PAHARPUR COOLING TOWERS LTD

Document No. PCTL/NDT/ASME/RT/001 Rev.00

Date of Issued 28th October 2016
Total Page:

RADIOGRAPHIC TESTING
PROCEDURE

Prepared By: Approved By: Accepted By: Reviewed By:

Panchandri Karmakar Goutam Kumar Deb S. Dutta Gupta

ASNT Level-II NDT Level-III QA Manager
PAHARPUR COOLING TOWERS LTD
RADIOGRAPHIC TESTING PROCEDURE
DOC NO : PCTL/NDT/RT – 001 Rev. 0
ISSUE DATE : 28.10.2016

Revision
Number Issue Date Changes Remarks

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PAHARPUR COOLING TOWERS LTD
RADIOGRAPHIC TESTING PROCEDURE
DOC NO : PCTL/NDT/RT – 001 Rev. 0
ISSUE DATE : 28.10.2016

CONTAINT

1. SCOPE 03
2. REFERENCE DOCUMENT 03
3. ABBREVIATION 03
4. OPERATION 03
5. PERSONNEL QUALIFICATIONS 03
6. RESPONSIBILITIES 04
7. RADIATION SAFETY 04
8. SOURCE OF RADIATION 04
9. GEOMETRICAL UNSHARPNESS 04
10. FILMS 05
11. INTENSIFYING SCREENS 05
12. SURFACE PREPARATION 05
13. IDENTIFICATION SYSTEM 05
14. LOCATION MARKER 05
15. BACK SCATTER 06
16. TECHNIQUES 06
17. IMAGE QUALITY INDICATOR 06
18. PLACEMENT OF IQI 07
19. NUMBER OF IQI 08
20. EXPOSURE TIME 10
21.FILM PROCESSING & QUALITY 10
22. EVALUATION OF RADIOGRAPH 10
23. RADIOGRAPHIC DENSITY 11
24. IQI SENSITIVITY 11
25. ACCEPTANCE STANDARD 12
26. DOCUMENTATION 13
27. TABLE-1 & TABLE-2 14
28. TABLE-3 15
29. TABLE-4 16
30. RADIOGRAPHY REQUEST FORMAT 17
31. RADIOGRAPHY EXAMINATION REPORT 18

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RADIOGRAPHIC TESTING PROCEDURE
DOC NO : PCTL/NDT/RT – 001 Rev. 0
ISSUE DATE : 28.10.2016

1.0 SCOPE:
This procedure is applicable for Radiographic Examination for welds in Pressure Vessels
and components manufactured in accordance with Code ASME Section VIII Division 1.
Material thickness up to 100mm of carbon steel and stainless steel with ϒ-rays Ir-192/
or X-rays.
2.0 REFERENCE DOCUMENTS:
2.1 ASME Section V – Article 1, 2 & 22 (2015 edition)
2.2 ASME Sec VIII Div. 1, UW 51 & UW 52.
2.3 ASTM Standard E142-92, Standard Method for Controlling Quality RT
2.4 ASTM E747-97, Practice for Design, Manufacturer and Material Grouping
Classification of Wire Image Quality Indicators (IQI) Used for Radiology.
2.5 ASTM E1025-95, Practice for Design, Manufacturer and Material grouping
Classification of Wire Image Quality Indicators (IQI) Used for radiology.
2.6 ASTM E1032-95, Standard Test Method for Radiographic Examination of weldments.

3.0 ABBREVIATION:
ASME - AMERICAN SOCIETY OF MECHANICAL ENGINEERS
ASTM - AMERICAN SOCIETY FOR TESTING AND MATERIALS
RPI - RADIATION PROTECTION INSPECTORATE
RPO - RADIATION PROTECTION OFFICER
IQI - IMAGE QUALITY INDICATOR
DIN - DEUTSCHES INTITUT FǕR NORMUNG
HAZ -HEAT AFFECTED ZONE
4.0 OPERATION:

The exposure device and related equipments used to achieve the above scope shall be
carried out by a team of two (2) personnel as a minimum. (RPI licensed Radiographer
Level-II and a Radiographer Level-I or Assistant).

5.0 PERSONNEL QUALIFICATIONS:

The Personnel who carry out Radiography Testing shall be qualified and certified in
accordance with PCTL’s written practice.
Interpretation shall be carried out by experienced NDE Level-II or NDT Level-III.

