MECON LIMITED STANDARD TECHNICAL SPECIFICATION

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Note :

1) Only one value is permitted to be lower than average value upto the value
specified.
2) These values are specified for resistance to brittle fracture only, where
additional requirements are specified in project data sheet. (Ex. pipeline
materials with arrest properties i.e. a higher upper shelf charpy V-energy for
resistance against propagating ductile fractures) the same shall be followed.

14.7 Bend Test Requirements

The Bend test Specimens shall be made and tested as per the requirements of API
1104 Sixteenth Edition May 1983 except that the dimensions of the Jig for guided bend
test Fig. 5 para 2.6 API 1104 shall be modified as follows:

Radius of the Plunger `A' : 2t

Radius of the die `B' : 3 t + 1.6mm
Width of the die `C' : 50.8mm

The acceptance criterion on shall however be as per para 2.643 and 2.653 of API 1104
nineteenth edition Sept. 1999.

Note : t = thickness of specimen

15. ULTRASONIC INSPECTION

In addition to the radiographic inspection, ultrasonic inspection is required as per

conditions listed in paragraph 12.5 of this specification. This section concerns manual
ultrasonic inspection. However ultrasonic by automatic equipment may be used if
approved by the COMPANY.

15.1 Equipment and Operators

The CONTRACTOR who carries out the ultrasonic inspection shall have sufficient
qualified personnel equipment and instruments at his disposal to be able to effect the
tests without hindering or delaying the pipeline assembly operations.

The operators shall be fully qualified as per a recognised standard (ASME Sec. V or
equivalent) and they shall have as minimum level II as described in para 11.4.3, API
1104; nineteenth edition. The operators shall be able to :

„ calibrate the equipment ;

„ perform an operational test under production conditions;
„ interpret the screen picture ;
„ evaluate the size and location of reflectors
„ interpret the type of defects detected

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The COMPANY has the option of checking the ability of personnel employed for
ultrasonic testing by means of qualification tests.

The CONTRACTOR appointed to carry out ultrasonic inspection shall supply all the
instruments necessary for their execution on site.

15.2 Specification for Ultrasonic Inspection Procedure Qualification

Before work begins, the CONTRACTOR shall present a specification describing the
proposed U.T. procedure qualification.

This specification shall state, as an indication only but not limited to the following
information :

„ type of U.T. equipment used

„ type and dimensions of transducers
„ frequency range
„ details for calibration
„ coupling medium
„ inspection technique
„ record details
„ reference to the welding procedure where it is intended to adopt the
specification.
„ temperature range of the joints to be inspected.

15.3 Qualification of Ultrasonic Inspection Procedure

The ultrasonic inspection procedure shall be approved by the COMPANY. Before

inspection begins, the COMPANY may require the qualification test of the ultrasonic
inspection procedure. This specification test consists in testing (under normal operating
conditions) some CONTRACTOR welds made according to the same production
procedure, where there are typical defects the test intends to detect.

This test shall be conducted in the presence of the COMPANY. The Ultrasonic
inspection procedure shall be approved by the Company.

15.4 Test Procedure

Circumferential welds shall be inspected from both sides using angled probes.

The surface with which the probes comes into contact shall be free of metal spatter,
dirt, iron oxide, and scales of any type; therefore it shall be necessary to clean a strip
at least 50mmwide on both sides of the weld with steel wire brushes and anyhow the
cleaned strip must be atleast wide enough to allow full skip examination.

If, during the test, echoes of doubtful origin appear, it shall be necessary to inspect a
convenient area on the pipe surface, close to the weld, with a straight beam transducer
in order to check whether any manufacturing defects are present which could have

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interfered with the ultrasonic beam.

By way of an example, the equipment shall include but not be limited to the following:-

„ ultrasonic equipment and coupling medium

„ sample sections for calibration of instruments
„ equipment for cleaning of surface to be examined
„ rules calibrated in centimeters for exact location of the position of defects.

The characteristics of the above - listed instruments and equipment shall guarantee:

a) that the required standards of the inspection procedure, as previously

established and approved by the COMPANY, are satisfied.

b) continuous operation

All the instruments and equipment shall be approved by the COMPANY before
being used. The COMPANY has the authority to reject any item which is
considered unsuitable. The decision of the COMPANY is final. The
CONTRACTOR appointed to carry out ultrasonic inspections shall also ensure
the operational efficiency and maintenance of the instruments and equipment,
and shall immediately substitute any item rejected by the COMPANY.

