Document No:- 9560/NBEL/SITE/QAC/026, REV.

PROJECT : 500 TPD Sulphuric Acid Plant with 5.0 MW Power Generations

LOCATION: 10th of Ramadan City, Industrial Area A1, Egypt

CLIENT EPC CONTRACTOR

SPREA MISR NUBERG ENGINEERING LIMITED

DOCUMENT TITLE

JOB PROCEDURE FOR TANKS RADIOGRAPHY TEST

DOCUMENT NUMBER

9560/NBEL/SITE/QAC/026, REV.0

Document Category Document Review Status (by Owner/PMC)

(Submission Purpose)
Approval ☐ 1. Approved / Reviewed
☐ Review ☐ 2. Approved / Reviewed with comments as marked
☐ Information ☐ 3. Not Approved / Resubmit
FOR REVIEW AND ANAND ASHWANI
☐
00 Implementation ☐ R. Retained for InformationTYAGI
/ Records RAJEEV SHARMA
APPROVAL SHARMA
Rev Date: ___/____/____ Name: ____________________
Checked By
Date Document Status Prepared By Approved By
. This approval does not absolve the Contractor from meeting their contractual obligations of delivering a
complete, safe and efficiently operating units/facilities meeting all requirements of the contract
 Document No:- 9560/NBEL/SITE/QAC/026, REV.0

JOB PROCEDURE FOR TANKS RADIOGRAPHY TEST

TABLE OF CONTENTS

Sl. No. Description

1 PURPOSE

2 SCOPE

3 REFERENCE

4 RADIATION SAFETY

5 QUALIFICATION OF EXAMINATION PERSONNEL

6 EQUIPMENT & MATERIAL

7 PROCESSING REQUIREMENT

8 EXAMINATION PROCEDURE

9 EVALUATION

10 ACCEPTANCE CRITERIA

11 RECORDS

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JOB PROCEDURE FOR TANKS RADIOGRAPHY TEST

1. PURPOSE:
The purpose of this procedure is to ensure that the radiographic images produced are acceptable
quality and that all radiographic examinations are performed in a safety policy, project specifications,
quality control plan and applicable codes.
2. SCOPE:
The scope of this procedure shall apply to all radiographic examinations carried out during the
execution of the Tankage jobs with a special emphasis on radiation safety.
3.REFERENCE:
ASME V Article-2 & 2.2 Non-destructive Examination-Boiler & pressure vessel Code
ASME Sec-VIII Div.1 RULES FOR CONSTRUCTION OF PRESSURE VESSELS
ASME IX Welding and Bracing Qualification
API 650 Welded Steel tanks for Oil Storage.
SNT-TC-1A Recommended Practice for Non-destructive Testing Personnel
Qualification & Certification.
ASTM-E94 Recommended Practice for Radiography Testing
NBEL ITP 9560/SITE/QAC/022/ITP-13

4. RADIATION SAFETY
4.1 General
The radiographic technician (radiographer) shall be fully trained / qualified, and shall be fully aware of
the hazards of radiation.
Human body tissue will be severely damages if they are over exposed to radiation and even
small amount of exposure on a daily basis, with insufficient recovery periods, will eventually produce
a serious deterioration in health.
All possible safety precaution shall always be taken to avoid unnecessary exposure.
Prior to commencing any radiation work on site, emergency procedures shall be established.
All radiographic discipline personnel who are involved with working with ionizing
Radiation shall take all reasonable safety precautions.
Not knowingly expose either themselves or any other person to radiation greater than is absolutely
necessary for the purposes of their work.
Make full and proper use of all personal protection equipment provided . Report any defects to
radiographic equipment to his employer immediately upon discovery.

