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RADIOGRAPHIC EXAMINATION
DOCUMENT NO.: BITS-SOP-801

ISSUE STATUS

Signature A 05-Mar-11 Draft Copy V. Jagadish

REV. NO.

DATE

DESCRIPTION

PREPARED BY

APPROVED BY

BITS-SOP-801, dated 05-Mar.-2011

TABLE OF CONTENTS

CONTENTS
1.0 2.0 3.0 4.0 5.0 PURPOSE SCOPE REFERENCES DEFINITIONS PROCEDURE 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 6.0 Radiographic Examiner Surface Preparation Lead Intensifying Screens Films Density Identification of Radiographs Image Quality Indicators Geometric Unsharpness Exposure Techniques Film Processing Viewing Radiographs Acceptance Criteria & Reporting Retention of Records

ATTACHMENTS

BITS-SOP-801, dated 05-Mar.-2011

1.0

PURPOSE The purpose of this document is to provide the minimum requirements for the radiographic examination of welds, which will be revised as and where necessary to meet the specific contractual specifications and requirements of a project and thus become a project specific procedure.

2.0

SCOPE This work instruction can be used on welded joints of carbon, low alloy, high alloy steels and non ferrous materials of final product form of Pressure vessels, piping and structures. This work instruction is not applicable for radiographic examination of castings.

3.0 3.1

REFERENCES ASME Sec. V Article 2, Radiographic Examination

4.0

DEFINITIONS ASME IQI NDT RT RTFI

American Society of Mechanical Engineers Image Quality Indicator Non Destructive Testing Radiographic Testing Radiographic Testing Film Interpretation

5.0 5.1

PROCEDURE Radiographic Examiner

Personnel involved in performing, interpreting and evaluating radiographic examination shall be qualified to RT Level II (minimum) in accordance with SNT-TC-1A. Personnel operating radioactive isotope/X-ray unit shall follow safe practices in compliance with the requirements of Companys Radiation Safety Manual.

5.2

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 resulting radiographic image due to any surface irregularities cannot mask or be confused with the image of any discontinuity. 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.

BITS-SOP-801, dated 05-Mar.-2011

5.3

Lead Intensifying Screens

Lead (Pb) screens shall be of 0.005 inch (0.125mm) thick for the front and 0.010 inch 0.250mm) for the back. Intimate contact shall be ensured during exposure. If necessary, additional lead protection shall be provided to prevent back scattering. A lead letter B with a minimum 1/2 in (13mm) height and 1/16 in (1.5mm) thickness shall be attached to the back side of each film holder during exposure. If the light image of this B appears on the background of the radiograph, then the protection from back scattered radiation is insufficient and additional protection with thicker lead shall be provided to the back side of the film holder. A dark image of the B on a lighter background is not cause for rejection. All lead screens shall be handled carefully to avoid dents, scratches, dirt, etc. on lead screen surface. All damaged lead screens shall be discarded.

5.4

Films
Films used for industrial radiography shall be silver bromide coated only. Industrial Radiographic films of different manufacturers and brands are classified based on the silver bromide grain structure as given in table 1 below. TABLE - I Film Class 1 Manufacturer Kodak Agfa Kodak Agfa Brand MX-125/T200 D5 / D4 / D2 AA-400 D7

Equivalent films of other brands and manufacturers may also be used subject to the approval by Companys NDT Level III. Selection of Films shall be based on the specific contractual specification requirements. Note: Lower the class number, finer the grain size.

5.5
5.5.1

Density
The film density through the area of interest of the radiographic image shall be 1.8 minimum for radiographs made with X-ray and 2.0 with Gamma rays source and the maximum density shall be 4.0 HD. The density of the radiograph anywhere through the area of interest shall not vary by more than -15% or +30% from the density adjacent to the designated wire of the wire IQI. The radiograph film viewer shall be capable of discerning images on films with a density of 4.0.

BITS-SOP-801, dated 05-Mar.-2011

Note: The density limitations of the radiographs may differ for different Codes and specifications. Hence the clause related to density shall be revised wherever applicable to meet the specific contractual specifications. 5.5.2 5.5.2.1 Densitometers shall be calibrated at least every 90 days during use as follows: A national standard step tablet or a step wedge calibration film traceable to a national standard step tablet and having at least 5 steps with neutral densities from at least 1.0 through 4.0 shall be used. The step wedge calibration film shall have been verified within the last year by comparison with a national standard step tablet unless, prior to first use, it was maintained in the original light-tight and water proof sealed package as supplied by the manufacturer. Step wedge calibration films may be used without verification for one year upon opening, provided it is within the manufacturers stated shelf life. The densitometer manufacturers step-by-step instructions for the operation of the densitometer shall be followed. The density steps closest to 1.0, 2.0, 3.0 and 4.0 on the national standard step tablet or step wedge calibration film shall be read. The densitometer is acceptable if the density readings do not vary by more than +0.05 density units from the actual density stated on the national standard step tablet or step wedge calibration film. Periodic calibration verification checks shall be performed at the beginning of each shift, after 8 hours of continuous use, or after change of apertures, whichever comes first. Record of densitometer calibration shall be maintained, however periodic verification (daily check) records need not be maintained.