All the instruments and equipment necessary for carrying out ultrasonic
inspection on site shall satisfy the requirements laid down by the public boards
of institutions which regulate `safety at work'.

15.5 Ultrasonic Instruments

The Ultrasonic Instruments shall satisfy the following:

„ be pulse-echo type, able to generate, receive and display, on the screen a

cathode ray tube (CRT) pulse at frequencies between 1 and 6 MHz. The useful
part of the CRT screen shall be at least 70mm wide and at least 50mm high.
„ shall have variable amplification, with steps of 1 or 2 dB over a range of a least
60 dB.
„ the regulation control shall be accurate to within ±1 db and this accuracy shall
be certified by the instrument manufacturer.
„ may be powered by a battery or an electric generator. In the first case, the
autonomy of operation (endurance) of the instrument shall be sufficient to
carry on working without frequent interruptions, and the instruments shall be
equipped with an automatic switch which switches it off when the battery runs
down; in the second case, there must be a voltage stabilising device with a
tolerance of ±2 Volts.

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15.6 Probes

The probes used shall have dimensions, frequencies, and a refraction angle suited to
the type of steel, the diameter, the thickness of the pipe and to the joint design.

15.7 Reference Sample Pieces

The efficiency of the equipment used, the effective refraction angle of the probe, and
the beam output point, shall be checked using a V1 and V2 sample block, IIW type or
calibration block ASTM E-428.

For manual Ultrasonic testing and automated Ultrasonic testing, the reference sample
pieces shall be as described in API 1104, Nineteenth Edition, para 11.4.5.

For the calibration of runs and the regulation of detection sensitivity during the test, a
calibration piece shall be used. This piece shall be taken from the production material,
and will be at least 150mm long (measured in the direction of the axis), and at least
50mm wide (measured in the direction of the circumference) (see Fig. 5 of this
specification).

In the middle of the inside and the outside surface of the calibration piece a groove
shall be made. The groove will have a rectangular cross-section, a flat bottom and the
following dimensions.

„ depth : 1 ± 0.1mm
„ breadth (measured parallel to the 150mm side) : 1 ± 01mm
„ Length (measured parallel to the 50mm side) not less than 30mm

In addition, the calibration piece shall have a hole, 2mm in diameter, passing through
its thickness and positioned so that during calibration the echoes returning from the
two grooves do not interfere with those returning from the hole.

15.8 Calibration

For a precise check of the sound paths necessary for a full inspection of the weld joint,
the probe shall be moved (half skip and full skip distance) until internal and external
notches on the test piece are detected (See Fig. 5 of this specification).

The relevant defect limits the path lengths on the time base. The calibration of
reference sensitivity is obtained by utilising the through - drilled test hole in the
thickness of the reference block to draw the distance - amplitude correction curve
relevant to the test probe.

Calibration shall be carried out according to the following procedure ; place its internal
vertex until the maximum height of echo is displayed on the screen ; this echo is
adjusted to 80% of full screen height by means of the sensitivity adjuster set in dB.
Without varying the amplification, the probe placed at full skip distance from the hole
is moved to detect the external vertex of the hole until the maximum height of echo is

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obtained. The straight line connecting the peaks of the two echoes obtained by the
above procedure, represents 100% reference level, while the one connecting the two
points at half height of the same echoes represents "50% reference level".

The two straight lines shall be marked on the screen with a pen. Calibration shall be
repeated each time tests are re-started ; at intervals not longer than 30 minutes during
normal operations; each time the conditions fixed in advance are altered. This
calibration is applicable provided that the crystal of the probe is 8 x 9mm size. Should
this size of the crystal be different, the value of the sensitivity obtained from the
calibration by a crystal of a different size shall be brought to the value of sensitivity
obtained from the calibration by a 8 x 9mm crystal. The sensitivities of the two
different size probes shall be compared through the echoes obtained on the notch of
the test piece with the probe position at half skip of the distance.

