Procedure For

RADIOGRAPHY

PROJECT NO.

LAYING & CONSTRUCTION OF 12”, 6” & 4” NB U/G

STEEL
PROJECT NAME
P/L NETWORK & ASSOCIATED WORKS AT
HYDERABAD.
OWNER BHAGYANAGAR GAS LIMITED (BGL)
CLIENT MECON LIMITED
CONTRACTOR MPEC

JOB PROCEDURE MPEC/BGL/MEC/BF/01

Rev. 0

Job Procedure
For
Radiography

For Review &

0 30.09.2016
Approval

Checked &
Prepared By Approved By
Rev. Date Description Reviewed By
MPEC MECON
MPEC

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TABLE OF CONTENTS

1. PURPOSE

2. SCOPE

3. REFERENCES

4. TERMS AND DEFINITIONS

5. METHODOLOGY

6. HEALTH, SAFETY & ENVIRONMENT

7. QUALITY ASSURANCE & QUALITY CONTROL

8. DOCUMENTATION

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1.0 PURPOSE

The purpose of this procedure is to lay guideline and requirements and to establish a
method or a system to control the radiographic examination in the BGL CNG & CGD
pipeline project at Hyderabad e by MPEC for executing the project.

2.0 SCOPE
This covers the method of Radiographic test for the weld joints of 12”,6” & 4”dia BGL CNG
& CGD Pipeline Project at Hyderabad.

3.0 REFERENCES

Following documents in totality or in part shall form the reference documents:

1. MEC Specification no: MEC/S/05/21/02

2. ASME SEC. V & API 1104 latest edition.
3. ASTM standard E94,E142,E747

4.0 TERMS & DEFINITIONS

Terms & Definitions shall be as per the contract document of subject works.
For the Purpose of this document, the term “shall” indicates a mandatory requirement and
“should” indicates a recommended practice.
Acronyms or abbreviation are followed by their full meaning in brackets.

5.0 METHODOLOGY

Radiographic examination shall be done by using x-rays; Gamma ray may be used with
the prior permission from client/consultant as per site condition. Only approved agencies
shall be engaged for radiography works.

The following techniques shall be carried out for radiographic works:

1. For mainline joints, the radiography shall be taken using internal crawlers by single
wall single image technique.

2. For Tie-in joints and joints with fittings where internal crawlers can not be used, the
radiography shall be taken using external x-ray machine by double wall single image
technique.
3. Incase of inaccessible main line joints and Tie-In joints radiography using Gamma ray
source with slow speed film ( AGFA D7 or Equivalent) shall be done with prior
permission from MEC/BGL

All the repaired areas shall be re-radiographed covering additional 6” of weld length on
either side of repaired area and while evaluating the repair films, the interpreter shall
compare, each section of the weld with original films to assure the repair was correctly
marked and original defect is removed completely.

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PROCEDURE:-

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 between 2.0 to 3.5 throughout the weld. The unexposed has
density of the film shall not exceed 0.30.

RADIATION SOURCE:-

Wherever possible, pipeline welds will be inspected by placing the radiation source inside
the pipe, on the pipeline axis, with a radiation of 6.28 red. (360)
If it is impossible to place the radiation source inside the pipe, the weld will be inspected
with the source on the outside if pentameter placed on film side suffix by Letter-F. An
overlap of 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 weld has been omitted.

LEVEL OF QUALITY:-

The quality level of Radiographic sensitivity required for radiographic inspection shall be at
least equivalent to the value 2%.

PENETRAMETERS:-

The image quality indicator (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 DIN-54109 or ISO-1027.
For radiographers made with the source on the outside, a penetrameter shall be placed on
each side of the film with the smaller wire 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 penetrameters approximately equally spaced around the
circumstance 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 shall not be less
than the 2%.

PLACEMENT OF MARKER AND I.Q.I

Each radiographic film shall contain the following identification information.

