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PROCEDURE FOR RADIOGRAPHY

TESTING BY X-RAY METHOD


Doc no.- CEL/IOCL/TEPL/RT/JP-12 Rev 00

WORK PROCEDURE FOR RADIOGRAPHY TESTING BY X-RAY


METHOD

Project Details

LAYING OF 3LPE COATED CARBON STEEL PIPELINE IN


PROJECT LAKHISARAI, MUNGER & BHAGALPUR GA, SPREAD-A
(GROUP-A)

CLIENT M/S INDIAN OIL CORPORATION LIMITED.

CONSULTANT M/S TRACTEBEL ENGINEERING PVT. LTD.

CONTRACTOR M/S CORRTECH ENERGY LIMITED

LOI NO. CEL/IOCL-TE/PLCGD-19-16/GrA/LOI/001, DATED 30.05.2020

APPROVED
DATE PREPARED BY CHECKED APPROVED
REV BY
CEL BY CEL BY TEPL
TPI/IOCL

WASIM WASIM
HASHMI HASHMI

00 NAME
15.07.2020

SIGNATURE

DOCUMENT NO. REV. SHT.


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PROCEDURE FOR RADIOGRAPHY
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INDEX

Page
Sr. Description
No.

1.0 Scope 3

2.0 Applicable Codes & Specification 3

3.0 Procedural Step 3-12

4.0 Documentation 13

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1. Scope
This scope of this procedure covers Radiographic Testing of Welds using X-Ray generators for
detecting the discontinuities in the Welded joints of pipeline of various diameters for construction
of Steel network for transportation & distribution of natural gas transmission pipeline and city
gas distribution network.
The welded joints shall include the following:
 100% of all Butt Weld Joints.
 Full girth welds on the mainline construction including double jointing of pipe, if adopted.
 Welds for installation of block valves, insulating joints and other appurtenances and tie-
ins.
 Welds at scraper launching and receiving barrels.
 Terminal Piping.

2. Applicable Codes & Specification


Following standards and codes of latest edition have been used in this specification.
2.1 Governing Standard
 ASME B 31.8 - Gas Transmission and Distribution Piping Systems.
 PNGRB, IOCL Tender document
 ASTM E94,- Recommended Practice for Radiographic Testing
2.2 Reference Standard
 IOCL Specifications
 OISD Standard 226 Natural Gas Transmission Pipeline and City Gas Distribution network
 ASME Section V
 ASTM E142:- Standard method for controlling quality of Radiographic Testing.
 The American Society for Non-destructive Testing Recommended Practice no. SNT-TC-1A
Supplement A
 API 1104 Latest Edition
 ASNT SNT TC –1A/CP-189

3. Procedural Step
3.1 Health, Safety & Environment
 Safety permit shall be approved from IOCL for execution of radiography.
 All Radiography Technicians shall have responsibilities to ensure to evacuate the public and Non-
Classified worker to the safe distance and the area where radiography is being performed. If
Required Effective radiography area has to be barricaded.
 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

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like prior to commencement of operations.


o Qualified personals of ASNT recommended practice SNT-TC-1A/CP-189 is engaged for
radiography work Injuries.
o Working Crew informed about Hazards due to Radiation.
o Radiography team shall have a personal TLD for determining
the personal dosimeter.
o Use of Calibrated Radiation Survey meter for marking/cordoning of radiation exposure zone
shall be done.
o A radiation survey shall be conducted during the activation of the source.
o Each radiographic area shall be barricaded off and warning signs placed around the
perimeter.
o If the TLD badge evaluation shows exposure to be in excess of the allowable limits, non-
radiation work shall be given until return to active radiographic work.
o PPEs are used in this activity as per the PPE‟s Matrix approved by IOCL.
3.2 METHODOLOGY:-
3.2.1 Personnel Qualification
o Only Experienced Crawler / External Radiography Technicians shall carryout the job.
o The Interpretation of the results of the Radiography Testing shall be carried out only by an
ASNT RT level II Inspector.
3.2.2 Procedure Qualification:
o 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. The Testing of WPS qualification may be used for NDT Procedure
Qualification.
o X-Ray generator of 225 KV or 300 KV, 6mA / 3mA, and Agfa D5, or Laser or NDT 7, or Kodak
AA-400, or Fuji 100, or NPIX 100 or any equivalent films and proper technique used to
produce the quality radiograph, shall be performed and qualified before the starting of work
at the work site. All the Radiography technique stated in this procedure shall be qualified as
per the technique sheet attached along with this procedure.
3.2.3 Equipment, Consumables & Accessories
o Unidirectional X-ray Generator with control units.
o Power cables
o Inter connecting cables
o Stabilizers
o Generators
o Belts for fixing the tube head