15.9 Regulation of Amplification During Production Testing

Scanning sensitivity shall be as provided in API 1104 para 11.4.7.2 &11.4.7.3.

15.10 Qualification of Ultrasonic Testing Operators

Before the inspection begins or during the same inspection, the COMPANY may require
a qualification test for the ultrasonic equipment operators.

15.11 Evaluation of Indications Given by Ultrasonic Tests

Each time that echoes from the weld bead appear during production testing, the
instrument amplification shall be altered to coincide with the reference amplification
and the probe shall be oved until maximum response is obtained, paying attention all
the time of the probe-tube coupling.

If, under these conditions, the heights of the defect echo is equal to or greater than
that of the reference echo, the defect shall be evaluated according to other clauses of
this Specification. If the defect has also been detected by the radiographic and or
visual examination, the dimensions shall be judged according to the type of
examination which detects the greater defect. Returns which are less that 50% of the
reference echo, will not be considered. If returns are above 50% but lower than 100%
of the reference echo, and if the operator has good reasons to suspect that the returns
are caused by unfavourably oriented cracks, the same shall be informed to the
COMPANY. Moreover, when there is a defect to be repaired, such defect shall be
removed for a length corresponding to the one where no more return echo is given.

15.12 Other Equipment

The use of rules calibrated in centimeters, attached if possible to the probe, for the
precise location of the position of welding defects, is recommended. Defect location is
effected by measuring the projection distance between the probe output and the
reflecting surface.

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The operators carrying out the tests shall have besides the probing instrument, tools
for cleaning the pipe surface (files, brushes, etc.), as well as, the coupling liquid or
paste appropriate for the temperature of the section to be examined.

16.0 AUTOMATED ULTRASONIC TESTING (AUT)

ƒ INTRODUCTION

The specification shall be applicable for Automated Ultrasonic Testing (AUT) system
suitable for pipeline girth welds. The system shall be based on focused pulse-echo,
tandem or through transmission methods enhanced with mapping image and
augmented by Time Of Flight Diffraction (TOFD) technique.

ƒ REFERENCE DOCUMENTS

ASTM E 1961-98 “Standard Practice for Mechanized Ultrasonic examination of Girth

Welds using Zonal Discrimination with Focused Search Units”. The inspection system
shall meet and exceed the requirements of ASTM E 1961-98.

Appendix-E, “Automated Ultrasonic Girth Weld Testing”, OS-F101, Submarine Pipeline

Systems, January 2000.

API Std. 1104 – “Welding of Pipeline and Related Facilities”.

ƒ APPROVED AGENCIES

Automated Ultrasonic Testing (AUT) systems and agencies who have proven track
record and have done a single project of diameter 20” or above and minimum length
of 50 km and also have inspected a cumulative length of 500 km or above on large
diameter Pipe lines in the last ten years shall be accepted. The agency should have
been approved by the reputed inspection agencies. The track record shall be submitted
to the COMPANY for approval prior to engagement.

ƒ AUT SYSTEM

The system shall meet and exceed the requirements of ASTM E1961-98.

The system shall provide an adequate number of examination channels to ensure the
complete volumetric examination of the weld through the thickness in one
circumferential scan. The evaluation zones should be of maximum 2.0mm height. The
instrument linearity should be such that the accuracy is within 5%.

Each examination channel should be selective for pulse-echo or through transmission

mode gate position and length for a minimum of two gates and gain.

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TOFD techniques & B-scan mapping should be available to improve characterization.

Recording thresholds should be selectable to display signals between 0 and 100% of
full screen height for simple amplitude and transit time recording and it should be from
0 to 100% for B-scan or mapping type recording of data. Two recordable signals
output per gate should be available being either analog or digital and representative
of signal height and time of flight. Measuring distance accuracy of circumferential weld
shall be within 1.0 cm from zero (0) position.

Electronic noise shall be lower than acoustical noise in all channels for the probes and
sensitivities to be used during inspection. The signal to noise ratio for each channel
during examination shall be at least ≥ 20 dB for shear waved probes.

ƒ COUPLING

The coupling shall be obtained by using a medium suitable for the purpose. It shall be
suitable for the temperature used. No residue shall remain on the pipe surface. A
method should be employed to determine that constant coupling is achieved during
examination. An examination of the test piece with its surface wiped dry should
produce a record showing an absence of the couplant recording signal.