1) Pipeline:
Line identification
Weld number
Pipeline station
Pipe diameter and wall thickness
Date
Film location markers related to the area of weld that the film covers
NDE Contractor’s symbol

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Welder Identification No. (for all passes)

Weld thickness
Image Quality Indicator

2) Tie-Ins:
Line identification
Weld location mark (Pipeline Station)
Tie-In number
NDE Contractor’s symbol
Welder identification No (All Passes)
Pipe diameter and wall thickness
Date
Film location mark
Weld thickness
Image Quality Indicator

Radiographic film sensitivity shall be 1.6 percent of the pipe wall thickness or better. Only
wire type image quality indicator (IQI) hall is used. Refer DIN 54109, Part 1. IQI’s shall be
placed so that each film has at least two IQI. When a complete girth weld is radio graphed
in a single exposure, four IQI shall be placed 90° apart.

FILM PROCESSING:

Developing 5 minutes,
Temp. For development 180 to 230
Stop Bath with Acetic Acid 2% of water – 30 second.
Fixing – 10 minutes,
Running water 20 minutes,
Rinsing with wetting Agents – 2 minutes,
Drying time – 2 hrs.

RE-RADIOGRAPHY

All the repaired weld joints shall be re-radiographed in 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.

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

EQUIPMENT AND ACCESSORIES

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

Case - I. By Using Internal X-ray Crawler

(Single wall - single image technique)

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Prior to start of radiographic work procedure qualification shall be done by actual

demonstration of the technique at site and the film shall be submitted to for review and
approval of the technique.

This procedure is adopted to radiograph all the production welds other than tie-ins. The
minimum length of the film shall not be less than complete circumference length and to
have sufficient overlap at the ends of 40mm.

The unexposed film packed in the cassette ready with the joint identification
number and [Link] shall be wrapped around the circumferential weld. The x-ray crawler
shall be inserted from the open end of the pipe and shall be propelled by battery power to
the place of interest by use of a remote control. Radiation safety regulations must be
taken into account.

Case - II. By Using External X-ray Equipment

(Double wall, single image technique)

Prior to start of radiographic work procedure qualification shall be done by actual

demonstration of the technique at site and the film shall be submitted to MEC for review
and approval of the technique.

This procedure is adopted to radiograph tie-in / repair joints or joints which are
inaccessible to internal x-ray crawler. In this technique the number of exposures shall be
four per weld minimum subject to demonstration of sensitivity and required density. The
minimum length of each film shall not be less than 6” and should maintain a minimum film
overlap of 40mm.

Maximum film length (diagnostic film length) per exposure shall not be more than that
qualified in the procedure.

The equipment shall be positioned so that the radiation beam passes through the centre of
the section under examination and will be offset from the plane through the weld by the
minimum distance required to prevent the image of one side of the weld falling the image
on the other side. The film will be placed diametrically opposite the focal point with a
minimum of 4 number exposures at 900 displacements.

Marker system shall be used to produce permanent identification on the radiograph with
the following information:

Case - III. By Using Gamma-ray Equipment

(Double wall, single image technique)

Radiographic examination shall be carried out using X-radiations, radiographic

examination by Gamma rays using slow speed films may be allowed, at the discretion of
the MEC/BGL, in case inaccessible joints. Radiography by gamma ray for tie-in-joints shall
be acceptable provided D7 AGFA film or equivalent is used and the required sensitivity
obtained.

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Wherever possible, pipeline welds will be radiographed by placing the radiation source
inside the pipe, on the pipeline axis.

The equipment shall be positioned so that the radiation beam passes through the centre of
the section under examination and will be offset from the plane through the weld by the
minimum distance required to prevent the image of one side of the weld falling the image
on the other side. The film will be placed diametrically opposite the source.

INSPECTION PERSONNEL

Interpretation of radiography film should be done by ASNT Level-II qualified person.

ACCEPTANCE CRITERIA

Acceptance standard as per MEC Specification and API 1104.

