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: PCTL/NDE/RT-1
Revision :6
RADIOGRAPHIC EXAMINATION Date : 01-01-2020
OF WELDS
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PROCEDURE FOR Procedure No.: PCTL/NDE/RT-1
Revision :6
RADIOGRAPHIC EXAMINATION Date : 01-01-2020
OF WELDS
TABLE OF CONTAINTS
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PROCEDURE FOR Procedure No.: PCTL/NDE/RT-1
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1.0 Scope
This procedure covers the technique and acceptance standard for radiographic Examination of
welds in Pressure Vessels and Components manufactured in Accordance with Code ASME
Section VIII Div.1
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PROCEDURE FOR Procedure No.: PCTL/NDE/RT-1
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8.0 Screens:
8.1 Intensifying screens made of led should be used.
The finished surface of all butt-welded joints may be flush with the base material or should have
reasonability uniform crowns, with reinforcement no to exceed that specified in the reference.
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13.0 Technique:
13.1 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.
13.2 Double Wall Technique: when it is not practical to use a single wall technique, one of
the following double-wall technique shall be used.
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.
14.1 IQI shall be either hole or wire-type conforming to the specification SE-1025
for hole type and SE-747 for wire-type.
14.2 IQI shall be 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.
14.3 IQI selection shall be as per Table 3. A thinner or thicker hole type IQI may be substituted
for any section thickness listed in Table 3 provided and equipment IQI sensitivity is
maintained as given in Table 4.
14.4 Welds with reinforcement: Selection of IQI shall be based on the nominal single wall
material thickness plus the actual weld reinforcement thickness estimated to be present
on the both side of weld (ID & OD). The values used for estimated weld reinforcement
of actual weld reinforcement is not required. Backing ring or strip shall not be
considered as part of thickness of IQI.
14.5 Welds without reinforcement: Selection of IQI shall be based on the nominal single wall
thickness. Backing strip are excluded.
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14.6 Welds jointing dissimilar materials or welds with dissimilar filler metal: When the
weld metal is of an alloy group or grade with a radiation attenuation different from base
material, the IQI material selection shall be based on the weld metal and be in accordance
with para 14.2. When the density limits as specified in para 19.4 cannot 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.
15.2 When, due to part or weld configuration or size of the object prevents placing the IQI as
described above, it may be placed on a separate block. Separate block shall be
made of the same or radiographically similar material (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 Para 19.0
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 radiograph.
ii) The separate block shall be placed as close as possible to the part being radiograph.
iii) When hole type IQIs are used, the block dimensions shall exceed to the IQI dimensions
such that outline of at least three sides of the IQI image shall be visible on the radiograph.
a) Hole Type IQI location for welds: The IQI shall be placed adjacent to the weld or on the
weld such that 2T hole is towards the end of the spot to be radiograph. The identification
numbers and film side indicator lead letter “F” when used shall not be in the area of interest,
except when geometric configuration makes it impractical to place the IQI, the lead numbers
and the lead letter “F” may be placed in the area of interest.
b) Wire Type location for welds: The IQI shall be placed on the weld with the length of
wires perpendicular to axis of weld & thinner wire towards the end of the spot to be
radiograph. The identification numbers and lead letter “F”, when used shall not be in the
area of interest, except when geometric configuration makes it is impractical to place the
IQI, the lead numbers and lead “F” may be placed in the area of interest.
