PROCEDURE FOR RADIOGRAPHY TEST OF

PIPING(GAMMA)

Project Details

PROJECT

CLIENT

PMC

CONTRACTOR

00

REV DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY

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Table of Contents

SL nos. Descriptions Page nos.

1.0 PROJECT........................................................................................03

2.0 PURPOSE................................................................................................03

3.0 REFERENCES...............................................................................03

4.0 METHODOLOGY...................................................................................03

5.0 REPAIR WELD.......................................................................................05

6.0 EQUIPMENT & MATERIALS........................................................06

7.0 EXPOSURE....................................................................................09

8.0 FLIM PROCESSING…..........................................................................14

9.0 INTERPETETION…................................................................................15

10.0 RADIATION SAFETY…........................................................................17

11.0 QA/QC…..................................................................................................18

12.0 APPENDICES/FORMATS.....................................................................18

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1.0 PROJECT
Project name.

2.0 PURPOSE
The purpose of this document is to lay down specific guidelines and requirements for
Radiography Test of Piping to be used at client site

3.0 REFERNCE

2.1 ASME Section V : Non-destructive Testing

2.2 SNT-TC-1A : ASNT Recommended practice
2.3 HPCL Client Specification
2.4 ASME 31.3 & 31.4 & API 1104

4.0 METHODOLOGY

4.1 General

The piping -------------------------------------------------------------------------------------- shall be

subjected to 100% radiography inspection whereas the fire water lines including MVWS piping
and air lines shall be subjected to radiographic inspection. The Contractor shall arrange
radiographic inspection of welds through an experienced and reputed independent agency that
will be treated as a sub-Contractor.

4.2 Personnel Qualification

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At least one radiographic Level II personnel qualified in accordance with SNT-TC-1A or

equivalent shall be involved for each of radiographic testing team. The Level II personnel shall
perform his work with Level I personnel. The Level II personnel has the responsibilities for
radiography agency work & shall ensure that radiography agency takes correct joint as offered.
Individual who interprets the radiographs shall also be qualified to ASNT Level II of radiographic
testing or equivalent. A person qualified to ASNT to ASNT Level II in RT shall prepare the
procedure and shall be established to demonstrate that the required sensitivity can be consistently
achieved under the most unfavorable parameters without procedure qualification for each
technique production shall not be permitted.

4.3 Surface preparation

Before radiography work, visual inspection shall be carried out. Rough weld ripples and surface
which can mask the relevant defects shall be removed or dressed by suitable means. Surface of
the weld shall be free from undercut, overlap and abrupt ridges or valleys. The reinforcement of
the welds should not exceed the specified limits.

4.3.1 The extent of Radiography shall be as per specification. For welds between dissimilar
materials, the extent of Radiographic examination shall be more stringent of the two
recommended for the materials being welded. Wherever random radiography is called for in a
particular piping class, the dissimilar materials weld joints shall essentially be included.
4.3.2 Type of radiation source and film to be used shall be as per of Client Specification for
carrying out radiographic examination.
4.3.3 All regulatory, statutory & safety requirement shall be fulfilled by contractor before start of
work.

4.3.4 The joints for Radiography shall be selected by the Client inspector and the Radiography shall
be performed in his presence if he instructs the contractor to do so. Contractor shall furnish all
the radiographs, to the Client inspector immediately after

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processing along with evaluation by a person qualified to ASNT Level II in Radiographic

testing.

4.3.5 Contractor shall provide the client inspector all the necessary facilities at site such as dark
room, illuminator (viewer) suitable for varying densities, a duly calibrated electronic
densitometer with batteries, magnifying glass, ruler, marking pencils etc. to enable him to
review the radiographs.

4.3.6 To avoid the possibility of too many defective welds by a single welder remaining undetected
for a long period of time, Contractor shall promptly arrange for Radiographic examination so
that there is no accumulation of defective joints. Pipe 2” and below shall not be repair and cut
out the weld. No weld shall be repair less than twice. If any weld is not accepted after two
attempts shall be cut out and reweld.

