JOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP.07 [ Rev: No. 01] Page tof ld PROJECT | , | LAYING & CONSTRUCTION OF 6” & 4°NB UNDERGROUND STEEL PIPELINE NETWORK & ASSOCIATED WORKS AT GODHAVARI 6” X 24 KM ULLAMPURA to BHIMAVARAM & 4” X 13 KM KOPPAKA PARASAD SEAD. OWNER : | GODAVARI GAS PRIVATE LIMITED PMC : |MECON LIMITED FOA NO. 2 | GGPL/KKD/C&P/CGD/PMC/PL/PART A/31/18-19 CONTRACTOR : | TECHNO GLOBAL SERVICES PVT LTD. Wed, / APPROVED pees Cth minor Stipmeris) ume P Siwaw tian” SDE Date of |reoezow | vers | [Link] " Reviewed & Approved by "MECON /GGPL ti Prepared & Checked by Rev.| Date | Description TesGODAVARI PIPELINE PROJECT Z—- ie G&PL JOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 I [Link].01 | Page 2of14 TABLE OF CONTENTS: 1.0 PURPOSE...... 2.0 SCOPE secretes 3.0 REFERENCES... 34 RESPONSIBILITY... 4.0 PERSONNEL QUALIFICATION . 5.0 EQUIPMENT , MATERIALS & ACCESSORIES FOR RADIOGRAPHY INSPECTION .. 6.0 | METHODOLOGY... 7.0 HEALTH SAFETY & ENVIORNMENT ...... 8.0 QUALITY ASSURANCE / QUALITY CONTROL....... 9.0 APPENDICES AND FORMATS «...esssssscnsesGODAVARI PIPELINE PROJECT JOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 Rev. No. 01 1.0 PURPOSE: The purpose of this procedure is to lay guidelines and requirements and to establish a method to control the Radiography activities to be used in the 6” X 24 KM ULLAMPURA to BHIMAVARAM & 4” X 13 KM KOPPAKA PARASAD SEAD. 2.0 SCOPE: The scope of work covers the minimum requirements of Radiography of Girth welds using x-ray or gamma ray by Ir 192 isotopes for detecting the discontinuities/defects in pipeline/terminal piping welded joints and other components for the 6” X 24 KM ULLAMPURA to BHIMAVARAM & 4” X 13 KM KOPPAKA PARASAD SEAD. 3.0 REFERENCES: Following documents in totality or in part shall form the reference documents: * Specification for Pipeline Construction (Onshore) MEC/S/05/21/02 * API: 1104 Latest Edition — Standard for welding pipelines and related facilities, + ASME SEC -V. * ASME B31.8 - Gas Transmission and Distribution Piping + ASTM E94, Recommended practice for Radiographic Testing * ASTM £142, Standard Method for Controlling Quality of Radiographic Testing * The American Society for Non-destructive Testing. Recommended Practice No. SNT - TC-1A Supplement A.GPL GODAVARI PIPELINE PROJECT JOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 [Re No. 01 L 3.1 RESPONSIBILITY: Project Manager Resident Construction Manager QA/QC Manager/QA/QC Engineer HSE Officers - 4.0 PERSONNEL QUALIFICATION Shall report to Project Director. Shall provide all necessary resources to implement this Procedure. Shall report to the Project Manager. Construction manager shall provide adequate resources (manpower, machineries, tools etc) to implement the procedure and should also ensure quality & workmanship. . —[Link] OMA Lplenre false, rno ond conh the contliivelon hetrvihes Shall report to Project Manager. Shall ensure proper implementation of this procedure. Shall checks and verifies the activities. Shall be responsible for the compliance of this procedure. Shall report to Resident Construction Manager / Project Manager administratively and to HO for technical matters. Implementation of all safety requirements during Radiography Ensuring that the ‘Communication system is working properly and that Emergency equipment is in place. Only qualified personals, certified in accordance with recommendations of ASNT recommended Practice No. SNT-TC-1A, shall be engaged for radiography work. Only ASNT Level-lI personnel shall be interpreted the Radiography film. All such qualification certificates (authenticated copies) shall be submitted to MECON/GGPL for review & approval. ( ASNT Level-I technician shall carry out the testing under supervision of NDT Level-II inspector)GGPL GODAVARI PIPELINE PROJECT ha JOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 I Rev. No.01 | Page 5of ca 5.0 6.0 Equipment, Materials & Accessories for Radiography Inspection For Radiographic examination of welded joints, the following units or materials are used, X ray units with tubes up to 300 kV, 3 - 6 mA of