
side IQI may be used and letter F shall be placed adjacent to or on the IQI.

4.12 Number of IQIs:

4.12.1Except as required in the following paragraphs, each film shall have minimum
one IQI. Each IQI shall represent an area of essentially uniform radiographic
density as judged by the densitometer.

4.12.2 If the density of the radiograph through the length of the area of interest varies
by more than minus 15J't or plus 30J't from the density through the body of
designated hole type IQI adjacent to the essential hole or adjacent to the
essential wire type IQI then additional IQIs shall be placed in the areas where
the densities are beyond the limitations and the radiographs shall be retaken.

4.12.3Exposure with more than one film: (Special Cases).

4.12.4 If radiography is carried out by using more than one film in single shot as
mentioned following cases, IQI shall be placed as mentioned below.
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4.12.5For cylindrical vessels where one or more films are used and complete
circumference or length between the ends of the outermost sections span 240°
or more degree is radiographed by panoramic shot, at least three IQIs shall be
used each located at approximately 120° apart. Where sections of longitudinal
weld adjoining the circumferential shall be radiographed simultaneously with the
circumferential weld, an additional IQI shall be placed on each such longitudinal
weld at the end of each section most remote from the junction with the
circumferential weld being radiographed. (Reference Figure no. D-210-1 and D-
210-2 of non-mandatory appendix D of Article 2}.

4.12.6For cylindrical vessels where the source is placed at the axis of the object and
more films are used for single exposure of a section of the circumference, at
least three IQI shall be used. One IQI shall be in the approximately center of
the section exposed and others at equal interval. In each case, additional film
location may be required to establish proper IQI spacing; otherwise at least one
IQI images shall appear on each radiograph. (Reference Figure no. D-210-3
and D-210-4 of non-mandatory appendix D of Article 2}.

4.12.7Where the spherical vessel with circumferential and long seams are
simultaneously radiographed with one or more films by keeping the source at
the center of the vessel at least three IQI at approximately 120° apart shall be
placed on the circumferential seam and on all the other welds radiographed
simultaneously on the same vessel, one additional IQI shall be used. (Reference
Figure no. D-210-5, D-210-6 and D-210-7 of non-mandatory appendix D of
Article 2)

4.12.8For segments of spherical vessel where the source is located at the center of
the vessel and four or more film holders are used for a single exposure.

4.12.9Where one or more components are radiographed simultaneously by a

panoramic technique, each film should have image of IQI. (Reference Figure no.
D-210-8 of non-mandatory appendix D of Article 2).

4.12.10 When Panoramic Technique is used the no. of exposures/ films represented
by the film containing IQI, shall be documented in the technique sheet to
enable correct identification of radiographs that would require re -shoots due
to improper sensitivity exhibited on the reference radiograph.

4.13 Radiography Exposure Tie:

For Gamma Ray Radiography, exposure time shall be calculated as per following
formula for achieving density 2.0:
Exposure time in minutes = (F.F x 2(THK. /HVT) x (SFD)2 X 60)
Curie x RHM

F.F. = Film Factor= 1.9R for Kodak AA 400 film 3.4R for Kodak MX 125 film.
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THK =Thickness which cause attenuation of gamma ray between source to film.
HVT=Half Value of Thickness of the material cause attenuation between source
to film.
SFD=Source to film distance in meter.
Curie=Source Strength.
RHM= RHM value of the gamma ray source. (For lr. 192- RHM = 0.5)

The above formula is for achieving density 2.0. The actual exposure time shall be
kept approximately 20% more so that the required density shall be within 2.0 to
3.5.

4.14 Radiography Film Processing:

4.14.1 Standard Guide for Controlling the Quality of Industrial Radiographic Film
Processing, SE-999, or paragraphs 23 through 26 of Standard Guide for
Radiographic Examination SE -94 shall be used as a guide for processing film.
4.14.2 Radiography films shall be processed manually in the dark room under
safelight condition. The separation between the adjacent films shall
maintained minimum 12.7 mm.
4.14.3 Development of film is to be done following the Time/Temperature conditions
as recommended by Film Manufactures.
4.14.4 Films shall be agitated in two directions for first 10 sec. of each minute
during development. This will help film develop evenly.
4.14.5 Following development, the film shall be immersed completely in the stop
bath solution for A to 1minute with agitation for first 10 sec.
4.14.6 Films will be fixed in fixer solution for at least twice the development time
with agitation for the first 10 sec of each minute.
4.14.7 After fixation films shall be washed in running water for sufficient time.
4.14.8 After washing in running water, films shall be dipped in wetting agent for
1min.
4.14.9 After wetting agent, films shall be dry in air.