5.0 REPAIR WELD:

If random examination reveals a defect that is to be repaired then, after repair in additional to the repaired
weld following shall be followed:

a) Two additional welds in same kind of weld by the same welder or some process or both shall be
examined.

b) If any of the additional welds reveals a defect, requiring repair two further comparable welds shall be
examined for each defection then found by the examination.

6.0 EQUIPMENTS AND MATERIALS

6.1 Radiation source & films

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Ir-192 radiation sources and films to be used for radiography shall be as per Client specification

6.2 Intensifying screen

Lead screen of thickness 0.125mm both front & back shall be used for intensification purpose when
dark packaged bare films are used, or standard lead backed day light films shall be used. All screens
should be handled carefully to avoid dent, scratches, and dirt on the surfaces. Screen that given non-
relevant indications shall be usually examined and discarded if physically damaged observed.

6.3 Equipment, Consumable & Accessories

a) Ir-192 (Gamma Source)

b) Standard Control units with guide tube

c) Collimator & leads sheets

d) Survey Meter

e) Dosimeter

f) Warning placards

g) Cordoning rope

h) Lead markers

i) Measuring tape & elastic

j) Penetrometer (IQI)

k) Dark room accessories

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6.4 Film Loading Details: -

Film shall be loaded in the dark room under proper safe light, Filters. Films shall be cut carefully
without any damage, scratches, or finger marks. Sandwich the film between pair of screen &
loaded in the light tight PVC cassettes or holders.
TYPE OF SOURCE AND FILMS TO BE USED FOR RADIOGRAPHY

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Joint welded is field on ground level shall be considered as shop welded joint. Fine grain – High
contrast – S curve than the above film shall be used, if radiographic sensitivity is not achieved constantly

6.5 Penetrometer

Wire type ASTM/DIN Penetrometer shall be used. Selection of Penetrometer shall be as per
ASME SEC V article 2 tables T276 for DIN/ ISO wire type Penetrometer. Material of the wire
should be radiographically similar to the material to radiograph.

6.6 Facilities for viewing radiographs.

Viewing facilities shall provide subdued background lighting of an intensity that will not cause
trouble some reflections, shadows, or glare on the radiograph equipment used to view
radiographs for interpretation and, shall provide a light source sufficient for the essential
Penetrometer wire to be visual for the specified density range.

6.7 Densitometer:

The Densitometer calibration and step wedge comparison film shall be as per T-262 of Article 2 of
Sec v.

7.0 EXPOSURE
7.1 Geometric un-sharpness

Geometric un-sharpness is very important to obtain good contrast and definition. Therefore,
maximum geometric un-sharpness describes below should be kept in anytime, under any
condition.

Ug = Fd / D

Where:
Ug : Geometric un-sharpness
F: Source size in mm, maximum projected dimension / effective foul spot.
D: Distance in mm from source to weld or object to be radiographed.
(Source side surface)
d: Distance in mm from source side of the weld to film / material thickness
in normal case
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Geometric un-sharpness to be obtained is;

Material thickness in mm Ug max in mm

Under 50 0.510
50 ~ 75 0.760
75 ~ 100 1.020
100 and over 1.780

7.0 TECHNIQUE OF RADIOGRAPHIC TESTING

A single wall exposure technique shall be used for radiography, whenever it is practical to use a
single wall technique. Details of applicable technique are as follows:

7.0.1 Single Wall Technique

In the single wall technique, the radiation passes through only one wall of the weld (material),
which is viewed for acceptance on the radiograph. An adequate number of exposures shall be
made to ensure that the required coverage has been obtained.

7.0.2 Double Wall Technique

When it is not practical to use a single wall technique, one of the following double wall
techniques shall be used.
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7.0.1 Single Wall Viewing

For materials and for weld components, a technique will be used in which the radiation passes
through the two walls and only weld (material) on the film side wall is viewed for acceptance.
An adequate number of exposures shall be made to ensure that the required coverage has been
made. At least 3 exposures at 120° to each other for complete coverage shall be taken.

