FIELD RADIOGRAPHY USING 100 Ci OF Co-60

WITHOUT INTERRUPTING ADJACENT MANUFACTURING OPERATIONS

By

C. W. DONNELLY

ROCKWELL INTERNATIONAL CORPORATION

ENERGY SYSTEMS GROUP

- DISCLAIMER •

vv 1 nGf«w«Ji«.a n Mc;'>n;of work nwniored bv an agency o< tr.« U

e Ui:i«J 5 I » ' M G o *

DISTRIBUTION OF TKIS GOLiiiKEHT IS UNLfMITB

 FIELD RADIOGRAPHY USING 100 ci.OF Co-60
WITHOUT INTERRUPTING ADJACENT MANUFACTURING OPERATIONS

C, M. DONNELLY

INTRODUCTION
Radiography is the primary method of Nondestructive Examination recognized by
the ASME B&PV Code as providing objective evidence of volumetric examination of the
pressure boundary welds that are present in the Clinch River Breeder Reactor
Program (CRBRP) Steam Generator.
However, conventional radiography cannot be performed on the major portions of
the steam generator pressure boundary welds because of its unique design, the
fabrication methods required because of the design and the limitations imposed by
the fabrication facilities. The "hockey stick" design precludes rotation of the
generator. The tube-to-tubesheet joint design in which the tubes are butt welded to
the tubesheet requires that the elbow sections and reducers be assembled around the
completed tube bundle. The facility has no crane capable of lifting a generator, so
the support fixtures are mounted on air pallets. There is no provision for moving
an incomplete generator once it is set in place and installation of steam tubes is
started.
In order to support the steam generator production schedule, the radiographic
examinations must be performed without interrupting any other manufacturing or
inspection operations taking place within a 20-ft radius from the source. This
condition imposes rigorous radiation safety requirements since the gamma radiation
sources chosen to be used for examination of the pressure boundary welds, Co-60
and Ir-192, are very energetic. Co-60 gamma ray energy is 1.17 and 1.33 MEV and
Ir-192 gamma ray is .6 MEV.
The hazard of using such high energy sources in the immediate vicinity of
working personnel has necessitated the need for a thorough evaluation of methods of
protection. Personnel protection from penetrating radiation, both x-ray and gamma
ray, is accomplished by ingenious use, singly or in combination, of two factors
which reduce radiation intensity. These factors are distance and shielding. In
all radiographic operations the primary consideration is for personnel safety. The
maximum radiation dose rate limit will be 0.002 rem/hr. This document describes how
the factors of distance and shielding have been used to assure personnel safety at
all times.
DEFINITIONS
Field Radiography
Field radiography is defined as radiography which is performed outside of a
permanent radiographic facility.
 Field radiographic conditions require a radiation survey for each set-up and
requires the placement of warning lights, signs, and physical barriers at the
minimum safe distance from the exposed source. The minimum safe radiation level is
I .002 R/hr (2 MR).
Primary Radiation
Radiation emitted directly from an x-ray target or gamma radiation source.
Scatter Radiation
Radiation scatter is emitted at various angles as a result of the interaction
of X or Gamma Ray Primary photons with electrons in the matter irradiated. The
angle of emission of scatter radiation is a function of the energy of the photon
which produces it. The higher the primary photon energy, the lesser the angle of
scatter. Scatter radiation is always less energetic than the primary radiation
which produces it.
The energy of scatter radiation may be calculated as follows:
E = .511
S
1 - Cos 0 + 4 ^
Where E, = Energy of primary radiation (MeV)
9 = Angle of scatter radiation
Eg = Energy of scatter radiation (MeV)
.511 MeV = Rest mass of the electron; energy equivalent
Isotope
Isotopes are varieties of the same chemical element having different atomic
weights. All isotopes of the same chemical element have the same number of protons
in their nuclei but different numbers of neutrons. Some 800+ isotopes have been
identified and 500+ of these are radioactive.
Radioactive Isotope Strength
Radioactive isotope strength or activity is measured in curies (Ci). One
curie of activity of any isotope is equal to 37 billion disintegrations/second.
(3.7 x 10 r o d/s) In SI Units 3.7 x 10 1 0 Bg.
Roentgen (R)
The roentgen is a measure of radiation exposure. It is measured at a
specified distance from the radiation source. For example:
Roentgen/hour @ 1 ft
Roentgen/hour @ 1 meter
A roentgen is defined as that quantity of radiation that will produce one
electrostatic unit (ESU) of charge in 0.001293 gram of air.
 °'2°-yh- = 0.002 R/hr, an allowable value
Therefore, incorporating a 0.750-in. lead external collimator extending from
the source camera to the surface of the part and enforcing a 10 ft distance limit,
safety is assured.
CONCLUSION
The calculations indicated that the approach was feasible: it should be
possible to use 100 ci of Co-60 properly shielded and colimated to produce accept-
able radiographs within the safety requirements stated.
The Roatating Radiographic Fixture was fabricated and tested on a section
mockup of the steam generator. Radiation measurements taken with the source exposed
indicated that the worst case analysis was indeed conservative. The .002 R/hr limit
was located at 10' from the source. There was no measureable radiation detected at
the longitudinal axis of the part. No primary radiation was detected at the back of
the beam catcher. At 96" source to beam catcher distance the primary beam was still
safely inside the 36" diameter beam catcher.
Radiographs were taken on "AA" film, using .010" lead screens, front and back.
2-1T sensitivity was obtained with a density of 2.7 after two minutes exposure
through 2.25" of 7k Cr-1 Mo Steel. The penetrameter was a #35. The diameter of
useable film density was 9.25".
The unit was used to radiograph the Inlet Header to Shell and Outlet Header to
Shell welds of the Prototype Steam Generator fabricated at Building 902 in
El Segundo. (See Figure 3 and 4 ) .
The original Rotating Radiographic Fixture is in service and three more
slightly modified designs are being fabricated.
For the radiographic examination of the CRBRP Steam Generator, the Rotating
Radiographic Fixtures have been successful in solving the problems of personnel
safety and acceptable radiographic film.
ASNT 7 x i 0 in

