INDEX

PAGE
S.No: DESCRIPTIONS

COVER PAGE 1
INDEX 2
1 SCOPE 3
2 REFERENCE DOCUMENTS 3
3 PERSONNEL QUALIFICATION 3
4 PROCEDURE QUALIFICATION 4
5 SAFETY 4
EQUIPMENT, CONSUMABLES &
6 4
ACCESSORIES
7 IMAGE QUALITY INDICATOR 5
8 FILM 6
9 INTENSIFYING SCREEN 6
10 SURFACE PREPARATION 6
11 PREVENTION OF BACK SCATTERING 6
12 TECHNIQUES 7
13 IDENTIFICATION 7
14 GEOMETRICAL UNSHARPNESS 8
15 EXPOSURE TIME 8
16 FILM LOADING 8
17 FILM PROCESSING 8
18 FILM VIEWING 9
19 FILM DENSITY 9
20 FILM CONTRAST 10
21 SENSITIVITY 10
22 INTERPRETATION 10
23 RETEST 11
24 REPORTING 11
25 TECHNIQUE SHEET 12
26 REPORT FORMAT 14

Project No.: P14333

DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 2 OF 14
1.0 SCOPE:

This Procedure describes Radiographic Testing of Carbon steel and Stainless Steel
welds of Piping and Pipelines by using Panoramic X-Ray Generators for detecting
the discontinuities in Weld and as well as Heat effected Zone . The applicable
diameter shall be 6” to 30”and a thickness range of 5 to 25mm.

2.0 REFERENCE DOCUMENTS: (ALL LATEST EDITIONS)

ASME Section V Boiler and Pressure Vessel Code for Non

2.1
Destructive Testing
ASME B 31.4 Pipeline Transportation System for Liquid
2.2
Hydrocarbons and other Liquids
2.3 DEP 61.40.20.30-Gen Welding pipelines and Related Facilities

2.4 ASTM E – 94 Standard Guide for Radiographic Testing

Standard Method for Controlling Quality of
2.5 ASTM E – 142 Radiographic Testing
Standard Method for Controlling Quality of
2.6 ASTM E – 747 Radiographic Testing using Wire
Penetrameters

ADCO DOC NO : 30-99-00- Amendments/Supplements to DEP

2.7
0041-1 61.40.20.30-Gen
ASNT SNT TC –1A Guidelines for Personnel Qualification &
2.8
Certification
Non-Destructive Testing: Image Quality of
2.9 DIN 54109-Part 1
Radiographs of Metallic Materials
Specifications for minimum requirements for
2.10 BS EN 25580: 1992
Industrial Radiographic Illuminators for NDT
LTIS– written practice for Training and
2.11 NDT-SOP-001-03
Certification of Personnel
Radiography Safety
2.12
Procedure ADCO Doc. No.14.78.90.9936
Radiation Emergency
2.13 ADCO Doc. No 14.78.90.9935
Procedure

3.0 PERSONNEL QUALIFICATION:

The qualification of NDT Inspector to carry out this Testing shall be minimum of
ASNT Level II in accordance with the company’s Written Practice NDT-SOP-001-03,
which is in accordance with documents ASNT SNT- TC -1A in Radiography Testing
method. The Level II inspector shall always carry out the testing and the

Project No.: P14333

DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 3 OF 14
Interpretation of the results of the Radiographs. Certifying Level III shall have
approval from the company.

4.0 PROCEDURE QUALIFICATION: -

Procedure Qualification test shall be performed to the satisfaction of the company

before starting of the work. The company representative shall witness all
Qualification test. NDT of a test weld may serve as a qualification test for the NDT
procedures and shall be witnessed by the company.

IPSI Crawler suitable for 6” to 18” dia and IPSI pipe line Crawler suitable for 12’’ to 60’’
dia With panoramic X-ray generator of IPSI make of 180 kv,2 mA and IPSI make of
300Kv 3 mA. Films of AFGA D7 or Kodak AA 400 or IX 100 and proper Manual / Auto
Processing Technique used to produce the quality radiograph, shall be performed &
qualified before the starting of work at the work site. All the Radiography technique
stated in the procedure shall be qualified as per the technique sheet attached along with
this procedure.

