Steps For Carrying Out Radiographic Testing On Weld: 5. Calculate Exposure Time For Actual SOD (SOD-A)

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Steps for Carrying out Radiographic Testing on Weld

1.
Check the weld surface finish and maximum

reinforcement outside and inside.
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
flushed with base material or may have reasonably
uniform crowns, with reinforcement not to exceed that
specified in the Table-1.
Material Nominal Thickness
mm (inches)
Less Than 2.4 (3/32)
2.4 (3/32) to 4.8 (3/16), incl.
4.8 (3/16) to 13 (1/2), incl.
13 (1/2) to 25 (1), incl.
25 (1) to 51 (2), incl.
51 (2) to 75 (3), incl.
Category B & C Butt welds

mm (inches)
2.4 (3/32)
3.2 (1/8)
4.0 (5/32)
4.8 (3/16)
5.0 (1/4)
6.0 (1/4)
Other Welds
mm (inches)
0.8 (1/32)
1.6 (1/16)
2.4 (3/32)
2.4 (3/32)
3.2 (1/8)
4.0 (5/32)
2. Find out actual weld thickness + I/S reinforcement + O/S reinforcement

3. Calculate minimum permissible SOD (D) using formula.
Ug = F.d/D. (Maximum Ug permissible up to 50 mm thickness = 0.51 mm).
4. Actual SOD to be used = maximum of D (minimum permissible SOD, as
calculated in step no 3) and twice of segment length as marked on the job.
5. Calculate exposure time for actual SOD (SOD-A)
5.1 For X- RAY; Using exposure chart, find out exposure (E1) for given
thickness, SOD1 (as mentioned in chart) and KV. (KV to be used shall be less
than permissible KV for actual thickness.
WELD THICKNESS
Up to 6.0 mm (1/4)
> 6.0 mm (1/4) < 10.0 mm (3/8)
> 10.0 mm (m3/8) < 25.0 mm
(1)
> 25.0 mm (1)
< 50.0 mm (2)
MAXIMUM kV
100 kV
150 kV
200 kV
250 kV
a) Calculate EA for actual SOD using formula;

E1/EA= (SOD-1)2/ (SOD-A) 2
b) Find out exposure time using formula ; E2= MA-2x T2 (time in
Minutes)
(MA-2=Machine Current to be used Minimum permissible time 30
seconds).
5.2 For Gamma RAY (IR-192 Source)
a) Formulae
Exposure Time in minutes = FF x 2X/HVT x (Actual SOD in cm) 2 x 60
S.S. (in curie) x RHM x (100)2
FF = Film factor for film to be used (1.7 for D7 film (for 2.5 density), HVT= 12.5mm for Steel
X- actual weld thickness in mm, S.S source activity in curie, RHM factor for Ir-192 =0.5
6 Cut the film with wrapper of size to be used (depending upon weld, segment
length overlapping on both ends) in dark room.
7 Load the cut film without wrapper .sandwiched in intensifying lead (front
0.10mm/ back 0.15mm) in PVC cassettes in the dark room.
8Mark the segment length, identification marks on the job (item). Manufacturers
symbol ,Job number, Tag Number, Weld / part number,
9 Punch the details as mentioned in (8) on the job, if permissible. Otherwise use
permanent marker.
10 Paste the lead numbers / letters on the punch mark/ permanent marker. Also
paste the date of radiography, R1/R2 / RS-1 etc if applicable using cello tape.
11 Put applicable IQI on job on source side, if possible. (as per T-276)
12 Fix the loaded cassette, with Lead Letter B on back side of cassette, on the
back side of the job.
13 Align the source, at actual SOD
14 Expos the film for calculated time
15 Remove the cassette from job, after the exposure.
16 Develop the film in Dark room as per procedure
Development ------- 5 minutes at 20 degC,
Stop bath- 30 sec
Fixer -------10 minutes, Washing in running water----- 20 minutes
Wetting agent- a few seconds, Dry in still Air or Hot Dryer, till
complete dry.
(Maximum dry temp-40 deg C)
17 Put dried film, in the wrapper
18 Mark the detail of Radiograph on wrapper
19 Check the density (minimum/maximum) in the area of interest
20 Check the sensitivity as per table T-276 if acceptable; find out density near the
required IQI wire / IQI hole, using calibrated densitometer.
(Maximum minimum density should be +15%, +30% of the density near
the designated wire / hole.)
21 If density / sensitivity is acceptable check discontinuity as per UW-51 (Full
radiography) /UW-52( Spot radiography)
21, 1 Full Radiography as per UW-51 of ASME Section VIII Division 1