panoramic type and directional type. Dark room with controlled temperature for manual radiographic film development. Lead foil intensifying screens with thickness between 0.02 - 0.25 mm. Densitometer for determination of radiographic films optical density. Identification symbols - numbers and letters, measuring tape for marking and coding of weld joints, Film illuminator capable of providing required illumination. Magnifying glasses, measuring scales, templates. "X-ray/Gamma ray Ir 192 source projector (Internal & external crawlers), Warning placards, Film viewer/radiograph" METHODOLOGY All Girth welds 100% Radiography examination shall be done by using X-rays. Procedure qualification shall be performed to the satisfaction of the company before start the production welding. The Company representative shall witness the entire qualification test. NDT of a test weld may serve as a qualification test for the NDT procedure and shall be witnessed by the company. For main line joints, the radiography shall be taken using internal crawlers i.e., by Single Wall Single Image (SWS). Panoramic (SWS) - film is placed outside on weld seam along the whole weld joint while the radiation source is installed inside the pipe in its center. For Tie-In joints, the radiography shall be taken by using external X-ray machine i.e. by Double Wali single Image (DWS). Film is placed outside on weld joint, while the radiation source is installed outside the pipe in the opposite direction. The repair shall be subjected, a minimum requirement, to. he same testing and inspectionGODAVARI PIPELINE PROJECT nes GGPL JOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 [Link].01 | Page 6of 14 out. In addition, a minimum 6° weld length on the either side of the repaired area shall be re-radiographed. While evaluating the repair films, the interpreter shall compare each section of weld with original films. * Radiographic examination by Gamma rays may be allowed, at the discretion of the COMPANY, In case of inaccessible main line joints and Tie-in joints radiography using gamma ray source with slow speed films (D4or equivalent) shall be done with prior permission from MECON/GGPL. * When the radiation source and the film are both on the outside of the weld and located diametrically opposite each other 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. © Type 2 &3 Films shall be used as per ASTM E-94. Radiation Source 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 40 mm 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. Level of Quality The quality level of Radiographic sensitivity required for radiographic inspection shall be at least equivalent to the values in 2%, > Case-l,( Internal Unit, Single Wall Single Image Technique) * This procedure is adopted to radiograph mainly in production welds other than tie-in welds. In this technique the no of exposure shall be depends on the pipe size. The minimum length of the films shall not be less then completed circumference length and to have minimum 40mm overlaps at the ends. * The positions markers shall also be marked on the pipe to be radio graphed and maintain such as way with minimum intervals from the datum points (Zero Point shall be on top ofGODAVARI PIPELINE PROJECT GEPL — ii | JOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 | Rev. No. 01 [fs 7 of 14 pipe) and the divisions shall run clockwise in ascending order, viewed in the flow direction of the pipeline laying progress around complete circumference. + The unexposed film packed in the cassette ready with the joint identification number and 1.Q.!'s 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 using of a remote control. Radiation safely regulations safety regulations must be taken into account. Radiation source shall be shall be positioned with in 5 mm of center of weld circle. Radiation angle is 90°. The machine emits radiation as per pre-set exposure time. + Marker system shall be used to produce permanent identification on the radiographs with the following information: 1) Project Name Il) Weld Number ( KM & Joint No) ll) Dia of Pipe & Wall