5.0 SAFETY: -

All Radiography Technician shall have responsibilities to ensure to evacuate the

Public and Non-Classified workers to the safe distance. The area where radiography
is being performed shall be cordon off using cordoning ropes and Signboards prior
to commencement of Radiography operations.

All Radiography Personnel shall use Pocket dosimeter while performing the
Radiography work. Calibrated survey meters shall be used to survey the radiation
area to verify radiation safe area.

All Radiography Personnel shall have responsibilities to themselves and other

persons with regard to safety and shall ensure site facilities are adequate with
regard to lighting, scaffolding and the like prior to commencement of operations.

Safety in this NDT method is the first priority, hence all technicians must work as per
LTIS – Radiation Safety Procedure.

6.0 EQUIPMENT, CONSUMABLES & ACCESSORIES:

 IPSI Pipeline Crawler suitable for 6” to 18” Dia.

 180 kV 2 mA IPSI X Ray tube
 IPSI Pipeline Crawler suitable for 12’’ to 60’’ Dia
 300 KV 3 mA IPSI X ray Tube
 Battery packs and chargers
 Pilot Command
 Collimator & Lead Sheets
Project No.: P14333
DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 4 OF 14
 Survey Meter
 Dosimeter
 Warning Placards
 Cordoning Rope
 Lead Markers
 Indelible Markers
 Measuring tape
 Elastic
 Penetrameters (I.Q.I’s)
 Dark Room Accessories & Consumables

All the Survey / Dosimeter / Monitoring equipment shall be calibrated once in year and
following any repair. Copy of calibration certificate shall accompany the Equipment /
Survey meter at all times.

7.0 IMAGE QUALITY INDICATOR:

7.1 DIN Standard (DIN 54109 – Part1) Wire Type Penetrameter shall be
used to determine Radiographic Sensitivity.
7.2 I.Q.I. selection shall be by the sensitivity requirement for the materials
thickness under examination and shall be compatible with materials
involved.
7.3 The image Quality Indicator selection shall be based on:

IQI Selection
S.No: Wall Thickness
(DIN 54109-Part 1)
1 ≤ 17 mm 10 - 16
2 18mm to 45 mm 06 – 12
3 > 45 mm 01 – 07

7.4 The Sensitivity requirement for Off-Plot Pipeline shall be 2.0% or better.
7.5 Whenever possible, IQI’s shall be placed on the source side of the part
being examined.
7.6 Where inaccessibility prevents for placing IQI on the source side, it shall be
placed on the film side in contact with the part being examined and a lead
letter “F” shall be placed adjust to the IQI.

Project No.: P14333

DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 5 OF 14
8.0 FILM:

Radiographs shall be obtained using Industrial Radiography films. The Films used shall
conform to ASTM/ASME specification E 94/SE 94 Type 1 or Type 2 except for pipe size B
8 inch NPS or less, for which only Type 1 film shall be used. Types of films are
explained in the Table-1 below.

Table-1: Definition of Film Type

Film Speed Contrast Grain Examples
Type
Very High Very Fine Kodak Industrex MX
1 Slow Agfa D4 B
Or Equivalent
High Fine Kodak Industrex AA
2 Medium Agfa D7
Or Equivalent

Unexposed films should be stored in such a manner that they are protected from the
effects of light, pressure, excessive heat, excessive humidity, damaging fumes, vapors’
or penetrating Radiation. Storage of film should be on a first in first out basis.

9.0 INTENSIFYING SCREEN:

Lead screen of Thickness 0.125 mm both front & back shall be used for intensification
purposes when Dark packaged bare films are used or Standard Lead backed daylight films
shall be used. All screens should be handled carefully to avoid dent, scratches and dirt on
the surfaces. Screens that giving non-relevant indications shall be usually examined and
discarded if physical damage is observed.