4.1 Controlled areas

Radiography shall only be undertaken in designated and clearly identified” controlled areas”.
These areas shall be identified and sealed by the use of the following as a minimum
Radiation tape Barriers-which surround and seal off the controlled area in its entirety.
Radiation Hazard Warning Signs in English.
The sign shall be a minimum size of 450 x 450 mm.
These shall be positioned every 30 meters around the periphery of the controlled area.
Flashing yellow lights to indicate radiation hazard area, these shall be positioned adjacent to
warning signs.
Under no circumstances shall non radiographic discipline (unclassified)
Personnel cross or enter the barriers to a controlled area.
Any infringement of this safety rule / regulations concerning controlled areas will result in the
immediate removal of the individual concerned and expulsion from the Tankage Project

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.

4.2 Radioactive isotope

The container in which radioactive isotopes are housed shall be lockable and sealed. They shall
be manufactured from expended uranium or similar materials, to international safety
standards.
These containers shall be re-certified as safe to use every of 26 months (maximum).The senior
radiographic technician on site shall hold the keys at all times (other than usage).The where about
of all radioactive isotopes on site shall be logged and known at all times.

5. QUALIFICATION OF EXAMINATION PERSONNEL

The qualification of examination personnel shall be in accordance with PCN or ASNT
recommended practi ce.SNT-TC-1A shall carryout Radiography Examinati on.
BARC certi fi ed Level I/II personal shall perform Radiography Testi ng.

6. EQUIPMENT AND MATERIALS

6.1 Film
Radiographs shall be made using industrial radiographic films that are available to meet the
required quality of radiographs. M e d i u m s p e e d c l a s s - I I o f Kodak, AGFA & FUJI made D7 or
equivalent film to be used for 6 mm to 19 mm thick materials.

6.2 Identifying screen

The function of the lead intensifying screens is to reduce exposure times by the emission of
electrons and secondary radiation in reaction to the primary radiation source and at the same time
reduce film fogging by acting as a filter for the absorption of back scattered radiation.
The lead screens used shall be clean and in good condition, with a thickness of
0.125 mm (front) and 0.25 mm (rear), and shall be in direct contact with the radiographic film.

6.3 IQI (Image Quality Indicator)

Pentameter shall be either the hole type or the wire type and shall consist of those in Table 1 for
hole type and those in Table 2 for wire type.
6.4 Radiation source
Iridium 192 will be used as a radiation source.

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Table .1.Hole Type IQI Designation, Thickness and Hole Diameters, in

Penetrameter Penetrameter 1T Holes 2T Holes 4T Holes

Designation Thickness Diameter Diameter Diameter
5 0.005 0.010 0.020 0.040
7 0.007 0.010 0.020 0.040
10 0.010 0.010 0.020 0.040
12 0.012 0.012 0.025 0.050
15 0.015 0.015 0.030 0.060
17 0.017 0.017 0.035 0.070
20 0.020 0.020 0.040 0.080
25 0.025 0.025 0.050 0.100
30 0.030 0.030 0.060 0.120
35 0.035 0.035 0.070 0.140
40 0.040 0.040 0.080 0.160
45 0.045 0.045 0.090 0.180
50 0.050 0.050 0.100 0.200
60 0.060 0.060 0.120 0.240
80 0.080 0.080 0.160 0.320
100 0.100 0.100 0.200 0.400
120 0.120 0.120 0.240 0.480
160 0.160 0.160 0.320 0.640
200 0.200 0.200 0.400 …….

7. PROCESSING REQUIREMENTS

7.1 Quality of radiographs

All radiographs shall be free from mechanical, chemical or other artefacts to be extent that they
cannot mask or be confused with the image of any discontinuity in the object being radiographed.
Such artefacts include but are not limited to:
[a] Fogging
[b] Processing defects such as water or chemical marks.
[c] Scratches, Finger marks, crimps, static smudges or tears
[d] Loss of details due to poor film Contrast. [e] False indication due to defective screens.