ƒ SEARCH UNITS

The search unit shall meet all the requirements specified in Para 6.4 of ASTM E1961¬-
98.

ƒ CALIBRATIONS

Reference standards shall be manufactured from a section of unflawed project specific

line pipe supplied by pipeline CONTRACTOR. The agency shall then submit the
reference standard design to the COMPANY before manufacturing. No design changes
in the reference standard shall be made without the prior approval. Annexure A3 of the
standard ASTM E1961-98 provides an example for minimum requirements for
reference standards.

The system shall be optimized and calibrated as stated in Para 7.0 and 8.0 of ASTM E
1961-98. Static and Dynamic calibration shall be done and the approved procedure
shall clearly state the gain setting fixed for each channel.

The reference standard should be used to verify the scanning sensitivity at the start of
each shift and thereafter at intervals not exceeding two (2) hours or ten (10) welds.

A re-calibration shall be carried out if :

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a) The calibration of an inspection function differs more than +/- 3dB from the
previous calibration
b) The gate settings need to be adjusted with more than +/- 1.5 mm with the
previous calibration – i) after a weld repair, ii) after equipment breakdown.

In case the calibration differs from the initial setting, outside the given tolerances, the
applicable probe(s) and coupling shall be checked. If the calibration has to be changed,
the welds before this calibration upto the previous calibration will be re-examined.

The reference standard design for calibration shall be approved separately. The
procedure for calibration and verification shall be same as given above.

ƒ PROCEDURE

A detailed AUT procedure shall be prepared and qualified for each wall thickness and
joint geometry to be examined prior to the start of any NDT work. Repair procedure
shall be separately qualified for each joint geometry. All the requirements of ASTM
E1961-98 should be met. The procedure as a minimum shall include the following:

- Functional description of equipment

- Reference standards and guidelines controlling equipment maintenance
- Instructions for scanning device, Ultrasonic instrument, Ultrasonic electronics,
Hard & Software for recording processing, Display presentation and storage of
inspection data
- Transducer configuration(s), characteristics types coverage.
- Number of examination zones for each wall thickness to be examined.
- Gate settings
- Equipment settings -Description of calibration blocks including type, size and
location of calibration reflectors, a) calibration intervals, b) calibration records -
Static and dynamic calibration procedure
- Identification of inspection starting point scanning direction and indication of
length inspected
- Method for scanner alignment and maintenance of alignment
- Allowed temperature range
- Couplant coupling and coupling control and channels provided to indicate lack
of coupling and method to ensure constant coupling
- Transducer and over all functional checks
- Height and length sizing methodology
- Surface condition and preparation
- Description of inspection work
- Acceptance criteria and instructions for reporting including example of recorder

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chart and form to be used.

- A table indicating corresponding channel no., probe, type, location of reflector,

probe coupling etc.

ƒ Setting of Inspection Gates

Pulse-echo and Tandem Channels

With each transducer positioned for the peak signal response from the calibration
reflector the detection gates are to be set. The gate shall start 2-6mm (allowance for
width of heat affected zone) before the theoretical weld bevel preparation. The gate
ends shall be after the theoretical weld centerline. All gates will be programmed to
record amplitude and/or transit distance information. The length of the transit distance
in the root channel will be extended to enable root penetration registration.

Mapping Channels

The mapping gates in the body of the weld shall start 2-6mm (allowance for width of
heat affected zone) before the theoretical weld bevel preparation. The gate length will
be extended to enable cap reinforcement registration. The mapping gates in the root
will be set identical to the pulse-echo transit distance channels to enable the
registration of the root penetration.

TOFD Channel

The TOFD gate start will be set 1 µSec before the arrival of the lateral wave and
should extend up to the first back wall echo to achieve full cover of wall thickness.

Note: The gate settings may be altered if geometry indications dictate.

Sensitivity Settings

With each transducer positioned for the peak signal response from the calibration
reflector (flat bottom holes), the detection gates are to be set. In this position, the
probe holder is fixed to the probe frame. The equipment sensitivity (echo amplitude)
for all inspection channels shall be set at 80% Full Screen Height (FSH).