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o Survey Meter
o Dosimeter
o Warning Placards
o Lead Markers
o Crayon or Paint Markers
o Measuring tape
o Elastic
o Penetrometers (I.Q.I)
3.2.4 Dark Room Accessories such as
Manual or Automatic Processor
o Film Drier
o Densito meter
o Film Viewer
o Thermometer & Consumables
o A.C for temperature control.
3.2.5 I.Q.I. Selection (Image Quality Indicator):
 I.Q.I shall be placed on film side. The reference ASME section V Article-02 Table T-276 latest
addition for DIN/ISO wire type penetrometer.

3.2.6 Film Selection:


Radiography shall be obtained using industrial Radiography films. The film shall be class 2 or class 3
as per ASTME94 (D4/D7, Kodak AA400 Or equivalent) with the fine grain & high Contrast. It‟s other
equivalent will be used. It shall be demonstrate & approved by TEPL/IOCL. Photographic fog density is not
more than 0.30 .
3.2.7 Intensifying Screen:
o Lead screen of thickness 0.12 mm front & back of film shall be used.
3.2.8 Surface Preparation:
o As far as possible all irregularities from the surface (to the extent of coverage of films) shall be
removed for better results and interpretation.
3.2.8 Prevention of back scattering (if require):
o 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 1.5 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. In such case,
it is advised to place lead sheets on the backside of holder and radiography shall be retake.
3.3 Procedure:
o Radiography shall be carried out using the following Techniques with X- Radiation.

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3.3.1 Single Wall Single Image:


o This Technique is ideal for plates, & Pipelines or Vessels. In this technique the
radiation penetrates through single wall of test Object & image of the single wall is recorded
on the Radiograph.
o 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°) crawler type of x-ray machine shall be used
for all main line joints.
o An overlap of at lest 40mm at the end of each film shall be required.
3.3.2 Double Wall Single Image:
o In the case of Pipelines, the Radiography Equipment Directional X-ray tube is placed outside
the pipe. This technique is carried out above or equal 3” Dia of pipe.
3.3.3 Placement of Marker and I.Q.I.
o Lead markers shall be kept to identify the test Object, Date of Radiography, area of Interest of the
object, the location of the Radiographs and any other information as Specified by the client.
o When a complete weld is radio graphed in a single exposure using a source inside the piping,
four Penetrometer approximately equally spaced around the circumference sh all be used.
During the procedure qualification, IQI shall be placed both on the source side and on the film
side
o 2 no‟s wire type I.Q.I. shall be placed approximately at the edges, thinnest wire facing the outer
extreme of the film of the radiograph to Determine the quality of the radiographs.
o The film with the cassette shall be in firm contact with the object to be radiographed for better
contrast.
3.3.4 Focus to Film Distance
o 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.
o Four exposures at 90 deg to each other shall be taken to ensure complete weld coverage.
o Focus to Film distance shall be such that the geometrical unsharpness (Ug) shall be as per the
chart below.
Material thickness (inches) Ug Maximum ( inch)
Under 2 0.020
2 to 3 0.030
Over 3 to 4 0.040
Greater than 4 0.070

 The Ug is determined by
Ug = Fd/D
Where Ug – geometrical unsharpness
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F – Focal spot the maximum projected dimension facing perpendicular to film center.
D- Distance from focus of radiation to the specimen being radiographed. (F.F.D.)
d- Distance from source side of the specimen to the film (thickness)
3.3.5 Exposure time:
o Exposure time shall be calculated with film speed using Exposure chart or arrived at actual,
during Procedure Qualifications.