r
1— First line of tex.
2—
3—
4—
5— F;R£;
;R£; LLI :E CREFERENCEO OOCtWENTS:
6-
7— 1. Califoraia Radiation Control Regulations, Title 17, California Administrative
8 - Code, Chapter 5, Subchapter 4 ' -t-,3
g
i n- 2. Introduction to Nuclear Engineering by Richard Stephenson, Published 1958,
f- i
G l
McGraw-Hill
S'rst irNodiiiar Assembly Steam Generator Drawing R-N0364100006
4. National Bureau of Standards (NBS) Handbook 114
1 R._.

46- •
A7— i
ASM! 7 x 1 0 in

Hwhftrecf textx....-.55 Number of.value, layefs

y = Value of the layer, thickness, e.g. 1/2, 1/10
I, = Incident radiation in R/hr
r_ li.
C
= ^Transmitted Radiation-in R/hr
£,-.--; I RRSTUNE OFTiTLE: ALL CA"3 AND Ci^NTe^
6 ] Tliis equation jnay be solved for xanii various value layer thicknesses. ;The
7 I exact solution .for the exponent "x" for half values is
8— f I T. Aulf-or's narna, cercr <

x Log 2 = Log Ij - Log I

Frstfine C text . Log I , - - -Log I
x
Log 2
Half Value layers will be used for the determination of shielding thickness in
this document.
To find the thickness of some common shielding materials necessary to reduce
1450 R/hr @ 1 ft from 100 Ci of Co-60 to 0.002 R/hr at 1 ft then:
Log 1450 - Log 0.002
Log 2