5.5.2.2 5.5.2.3 5.5.2.4

5.5.3

5.5.4

5.6

Identification of radiographs
5.6.1 A system of radiographic identification acceptable to specific contractual specification and client requirements shall be used to produce permanent traceable record of radiographs to individual welds. As a general requirement, identification on the radiograph shall include job / plant no., line/tank/vessel no., joint no., welder no. and date. The image of identification shall not interfere with the interpretation of the weld image on the radiograph. 5.6.2 For identifying the exact location of the total weld, location lead marker tape may be used in the form of number belts with 0 as starting point and interval numbers and spacing shall be 5cms or 10cms. The location of the marker shall be on the surface of the part. The number belt shall be of sufficient length to cover the entire weld length. They shall be positioned adjacent to the weld and at no. 0 position, an arrow showing the direction of numbering shall be marked on the part, clearly with a permanent paint marker, in a manner permitting the area of interest on a radiograph to be traced accurately on the weld. For spot radiography instead of location marker, lead letter A, B etc. may be used on the spot radiographed and the

BITS-SOP-801, dated 05-Mar.-2011

location of letter A, B and spot number shall be clearly punched/marked on the vessel/item. 5.6.3 Welds radiographed after repair shall retain all the same numbers and be identified by the additional letter R1 for first repair, R2 for second repair etc. 5.6.4 Location of marker shall be placed on the source side when radiographing the following. 5.6.4.1 5.6.4.2 Flat components components. or longitudinal joints in cylindrical or conical

Curved or spherical components whose concave side is toward the source and when the source to material distance is less than the inside radius of the part.

5.6.4.3

Location of markers may be placed on either the source side or film side when radiographed joints are in curved or spherical parts whose concave side is toward the source and the source to material distance is equal to inside radius of the part.

5.7

Image Quality Indicators (IQI)

IQI shall be the wire type and shall be manufactured & identified in accordance with the specific contractual specification requirement and appendices. Radiography shall be performed with a correct technique of sufficient sensitivity to display the designated wire of the pentameter. Table 3 in general shows the selection of pentameter. Selection of IQI may differ for different contractual specifications. Hence it is recommended to revise the clause related to sensitivity to meet the particular contractual specification

5.7.1

IQI Wire Diameters & Selection IQI shall be selected based on sensitivity requirements, thickness of object to be radiographed and placement of IQI such that the required wire shall be clearly visible on the radiography films. Selection of IQI shall be based on single wall thickness with permitted reinforcement. Backing strip if used shall not be considered for IQI selection.

5.7.2 .

Placement of IQI Wire type IQI shall be placed on the weld so that the length of the wire is perpendicular to the length of the weld.

BITS-SOP-801, dated 05-Mar.-2011

For determination of sensitivity of the radiograph, the IQI shall be placed during the exposure on the side of the section being inspected, which is farthest to the film and nearest to the radiation source. If hand placement of IQI on source side is not possible, the IQI shall be placed on the side nearest to the film. The arrangement of the IQI on the film side shall be indicated by the letter F on the radiograph. When one or more film holders are used for an exposure, atleast one IQI image shall appear on each radiograph. If density requirements of section 5.5.1 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 on the radiograph shall be considered as having acceptable density. When a complete circumferential weld of a cylindrical component is radiographed in a single exposure (panoromic technique) with the source placed at the geometric centre of the component at least 3 IQIs, spaced approximately 120 degree apart shall be used. For double wall single image technique when more than one film holder is used for one exposure, at least one IQI image shall appear in each radiograph. In case of only one film holder, one IQI shall be used. For double wall double image technique, a source side IQI shall be used. 5.7.3 Material for IQI IQI shall be made of radiographically similar material to the object being inspected. For selecting similar material IQI refer to materials or alloys that have approximately the same radiation - absorption as the material being radiographed.

5.7.4

Film Sensitivity The radiography shall be performed with a technique of sufficient sensitivity to display the designated wire of the wire IQI and identifying numbers and letters which shall be the acceptance criteria for the image quality of a radiograph.

5.8

Geometric Unsharpness The geometric unsharpness shall not exceed as shown in table-III. The source to film distance shall be determined by the formula as follows. Ug = Fd D where, F = Source size, the maximum projected dimension of the radiation source in the plane perpendicular to the distance D from the weld or object being radiographed.