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

Pipe Wall Thickness or Weld Essential Wire

ASTM SET DIN set
Thickness(mm) Dia (mm)
0-6.4 0.20 A 10 ISO 16
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

RADIOGRAPHIC EXAMINATION TECHNIQUE

( PIPELINE RADIOGRAPHY ) – EXTERNAL

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1. Object Butt Welds of 12”,8”,6” & 4” dia

Pipeline
2. Wall thickness range and length Butt Welds of 6.4mm
3. Extent of Examination 100%
4. Material to be Radiographed API 5L,Gr.B
5. Make of Equipment
6. Type of Equipment
7. kV Range 120 kV to 300 kV max.
8. mA X-Ray
9. Effective dim. Focal spot
10. I.Q.I Type DIN Wire Type
11. Sensitivity 2% or Better
12. Technique as specified in As per API 1104
13. Radiation angle with respect to weld and film 90
14. Focus to film distance Diameter of the Pipe + 6”
15. Object to film distance In Full contact
16. Geometrical Unsharpness 0.5 mm or less
17. Film type D7 or equivalent, class II, medium
speed
18. Film dimensions Full weld covered in 3 shots.
19. Overlap of film 50 mm on either side
20. Diagnostic film length Entire length of the film
21. Intensifying screens Lead
22. Screen thickness 0.1 mm / or 0.02 mm Front and Back
23. Maximum base fog level 0.3
24. Film density Between 2.0 and 3.5 in sound weld
25. Check on back scatter Yes
26. Identification on film As per Client’s/Consultant’s requirement
27. Film processing Manual
28. Processing chemicals Developer, stop bath, Fixer, wetting
agent
29. Acceptance Criteria API 1104 & Client’s specifications
30. Reporting Standard Reporting Format-
Client’s format
31. Identification of repairs R-for repair, CRW- for Cut & reweld, RT
for Retake, RS for Reshoot

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Double – Wall Radiographic Techniques

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Pipe Exposure Radiograp Source-Weld-Film Arrangement IQI Penetrameter Locati

O. Techniqu h Viewing on
D. e Mark
End View Side View Selecti Placeme
er
on nt
Place
ment

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

TABLE 276

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NOMINAL SINGLE- PENETRAMETER

WALL MATERIAL SOURCE SIDE FILM SIDE
HOLE TYPE ESSEN WIRE HOLE TYPE ESSEN WIRE
THICKNESS RANGE,
DESIGNATION TIAL DIAMETER, DESIGNAT TIAL DIAMETER,
INCH.
HOLE INCH ION HOLE INCH
Up to 0.25, incl. 12 2T 0.008 10 2T 0.006
Over 0.25 through 15 2T 0.010 12 2T 0.008
0.375
Over 0.375 through 17 2T 0.013 15 2T 0.010
0.50
Over 0.50 through 20 2T 0.016 17 2T 0.013
0.75
Over 0.75 through 25 2T 0.020 20 2T 0.016
1.00
Over 1.00 through 30 2T 0.025 25 2T 0.020
1.50
Over 1.50 through 35 2T 0.032 30 2T 0.025
2.00
Over 2.00 through 40 2T 0.040 35 2T 0.032
2.50
Over 2.50 through 50 2T 0.050 40 2T 0.040
4.00

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Over 4.00 through 60 2T 0.063 50 2T 0.050

6.00
Over 6.00 through 80 2T 0.100 60 2T 0.063
8.00
Over 8.00 through 100 2T 0.126 80 2T 0.100
10.00
Over 10.00 through 120 2T 0.160 100 2T 0.126
12.00
Over 12.00 through 160 2T 0.250 120 2T 0.160
16.00
Over 16.00 through 200 2T 0.320 160 2T 0.250
20.00

Thickness to be considered for Sensitivity Calculations / Penetrameter selection.

. Double Wall Single Image Technique: Single wall Thickness. + Weld reinforcement Thickness

Minimum Specimen Thickness Wire Diameter, Inch (mm)

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)

6.0 HEALTH, SAFETY & ENVIRONMENT

Radiation safety rules as per BARC & other authorities/regulations shall be followed.
Area to be cordoned off during the operation.
Operators should always crosscheck radiation level with survey meters before approaching
the machine.
7.0 QUALITY ASSURANCE & QUALITY CONTROL
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.

8.0 DOCUMENTATION

ITP NO.:MPEC /PL/MNGL/ITP-16 Inspection Test Plan.

FORMAT NO.: MNGL/E&P/F/8.4.B/00 Radiographic Inspection Report.
FORMAT NO.:MPEC /PL/MNGL/IR-16 Radiographic procedure.

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