10.0 SURFACE PREPARATION:

As far as possible all irregularities from the surface (to the extent of coverage of films) shall
be removed for better results and interpretation.

11.0 PREVENTION OF BACK SCATTERING:

To achieve better Radiography definition, it is required to check back scattering by

placing lead Letter. “B” with minimum dimension of 13 mm (0.5inch) high and 1.6
mm(1/16 inch) thick on the backside of film holder to ensure the back scattering
does not harm the film quality. If the image of “B” appears on the radiograph as a
lighter density than background, it is an indication that protection against back-
scattered radiation is insufficient and the radiograph is not acceptable. In such case,
it is advised to place lead sheets on the backside of holder and If the image of “B”
appears on the radiograph as a darker density than background is acceptable.

Project No.: P14333

DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 6 OF 14
12.0 TECHNIQUES:

Single Wall Exposure technique shall be used for Radiography. An adequate

number of Exposure shall be made to demonstrate that the required coverage,
sensitivity, Density, Geometrical Unsharpness etc. has been obtained.

12.1 Single Wall Single Image:

In this technique, the radiation passes through only one wall of the weld and Image of single
wall is recorded on Radiograph.
For single wall single image panoramic exposure, a minimum of three IQI’s shall be placed
equidistant around the circumference across the pipe weld for each exposure.

13.0 IDENTIFICATION:

Each Radiography shall be identified uniquely so that there is a permanent co-

relationship between the part radiographed and the film. Lead markers shall be kept
to identify the Contract Number, Weld Number, Pipeline Station, Nominal diameter
of Pipe, wall thickness, Date of Radiography, Film Location markers, IQI, Welder’s
Number, Repair Number.
The following identification shall be given.

Description Identified
as
Radiographs of the repaired welds shall contain letter R
Retake of film due to scratch or other film marks shall contain
RT
letter
Cut Out Welds RW
Welds Re-shoots due to grinding, cleaning etc. RS

Location Markings:

On pipe welds over 6 inch NPS, a tape measure with Lead numbers every 5 Cms.
or 10 Cms. shall be placed adjacent to the weld. The Zero point shall be on the top
of the pipe and the divisions shall run clockwise in the ascending order. Each weld
shall be marked using indelible non-contaminating marker to provide reference
points.
14.0 GEOMETRICAL UNSHARPNESS

Source to film distance shall be such that the geometrical unsharpness (Ug) shall
be as per the chart below.

Project No.: P14333

DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 7 OF 14
 Ug Maximum (mm)
Material thickness (mm)
Under 50 mm 0.5
50 mm to 75 mm 0.75
Over 75 mm to 100 mm 1.00
Greater than 100 mm 1.70

The Ug of the radiograph shall be determined by

Ug = ft / d,

Where Ug Geometrical unsharpness

f  Effective Source size
d  Distance from Source to the specimen being radiographed
(S.O.D.)
t  Distance from source side of the specimen to the film

15.0 EXPOSURE TIME:

Exposure time shall be calculated with actual Kv and mA, penetrated wall thickness, F.F.D.
and film speed using Exposure chart or Exposure calculator.

16.0 FILM LOADING:

Film shall be loaded in the dark room under proper safe light, Filter. Films shall be cut
carefully without any damages, scratches or finger marks. Sandwich the film between pair of
screens & loaded into light tight PVC cassettes or holders. The maximum Residual Fog
level for unexposed film shall not be more than 0.3.

17.0 FILM PROCESSING:

Film shall be processed in a dark room under safe light. The temperature of the
chemical shall be 20C  1C or as specified. The film shall be unloaded in hangers
/ spools carefully to avoid any processing marks. Lead intensifying screens from the
films shall be removed carefully.
The Manual processing involves the following steps.

All the steps shall be performed on a test film initially to determine any effect
of processing.