3.3.6 Film loading:


o 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.
3.3.7 Number of Exposures:
o The number of Exposures will be such that the area of Interest is completely covered used.
o The overlap of about 40mm total at the ends. Minimum Nos of 4/5 Exposures to cover the entire
weld circumference.
3.3.8 Film Processing:
o Film shall be processed in a dark room under safe light. The temperature of the chemical shall be
18 Deg Centigrade to 23 Deg Centigrade. The film shall be unloaded in hangers / spools carefully
to avoid any marks.
The Manual processing involves the following steps.
o All the steps shall be performed on a test film initially to determine any effect of processing.
Step: 1
o Developer: Shake the hangers or spools to avoid any uneven developing marks. Developing time
shall be as recommended by film manufacturer, varies from 2 to 3 minutes for class II films.
Step: 2
o Stop bath: The stop bath is water with 5 to 6 drops of Acetic Acid per gallon of water. To arrest
developing action films are immersed in a stop bath.
o Shake hanger for 2 to 3 minutes in the stop bath.
Step: 3
o Fixer: To remove the excess silver grains from unexposed or less exposed part of film & to harden
base of film, the hangers shall be immersed in fixer for 6 minutes to 10 minutes.
Step: 4
o Water Washing with Wetting Agent: Films shall be kept in water bath with Wetting Agent
(Kodak Photo flow) where excess fixer will be washed from the surface of the film. Wash at least
for 20 minutes.
Step: 5
o Drying: Film shall be dried in open space or in dryer with circulating hot air less than 55 degree

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C in Dark room by hanging vertically.


3.3.8 Film Viewing:
o 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.

3.3.9 Film Density:


o To measure the film density a calibrated densitometer (or) certified Step Wedge Density Strip
should be used.
o The transmitted film density shall be 2.0 to 3.5 throughout the weld. „‟The unexposed base
density of the film shall not exceed 0.30. (As per tender Specification)
o The density of the radiograph anywhere through the area of interest varies by more than minus
15% or plus 30% from the density through the body of the hole IQI or adjacent to the designated
wire of a wire IQI.

3.3.10 Film Contrast:


o Contrast of the film shall be adequate to manifest on the Radiograph even the smallest thickness
differential. Better the contrast is better for the interpretation of discontinuity.
3.3.11 Sensitivity:
o Radiographic sensitivity shall be measured with the wire image quality indicator (Penetrometer).
The Penetrometer shall be selected accordance with ASME Section V, Article 2, and Table 276
equivalent wire size or API 1104 Table 6 for ISO Wire type IQI.
Diameter of thinnest wire Visible on the Radiograph
% Sensitivity = --------------------------------------------------------------  100
Penetrated thickness at the area of interest (diagnostic area)
3.3.12 Interpretation:
o All indications that are equal to or greater than rejection level described in acceptance /
rejection criteria of API 1104 or as agreed by client‟s inspector, shall be considered representing
defects and may be cause of rejection or repair of the weld or base metal. All Radiographs showing
film marks in the area of interest shall be retake in accordance with this procedure.

3.3.13 Acceptance or rejection criteria:


o Acceptance or rejection criteria shall be in accordance with API 1104 Latest Edition/ASME B
31.3/ASME B 31.8 & Client‟s Specifications. All defect location shall be marked for repairing.

3.3.14 Retest:
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o Retest of the repaired area shall be carried out in accordance this procedure and repair Joint
shall be indicated with “R”.
3.3.15 Reporting:
o All details of inspection and results of inspection shall be documented in report format or The
Format suggested by Consultant and shall be signed by NDT inspector and client‟s representative.

3.3.16 Film Storage:


o Unexposed film shall be kept in clean and dry place. When doubt arisen for the quality of film on
section at the length about perimeter at the roll on the began and end at the roll or one film from
the same location shall be take out to treat with the normal procedure. If punch-drunk image are
found on the inspected film. The roll at the film shall not be used except there in further that the
remain film are good. The film shall be stored in dry place with humidity less than 80% in proper
storage boxes with identification.
Table For DIN Wire Type And Also ISO Penetrometer
 The Penetrometer shall be selected according to DIN 54109 or ISO 1027 & to be selected DIN10IS016

The reference Tables are as follows.