Thickness. IV) Welder Identification V) Date of Radiography VI) Repair ( R/RT/RS/CRS/DRS- Identification marks) The marker shall be placed away from the area of interest. All the radiography technique stated in this procedure shall be qualified, » Case-Il,( By using External X ray- Double Wall - Single Image technique) * This procedure is adopted to radio graphed tie-in weld joints. Which are inaccessible to internal x-ray crawler by using X ray. In this technique the no of exposure shall be more per weld minimum subject to demonstration of sensitivity and required density. An overlap of the films shall not be less minimum 40mm at the ends of each film. Double Wall Single Image technique shall be used in which the radiation passes through two walls and only the weld on the film side wall is viewed for acceptance of the radiograph. QI (Image Quality Indicator) selection and Placement The image quality indicator (abbreviation: IQ!) 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 (Penetrometer). ‘he gsreiprete shall be selected according Lo & aJOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY | 5] ee | DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 [ [Link].01 | Pays Bof 14 | to DINS4109 or 1S01027. For radiographs made with the source on the outside, a penetrometer shall be placed on each side of the film with the smaller wire of the penetrometer turned towards the end of the film itself. When a complete weld is to be radiographed in a single exposure using source inside the piping, four penetrometer approximately equally spaced around the circumference shall be used. For DWSI process 02 nos. penetrometers (IQ) shall be placed at every film. During the procedure qualification, IQ! 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 less than the values shown in the MECON specification. The sensitivity limit may be considered to have been reached when the outline of the Ql, its identification number and the wire of the required diameter show up clearly on the radiograph. The COMPANY may authorize use of types of IQ other than those planned, provided that they conform with recognized standards and only if the TGS is able to demonstrate that the minimum sensitivity level required is obtained. For this demonstration, a test shall be carried out comparing the IQI specified and the TGS's, to show up the identification number and other details of the proposed IQI, which must be visible in the test radiography. > Film Selection * AGFA D7, DS, D4, or Kodak AA-400, T200, MX125, or FUJI IX100, IX80, IX50 any one of these films shall be used. For Piping refer MECON Specification. > Surface Preparation As far as possible all irregularities from the surface (to the extent of coverage of films) shall be removed for better results and interpretation > Prevention of Back Scattering * To achieve better Radiography definition, it is required to check back scattering placing lead no. B on the backside of the holder to ensure the back scattering does not harm the film quality. > Source to Film Distance * For Internal Unit: X-Ray tube to place at the center of the pipe.GODAVARI PIPELINE PROJECT JOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 Rev. No. 01 [ Page Qof 14 * For External Unit: Diameter of the pipe plus 6” will be the distance between the source & the film. > Exposure Time + Exposure time shall be calculated with the film speed using Exposure chart or arrived at actual during procedure qualifications. > Film Loading Film shall be loaded in the dark room under proper safe light. Films shall be cut carefully without any damages, scratches or finger marks. Sandwich the film between pair of lead foil intensifying screens & loaded in PVC cassettes or holders. v Number of Exposure * The number of Exposures will be such that the area of Interest is completely covered and when multiple films are used the overlap between any 2 films will be minimum of 40 mm. * Incase of external unit 4 Exposures taken at 90° apart to cover the entire weld circumference. > Film Processing * Films shall be processed in a dark room. The temperature of the chemical