Step: 1 Developer: Shake the hangers or spools to avoid any uneven developing
marks. Developing time shall be as recommended by film manufacturer varies from
minimum 3 to 6 minutes for, class II film & 3 to 8 minutes for class I Film.

Step: 2 Stop bath: The stop bath is water with 5 to 6 drops of Acetic Acid per gallon

Project No.: P14333

DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 8 OF 14
of water, to arrest developing action of films are immersed in a stop bath. . Shake
hanger / Spools for 2 to 3 minutes in the stop bath.

Step: 3 Fixer: To remove the excess silver grains from unexposed or less exposed
part of film & to harden base of film, the hangers / Spools shall be immersed in fixer
for at least 10 minutes.

Step: 4 Running water: Films shall be kept in running water tank where excess
fixer will be washed from the surface of the film. Wash at least for 30 minutes.

Step: 5 Wetting Agent: The film shall be dipped in wetting solution before drying.
This would facilitate quick and even drying and avoid watermarks.

Step: 6 Drying: Film shall be dried in open space or in dryer with circulating hot air
less than 55C.

18.0 FILM VIEWING:

The Films shall be viewed under a high intensity Film Viewer, capable of reading
Radiographs of Density up to 4 & with adjustable light intensity. Viewing shall be done under
subdued background lighting of an intensity that will not cause troublesome reflections,
shadows or glare on the radiograph.
Equipment used to view radiographs for interpretation shall provide a variable light source
sufficient for the essential designated wire to be visible for the specified density range. The
viewing conditions shall be such that light from around the outer edge of the radiograph or
coming through low-density portions of the radiograph does not interfere with interpretation.

Viewing conditions shall confirm to the requirements of EN 25580 (identical to ISO

5580:1985).

19.0 FILM DENSITY:

The density is the quantity measurement of the degree of blackening on the final
radiograph and shall be assessed in the location of the weld.

D = log (Io / It)

Where
D  Density
Io  Light intensity incident on film
It  Light intensity transmitted through the film

For X-Ray Radiography the density of the film throughout the area of interest
acceptable shall be between 1.8 to 3.5.

Project No.: P14333

DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 9 OF 14
To measure the film density a calibrated Densitometer or calibrated Wedge Strip
shall be used. The Densitometer shall have a range to measure density from 0 to 4.

The Calibration of the densitometer shall be checked once in 90 days with calibrated
step wedge film or calibrated densitometer traceable to national & international
Standards
Calibration shall be done in accordance with T-262 of ASME Section-V.

20.0 FILM CONTRAST:

Contrast of the film shall be adequate to manifest on the Radiograph even the
smallest thickness differential. Better the contrast better the interpretation of
discontinuity.

21.0 SENSITIVITY:

Radiographic sensitivity achieved will be 2.0 % or better wherever practical and if the
requirements of ASME Sec V Table T-276 are met the radiograph shall be
considered as acceptable meeting Client requirements. This shall be demonstrated
on the procedure radiograph and accepted by Company prior to commencement of
Production work.

Diameter of thinnest wire Visible on the Radiograph

% Sensitivity = ----------------------------------------------------------------------------------  100
Single penetrated thickness at the area of interest (diagnostic area)

For Single wall Exposure and Single-Wall viewing techniques, the diameter of the
wire shall be based on the nominal single wall thickness of the pipe plus maximum
allowable external weld reinforcement and allowable internal weld protrusion.

22.0 INTERPRETATION:

All indications that are equal to or greater than rejection level described in
acceptance / rejection criteria shall be considered representing defects and may be
cause of rejection or repair of the weld or base metal as per the following
acceptance criteria.

22.1 On- Plot Piping : ASME B 31.4

22.2 Off- Plot Pipelines : API-1104

Project No.: P14333

DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 10 OF 14
23.0 RETEST:
Any relevant indication detected shall be brought to the notice of company
representative prior to the repair. Retest of the repaired area shall be carried out in
accordance with this procedure or External X ray procedure also can apply.