Mapping channels in the body of the weld will be used to detect the presence of
porosity and in addition to identify the position of the weld cap reinforcement for
pattern recognition purpose. The sensitivity as a minimum is equal to the related
pulse- echo channels, increased with additional gain to ensure proper detection.

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Mapping channels in the root will be used to identify the position of the root
penetration for pattern recognition purpose. The sensitivity as a minimum shall be
equal to the related pulse-echo channels, increased with additional gain to ensure
proper detection.

The lateral wave of the TOFD channel sensitivity is set at 80% FSH.

ƒ TRAINING AND QUALIFICATION

1. All Inspectors’ of the COMPANY (Owner) shall be imparted training at the

CONTRACTOR’s cost. The inspector shall be provided complete awareness and
knowledge regarding the equipment, limitations, capabilities complete range,
method of operation, calibration, scanning, including development of suitable
procedure, training on variables effecting the system performance and
interpretation of results.

2. The Ultrasonic lead operator performing the examination shall be qualified in

accordance with the COMPANY’s written practice and in accordance with ASNT
Practice SNT-TC-1A and EN 473 Level II. He should have experience in
multichannel UT equipment and be trained in using mechanized UT
manipulators.

ƒ FIELD EXAMINATIONS AND REPORTING

All the requirements stated in Para 9 and 10 of ASTM E1961-98 shall be followed a
minimum.

ƒ INTERPRETATION OF RESULTS

General

With the transit distance measurements and with the information from the mapping
and TOFD channels visible on the result presentation, indications shall be judged
whether they are from the weld geometry or from the defects. The coupling channels
will check for coupling loss; in case of coupling loss, a re-scan shall be carried out.

Inspection Result

The inspection result should be evaluated and/or reported as follows:

Welds shall be evaluated using both the pulse-echo and TOFD criteria shown below.

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This shall be performed in parallel and rejection against either of these criteria shall be
cause for rejection of the weld. The exceptions to this are described in the following
notes:

1. All indications in the pulse echo channels should be evaluated which exceed the
threshold level of 20% FSH.
2. Defect length shall be measured for the pulse-echo channels from the point
where the signal exceeds 20% FSH to the point the signal falls below. The
largest height assessed with TOFD or the greatest measured amplitude with
pulse-echo shall be assumed to apply over the whole defect length.
3. If the indication cannot be resolved by TOFD i.e. the upper and lower flaw
diffraction tips cannot be separately distinguished, no measurement can be
made to determine the defect height. In this case, the signal from the pulse-
echo channels will be solely used to determine that particular area of the scan.
4. Defects shall be assessed for interaction as follows:

a) Horizontal interaction

If the distance between two adjacent defects is less than the length of
the smaller of the two defects, then the defect shall be treated as a
single defect.

b) Vertical interaction
Vertical interaction of defects shall be assessed using TOFD. If the
distance between the two adjacent defects is less then the height of the
shorter of the two defects, than the defect shall be treated as a single
defect. Where the individual defects cannot be resolved by TOFD for
the vertical interaction, then the defects are assumed to interact and
shall be treated as a single defect.

5. The maximum allowable accumulated defect length shall be as per the criteria
given in welding specification.

ƒ ACCEPTANCE CRITERIA

Weld quality shall be judged on the basis of the acceptability criteria mentioned in
welding specification.

17.0 RADIOGRAPHY

17.1 Scope

This covers the radiographic inspection of all types of welded joints of the main
pipeline.

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The welded joints shall include the following :-

i. Full girth welds on the mainline construction including double jointing of pipe, if
adopted.

ii. Welds for installation of block valves, insulating joints and other appurtenances
and tie-ins.

iii. Welds at scraper launching and receiving barrels.

iv. Terminal Piping

17.2 Applicable Standards

This specification shall apply in conjunction with the following (all latest edition):

i. API 1104, Standard for welding Piplines and Related Facilities.

ii. ANSI B31.8, Code for Gas Transmission and Distribution Piping Systems.

iii. ANSI B31.4, Code for Liquid Petroleum Transportation Piping Systems.

iv. ASTM E94, Recommended practice for Radiographic Testing.

v. ASTM E142, Standard Method for Controlling Quality of Radiographic Testing.

vi. The American Society for Non-destructive Testing. Recommended Practice No.
SNT - TC-1A Supplement A.