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6.0 RESPONSIBILITIES:
Radiographer Level-II is responsible for selecting appropriate Techniques, ensuring Site
Safety, processing, and interpretation as per applicable codes.
Radiographer Level-I shall assist the Level-II to achieving the above.
7.0 RADIATION SAFETY:
Duties of the radiographer include personnel protection and protection of general public
according to the latest maximum permissible limits. All work shall be carried out in line
with the regulations of BARC India and modified as and where necessary by
PCTL/client’s safety standards.
The Radiographic Testing Company’s Radiation Protection Officer (RPO) shall be a
qualified person and certified by a National Radiation Protection Body. He is responsible for
overall site safety, Dosimeter, and Handling of Emergency situation.
8.0 SOURCE OF RADIATION :
Remotely operated projectors shall be used such as Amertest-660/Delta 880 or equivalent.
Ir.192/Cobalt-60 isotope with maximum activity of 50 Curies or X-rays with voltage not
exceed 440volts.shall be used.
9.0 GEOMETRIC UNSHARONESS (Ug) :

9.1 Geometric unsharpness of the radiograph shall be determined in accordance with:

Ug = Fd /D
where, Ug = Geometric unsharpness.
F = Source size: 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 radio graphed.
D = Distance from source of radiation to weld or object being radio graphed.
d = Distance from source side of weld or object being radio graphed to the
film D and d shall be determined at the approximate center of the area of
interest.
Recommended maximum values for geometric unsharpness are as follows:

Material Thickness, in. (mm) Ug Maximum, in. (mm)

Under 2 (50) 0.020 (0.51)
2 through 3 (50–75) 0.030 (0.76)
Over 3 through 4 (75–100) 0.040 (1.02)
Greater than 4 (100) 0.070 (1.78)

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RADIOGRAPHIC TESTING PROCEDURE
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10.0 FILMS:

10.1 Film used shall be industrial radiographic film. The following films or equivalent may
be used:

Brand Designation Factor

Agfa D7, D5,D4, D2 1.4 /2.2 /4.2 /6.0
Kodak AA400/T200/MX125/DR50 1.2/2.4/4.6/6.2

10.2 Films shall be stored in a clean, dry place that is free from radiation, excessive heat,
undue pressure, or chemical vapor.
11.0 INTENSIFYING SCREENS:
11.1 Lead foil intensifying screens shall be used at front and back of the film. Film and
screens shall be placed together and sealed inside a light proof cassette, maintaining
good contact throughout the exposure.
11.2 For Iridium-192, Front and Back screen thickness shall be minimum of 0.125mm and
0.100mm respectively.
11.3 Lead screens shall be maintained clean and free of scratches, dust and moisture that
might create film artifacts and impair radiographic quality.
12.0 SURFACE PREPARATION :
The 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 images of
surface irregularities cannot mask or be confused with the image of any discontinuity on
the resulting radiograph.
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.

13.0 IDENTIFICATION SYSTEM :

Radiographs shall be identifiable as to job No. weld seam No., welder no., date of
radiograph, Manufacturer’s name or symbol. This identification system in form of
radiograph image.

14.0 LOCATION MARKER:

Location markers (see Fig. T-275), which are to appear as radiographic images on the film, shall be
placed on the part, not on the exposure holder /cassette. Their locations shall be permanently
marked on the surface of the part being radio graphed 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,

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for the required retention period of the radiograph. Evidence shall also be provided on the
radiograph that the required coverage of the region being examined has been obtained.
Location markers shall be placed as either on source side or film side as per the guidelines
shown in Fig.001.
For, Double Wall Viewing , at least one location marker shall be placed adjacent to the
weld for each radiograph.
15.0 BACK SCATTER :
A Lead letter ‘B’ of minimum height 13mm and 1.5 mm thick shall be attached to the back
of each film holder during exposure to indicate the presence of back scatter radiation if any,
Light image of ‘B’ on darker background of radiograph indicates insufficient protection
from back scatter and shall be not acceptable.
16.0 TECHNIQUE :
16.1 Single Wall Single Image (SWSI) : In the single wall technique, the radiation passes
through only one wall of weld material, which is viewed for acceptance on the radiograph.
16.2 Double Wall Technique : when it is not practical to use a single wall technique, one of
the following double-wall technique shall be used.
16.2.1 Double Wall Single Image (DWSI):
Radiation pass through the two walls and the image of the further weld on film side
is viewed for acceptance. when complete coverage is required of circumferential
welds, a minimum of three exposure shall be taken 120 º to each other.
16.2.2 Double Wall Double Image (DWDI):
For materials and welds in components 31/2 in(89mm) or less in nominal outside
diameter, a technique may be used in which Radiation pass through the two walls
and the weld material in both walls is viewed for acceptance on the same
radiograph. For weld , the radiation may be offset from the plane of weld at an angle
sufficient to separate the image of source side and film side areas of weld such that
there is no overlap of areas to be taken 90º to each other for each joint.
As an alternative, the weld may be radio graphed with the radiation beam positioned
so that the image of both walls are superimposed. When complete coverage is
required , a minimum of three exposures taken at either 60º or 120º to each other
shall be made for each joint.