7.0.2 Double Wall Viewing

For materials and for welds in components 3/1/2 (88mm) of less in nominal outside diameter, a
technique will be used in which the radiation passes through two wall and the weld (material)
in both walls is viewed for acceptance on the same radiograph. For double wall viewing only a
source side Penetrometer shall be used. Care will be exercised to ensure that where the
required geometric un-sharpness requirement cannot be met, then the single wall viewing shall
be used.

For welds, the radiation will be offset from the plane of the weld at an angle sufficient to
separate the image of the source side and film side portions of the welds so that there is no
overlap of the areas to be interpret. When complete coverage is required, a minimum of two
exposures taken 90 to each other shall be made for each joint.
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7.0.1 Double Wall Superimpose Technique:

As an alternative, the weld may be radiographed with the radiation beam positioned so that the
images of both wall are superimposed. When complete coverage is required a minimum of three
exposures taken at either 60 or 120 to each other shall be made for each joint

Additional exposures shall be made if the required radiographic coverage cannot be obtained using
the minimum number of exposures indicated.

7.0.2 Panoramic

This is one kind of single wall single image technique. The radiation source locates on center of
the pipe and exposures all of circumference at once.
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7.0 Penetrometer (Image Quality Indicator)

Wire type ASTM or DIN Penetrometer shall be located either on the source side or on the film side
of the weld. During establishing radiographic procedure, Source side Penetrometer shall be used.

Two penetrometers shall be placed on the end of film for DWSI technique. For DWDI technique
one Penetrometer shall be placed on source side. A minimum of four penetrometers 90o apart shall
be placed for panoramic technique.

The sensitivity of the film shall be as per ASME Sec. V Article-II. The IQI sensitivity obtained
shall be equal or better than the requirement of Sec v Article-II.

7.1 Identification Mark

Identification marks shall contain all the necessary information as required for easy identification of
the weld joint; LINE/DWG NO, JOINT NO, MATERIAL CLASS, WELDER NO, etc.

7.2 Exposure Time:

Exposure time shall be calculated with actual activity / Kv and mA, penetrated wall thickness, SFD
and film speed using exposure chart or exposure calculated.
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7.3 Back scattering of radiation

A lead symbol “B” with minimum dimensions of 1/2” in height and 1/16” in thickness shall be
attached to the back of each film cassette during each exposure to determine if backscatter
radiation is exposing the film.

8.0 FILM PROCESSING

8.1 Developing of the exposed films should be done in the air-conditioned dark room. The dark room
shall be divided into two sections one (dry zone) for loading and unloading the films and other zone
(wet zone) for processing the films. Film developer shall be maintained at 20℃±1°C or as
recommended by film /manufacturer.

8.2 Details of Film loading: - Film shall be loaded in a darkroom 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 marks. The manual processing involves the followings steps. All the steps
shall be performed on a test film initially to determine any effect of processing.

8.3 Developer:- Developing time shall be recommended by film manufacturer varies from 3 to 5
minutes for class II films & 4 to 6 for class I film.

8.4 Stop Bath: - After development is complete, the activity of developer is remaining in the emulsion
should be neutralized by an acid stop bath or, if this is not possible by rinsing with vigorous
agitation in clean water. The stop bath is water with 2% of acetic acid per gallon of water, to arrest
developing of films are immersed in a stop bath for 30 second in the stop.

8.5 Fixer: - To remove the excess silver grains from unexposed or less exposed part of film & to
harden base of film, the hangers / spool shall be immersed in fixer. The films must not touch one
another in the fixer. Agitate the hangers vertically for about 10s and again at the end of the first
minute, to ensure uniform and rapid fixation. Keep them in the fixer until fixation is complete (that
is, at least twice the clearing tin than 15 min in relatively fresh fixer. Frequent agitation will shorten
the time of fixation).
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8.6 Running Water: -

Films shall be kept in running water tank where excess fixer will be wash troll of the film, wash at
least for 30 minutes. The washing efficiency is function of wash water, its temperature and flow and
the film being washed. Generally washing is very slow below 16°
C. When washing at temp above 30° C, care should be exercised not to leave films in the water too
long. The films should be washed in the batches without contamination from new film brought over
from the fixer. If pressed for capacity, as more films are put in the wash, partially washed should be
moved in the direction of the inlet.