Indications shown on the radiograph of welds and characterized as imperfections are unacceptable
under the following conditions and shall be repaired and re-radiographed.
(1)
Any indication characterized as a crack or zones of incomplete fusion or

penetration.
(2)
Any other elongated indication on the radiograph which has length greater
than:
(a) 6mm (1/4) for t up to 19mm (3/4)
(b) 1/3 t for t from 19mm (3/4) to 57mm (2 ).
(c) 19mm (3/4) for t over 57mm (2 )
Where, t = the thickness of the weld excluding any allowable reinforcement. For butt weld
joining two members having different thicknesses at the weld, t is thinner of those two
thicknesses. If a full penetration weld includes a fillet weld, the thickness of the throat of the
fillet shall be included in t.
(3)
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.
(4)
Rounded indications in excess of that specified by the acceptance

standards given in Appendix-4 of ASME Code Section VIII Division 1.
21.2
Spot Radiography as per UW-52 of ASME Section VIII Division 1
The acceptability of welds examined by spot radiography shall be judged by the following
standards:
Welds in which indications are characterized as cracks or zones of incomplete fusion or penetration
are unacceptable
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 thicknesses at the weld, t is the thinner of these thicknesses. If a full
penetration weld includes a fillet weld, the thickness of the throat of the fillet shall be
included in t.
21.2.1.1 For all thicknesses, indications less than in. (6 mm) are acceptable, and indications
greater than in. (19 mm) are unacceptable. Multiple aligned indications meeting these
acceptance criteria are acceptable when the sum of their longest dimensions indications
does not exceed t within a length of 6t (or proportionally for radiographs shorter than 6t),
and when the longest length L for each indication is separated by a distance not less than
3L from adjacent indications.
21.2.1.2 Rounded indications are not a factor in the acceptability of welds not required to be fully
radiographed.
22.0;
Date,
Make the test Report and put acceptability and Remarks. And Sign the report with name and
------------------------------------------------------------------------------------------------------------------------
Table- - Wire IQI Designation, Wire Diameter and Wire Identity

(Based on ASME Section V, Table T233.2)
Set A
Wire Diameter
mm
inch
Wire
Identity
Set B
Wire Diameter
mm
inch
Wire
Identity
Set C
Wire Diameter
mm
inch
Wire
Identity
0.08
0.0032
0.25
0.010
0.81
0.032
11
0.10
0.004
0.33
0.013
1.02
0.040
12
0.13
0.005
0.41
0.016
1.27
0.050
13
0.16
0.0063
0.51
0.020
1.60
0.063
14
0.20
0.008
0.64
0.025
10
2.03
0.080
15
0.25
0.010
0.81
0.032
11
2.54
0.100
16
IQI Selection (Based on ASME Section V, Table T-276)Nominal Single-Wall Material Thickness Range,
mm (inch)
Source Side
Film Side
Wire Type
Wire Type
Essential Wire Essential Wire
Up to 6.4 inclusive (0.25)
Over 6.4 through 9.5 (0.25 through 0.375)
10
11
10
12
11
13
12
SOD (D) ----- Source to Object Distance, OFD (d) ----- Object (Source side) to film distance
I (R/Hr) = Source Strength (in curle) x RHM
D2 (in meter)
RHM Roentgen / hr at 1 meter, for 1 curie, 0.5 for Ir-192, 1.3 for Co-60.
I1 = (D2)2
(D1)2
Inverse Square Law ;
I2
I1 = Intensity at D1 distance,
I2 = Intensity at D2 distance
GAMMA RAY SOURCE PROPERTIES

SOURCE HALF
LIFE
Ir- 192
74days
RHM
factor
0.5
ENERGY USEFULL HVT

Mev
RANGE
STEEL
0.4 (Avg) 10-75 mm 12.5mm
HVT
LEAD
4.8 mm
Co .60
1.3
1.17, 1.33
12mm
5.3
Years
38-150mm
20.0 mm
HVT
TVT
CONCRETE
46 mm
=3.3x
HVT
66mm
=3.3x
HVT
Gamma ray
Exposure Time
(in minutes)
FF x 2X/HVT x (Actual SOD in cm) 2 x 60