17.0 IMAGE QUALITY INDICATOR (IQI) :

17.1 The IQI shall be either hole type or wire type conforming to the specification SE-
1025 for hole type or SE-747 for wire type.
17.2 IQI shall selected from either the same alloy material group or grade as identified in
SE-1025 or SE-747, as applicable or from an alloy material group or grade with less
radiation absorption than the material being radiograph.

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17.3 IQI selection shall be as per Table-003. A thinner hole type IQI may be substituted
for any section thickness listed in table provided an equivalent IQI sensitivity is
maintained as given Table-004.
17.4 Welds with reinforcement : selection of IQI shall be based on the nominal single wall
thickness plus the estimated weld reinforcement not exceed the permissible limit.
Backing strip are excluded.
17.5 Welds joining with dissimilar materials or welds with dissimilar filler metal. when the
weld metal is of an alloy group or grade with a radiation attention different from base
material, the IQI material selection shall be based on weld metal and be in accordance
with para 14.2. when the density limits as specified para 19.4 canot be met with one
IQI, and the exceptional densities are at the interface of weld metal and the base metal,
the material selection for additional IQI shall be based on the base material and in
accordance with para 14.2.

18.0 PLACEMENT OF IQI :

18.1 A source side IQI of the thickness shown in Table-3, as may be applicable shall be
placed on the on the side nearest the radiation source (i.e. source side of the object).
Where it is impractical to hand place the IQI on the source side , a film side IQI from
Table-3, as may be applicable shall be placed on the film side of the object and lead
“F” as high as the IQI identification number shall be placed adjacent to or on the IQI
identification number shall be placed adjacent to or the IQI but shall not musk the
essential hole of the IQI, where hole type IQI are used.
18.2 When, due to part or weld configuration or size, it is not practical to place the IQI on
the part or weld, the IQI may be placed on a separate block. Separate blocks shall be
made of the same or radio graphically similar materials (as defined in SE-1025) and
may be used to facilitate
IQI positioning. There is no restriction on the separate block thickness, provided the
IQI/area-of-interest density tolerance requirements of T-282.2 are met.
i) The IQI on the source side of the separate block shall be placed no closer to the film
than the source side of the part being radio graphed.
ii) The separate block shall be placed as close as possible to the part being radio
graphed.
iii) When hole-type IQIs are used, the block dimensions shall exceed the IQI dimensions
such that the outline of at least three sides of the IQI image shall be visible on the
radiograph.

(b) Film-Side IQI, Where inaccessibility prevents hand placing the IQI on the source side,
the IQI shall be placed on the film side in contact with the part being examined.
A lead letter “F” shall be placed adjacent to or on the IQI, but shall not mask the
essential hole where hole IQI are used.

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(c) IQI Placement for Welds — Hole IQI, The IQI may be placed adjacent to or on the
weld. The identification numbers and, when used, the lead letter “F,” shall not be in
the area of interest, except when geometric configuration makes it impractical.
(d) IQI Placement for Welds — Wire IQI, The IQI shall be placed on the weld so that the
length of the wires is perpendicular to the length of the weld. The IQI identification
and, when used, the lead letter “F,” shall not be in the area of interest, except when
geometric configuration makes it impractical.
(e) IQI Placement for Materials Other Than Welds. The IQI with the IQI identification
and, when used, the lead letter “F,” may be placed in the area of interest.