17.3 Procedure

17.3.1 The radiographic examination procedure to be adopted shall be submitted by the

CONTRACTOR as per Annexure VI.

17.3.2 The procedure of radiographic examination shall be qualified to the entire satisfaction
of COMPANY prior to use. It shall include but not be limited to the following
requirements :

i. Lead foil intensifying screens, at the rear of the film shall be used for all
exposures.

ii. Type 2 and 3 films as per ASTM E-94 shall be used.

iii. A densitometer shall be used to determine film density. The transmitted film
density shall be 2.0 and 3.5 throughout the weld. The unexposed base density
of the film shall not exceed 0.30.

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iv. Radiographic identification system and documentation for radiographic

interpretation reports and their recording system.

17.3.3 The CONTRACTOR shall qualify each procedure in the presence of the COMPANY prior
to use.

17.3.4 The procedure of radiographic examination shall produce radiographs of sufficient

density, clarity and contrast so that defects in the weld or in the pile adjacent to the
weld, and the outline and holes of the penetrameter are clearly discernible.

17.3.5 All the girth welds of mainline shall be subjected to 100% radiographic examination.
The CONTRACTOR shall furnish all the radiographs to the COMPANY, immediately after
processing them, together with the corresponding interpretation reports on approved
format. The details of the radiographs all alongwith the joint identification number shall
be duly entered in a register and signed by the CONTRACTOR and submitted to the
COMPANY for approval.

17.3.6 When the radiation source and the film are both on the outside of the weld and located
diametrically opposite each other, the maximum acceptable length of film for each
exposure shall not exceed the values given in Table-4 of API 1104. The minimum film
overlap, in such cases, shall be 40mm. The ellipse exposure technique may be used on
nominal pipe sizes of 2 inch and smaller provided that the source of film distance used
is a minimum of 12 inch.

17.3.7 Three copies of each acceptable radiographic procedure (as per Annexure-VI) and
three copies of radiographic qualification records, shall be supplied to COMPANY. One
set of the qualifying radiographs on the job shall be kept by the CONTRACTOR's
authorised representative to be used as a standard for the quality of production
radiographs during the job. The other two sets shall be retained by COMPANY for its
permanent record.

17.3.8 Three copies of the exposure charts relating to material thickness, kilo voltage, source
of film distance and exposure time shall also be made available to COMPANY by the
CONTRACTOR.

17.3.9 The CONTRACTOR shall, on a daily basis, record for each radiograph (1) radiograph's
number, (2) welder's number (3) approximate chainage of weld location, (4) whether
or not the welds meet the specified acceptance standards and (5) the nature and
approximate location of unacceptable defects observed. It must be possible to relate
back to a particular butt weld and welder on piping drawing and pipe line alignment
drawing.

17.3.10 Each day's production of processed radiographs shall be properly packaged separately,
identified by at least the (1) date, (2) radiographic unit, (3) job locations, (4) starting
and ending progress survey stations and (5) shall include original and three copies of
the daily radiographic record. The package shall be submitted to the COMPANY daily
when possible, but in no event later than noon of the following day.

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17.3.11 The CONTRACTOR shall provide all the necessary facilities at site, such as a dark room
with controlled temperature, film viewer etc. to enable the COMPANY to examine the
radiographs.

17.3.12 The CONTRACTOR, if found necessary, may modify the procedure of radiographic
examination suiting to the local conditions prevailing. This shall, however, be subject to
the approval of the COMPANY.

17.3.13 COMPANY shall have free access to all the CONTRACTOR's work facilities in the field.

17.3.14 Any approval granted by the COMPANY shall not relieve the CONTRACTOR of his
responsibilities and guarantees.

17.4 Radiation Source

17.4.1 Radiographic examination shall be carried out using x-radiations, Radiographic

examination by Gamma rays may be allowed, at the discretion of the COMPANY, in
case of inaccessible joints. Radiography by Gamma-Ray for tie-in-joints shall be
acceptable provided D4 AGFA film or equivalent is used and the required sensitivity
obtained.