7.2 Processing Manual (According to SE-94)

7.2.1 Preparation:–
No more film should be processed that can be accommodated with a Minimum separation of ½ “.
Hangers are loaded and solutions stirred before starting development.
7.2.2 Start of development:-
Start the timer and place the films into the developer tank. Separate
to a minimum distance of ½ “ and agitate in two directions for about 15 seconds.
7.2.3 Development:-
Normal development is 5 to 8 minutes at 68° F (20° C)
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7.2.4 Agitation:-
Shake the film horizontally and vertically, ideally for a few seconds each minute during
development. This will help develop evenly.
7.2.5 Rinsing:-
Rinse the films with vigorous agitation in clear water.
7.2.6 Fixing: -
The Films must not touch one another in the fixer. Agitate the hangers vertically for about 10
seconds and again at the end of the first minute, to ensure uniform and rapid fixation. Keep them in
the fixer until fixation is complete (i.e. at least twice the clearing time), but not more than 15
minutes in relatively fresh fixer. Frequent agitation will shorten the time of fixation.
7.2.7 Fixer Neutralizing: -
Use hypo eliminator or fixer neutralizer between fixation and washing.
7.2.8 Washing: -
Washing is very slow below 60° F(16° C).When washing at temperature above
85° F(30° C),care should be exercised not to leave films in the water too long. The films should be
washed in batches without contamination from new film brought over from the fixer. If pressed for
capacity, as more films are put in the wash, partially washed film should be moved in the direction
of the inlet.
7.2.9 Wetting Agent:-
Dip the film for approx. 30 seconds in a wetting agent added clear water.
7.2.10 Drying:-
Take Precaution to tighten film on hangers, so that it cannot touch in the dryer. Too hot a Drying
temperature at low humidity can result in uneven drying and should be avoided.
8.EXAMINATION PROCEDURE:-
8.1. Surface Preparation
The weld ripples or weld surface irregularities on both the inside (where accessible) and
outside shall be removed by any suitable process to such a degree that the resulting
radiographic image due to any irregularities cannot mask or be confused with the image of any
discontinuity.
8.2. RT request
Upon completion and visual acceptance of a weld that is subject to radiography, the controlling
engineer shall make a request for radiographic examination.
The request shall be entered into the schedule for radiographic examination and forwarded to the
radiographic technicians for execution.
8.3. Controlled area
Radiography shall only be performed at such times as the work site is clear of all non radiographic
discipline personnel and the area of exposure shall be designated a ‘ controlled area’
Prior to commencing exposure of the isotope, all safety precautions and requirements as stated in
4.0 radiation safety shall be implemented.
The area in which the isotope is to be exposed shall be treated as a ’controlled area’ and only
classified personnel may enter.
The boundaries of this ‘controlled area’ shall be identified with radiation tape barriers, warning
signs (in both English and Hindi) and flashing lights.
8.4. Marking on the weld
The QC Engineer shall identify the weld to be radiographed and mark the weld.

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8.5. Film identification

Each radiograph shall be uniquely identified by means of lead numbers and letters. The lead
letters and numbers shall not encroach into the weld area and shall not interfere with the
interpretation of the radiograph in any way.
The following information shall be displayed on each radiographic film as a minimum:
--- Tank No
--- Drawing No
--- Weld Joint number
--- Repair identification number (where applicable)
--- Welder identification number
--- Date of radiograph
--- Joint thickness and diameter/Length
8.6. Location markers
Location markers, which are to appear as radiographic images on the film, shall be placed on the
part, not on the exposure holder.
Their location shall be permanently marked on the surface of the part being radiographed
when permitted, or on a map, in a manner permitting the area of interest on a radiographed to be
accurately traceable to its location on the part.
8.7. Direction of radiation
The direction of the central beam of radiation should be centered on the area of interest
whenever practical.
8.8. Film handling
Care shall be taken to ensure that both exposed and unexposed films are kept segregated and are
stored in such a manner as that they shall not be subjected to radiation, excessive heat, dirt, fumes,
etc.
8.9. Radiographic technique
8.9.1 Single wall technique
In the single wall technique, the radiation passes through only one wall of the weld, which is viewed
for acceptance on the radiograph.
8.9.2 Double wall technique
When it is not practical to use a single wall technique, one of the following double wall
techniques shall be used.
[a] Single wall viewing
For welds in components, technique may be used in which the radiation passes through two
walls and only the weld on the film side wall is viewed for acceptance on the radiograph.When
complete coverage is required for circumferential welds, minimum of three exposures taken 120
deg. to each other shall be made.
[b] Double wall viewing
For welds in components 3.1/2 in. or less in nominal outside diameter, a technique may be used in
which the radiation passes through two walls and the weld in both walls is viewed for acceptance on
the same radiograph.
For double wall viewing, only a source side penetrameter shall be used.
[1] For welds, the radiation beam may be offset from the plane of the weld at an angle sufficient to
separate the images of the source side and film side portions of the weld so that there is no