19.0 NUMBER OF IQIs :

19.1 When one or more film holders are used for an exposure, at least one IQI image shall
appear on each radiograph except as outlined in (17.1B) below:
(a) Multiple IQIs. If the requirements of T-282 are met by using more than one IQI, one
shall be representative of 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.
(b) Special Cases3
i) For cylindrical components where the source is placed on the axis of the component
for a single exposure, at least three IQIs, spaced approximately 120 deg apart, are
required under the following conditions:
a) When the complete circumference is radiographed using one or more film holders,
or;
b) When a section or sections of the circumference, where the length between the
ends of the outermost sections span 240 or more deg, is radiographed using one
or more film holders. Additional film locations may be required to obtain
necessary IQI spacing.
ii) For cylindrical components where the source is placed on the axis of the component
for a single exposure, at least three IQIs, with one placed at each end of the span of
the circumference radiographed and one in the approximate center of the span, are
required under the following conditions:
a) When a section of the circumference, the length of which is greater than 120 deg
and less than 240 deg, is radiographed using just one film holder, or;
b) When a section or sections of the circumference, where the length between the
ends of the outermost sections span less than 240 deg, is radiographed using more than
one film holder.
iii) In (1) and (2) above, where sections of longitudinal welds adjoining the
circumferential weld are radiographed simultaneously with the circumferential
weld, an additional IQI shall be placed on each longitudinal weld at the end of the
section most remote from the junction with the circumferential weld being
radiographed.

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iv) For spherical components where the source is placed at the center of the component
for a single exposure, at least three IQIs, spaced approximately 120 deg apart, are
required under the following conditions:
a) When a complete circumference is radiographed using one or more film holders, or;
b) When a section or sections of a circumference, where the the length between the ends of
the outermost sections span 240 or more deg, is radiographed using one or more film
holders. Additional film locations may be required to obtain necessary IQI spacing.
v) For spherical components where the source is placed at the center of the component
for a single exposure, at least three IQIs, with one placed at each end of the
radiographed span of the circumference radiographed and one in the approximate
center of the span, are required under the following conditions:
a) When a section of a circumference, the length of which is greater than 120 deg
and less than 240 deg, is radiographed using just one film holder, or;
b) When a section or sections of a circumference, where the length between the ends
of the outermost sections span less than 240 deg is radiographed using more than
one film holder.
vi) In (iv) and (v) above, where other welds are radiographed simultaneously with the
circumferential weld, one additional IQI shall be placed on each other weld.
vii) For segments of a flat or curved (i.e., ellipsoidal, torispherical, toriconical, 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, one placed at each end of the radiographed span and one in the approximate
center of the span, are required.
viii) When an array of components in a circle is radiographed, at least one IQI shall
show on each component image.
ix) In order to maintain the continuity of records involving subsequent exposures, all
radiographs exhibiting IQIs that qualify the techniques permitted in accordance
with (i) through (vii) above shall be retained.
19.2 Shims Under Hole IQI :
19.2.1 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
throughout the area of interest is no more than minus 15% from (lighter than) the
radiographic density through the IQI.
19.2.2 The shim dimensions shall exceed the IQI dimensions such that the outline of at
least three sides of the IQI image shall be visible in the radiograph.

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20.0 EXPOSURE TIME :

20.1 For, X-rays, the exposure time may be calculated from the exposure chart provided by
the manufacturer of X-rays equipment.
20.2 For, Gamma Rays, the exposure time may be calculated with the help of exposure
time calculator or formula.

21.0 FILM PROCESSING & QUALITY :

21.1 Film quality requirements: All radiographs shall be free from mechanical, chemical or
other processing defects that could interfere with proper interpretation of the radiograph,
such as:
i. Fogging.
ii. Processing defects, like streaking, water marks or chemical strains.
iii. Scratches, finger marks, crimps, dirt, static marks, smudges and tears.
iv. Loss of detail due to poor screen-to-film contact, false indications due to
defective screens or artifacts cuse by defective film.
21.2 Film processing: Film will be processed manually. The manual processing film shall be
carried out as per Procedure No. PCTL/NDT/RT-004 based on SE-999 & the guidelines
of the film manufacturer.

22.0 EVALUATION OF RADIOGRAPH :

22.1 Viewing facility : Viewing facility shall provide the following:
i. Subdued lighting condition.
ii. Variable light source sufficient to show the designated wire or essential IQI hole
for the specified density range.
iii. No interference of the light from around the outer edge or low density areas of
the radiograph.

22.2 Radiographic density shall be monitored using a calibrated densitometer or step

wedge comparison film in accrodance with procedure no.PCTL.NDT/RT-2.