Pipe Wall Thickness or Essential Wire ASTM SET DIN set


weld Thickness (mm) Dia (mm) (Wire No) (Wire No)

A 10 ISO 16
0-6.4 0.20
(Wire No.-05) (Wire No.-04)

6.4-9.5 0.25 A OR B 10 ISO 16

9.5-12.7 0.33 B 6 ISO12 /10 ISO16

12.7-19.1 0.41 B 6 ISO 12

19.1-25.4 0.51 B 6 ISO 12

25.4 -50.8 0.64 B 6 ISO 12

3.3.17 Marking on Radiography film:


Line No: - As per PQR.

3.3.18 Film Manufacturer Detail:


As per client specification

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RADIOGRAPHIC EXAMINATION TECHNIQUE

(PIPELINE RADIOGRAPHY) – INTERNAL

Double – Wall Radiographic Techniques

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Pipe Exposure Radiograh Source-Weld-Film Arrangement IQI Penetrameter Location


O. D. Technique Viewing Marker
Placeme
End View Side View Selection Placement nt

Optional
Double- Single – Source T-276 Source Either
Wall: wall Location And Table Side Side
T-271.2 T-276 T-277.1(a) T-275.1
(a) (b) (1)
At Least 4 Film
Any Exposures Exposure Arrangement – D
120 To
Each
Other For
Complete
Coverage

Film
Side
T-277.1(b)

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NOMINAL SINGLE-WALL PENETRAMETER


MATERIAL THICKNESS
SOURCE SIDE FILM SIDE
RANGE, INCH.

HOLE ESSENTI WIRE HOLE ESSEN WIRE


TYPE AL HOLE DIAMETER, TYPE TIAL DIAME
DESIGNA INCH DESIGNAT HOLE TER,
TION ION INCH
Up to 0.25, incl. 12 2T 0.008 10 2T 0.006
Over 0.25 through 0.375 15 2T 0.010 12 2T 0.008

Over 0.375 through 0.50 17 2T 0.013 15 2T 0.010

Over 0.50 through 0.75 20 2T 0.016 17 2T 0.013

Over 0.75 through 1.00 25 2T 0.020 20 2T 0.016

Over 1.00 through 1.50 30 2T 0.025 25 2T 0.020

Over 1.50 through 2.00 35 2T 0.032 30 2T 0.025

Over 2.00 through 2.50 40 2T 0.040 35 2T 0.032

Over 2.50 through 4.00 50 2T 0.050 40 2T 0.040

Over 4.00 through 6.00 60 2T 0.063 50 2T 0.050

Over 6.00 through 8.00 80 2T 0.100 60 2T 0.063

Over 8.00 through 10.00 100 2T 0.126 80 2T 0.100

Over 10.00 through 12.00 120 2T 0.160 100 2T 0.126

Over 12.00 through 16.00 160 2T 0.250 120 2T 0.160

Over 16.00 through 20.00 200 2T 0.320 160 2T 0.250

TABLE 276
Thickness to be considered for Sensitivity Calculations / Penetrameter selection.
Double Wall Single Image Technique: Single wall Thickness. + Weld reinforcement Thickness

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Minimum Specimen Thickness Inch (mm) Wire Diameter, Inch (mm)


0.5 (12.7) 0.010 (0.25)
0.75 (19.1) 0.016 (0.4)
1 (25.4) 0.025 (0.64)

4. Documentation:
o Inspection Test Plan- CEL/IOCL/TEPL/RT/ITP-12,REV-00
o Inspection Report- CEL/IOCL/TEPL/RT/IR/FR-12,REV-00
o Procedure qualification Record- CEL/IOCL/TEPL/RT/PQR-12

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

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CORRTECH ENERGY LIMITED

INSPECTION TEST PLAN FOR RADIOGRAPHY TESTING BY X-RAY METHOD

PROJECT NAME LAYING OF 3LPE COATED CARBON STEEL PIPELINE IN LAKHISARAI, MUNGER & BHAGALPUR GA, SPREAD-A (GROUP-
A)
CLIENT M/s. INDIAN OIL CORPORATION LIMITED
CONSULTANT M/s. TRACTEBEL ENGINEERING PVT. LTD.
CONTRACTOR M/s. CORRTECH ENERGY LIMITED
DOCUMENT
: CEL/IOCL/TEPL/RT/ITP -12 Revision 00 Date:
NUMBER