S.S. (in curie) x RHM (0.5) x (100) 2
FF = Film factor for film to be used,

(1.7 for D7 film (For 2.5 density)
X= thickness, SS = source strengths
,
OFD,
Ug (Geometrical Unsharpness) = F x d F = Source size,

D= SOD
D
For x Ray
(Minutes)
E1
= (SOD1) 2
E2
(SOD2) 2
E= Current (MA) x Time
d=
Quality/ Quantity of Radiation (X-ray and Gamma

Rays)
Quantity /
Quality
Intensity (I)
(Quantity / Area)
Energy of
Radiation
Penetrating
Power
Quality
(Soft/Hard)
Soft Low
energy
Hard- high energy.
X- Ray machine
Depends upon
current(mA)
Distance(SOD)
Exposure time
Depends upon KV
(Voltage)
High KV
High Energy, (Smaller
Wave length, Higher f) Higher penetrating
Power.
Low KV- low Energy,
(larger Wave length,
smaller f) - Lower
penetrating Power.
Gamma ray
source
Depends upon
Source
strength
Exposure
time
Distance(SO
D)
I = S.SxRHM
(SOD)2
Depends upon
only on nature of
source
Ir 192 0.4 Mev
Co .60 1.17, 1.33
Mev
Remarks
I1 = (D2)2
I2 (D1)2
E = Current
x time
Does not
change
with
Time
Distance
Source
strength
Source size
Note: --- Gamma ray activity--- 1Curie= 3.7x1010 DIS (disintegration/ second)
With decay time;
Source Strength (Curie) Decreases
Energy --- Remains same
Size Remain same
Percentage sensitivity (wire type IQI)
(Low %-Better Quality)
= Dia of smallest visible wire x 100

Job (Weld) thickness,
For hole type IQI

Equivalent Sensitivity in % = 100 X(Tx h) 1/2
X
2
where T = IQI Thickness in thou,
h = Diameter of smallest visible hole
in thou,
X= Job (Weld) Thickness in thou.
1mm= 40 thou, 1 inch= 1000 thou.
Radiograph
For x ray
For Gamma ray
Density
1.8(Min) 4.0(Max)
2.0(Min) 4.0(Max)
(Radiograph Density (Optical Density- No unit, because it is ratio of
Incident light and Transmitted light from Radiograph.)
Radiograph Quality and Sensitivity improve

with;
1. Low radiation energy ( High contrast)
2. Low speed film( High contrast
3. High SOD- Better definition due to smaller Ug.
4. Smaller d (OFD), Better definition due to smaller Ug
5. High radiograph Density (1, 8-4.0) due to High contrast.
6. Processing in Developer at 20 deg C for 5 mts, ( High
contrast)

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Steps for Carrying out Radiographic Testing on Weld

Check the weld surface finish and maximum

Category B & C Butt welds

2. Find out actual weld thickness + I/S reinforcement + O/S reinforcement

a) Calculate EA for actual SOD using formula;

21, 1 Full Radiography as per UW-51 of ASME Section VIII Division 1

Any indication characterized as a crack or zones of incomplete fusion or

Any group of aligned indications that have an aggregate length greater

Rounded indications in excess of that specified by the acceptance

Spot Radiography as per UW-52 of ASME Section VIII Division 1

Table- - Wire IQI Designation, Wire Diameter and Wire Identity

Up to 6.4 inclusive (0.25)

Over 6.4 through 9.5 (0.25 through 0.375)

Over 9.5 through 12.7 (0.375 through 0.50)

Over 12.7 through 19.0 (0.50 through 0.75)

Over 19.0 through 25.4 (0.75 through 1.00)

Over 25.4 through 38.1 (1.00 through 1.50)

Over 38.1 through 50.8 (1.50 through 2.00)

Over 50.8 through 63.5 (2.00 through 2.50)

Over 63.5 through 75.0 (2.50 through 3.00)

Inverse Square Law ;

GAMMA RAY SOURCE PROPERTIES

ENERGY USEFULL HVT

FF x 2X/HVT x (Actual SOD in cm) 2 x 60

FF = Film factor for film to be used,

X= thickness, SS = source strengths

Ug (Geometrical Unsharpness) = F x d F = Source size,

E= Current (MA) x Time

Quality/ Quantity of Radiation (X-ray and Gamma

= Dia of smallest visible wire x 100

For hole type IQI

Radiograph Quality and Sensitivity improve

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