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23.0 RADIOGRAPHIC DENSITY :

23.1 Density Limitations. The transmitted film density through the radiographic image of
the body of the appropriate hole IQI or adjacent to the designated wire of a wire IQI
and the area of interest shall be 1.8 minimum for single film viewing for radiographs
made with an X-ray source and 2.0 minimum for radiographs made with a Gamma ray
source. For composite viewing of multiple film exposures, each film of the composite
set shall have a minimum density of 1.3. The maximum density shall be 4.0 for either
single or composite viewing. A tolerance of 0.05 in density is allowed for variations
between densitometer readings.
23.1 Density Variation
(a) General. If the density of the radiograph anywhere through the area of interest
varies by more than minus 15% or plus 30% from the density through the body of
the hole IQI or adjacent to the designated wire of a wire IQI, within the
Minimum / maximum allowable density ranges specified in 23.1, then an
additional IQI shall be used for each exceptional area or areas and the radiograph
retaken. When calculating the allowable variation in density, the
calculation may be rounded to the nearest 0.1 within the range specified in 23.1
(b) With Shims. When shims are used with hole-type IQIs, the plus 30% density
restriction of (a) above may be exceeded, and the minimum density limitation
of 23.1
24.0 IQI SENSITIVITY :

24.1 Required Sensitivity. Radiography shall be performed with such a technique, which
will have sufficient sensitivity to display the designated hole IQI image and 2T hole,
or designated wire of a wire IQI, which are essential indications of the image quality
of the radiograph. The radiographs shall also display the IQI identifying numbers and
letters. If the designated hole IQI image and essential hole, or essential wire, do not
show on any film in a multiple film technique, but do show in composite film
viewing, interpretation shall be permitted only by composite film viewing.

24.2 Demonstration of density and IQI image requirements of this written procedure on
production or technique radiographs shall be considered satisfactory compliance with
this procedure.

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25.0 ACCEPTANCE STANDARD :

25.1 Unless more restrictive standards are specified, the following acceptance standard
shall be followed for the radiographs.
25.2 FULL RADIOGRAPHY :
As per ASME SectionVIII Div.1 ,UW-51
(A) Any indication characterized as a crack or zone of incomplete fusion or penetration;
(B) Any other elongated indication on the radiograph which has length greater than:
(a) 1 4 in. (6 mm) for t up to 3 4 in. (19 mm)
(b) 1 3t for t from 3 4 in. (19 mm) to 21 4 in. (57 mm)
(c) 3 4 in. (19 mm) for t over 21 4 in. (57 mm)
where,
t = the 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.
(C) 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;
(D) Rounded indications in excess of that specified by the acceptance standards given in
Appendix 4 of ASME Section VIII Div.-1.
25.3 SPOT RADIOGRAPHY :
As per ASME SectionVIII Div.1 ,UW-52
(A) Welds in which indications are characterized as cracks or zones of incomplete
fusion or penetration shall be unacceptable.
(B) Welds having indications characterized as slag inclusions or cavities are
unacceptable when the indication length exceeds 2 3t, where t is the thickness
of the weld excluding any allowable reinforcement. For a butt weld joining
two member having different thickness at the weld, t is the thinner of the two
thickness.
If, a full penetration weld includes a fillet weld , the thickness of throat of the
fillet shall be included in t. If several indications within the above limitations
exist in line, the welds shall be judged acceptable if the sum of the longest
dimensions of all such indications is not more than t in a length if 6t
(or proportionately for radiograph shorter than 6t) and if the longest indication
considered are separated by at least 3L of the acceptable weld metal where
L is the length of the longest indication. The maximum length of acceptable
indications shall be ¾ in.(19mm). Any such indications shorter than ¼ in.
(6mm) shall be acceptable for any plate thickness.
(C) Rounded indications are not a factor in the acceptability of welds not required
to be fully radiograph.

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26.0 DOCUMENTATION :

26.1 Radiography request form : A radiography request shall be furnished by

Production in-charge to the QA & QC giving all relevant details for
performing the radiography.
26.2 Radiography Technique : technique sheet shall be prepared before
performing the radiographic examination. This shall be prepared by NDT
Level-II od NDT Level-III in the format attached to this procedure
(page No. 20).
26.3 Review od Radiographs: All the radiographs shall be interpreted and
evaluated by NDT Level-II or Level-III as per the acceptance standard
given in para 25.0 and additional requirements / specification if any.
Radiograph review details shall be filled in the format attached to this
procedure (page no. 20) and submitted along with set of radiographs to AI.

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