BITS-SOP-801, dated 05-Mar.-2011

D = d = Ug =

Distance from the source of radiation to weld or object being radiographed, distance from the source side of the weld or object being radiographed to the film, geometrical unsharpness. TABLE - III

Range of thickness to be radiographed (inch/mm) Upto 2" (50mm) From 2" to 3" (50 ~ 75mm) From 3" to 4" (75 ~ 100mm) Over 4" (100mm) Note :

Geometrical unsharpness maximum allowed (inch/mm) 0.02" (0.51mm) 0.03" (0.76mm) 0.04" (1.02mm) 0.07" (1.78mm)

'D' and 'd' shall be measured to the approximate center of the area of interest and their values shall be so selected to achieve the required sensitivity. Actual values shall be reported on the radiography report. For ASME Sec. VIII Div. 1 & 2 items, the requirements of geometric sharpness mentioned above are to be used only as a guide for selection of source to object distance. Final acceptance of radiographs shall be based on the ability to see the prescribed IQI image and the designated wire of wire type IQI. For ASME Sec. 1 & Sec. B31.1 items, geometric unsharpness shall not exceed 0.07 (1.8mm). 5.9 5.9.1 Exposure Techniques Single Wall Single Image Technique (SWSI) For unidirectional exposure, the film shall be on one side of the object in close contact and source on the opposite side of the object. For total weld examination of a circumferential weld with a single wall exposure (Panoramic exposure), the source shall be placed on geometric center in the pipe or vessel and positioned so that the projected beam passes through the center of the weld. For fixing the source to film distance, care shall be exercised to ensure that the required geometrical unsharpness value is not exceeded. Film overlap shall not be less than " (13mm). 5.9.2 Double Wall Single Image Technique (DWSI) The source is on one side of the pipe and film on the opposite side so that the centre of the projected beam passes through the centre of the section of the weld being examined. When complete coverage is required for circumferential welds (materials), a minimum of 3 exposures taken 120o to each other shall be made.
BITS-SOP-801, dated 05-Mar.-2011

Additional exposures shall be taken as the thickness of the part or diameter of the pipe or both increases. The film shall be centered to the section of the weld being examined and in direct close contact with the weld. Each radiograph shall have a minimum of " (13mm) overlap at each end of the acceptable (readable) film length. For keeping the source to film distance, care shall be exercised to ensure the required geometrical unsharpness value is not exceeded. 5.9.3 Double Wall Double Image Technique (DWDI) For welds having less than 3" (89mm) O.D., this technique shall be used so that the radiation passes through both the walls and the weld and both walls is viewed for acceptance on the same radiograph. For fixing the source to film distance, care shall be taken to ensure that the required geometric unsharpness is not exceeded. For welds, the radiation beam may be offset from the plane of the weld at an angle sufficient to separate the image of source side and film side portions of the weld so that there is no overlap of areas to be interpreted. When complete coverage is required, a minimum of two exposures taken at 90 degrees to each other shall be made for each joint. As an alternative, the weld may be radiographed with the radiation beam positioned so that the images of both walls are superimposed. When complete coverage is required, a minimum of 3 exposures taken at 60 or 120 degrees to each other shall be made for each joint. Only source side IQI shall be used. 5.10 Film Processing Processing of exposed radiographs may be carried out either by manual processing or automatic processing. 5.10.1 Manual Processing Manual processing using standard ready mix chemicals shall be in accordance with the chemical manufacturers recommendations. The temperature range for processing solutions including wash water shall be between 19 C and 22 C. Films shall be processed in such a way as to allow storage without discoloration for atleast 5 years after job completion. The processing chemicals shall be replenished and changed in accordance with manufacturers recommendations. After completion of washing, the films shall be dried in a room having closed atmosphere, free of dust or in a drying cabinet with circulating air at a maximum temperature of 50 C. The finished radiographs shall be free of all artifacts that would interfere with interpretation. The technique shall produce radiographs of sufficient density, sensitivity, contrast and clarity so that the defects in the weld and adjacent to the weld are clearly discern. 5.11 Viewing of Radiographs

BITS-SOP-801, dated 05-Mar.-2011

Viewing facilities shall include subdued background lighting of intensity that will not cause troublesome reflections on the radiographic interpretation. A variable high intensity light source shall be used for interpretation. The room shall be maintained at a comfortable temperature and shall be ventilated. 5.12 Acceptance Criteria & Reporting The acceptance criteria shall be based on applicable Codes & Standards amd project specification. A radiographic examination report (shown in Attachment 1) shall be prepared and submitted to the client along with the radiographs. 5.13 Retention of Records Retention of radiographs and reports shall be as per the contractual specifications. 6.0 6.1 ATTACHMENTS Attachment 1 Report of Radiographic Examination

BITS-SOP-801, dated 05-Mar.-2011