4.15 Viewing of Radiographs

4.15.1 Viewing facility shall provide subdued background lighting of an intensity that
will not cause reflection on the radiographic film.
4.15.2 The viewer used shall provide a variable intensity light source, which will emit
enough illumination to enable the interpreter to distinguish all the pertinent
details of radiography.

4.16 Quality of Radiographs

All radiographs shall be free from mechanical, chemical or other artifacts to
the extent that they cannot mask or be confused with the image of any
discontinuity in the area of interest of the object being radiographed. Such
images include but are not limited to: -

- Fogging.
- Processing defects such as water or chemical marks.
- Scratches, Finger marks, Crimps, Static, Smudges or Tears.
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- Loss of details due to poor screen to film contact.

- False indication due to defective screen
4.16.1 IQI Sensitivity
Radiography shall be performed with a technique of enough sensitivity to
display the designated hole type IQI image and the 2 T hole, or the essential
wire of a wire QI. The radiographs shall also display the IQI identifying
numbers and letters.
4.16.2 Radiographic Density

4.16.2.1 Only single film viewing techniques shall be employed.

4.16.2.2 The transmitted film density in the area of interest shall be from 2.0 to
4.0 for Radiography with Gamma ray radiation.
4.16.2.3 The density of the Radiograph anywhere through the area of interest
shall within range of -15 % to + 30 % from the density through the
body of the designated hole to essential hole or adjacent to the
designated wire of a wire IQI within the range. If it exceeds these
limits, an additional IQI shall be used for those areas and the
Radiographs shall be retaken.
4.16.2.4 When shim under hole type IQI is used the +30 % density restrictions
exceeded and the minimum density requirements do not apply for the
IQI, provided the required IQI sensitivity is displayed.
4.16.2.5 The calibrated Densitometer shall be used for measuring density of
radiographs. The densitometer shall be calibrated at the prior to
commencing of density check after completion of density check and at
every interval of 8 hours during radiography film interpretation. The
densitometer calibration shall be done as per procedure number:

4.17 Acceptance Criteria.

All the radiographs shall l be examined and interpreted to assure the compliance
as follows:

a. Acceptance criteria shall be as per QW-191 of ASME Section IX for welder

qualification radiographs.
b. Acceptance criteria shall be as per ASME Section VIII, Division I -
Paragraph UW-51 for full radiography. Indications shown on the
radiographs of welds and characterized as imperfections are Unacceptable
under the following conditions.
c. Any indication characterized as a crack or zone of incomplete fusion or
penetration.
d. Any other elongated indication on the radiograph which has length greater
than:

- ¼ “(6mm) for t up to ¾” (19 mm)

- 1/3 t for t from ¾ “(19 mm) to 2 ¼” (57 mm)
- ¾” for t over 2 ¼” (57 mm)
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Where, ‘t’ = thickness of the weld excluding any allowable reinforcement. For a
butt weld joining two members having different thicknesses at the
weld, t is the thinner of these two thicknesses. If a full penetration weld
includes a fillet weld, the thickness of the throat of the fillet shall be
included in t.
● Any group of aligned indications that have an aggregate length
greater than t in a length of 12t, except when the distance between
the successive imperfections exceeds 6L where L is the length of the
longest imperfection in the group;
● Rounded indications in excess of that specified by the acceptance
standards given in Appendix 4 of ASME Sec.VIII, Div I.
e. Acceptance criteria shall be as per ASME Section VIII, Division I - Paragraph
UW-52 for spot radiography.

5 Documents and Records

5.1 Radiography Report shall be prepared by NDE Level II (Radiography Testing)

5.2 Radiographic Test Report.