8.7 Wetting Agent: -

The film shall be dipped in wetting solution before drying for approximately 30 s this would facilitate
quick and even drying and avoid watermarks.

8.8 Drying: -

Films shall be dried in open space or in dryer with circulating hot air less than 55°C.

9.0 INTERPRETATION

9.1 The films to be interpreted shall be free from the film defects on the area to be evaluated as listed
below. If film defects appear on the image of weld, such films shall be re- radiographed.

1 Scratch
2 Finger mark
3 Foggy
4 Nail mark
5 Water mark (Dry mark)
6 Lead mark
7 Other indications which may mask the relevant
indication
8 Nail mark
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9.0 Film Density

The density of the films on any place shall be 2.0 ~ 4.0 for gamma-ray and 1.8 ~4.0 for X- ray
exposures. There should not be any deviation of the film density of +30%, -15% from the area
Penetrometer is placed. Calibrated digital densitometer shall be available to measure the density of
the films.

9.1 Evaluation

Acceptance or rejection criteria for the films evaluation shall be in accordance with ASME B 31.3
& applicable HPCL Specification.

9.2 Film Viewing:-

The films shall be viewed under a high intensity film viewer capable of reading radiographs of
density up to 4 and with adjustable light intensity viewing shall be done under subdued
background lighting of an intensity that will not cause trouble some reflections.

9.3 Re-Test

Retest of the repaired area shall be carried out in accordance with this procedure and repair welds
shall be indicated with R.

9.4 At the discretion of HPCL site engineer RT may be replaced or supplementary with UT.

9.5 Film Contrast: -

Film contrast refers to the slope (steepness) of the film system characteristic curve. Film contrast
is dependent upon the type of film, the processing, and the amount of film density. Contrast of
the film shall be adequate to manifest on the radiograph even the smallest thickness different are
there and better the contrast, better the visibility of discontinuity during interpretation.

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9.6 Sensitivity

Radiography sensitivity achieved shall be as per specification & shall be confirmed by compute
ring formula or in accordance with ASME SEC V for ISO wire type IQI wherever practical. This
shall be demonstrated on the procedure radiograph and accepted by HPCL prior commencement
of production work.

% Sensitivity = Diameter of thinnest wire visible on the radiograph X 100 Penetrated

thickness at the area of interest

9.7 Film Storage and Archive Life

Film shall be stored in dry place with humidity less than 80% in proper storage boxes with
identification. All film shall be stored as per the guide of E-1254.

10 RADIATION SAFETY

10.1 Radiation can destroy human cell tissue. Therefore, handling of the radiation source should
be under the strict rules.

10.2 When RT work is not performed, radiation source should be kept in the designated storage
area with locking system. This storage shall be inspected and approved by Bhaba Atomic
Research Centre (B.A.R.C) prior to RT work commencement. Relevant approval paper shall
be submitted to HPCL before start the job.

10.3 When RT work is being done, safety barrier to notice the radiation zone, warning lamps and
other suitable devices should be provided to protect the non-radiation workers from the
radiation.

10.4 Radiation workers should carry the film badge, pocket dosimeter (0~200 mrem), alarm and
survey meter to protect themselves from radiation. Physical examination for workers involving
this job shall be performed as per the guideline of AERB India.

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10.5 Radiographic testing shall be done at nighttime , where construction works are over in the site.
Permit of carrying out radiography to be obtained whenever Radiography is carried out.
Radiation dose shall be controlled not to exceed the limit as per IAEA recommendation. Daily
and monthly base radiation dose shall be in accordance with rule of respective country
regulations.

10.6 Radiation safety factors, distance, exposure time should be followed strictly to minimize the
radiation dose to the radiographers.

11.0 QUALITY CONTROL AND QUALITY ASSURANCE

Quality Assurance shall be maintained by ensuring the systematic implementation of this

procedure and ensure that necessary quality records are generated as appended to this procedure.

12.0 APPENDICES/FORMATS:

 Inspection Test Plan Piping Radiography Test

 IR for Radiography Test of Piping

Note: In case of any conflict between the requirements of this procedure and HPCL
Specification the later shall govern.