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a) Multiple IQIs: If the requirements of Para 19.0 are met by using more than one IQI, one
shall be representative of the lightest area of interest and the other darkest area of
interest; the intervening densities of the radiograph shall be considered as having
acceptable density.
b) Special Cases:
i) For cylindrical components where the source is places on the axis of the component
for a single exposure, at least three IQIs, spaced approximately 120degree apart, are
required under following conditions:
a) When a complete circumference is radiograph using one or more film holders or,
b) When a section or sections of the circumference the length between the ends of the
outermost sections span 240 or more degree is radiograph 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 IQI, with one placed at each end of the span of
the circumference radiograph and one in the approximate center of the span are
required under the following condition:
a) When a section of the circumference the length of which is greater than 120degree
and less than 240 degree is radiograph using just one film holder, or:
b) When a section or sections of the circumference, where the length between the ends
of the outer most sections span less than 240 degree is radiograph using more than
one film holder.
iii) In (i) and (ii) above, where sections of longitudinal welds adjoining the
circumferential weld are radiograph 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 radiograph.
iv) For spherical components, where the source is placed at the center of the components
for a single exposure, at least three IQI spaced approximately 120 degree apart, are
required under the following conditions:
a) When a complete circumference is radiograph using one or more film holders or.
b) When a section or sections of a circumference where the length between the
ends of outermost sections span 240 degree or more degree, is radiograph using one
or more film holders. Additional film location may be required to obtain necessary
IQI spacing.
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v) For spherical components where the source is placed at the center of the components
for a single exposure, at least three IQIs, with one placed at each end of the
radiograph span of the circumference radiograph and one in the approximate
enter of the span, are required under the following conditions:
a) When a section of circumference, the length of which is greater than 120 degree
and less than 240 degrees is radiograph using just one film holder or:
b) When a section or sections of circumference, where the length between the ends
of the outermost sections span less than 240 degree is radiograph using more than
one film holder.
vi) In (iv) (v) above, where other welds are radiograph simultaneously with the
circumference weld, one additional IQI shall be placed on each other weld.
vii) For segments of a flat or curved (i.e. ellipsoidal, torisperical, toriconical, elliptical
etc.) Component where source is placed is placed perpendicular to the center of length
of a weld for single exposure when using more than three film holders, at least three
IQIs, one placed at each end of the radiograph span and one in the approximate
center of the span are required.
viii) When array of components in a circle is radiograph, 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 IQI, which qualify the techniques, permitted in accordance
with (i) Through (vii) shall be retained.
16.2.2 The shim dimensions shall exceed the IQI dimensions such that the outline of at
least three sides of IQI image shall be visible in the radiograph.
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17.2 For Gamma ray, the exposure time may be calculated with the help of exposure
time calculator or formula.
Where,
FF = Film Factor
T = The thickness of the weld/object through which radiation passes(in mm/inch)
HVT = Haft Value Thickness (in mm/inch) SFD = Source to film distance(in cm)
RHM – radiation Intensity in Roentgens Ci = Source strength in Curies
18.1 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 and tears.
iv) Loss of detail due to poor screen-to-film contact, false indications due to
defective screens or artifacts caused by defective film.
18.2 Film processing: Film will be processed manually. The manual processing film shall be
carried out as per Procedure No. PCTL/NDE/RT-004 based on SE-999 & the guidelines
of the film manufacturer.
19.0 Evaluation of Radiographs:
19.1 Viewing facilities: Viewing facilities 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.
19.2 Radiographic density shall be monitored using a calibrated densitometer or step
wedge comparison film in accordance with procedure no. PCTL/NDE/RT-1
19.3 Density Limitation:
The transmitted film density through the radiographic image of the body of the
appropriate hole IQI adjacent to the designated wire of the wire IQI adjacent to
essential hole or adjacent to the designated wire of wire IQI and area of interest
shall be 1.8 minimum for single film viewing for radiographs made with X-ray
source and 2.0 minimum for radiograph made with a Gamma ray source.
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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 for variations between densitometer readings.
20.1 Require Sensitivity Radiographic shall be performed with such a technique, which
will have sufficient sensitivity to display designated hole IQI image, and 2T hole,
or the designated wire of wire IQI, which are essential indications of the image quality
of the radiograph. The radiograph shall also display the identifying numbers and
letters, If the designated hole IQI image and essential hole or essential wire, do not
show on any film in multiple film technique, but do show in composite film
viewing, interpretation shall be permitted only by composite fil viewing.