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overlap of the areas to be interpreted. When complete coverage is required, a minimum of two
exposures taken 90 deg. To each other shall be made for each joint.
[2] As alternative, the weld may be radiographed with the radiation beam positioned so that the
images of both walls are superimposed.
When complete coverage is required, a minimum of three exposures taken
at either 60 deg. To 120 deg. To each other shall be made for each joint.
8.10. Geometric unsharpness
Unless otherwise specified in the applicable job order or Contract, the geometric unsharpness shall
not exceed the following limits:

Material Ug
Thickness (in.) Maximum (in.)
Under 2 0.020
2 trough 3 0.030
Over 3 trough 4 0.040
Greater than 4 0.070

8.11. IQI Selection

The designed hole penetrameter with essential hole or designed wire diameter shall be as
specified in Table 3.
8.11.1.Weld with reinforcements
The thickness on which the penetrameter is based is the nominal single wall thickness plus the
estimated weld reinforcement not to exceed the maximum permitted by the referencing Code
Section.
Backing rings or strips are not be considered as part of the thickness in penetrameter
selection.
The actual measurement of the weld reinforcement is not required.
8.11.2.Weld without reinforcements
The thickness on which the penetrameter is based is the nominal single wall thickness. Backing rings
or strips are not to be considered as part of the thickness in penetrameter selection.

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Table.3 IQI Selection

Penetrameter
Normal
Single-wall Source Side Film side
Material
Thickness Hole Type Essential Wire Hole Type Essential Wire Diameter, in
Range, in. Designation Hole Diameter, Designated Hole
in
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