17.4.2 Whenever possible, pipeline welds will be inspected by placing the radiation source
inside the pipe, on the pipeline axis, with a radiation of 6.28 rad. (360°C).

If it is impossible to place the radiation source inside the pipe, the weld will be
inspected with the source on the outside. An overlap of at least 40mm at the ends of
each film shall be required to ensure that the first and last location increment numbers
are common to successive films and to establish that no part of a weld has been
omitted.

17.5 Level of Quality

The quality level of Radiographic sensitivity required for radiographic inspection shall
be at least equivalent to the values in Fig. 6

17.6 Penetrameters

The image quality indicator (abbreviation : IQI) shall be used for the qualification of
the welding procedure and during normal line production. Radiographic sensitivity shall
be measured with the wire image quality indicator (Penetrameter). The penetrameter
shall be selected according to DIN54109 or ISO1027. For radiographs made with the
source on the outside, a penetrameter shall be placed on each side of the film with the
smaller wiere of the penetrameter turned towards the end of the film itself. When a
complete weld is radiographed in a single exposure using a source inside the piping,
four penetrameter approximately equally spaced around the circumference shall be
used. During the procedure qualification, IQI shall be placed both on the source side
and on the film side. The sensitivity obtained with IQI on the source side shall not be

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less than the values shown in Fig. 6 of this specification.

The sensitivity limit may be considered to have been reached when the outline of the
IQI, its identification number and the wire of the required diameter show up clearly on
the radiograph.

The COMPANY may authorise use of types of IQI other than those planned, provided
that they conform with recognised standards and only if the CONTRACTOR is able to
demostrate that the minimum sensitivity level required is obtained. For this
demostration, a test shall be carried out comparing the IQI specified and the
CONTRACTOR's, to show up the identification number and other details of the
proposed IQI, which must be visible in the test radiograph.

17.7 Film Identification Markers

All films shall be clearly identified by lead numbers, letters, and/or markers. The image
of the markers shall appear on the films, without interfering with the interpretation.
These markers positions shall also be marked on the part to be radiographed and shall
be maintained during radiography.

17.8 Protection and care of film

17.8.1 All unexposed films shall be protected and stored properly as per the requirements of
API 1104 standard and ASTM E.94.

17.8.2 The exposed and unexposed film shall be protected from heat, light, dust and
moisture. Sufficient shielding shall be supplied to prevent exposure of film to damaging
radiation prior to and following the use of the film for radiographic exposure.

17.9 Re-radiography

17.9.1 The weld joints shall be re-radiographed in case of unsatisfactory quality of the
radiographs, at the expense of the CONTRACTOR.

17.9.2 All the repaired weld joints shall be re-radiographed at no extra cost to the COMPANY
in the same manner as that followed for the original welds. In addition, the repaired
weld areas shall be identified with the original identification number plus the letter R to
indicate the repair.

17.9.3 When evaluating repair film, radiographers shall compare each section (exposure) of
the weld with the original film to assure repair was correctly marked and original defect
removed.

17.9.4 The COMPANY will review prior to any repair of welds, all the radiographs of welds
which contain, according to the CONTRACTOR's interpretation, unacceptable defects.
The final disposition of all unacceptable welds shall be decided by the COMPANY.

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17.10 Qualification of Radiographers

17.10.1 Pipeline radiographers shall be qualified in accordance with the requirement of API
1104 and to the full satisfaction of COMPANY.

17.10.2 Certification of all the radiographers, qualified as per 16.10.1 above, shall be furnished
by the CONTRACTOR to the COMPANY before a radiographer will be permitted to
perform production radiography. The certificate record shall include :

i. Background and Experience Record

ii. Training Course Record
iii. Technical Examination Record
iv. Doctor's report on radiographer's Oaecuer 0-1 acquity eye test.
v. Date of qualification

17.10.3 The radiographers shall be required to qualify with each radiographic procedure they
use, prior to performing the work assigned to him in accordance with the specification.

17.11 Preservation of Radiographs

17.11.1 The radiographs shall be processed to allow storage of films without any discoloration
for at least three years. All the radiographs shall be presented in suitable folders for
preservation alongwith necessary documentation.