20.2 Demonstration of density and IQI image requirements of this written procedure on
production or technique radiographs shall be considered satisfactory compliance with
this procedure.
21.0 ACCEPTANCE STANDARD:
21.1 Unless more restrictive standards are specified, the following acceptance standard
shall be followed for the radiographs:
21.2 FULL RADIOGRAPHY: (As per ASME Section VIII 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 greater than.
(a) ¼ in.(6mm) for t up to ¾ in. (19mm).
(b) 1/3 t for t from ¾ in. (19mm) to 2 ¼ in. (57mm).
(c) ¾ in. (19mm0 for t over 2 ¼ in. (57 mm).
where,
t= thickness of the weld excluding any allowable reinforcement. For a butt weld
joining two members having different thickness at the weld, t is thinner of the
two thickness. If a full penetration weld includes a fillet weld, thickness of throat
of the fillet shall be included in t.
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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.
21.3 SPOT RADIOGRAPHY (As per ASME Section VIII 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 in which indications are characterized as slag inclusions or cavities shall be
unacceptable, if the length of any such indication is greater
than 2/3 t where t is the thickness of the weld excluding any allowable
reinforcement. For a butt weld joining two members 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 of 6t
(or proportionately for radiograph shorter than 6t) and if the longest indication
considered are separated by at least 3L of 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
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22.0 DOCUMENTAION:
22.1 Radiography request form: A radiography request shall be furnished by the Production-in-charge
to the IC-QC giving all the relevant details for performing the radiography.
22.2 Radiography Technique: Technique sheet shall be prepared before performing the radiographic
examination. This shall be prepared by NDT Level II or NDT Level III in the format attached to
this procedure (page no 19 Radiographic Examination Report).
22.3Review of Radiographs: All the radiographs shall be interpreted and evaluated by NDT Level II or
Level III as per the acceptance Standard given in para 21.0 and additional requirements /
specification, If any Radiograph review details shall be filled in the format attached to this
procedure (page no. 19) and submitted with set of radiographs to AI.
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TABLE-1
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TABLE-2
Set A Set B
Wire Diameter Wire Wire Diameter Wire
Inch(mm) Identity Inch(mm) Identity
0.0032(0.08) 1 0.010(0.25) 6
0.004(0.10) 2 0.013(0.33) 7
0.005(0.13) 3 0.016(0.41) 8
0.0063(0.16) 4 0.020(0.51) 9
0.008(0.20) 5 0.025(0.64) 10
0.010(0.25) 6 0.032(0.81) 11
Set C Set D
Wire Diameter Wire Wire Diameter Wire
Inch(mm) Identity Inch(mm) Identity
0.032(0.81) 11 0.10(2.54) 16
0.040(1.02) 12 0.126(3.20) 17
0.050(1.27) 13 0.160(4.06) 18
0.063(1.60) 14 0.200(5.08) 19
0.080(2.03) 15 0.250(6.35) 20
0.100(2.54) 16 0.320(8.13) 21
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TABLE-3
MATERIAL THICKNESS, IQI DESIGNATION AND ESSENTIAL WIRE
(Identical to ASME SEC. V Table No. T 276)
IQI
Nominal Single Wall Source Side Film Side
Material Thickness Range Hole Type Hole Wire Hole Type Hole Wire
Inches (mm) Designation Visible Type Designation Visible Type
Essential Essential
Wire
Up to 0.25 (6.4) 12 2T 5 10 2T 4
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TABLE-4
EQUIVALENT HOLE TYPE IQI SENSITIVITY
(Identical to ASME SEC. V Table No. T 283)
10 15 5
12 17 7
15 20 10
17 25 12
20 30 15
25 35 17
30 40 20
35 50 25
40 60 30
50 70 35
60 80 40
80 120 60
100 140 70
120 160 80
160 240 120
200 280 140
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