* " O f " 19'4676

and from Table I, the HVL thickness for lead, steel and concrete are respectively
0.5 in., 0.87 in., and 2.7 in. for Co-60 gamma ray's which would require the
following material thicknesses:
19.4676 x 0.5 in. = 9.73 of lead
19.4676 x 0.87 in. = 16.94 in. of steel
19.4676 x 2.7 in. = 52.6 in. of concrete
The general equation may also be used to find the "reduction factor" for
various thicknesses of materials used for shielding purposes., For example, by what
"reduction factor" will 3 in. of steel reduce the radiation from a Co-60 source?
From Table I, 0.87 in. of steel is a HVL for Co-60 radiation, then
3 in. steel _ J<
3 as HVI
HVL
0.87 in. HVL
and from the HVL equation
23*45 = 10.92.
This means radiation from a Co-60 source will be reduced by a factor of 10.92
when passing through 3 in. of steel.
Scatter Radiation Formula
The second type of radiation to consider is scatter radiation. The equation
used in the evaluation of scatter radiation is:
ASNT 7 x 10 in

1-1
2-|_
3-] Where: R/hr at "P" = R/hr at the center "P" of the cone
4—
g, 'ONE OMTTLE: ALL CAPS' AND CENTER"
8—
7— Nuclian Engi neeri ng, ,
ti ij

io-~! Scatter area in ft—- Area-of-the cone of incident

radiation aroiind "P"
id First line of text stance = distance fromyP" at which radiation
- is measured. ' — -
16-I WORST CASE ANALYSIS FOR CO-60 RAD^OGRAPHIC SHIELDING REQUIREMENTS
^ ~7 '
1 J "*" f i
-[ R J
The purpose of the "beam catcher" is1 to reduce the intensity of the primary
beam to less than .002 R/hr (2 MR). Thejthickness of the "beam catcher" is
dependent on the energy of the primary beam, the distance the source is from the
"beam catcher," and the thickness and composition of material between the source
and the "beam catcher." The "worst case" would require the thickest "beam catcher"
and would occur when:
(a) The highest energy source is used. 11_
(b) The minimum source to "beam catcher distance is attained.
(c) The thinnest part is being examined.
Worst Case Parameters
(Radiography of Minimum Thickness Shell Welds with 100 Ci of Co-60)
(See Figure 2)
Shell Section Thickness 2.25 in.
Shell Inside Diameter 49 in.
Radiation Source 100 Ci Co-60, 1450 R/hr @ 1 f t
Source to Shell Distance 24 n in. n
Source Collimation 20° ± 1°, Included angle
Source Camera Shield Depleted Uranium (No significant
radiation from source camera).
-Beam Catcher 36-!n diameter 4.0-in thick lead
shield on l-1n thick steel base
equivalent to 8.15 HVL t o t a l .
Calculation of R/hr at Back! Surface of Beam Catcher
(See Figure 2) >
(1) R/hr at 12 i n . from source 1,450 R/hr
100 Ci Co-60
(2) R/hr at 24 i n . from source at 362.5 R/hr
part O.D. surface
,2
1450 x 12' = 362.5
24'
ASNT 7 x 10 in

7
ar"
part I7D. surface (Thverse square)'

' ' • • ~ >

8—\ o R.Q_M*^_ L 3fla_O3.Ay.^9r's. n?01§j. 9?. n l?I

9—

(5) R/hr at for "I. D. T u r f ace j~"