8.11. Placement of penetrameters

8.11.1.Source side penetrameter(s)
The penetrameter(s) shall be placed on the source side of the part being examined, except for the
condition described in 8.11.2
8.11.2. Film side penetrameter(s)
Where inaccessibility prevents hand placing the penetrameter (s) on the source side, the
penetrameter(s) shall be placed on the film side in contact with the part being examined.
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A lead letter ”F” , at least as high as the penetrameter indication number(s), shall be placed adjacent
to or on the penetrameter(s), but shall not mask the essential hole where hole penetrameters are
used.
8.11.3. Penetrameter location for welds—hole penetrameters
The penetrameter(s) may be placed adjacent to or on the weld.
The identification number(s) and, when used, the lead letter ”F” shall not be in the area of
interest.
8.11.4. Penetrameter location for welds—wire penetrameters
The penetrameter(s) shall be placed on the weld so that the length of the wires is
perpendicular to the length of weld.
The identification number(s) and, when used, the lead letter”F” shall not be
in the area of interest.
8.12. Number of penetrameters
For components where one or more film holders are used for an exposure, at least one
penetrameter image shall appear on each radiographed except as outlined in 8.12.2.
8.12.1. Multiple penetrameters
If the requirements of 9.3.2 are met by using more than one penetrameter, one shall be
representative of the lightest area of interest and the other the darkest area of interest: the
intervening densities on th radiograph shall be considered as having acceptable density.
8.12.2. Special cases
[1] For cylinder vessels where the source is placed on the axis of the object and one or more film
holders are used for a single exposure of a complete circumstance, at least three penetrameters
shall be spaced approximately
120 deg.apart.
[2] For cylinder vessels where the source is placed on the axis of the object and four or more
film holders are used for a single exposure of section of the circumference, at least three
penetrameters shall be used.
One penetrameter shall be in the approximate center of the section
exposed and one at each end.
When the section of the circumference exposed exceeds 240 deg. the rules of [1] above apply.
Additional film locations may be required to obtain necessary penetrameter spacing: otherwise at
least one penetrameter image shall appear on the each radiograph.
[3] For spherical vessels, where the source is located at the centre of the
vessel and one or more film holders are used for a single exposure of a complete circumstance, at
least three penetrameters shall be spaced approximately 120 deg. apart.
For other welds radiographed simultaneously, one additional parameter is
shall be placed on each other weld.
[4] For segments of spherical vessels where the source is located at the centre of the vessel
and four or more films holders are used for a circumferential weld, at least three penetrameters
shall be used. One penetrameter shall be in the approximate centre of the portion exposed and
one each end.
When the portion exposed exceeds 240 deg., the rules of [3] above apply.
Additional film locations may be required to obtain necessary penetrameter spacing; otherwise, at
least one penetrameter image shall appear on each radiograph.

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8.13. Shims
A shim of material radiographically similar to the weld metal shall be placed between the part and
the penetrameter, if needed, so that the radiographic density throughout the area of interest is no
more than minus 15 % from
the radiographic density through the penetrameter.
The shim dimensions shall exceeds the pentameter dimensions such that the outline of at least
three sides of the penetrameter image shall be visible in the radiograph.
9. EVALUTION
9.1. Quality of radiographs
All radiographs shall be free of mechanical, chemical, handling related or other
blemishes to the extent that they do not mask and are not confused with the image of any
discontinuity in the area of interest of the object being radiographed. If any doubt exists as to the
true nature of an indication exhibited by the film, the radiograph shall be rejected and re-shot.
9.2. Viewing facilities for radiographs
Viewing facilities shall provide subdued background lighting of an intensity that will not cause
troublesome reflections, shadows or glare on the radiograph. Equipment used to view radiographs
for interpretation shall provide a variable light source sufficient for the designated wire to be visible
for the specified density range.
9.3. Radiographic density
9.3.1 Density Limitations
The transmitted film density through the radiographic image of the body of
appropriate hole penetrameter or adjacent to the designated wire of a wire penetrameter and the
area of interest shall be 2.0 minimum and 4.0 maximum.
9.3.2 Density variation
[a] General
If the density of the radiograph anywhere through the area of interest varies by
more than minus 15% or plus30 % from the density through the body of the hole penetrameter
or adjacent to the designated wire of a wire penetrameter within density limitations, then an
additional penetrameter shall be used for each exceptional area or areas and the radiograph
taken.
[b] With Shims
When shims are used the plus 30 % density restriction of [a] above may be
exceeded, provided the required penetrameter sensitivity is displayed and the density limitation are
not exceeded.
9.4. IQI sensitivity
Radiography shall be performed with a technique of sufficient sensitivity to display the hole
penetrameter image and the specified hole, or the designated
wire of a wire penetrameter, which are essential indication of the image quality of the radiograph.
The quality levels required using wire Penetrameters shall be equivalent to the 2-2T level of
method E 142/ or practice E1025, ASME Sec V Article 22 for hole type penetrameters. The table
T-276 Article 2 Sec V Provides a list of various hole type IQI’s and the diameter of the wires of
corresponding EPS (Equivalent Penetrameter Sensitivity) with the applicable
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2T holes in the IQI.