17.11.2 All radiographs shall become property of the COMPANY.

17.12 Equipment and Accessories

17.12.1 CONTRACTOR shall make necessary arrangement at his own expense, for providing
the radiographic equipment, radiographic film and all the accessories for carrying out
the radiographic examination for satisfactory and timely completion of the job.

17.12.2 For carrying out the mainline radiographic examination the CONTRACTOR shall be
equipped with suitable mobile/ stationary type dark rooms.

These shall have all the required facilities for film processing. Film viewer used shall be
equipped with the film illuminator that has a light source of sufficient intensity and
suitably controlled to allow viewing film densities upto 4.0 without damaging the film.

17.13 Radiation Protection

17.13.1 CONTRACTOR shall be responsible for the protection and personnel monitoring of
personnel with or near radiation sources.

17.13.2 The protection and monitoring shall comply with local regulations.

17.13.3 In view of visual hazards in the handling of Radioactive source of material,

CONTRACTOR shall be solely responsible for complying with all rules and regulations

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set forth by Atomic Energy Commission or any other Government agency of India in
this regard and COMPANY shall not be responsible and shall be kept indemnified by the
CONTRACTOR for default (s) of whatever nature by the CONTRACTOR. Safety
equipment as considered adequate by the COMPANY for all necessary personnel shall
be made available for use and maintained for immediate and proper use by the
CONTRACTOR.

17.14 Display of Safety Instructions

17.14.1 The safety provisions shall be brought to the notice of all concerned by display on a
notice board at a prominent place at the work spot. The person responsible for the
"safety" shall be named by the CONTRACTOR.

17.15 Enforcement of Safety Regulations

17.15.1 To ensure effective enforcement of the rules and regulations relating to safety
precautions, the arrangement made by CONTRACTOR shall be open to inspection by
COMPANY or its representatives.

17.16 First Aid and Industrial Injuries

17.16.1 CONTRACTOR shall maintain first aid facilities for its employees and sub-contractors.

17.16.2 CONTRACTOR shall make outside arrangements for ambulance service and for
treatment of industrial injuries. Names of those providing these services shall be
furnished to COMPANY prior to start of work and their telephone no. shall be posted
prominently in CONTRACTOR's field office.

17.16.3 All critical industrial injuries shall be reported promptly to the COMPANY and a copy of
CONTRACTOR's report covering each personal injury requiring the attention of
physician shall be furnished to the COMPANY.

17.17 No Exemption

17.17.1 Notwithstanding the above there is nothing in these to exempt the CONTRACTOR from
the operation of any other act or rules in force.

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ANNEXURE-VIII
Sheet 1 of 1

Type of Source and Films to be used for RADIOGRAPHY

NOMINAL WALL SHOP WELDED JOINTS IN-SITU WELDS

THICKNESS (T) IN mm SOURCE FILM : CEN Class SOURCE FILM : CEN Class
T> 19 All Materials Gamma Ray C5 Gamma Ray C5
8<T<19
8T< 19 Carbon Steel Gamma Ray C4 Gamma Ray C4
All other Gamma Ray C3 Gamma Ray C3
materials
<8 Carbon Steel Gamma Ray C3 Gamma Ray C3/C1
Other than
Inspection
Class IV *
All Thickness All other X-Ray C4
C5 X-ray with C5
C4 or Equivalent to be
materials and used. Gamma Ray (Se 75 Source
Carbon Steel only) with C3/C2 Equivalent may
of Inspection be allowed only if in the
Class IV * assessment of the owner's
inspector, Joints are inaccessible
for X-ray equipment and
radiographic sensitivity is achieved.

Note: Integral to above table

1) Films slower than the above may have to be used, if required radiographic sensitivity is not achieved
consistently.

* Piping classes where 100% RT is specified. Refer Std. Spec. No. MEC/S/05/21/06.

COMPARISON OF FILMS FROM DIFFERENT MANUFACTURERS

CEN Classification KODAK AGFA FUJI

--- CX D8 IX150
---
C5 AA400 D7 IX 100
C4 T200 D5 IX80
C3 MX125 D4 IX50
C2 M100 D3 ---
IX50
CI
C1 DR50 D2 IX25
--- SR** --- ---

* * Special films, extremely fine grain & very high resolution

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