12— 50.46 x 26.252 _ fi i n I , 1(1 D/hy>
13— First fine or ma . _ _o _ _ T_6_. 10 _ _ , _ . .6.10 R/hr
75.25^" - . . . - [ . .
1 5— (6) R/hr at for O.D. surface !
2
50.46 x 26.25 .5>79 j 5.79 R/hr
77.50^ '
(7) R/hr at for O.D. surface J7Q
shielded by 2.25 in. steel = !f£f- .96 R/hr
(8) R/hr at surface of "beam catcher" .79 R/hr
.96 x 77.52 _ 70
85 50
-
How thick should the "beam catcher" be?
2 X = -^| = x log 2 = Log 79 - Log .002
Log .79 - Log .002 = 86-
4 in. of lead
.00 HVL
.87 in. (HVL steel to Co-60)
1 in. steel 1.15 HVL 9.15 total
.87 in. (HVL steel for Co-60)
(9) R/hr at far side of "beam catcher"
-5^Ttr = -001 R/hr
ZZZZIZZZZZ _ I
Scatter Radiation Shielding Analysis
4 b— I the steam generator during Co-60 isotope!
Scatter radiation from the surface pf
4 o— radiography must be reduced by auxiliary1shielding attached to the rotating '
radiographic fixture. The worst case for scatter radiation vs personnel safety is
the scatter radiation leaving the first surface of the part at 90 to the primary
beam incidence. As previously shown, the equation for scatter radiation is as
follows:
2
(R/hr @ "P") (Reflection Coefficient) (Scattering area in ft ) ,R/hr
(Distance)*
Reflection coefficient for scatter |s taken as 0.03 which is conservative.
(Source: Introduction to Nuclear Engineering 1958, McGraw Hill)
I • '"
ASNT

1 Fist^neoffeyl I 1 Bsdiation "Calculations

[ A l l calculations are based on "worst ["case" analysis ( i . e . , maximum curie
4 \ strength and minimum material available fbr shielding).
5 | " _ FiRSf IME OF TITLE: ALL CAPS AND CLEiMT^R
6 I BASIC FORMULAEFOR SHIELDING CALCULATIONS I

8
y "j _
9 I Inverse SquarecLaw
0 Radiation Jntensity (I) yaries as the inverse square of the distance (D) from
the radiation source. :

13
1d i.e.
h . °2

1 6~•
Where: I, = R/hr at distance D,

O t '• I2 = R/hr at distance Dp

D, = Initial Distance

D2 = New Distance

Half Value Layer

The half value layer (HVL) is defined as that thickness of material which will
reduce the transmitted radiation to 1/2 the value of the incident radiation. The
thickness of the HVL is given in Table 1 for certain common materials with isotope
energies and strengths shown.
TABLE I
ISOTOPE HALF VALUE LAYERS (HVL) FOR COMMON SHIELDING MATERIALS
Half Value Layer (HVL) in Inches
Uranium
Isotope Energy R/hr/Ci @ 1 ft (Depleted) Lead Steel Concrete
1.17
c Co-60 1.3 MeV 14.5 0.33 0.5 0.87 2.7
A * ••
44 - Ir-192 0.6 MeV 5.9 0.16 0.19 0.55 1.9
Yb-169 0.2 MeV 1.44 0.015
47—
43—
Half Value Layer (H\IL) Determination
50—
o <•
The general equation for half value layer is:
s
;- / y i~
ASNT 7 x 10 in

First line of text Isotope -HaSf- Life

3—j The half life of a radioactive isotope is the time required for the isotope to
4— j decay £ Q _ o n e = h a l f _ o f - j ± s ~ i n i t i a j _ c u M e - s i ^ the
5— | CRBRP S/£LJ>nagrm_are-ai[ii$§tl<^ --^
6— 1 1 _ I
7-1 Isotope- J Half-Life s
Q j I AutiTor^s name.jpsnterj^ i
10- I r-192 - 75 days
11-
12- Yb-169 j 32 days
13- First line of text DE-SIGN CRITERIA j
14-
15
~] Radiographic examination of steam generator welds presents a twofold problem: i
16—! i !
1. We must assure personnel radiation safety at the stated 20' radius from the
18— source. '*
•• o
j

pi
2. We must produce acceptable radiographs of the welds insofar as density, \
sensitivity and coverage is required'by the ASME B&PV Code without being able !
to rotate the generator under a fixed source. ;
To produce acceptable radiographs the source must be positioned and rotated
around the part. : ?•;•••