Inspection By Inspection By
Sr. No. Activity Description Inspection By CEL Remarks
TEPL IOCL

1 Submission & Obtaining approval of procedure. P R A

2 Radiography procedure as per Spec./ Codes. P R R

3 Radiographic Examination. P R R
4 Review & Acceptance of NDT Reports S R R
5 RT Operator Qualification. S R R
6 Safety , Warning Boards Etc. P RW RW
Legend
W : Witness. A: APPROVAL
RM : Random Monitoring P: PERFORM/PREPARE
R : Review Documents. RW : Random Witness

WASIM HASHMI WASIM HASHMI

0 For Review and approval


Reviwed &
Reviwed & Approved By
Rev DATE DESCRIPTION Prepared by CEL Checked by CEL Approved By
TPI/IOCL
TEPL
LAYING OF 3LPE COATED CARBON STEEL PIPELINE IN LAKHISARAI,
MUNGER & BHAGALPUR GA, SPREAD-A (GROUP-A)
LOI NO: CEL/IOCL-TE/PLCGD-19-16/GrA/LOI/001 DATED 30.05.2020
CLIENT: M/s. INDIAN OIL CORPORATION LIMITED
CONSULTANT: M/s. TRACTEBEL ENGINEERING PVT. LTD.
CONTRACTOR: M/s. CORRTECH ENERGY LIMITED
INSPECTION REPORT FOR RADIOGRAPHY EXAMINATION
Doc No: CEL/IOCL/TEPL/RT/JP-12 Rev 00 Report No:
Chainage/KM: Date:
Pipe Size/WT: SFD: 30 cm Sensitivity: 2%
Material Grade: Technique: DWSI Film Type: D5
Type of Joint: BUTT WELD IQI: 10ISO 16 Film Size:
Radiography Equipment: Internal/External Density: 1.8 -3.5 Screen: LEAD
X-Ray : Ray Radiography Technique: Exposure:
KV: 180 Radiography Procedure: Lead: 0.25 mm both side
Source Size: m A: 5mA Acceptance Criteria:API 1104
Name of Supervision :
KM/Weld FOR FOR FOR FOR
SI. No. Welder No. WPS No. Segment Observation REMARKS
Joint No. NDT CEL TEPL TPI/IOCL

LEGEND- Acc-Accept, R-Repair, RS-Reshoot, RT- Retake, GRS- Grind & Reshoot, DRS:- Dressing & Reshoot, CRS- Clean & Reshoot

FOR NDT AGENCY FOR CEL FOR TEPL FOR TPI/IOCL

SIGN.
NAME

DATE WASIM HASHMI


LAYING OF 3LPE COATED CARBON STEEL PIPELINE IN LAKHISARAI, MUNGER &
BHAGALPUR GA, SPREAD-A (GROUP-A)

Procedure Qualification Record For Radiography Testing External X-Ray (DWSI)

Project Name LAYING OF 3LPE COATED CARBON STEEL PIPELINE IN LAKHISARAI, MUNGER & BHAGALPUR GA, SPREAD-A
(GROUP-A)
Client M/s Indianoil Corporation Pvt. Ltd. Doc. No. : CEL/IOCL/TEPL/RT/PQR/JP-12
Consultant M/s Tractebel Engineering Pvt. Ltd.
Contractor M/s Corrtech Energy Limited Rev-00

1 Location
2 Date of Testing
3 Material
4 Diameter & Wall thickness
5 Type of Weld Joint

6 Weld Joint Number of PQR

7 Make of Equipment
8 Radiation Source
9 Type of Equipment
10 KV Range
11 Used KV/mA during exposure
12 Radiation angle with respect to weld and film
13 Dimension of Focal spot
14 IQI type
15 Sensitivity
16 Technique
17 Focus to Film distance
18 Geometrical Unsharpness
19 Film Type & Make
20 Film Dimension
21 Overlap of film
22 Intensifying screens
23 Screen thickness
24 Density
25 Exposure Time
26 Film Processing
27 Developing Time / Temp
28 Stop Bath Time
29 Fixing Time
30 Acceptance Criteria
31 Processing chemicals
32 Drying Processing Time
NDT Agency CEL TEPL TPI/IOCL
Sign:

Name: WASIM HASHMI

Date :

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