shall be 18°C- 22°C. The film shall be unloaded in hangers / spools carefully to avoid any marks. + The manual processing involves the following steps. All the steps shall be performed on a test film initially to determine any effect of processing. Step: 1 Developer: Shake hangers or spools to avoid any uneven developing marks. Developing time shall be 2 to 3 minutes. Step: 2 Stop Bath: The stop bath is water with 5 to 6 drops Acetic Acid per gallon of water. To arrest developing action films are immersed in a stop bath. Shake hanger for 2 to 3 minutes in the stop bath. Step: 3 Fixer: To remove the excess silver grains from unexposed or less exposed part of film & harden base of films, the hangers shall be immersed in fixer for 6 to 10 minutes Step: 4 Water Washing with wetting Agent: Films shall be kept in water bath with wetting agent, where excess fixer will be washed from the surface of the film. Wash at least for 20 minutes. Step: 5 Drying: Film shall be dried in open space or in dark room by hanging vertically. > Film ViewingGODAVARI PIPELINE PROJECT GG&PL ; | = iT iGist JOB PROCEDURE FOR RADIOGRAPHY TEST BY DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 Rev. No. 01 * The films shall be viewed under 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 > Film Density * To measure the film density a calibrated densitometer or certified step wedge density strip shall be used. The transmitted film density as measured by digital density meter shall be between 2 and 3.5 throughout the weld. The unexposed base density of the film shall not exceed 0.30. > Film Contrast Contrast of the film shall be adequate to manifest on the Radiograph even the smallest thickness differential. Better the contrast better the interpretation of discontinuity. > Sensitivity Sensitivity shall be followed as per MECON specification. Diameter of thinnest wire Visi % Sensitivity = X 100 Penetrated thickness at the area of Interest The diameter of the wire shall be based on nominal wall thickness of the pipe plus the maximum allowable thickness of the external weld reinforcement and allowable internal weld protrusion. » Interpretation and Acceptance or Rejection Criteria * Interpretation and Acceptance or rejection criteria shall be in accordance with Technical Spec - MEC/S/05/21/02 and API 1104. All defect location shall be marked & recorded for repair. > Film Storage & Archive Life + The films will be stored in the boxes. Sealed packages of film may be affected by heat. Open packages are affected by both heat & humidity. Ideally, open packages of films should be stored at temperature between 10 and 21 degree C and less than 80% relative humidity. All films which have been exposed, processed and interpreted shall be arranged in Cubical cardboard with proper packing and precautions.( Methylene blue test shall be carried out to find out its archive life")GODAVARI PIPELINE PROJECT JOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 Rev. No. 01 © Hof 4 > Table for DIN Wire Type and Also ISO Penetrameter. Wire No Thickness (MM) 1 3.200 2 2.560 3 2.000 4 [ 1.600 DIN 62 FE 411SO7 5 1.280 6 1.000 | 7 0.800 8 0.640 9 0.500 DIN 62 FE (__siso12 10 0.400 Ti 0.320 12 0.250 [43 0.500 DIN 62 FE 10 1SO 16 4 0.160 15 0.125 16 0.400 2G&PL GODAVARI PIPELINE PROJECT Zz JOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY | POCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 I Rev. No. 01 | Page 12o0f 14 > Radiography Examination Technique. SINGLE WALL SINGLE RADIOGRAPHIC TECHNIQUES (Internal Unit Pipe | Exposure | Radiograph Source “Weld; ilm 1QI Pentameter _ OD | Technique | Viewing rangement = farker | End View | Side View | Selection | Placement | Placement Single ro" Film Side a Any ial) Single Wall Table bt 1.2753 . ‘T-276 T-275.1(c) Exposure Arrangement -A. | Source Single 7.276 and | 3587.) | Tumse Any | Wall: | Single Wall Table T- | 277 : T2711 276 oy) : Film Side T2711 )GODAVARI PIPELINE PROJECT JOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 Rev. No. 01 13 of 14 DOUBLE WALL SINGLE IMAGE RADIOGRAPHIC TECHNIQUES (External Unit) " | Source —Weld-Film Location [Ripe | Exposure | Radiograph Arrangement tar Pentameter | ‘Starker | a ‘8 | “End View | Side View _ | Selection | Placement | Placement x Mowe Double Wall: Source T271.2(a) Side T- at least 3 7276 | 277.1(@) | Film Side Any | exposure | Single Wall ane T-275.1 120°to a (xl) each other Film Side complete Exposure arrangement — D 1277.1 coverage b) _ Exposure Arrangement -A * Safety in this NDT method is first priority; > Radiation Safety ience all technicians must work as per radiation safety guide & all local rules and regulation. During radiographic inspection the safety measures shall be observed in accordance with the following Radiation safety requirements. * Each NDT person shall carry personal radiation protection device (Dosimeter, Survey meter. Film Badge, Hard Hat, Protective Clothes, and Shoes etc) to measure the amount of radiation exposure. The dosimeter shall be set to zero every day by the NDT supervisor prior to sending the NDT crews to work and at the end of each working day. NDT personnel will be equipped with the following means of PPE * At any location where radiography shall take place, a safe area shall be clearly defined and marked where radiation level are at maximum allowed exposure levels measured at the boundary of the marked. The area within the above-defined boundary shall be called Radiography controlled area and it is the responsibility and control of NDT supervisor in charge of executing the specified work [Link] defined area. In general the following instructions shall be adhered to: at SeemGODAVARI PIPELINE PROJECT =i JOB PROCEDURE FOR RADIOGRAPHY TEST BY X-RAY DOCUMENT NO. : GGPL-MEC-TGS-QCP-ML-JP-07 | Rev. No. O1 * The boundary of this area must be clearly identified and marked by the use of proper warning signs and tape + No person shall be allowed to remain or enter this area without the approval of NDT person in-charge * The distance from the radiation source shall depend on the strength of the source being used and determined by the Inverse Square formula, In general, the measured instantaneous radiation level at the boundary shall not exceed 2.5 micro sv. /h (0.25 mR/h). 7.0 HEALTH, SAFETY AND ENVIRONMENT ‘+ Radiation safety rules as per rules and regulations set forth by ATOMIC ENERGY COMMISSION or any Govt. agency of India in this regard. + PPE is must in this activity. + Operator should always cross check radiation level with survey meters before approaching the machine. 8.0 QUALITY ASSURANCE /QUALITY CONTROL Quality assurance will be maintained by systematic implementation of this procedure and generating necessary quality records. 9.0 APPENDIX/ FARMATS. Appendix: 01 Inspection Test Plan for Radiography GGPL-MEC-TGS-QCP-ML-JP-07-ITP Rev.-01) Appendix: 02 Interpretation report of Radiography (GGPL-MEC-TGS-QCP-ML-JP-07-F-01 Rev.-01) Appendix: 03. Radiography Film Handover Report (GGPL-MEC-TGS-QCP-ML-JP-07-F-02 Rev.-01) Note: In case on any conflict between the above procedure and project specification the later shall govern, without any prejudice to the terms and conditions of the contract.care Ee JPROJECT _:LAYING & CONSTRUCTION OF 6" & 4"UNDER GROUND STEEL PIPELINE NETWORK & ASSOCIATED WORKS AT GODHAVARI [oLIeNT GODAVARI GAS PRIVATE LIMITED Document No ‘[Link]-ML-JP-O7-TP |CONSULTANT : Wis MECON LiMiTED Revat SONTRACTOR_: TECHNO GLOBAL SERVICES PVTLTD, ‘Append INSPECTION TEST PLAN FOR RADIOGRAPHY BY NOT BY __ | Doos tobe submitted fev Activities aoency | ®YTSS- | weconccpt| nae Remarks [SGPL-MEC-TOS-OCF-| 1 |Submission and Approval of work Procedure w a Mang 2 [Procedure Quaiiteaton Record P w a Par Tevet or Leven 3 Jouatfication of NOT Technicians / A w R See 4 |RT Operator Quaifcation P w w 5 [inspection of Equipments P w R 6_[Devioping of RT Fins P R RW 7. [Radiographic Examination P w RW 8 [Review and Accoptance of RT Fins e w ® '@ [Report Preparation P w a [Fim Quality, Senstiviy, dens & overag" To ba 1 Ri © performed by NOT agency 7 ew w lLeGes "A" Approval PR" Review of Documents we wines, "pr" Porformed |-Rw" Random Witness. Tas MECONGGPL. 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