The solution to the twofold problem was the invention of the Rotating
Radibgraphic Fixture. The fixture incorporates elements for both primary beam and
scatter radiation protection and capability for precise positioning of the source in
relation to the pressure boundary welds. (See Figure 1).
Primary Radiation
For gamma ray radiography, the primary beam is collimated and shielded so
that the primary beam never exits the part except to enter a "beam catcher." This
design concept takes advantage of the part itself providing significant shielding
which results in less radiation at the "beam catcher."
As shown in Figure 1, the rotating radiographic fixture incorporates a ;
specially designed 100 Ci Co-60 projectoripositioned on the circumference of the \
A 9—.
fixture and located 180 from the massive,lead beam catcher. The source camera and !
/ir>
-beam-;-catctiqr;jrei'fjree to rotate, but theiif relative position, one to the other, is i
44 —
maintained^'ThV fixture is~desigried to encircle the steam generator and enable 1
precise positioning of the Co-60 source relative to thewelds to be examined. jj
46—
4.7—
For gamma radiography, the minimum distance from the radiation source to the I
O.D. surface of the steam generator is 24 pn. This is a compromise based on I
tooling considerations, facility limitations, and reasonable exposure times. This
source to part distance will satisfy the requirements for geometric unsharpness
required by the ASME B&PV Code Section V, Article 2.
Scatter Radiation
Scatter radiation from the part surface will be attenuated by the auxiliary
shielding attached to the source camera.!
ASNT 0 in

Rrst ine o t e x ; Intensity of Scatter Radiation

Calculating specific scatter radiation values yield:
;
5— r ,/,(-n Reduction factor of
!R/hF..§.."p" ..." - ^ T p R / h r L -•' 362$5*;R/tir*•$•'•ljp'u G 4 • derived from
5 ' inverse square law
1
9—
Where "pJ is the center of sc^tter^Sreaj at 2 ft from source.
Scatter area in f t = circle of radiation of a 20 collimated
(at point "p") cone 2 ft from source
12—
" rst WKere Tan 10° x 2 ft = Radius of circle (R) and T R 2 = 0.39 ft 2
Substituting values in Equation 6.3 and calculating distance at 1 ft from point of
1 6-— scatter yields: [
(362.5)(0.03)^0>29) = 4.24 R/hr-
Energy of Scatter Radiation
99— •
The energy of the scatter radiation is given by the formula
" .511
E =
Sa 1 - Cos 9 •

..Where . Ej = Energy of the primary beam MeV

9 = Scatter angle
E s = Energy of scatter radiation MeV
For the two gamma energies of Co-60, 1.33 and 1.17 MeV than 90° scatter angle
yields energies of .369 MeV and .355 MeV, respectively.
HVL Determination for Scatter Radiation
The expected HVL for lead of the 90° scatter radiation from Co-60 is 0.170 in.
(Table 5A of NBS Handbook 114.) Therefore, using 0.750 in. of lead at the 90
incidence for scatter, the radiation will be reduced as follows:
•' -i _~.. npte Subhead:01750-in.--... •_ A u m
44— 0.170 in. " 4 ' 4HVL
45—
then 24'4 = 21.1 (Reduction factor)
47
!
46— and resultant radiation at exterior surface of lead =
49—
50— |
pi i O.fcO R/nr
51—j I
52— | therefore, 10 ft from the point of scatter, through the shield, the radiation
53— i reduction by virtue of the Inverse Squarje Law for distance will be:
54-1
55- | Svandpra paas Depth
Lon;iv Page Depth
; •

Mfjy 79
ASNT ? x 10 in

First line of text

Co,W SOUKCEJOQCL
SOURCE

3 __ ..AuyTor^_narn_a. cenr

t
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t i" STEEL,
Figure 1