9.4. Excessive scatter

A lead letter “B” shall be attached to the back of each film holder during each
exposure to determine if backscatter radiation is exposing the film
If a light image of the “B” appears on a darker background of the radiograph, protection from
backscatter is insufficient and the radiograph shall be considered unacceptable.

9.5 Radiography and Inspection of Welds

9.5.1 All welds shall be inspected and tested as per Code and this Procedure.
9.5.2 Butt-welds in the tank shell and bottom annular plates shall be radio graphically inspected. In
addition to the extent of radiography mentioned in API-650 all the shell `T' joints shall be 100% radio
graphed & annular plate joints shall be radio graphed 12 inches length from outer edge only. Location
of radiographic joint will be at the discretion of TPIL.
9.5.3 The KKSEPL shall be responsible for taking the radiographs by his own equipment for the entire
job. The equipment and/or party with source shall be duly approved by TPIL. The KKSEPL shall obtain
necessary permission from BARC to operate the radiography source.
9.5.4 Radiographs shall be taken as soon as welding of joint is completed. If repairs are required,
these shall be carried out before starting other welds. Repaired joint radiographic examination also to
be carried out by the KKSEPL. Lifting of shell course shall be carried out only after successful
completion of radiography of all weld joints.
9.5.5 Radiographic film shall be of approved quality and of minimum size 6"X4".
9.5.6 All radiographic inspections shall be strictly as per API 650 or as instructed by TPIL Inspection.
Interpretations by TPIL inspection shall be final and binding on the contractor. All radiographic films
have to be handed over to TPIL inspection department.
9.5.7 All long seams of fabricated nozzles shall be fully radiographed.
9.5.8 Weld areas to be radiographed shall be designated by TPIL.
9.5.9 Radiographs shall be taken as soon as welding of the Joint is completed. If repairs are required,
these shall be carried out before starting other welds. New radiography examination of such repairs
shall also This document developed by KKSEPL the information it contains are property of TPIL.
9.5.10 Any additional radiography required by TPIL Inspection shall be carried out at no extra cost.
9.5.11 Weld Defects Welds that are shown by radiography to have any of the defects or imperfections
defined in the following shall be judged to be unacceptable, and the KKSEPL/TPIL Inspection shall
decide to what extent the welds have to be repaired. Interpretation by TPIL Inspection shall be final.
a) Any cracks, incomplete fusion or incomplete penetration shall be judged unacceptable.
b) Elongated Indications. Welding shall be accepted as per ASME Sect VIII, paragraph UW-51(b). c)
Porosity. Any gross porosity can be a reason for rejection.
9.5.12 Repairs to welds and additional radiography
a) When any of the defects defined above are present in a vertical seam, two additional spots in the
same seam shall be examined in order to determine the limits of the defective welding. These spots
shall be on either side of the original spot at locations to be indicated by TPIL Inspection. If the
welding at either of the additional spots does not conform to the minimum quality requirements, the
vertical weld seam shall be fully radio graphed.
b) Horizontal seams When any of the defects are present in a horizontal seam, two additional spots in
the same seam shall be examined in order to determine the limits of the defective welding. These
spots shall be on either side of the original spot at locations to be indicated by TPIL Inspection. If the

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welding at either of the additional spots does not conform to the minimum quality requirements,
additional spots shall be examined until the limits of the defective welding are determined.

c) Repairs and re-examination All defective joints which have been re-welded shall be re-examined as
may be required by TPIL Inspection, and shall conform to the minimum quality requirements given
above.
All repairs arising from the examination, and any additional radiographs required to assess the extent
of defects, shall be in the KKSEPL scope.

10. ACCEPTANCE CRITERIA

Radiographs shall be interpreted only in those areas in which Penetrameter(s)
have established that a suitable radiographic technique has been used
The following acceptance criteria shall be applied according to applicable code section.
[a] ASME Sec VIII Div 1 UW- 51
[b] API 650 Latest Edition cl.8.1.5

11. RECORDS

All records shall be maintained as per approved ITP.

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