24.0 REPORTING:

All details of inspection and results of inspection shall be documented in attached

report FORMAT and shall be signed by NDT inspector, Contractor and client’s
representative.

Project No.: P14333

DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 11 OF 14
 TECHNIQUE SHEET (For T 7-15mm) FOR SINGLE WALL SINGLE IMAGE
1 Source X - Ray ( Panoramic )
2 Weld of 8”, 6”&10”Φ pipeline
Object Object
Thickness 7 – 15mm
3 Extent of Examination 100%
4 Material Radiographed API 5L GR X 65
5 Make of Equipment IPSI
6 Effective Focal Spot Dia 4 x 0.5mm
7 IQI Type 10 ISO 16
8 No of IQI's 3 Equally Spaced
9 Sensitivity 2.0% or Better
10 Technique SWSI
11 Radiation angle with Respect to Film 90 Degree
12 Focus to Film Distance 3”, 4” & 5” ( OD / 2 )
13 Object To Film Distance Nil
14 Kv & mA used 160/180 Kv & 2 mA
15 Exposure time As per calculation
16 Geometric Unsharpness Less than 0.5mm
17 Type-1 up to dia 8”and Type-2
Film Type
over 8”- Lead Pack
18 Film Dimension 10 x 40cm/Roll pack
19 Film Overlap 50mm
20 Intensifying Screen Lead
21 Screen Thickness 0.125 mm
22 Maximum Fog Level Density < 0.3
23 Film Density 1.8 to 3.5 d.
24 Check On Back Scatter Yes With Lead Letter ' B'
Contract no. weld no. pipeline
25 Identification On Film station, Ø pipe date location, IQI,
welder no. & repair no.
26 Film Processing Manual
27 Processing Chemicals Kodak-Developer & Fixer
28 Acceptance Criteria API 1104
29 Reporting Approved Format

Project No.: P14333

DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 12 OF 14
 TECHNIQUE SHEET FOR SINGLE WALL SINGLE IMAGE
1 Source X - Ray ( Panoramic )
2 Weld of 12”, 16”, 20”, 24”, 26”,
Object 30” Φ pipeline
Thickness 16 - 20mm
3 Extent of Examination 100%
4 Material Radiographed API 5L GR X 65
5 Make of Equipment IPSI
6 Effective Focal Spot Dia 5 x 0.8 mm
7 10 ISO 16(upoto t 17mm)/06
IQI Type
ISO 12 (for t 17-20mm)
8 No of IQI's 3 Equally Spaced
9 Sensitivity 2.0% or Better
10 Technique SWSI
11 Radiation angle with Respect to Film 90 Degree
12 Focus to Film Distance 6”, 8”, 10”, 12” & 15 (OD/ 2 )
13 Object To Film Distance Nil
14 Kv & mA used 160/180 Kv & 2 mA
15 Exposure time As per calculation
16 Geomentric Unsharpness Less than 0.5mm
17 Film Type Kodak AA 400 Lead Pack B
18 Film Dimension 10 x 40cm/Roll pack
19 Film Overlap 50mm
20 Intensifying Screen Lead
21 Screen Thickness 0.125 MM
22 Maximum Fog Level Density < 0.3
23 Film Density 1.8 to 3.5 d.
24 Check On Back Scatter Yes With Lead Letter ' B'
Contract no. weld no. pipeline
25 Identification On Film station, Ø pipe date location, IQI,
welder no. & repair no.
26 Film Processing Manual
27 Processing Chemicals Kodak-Developer & Fixer
28 Acceptance Criteria API 1104
29 Reporting Approved Format

Project No.: P14333

DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 13 OF 14
 Project No.: P14333
DOCUMENT TITLE:
ADCO DOC. NO. 14.78.90.9932
NDT PROCEDURE FOR INTERNAL X – RAY REV. B DATE :01/08/2010
TESTING

PAGE 14 OF 14