Kuwait International Industrial Laboratory

& Inspection Services (KIL)

Quality Control Procedure

RADIOGRAPHIC INSPECTION

QCP-KIL-04 Rev.0

0 For Review & Comments PRASANTH.S

Rev Comments Prepared By Checked By Approved By

 Kuwait International Industrial Laboratory & Inspection
Services. (KIL)
RADIOGRAPHIC INSPECTION
QCP-KIL-04 Rev.0

Index

1. Scope

2. Purpose

3. References

4. Definitions

5. Responsibilities

6. Procedure

7. Attachments

QCP-KIL-08 RT Procedure
 Kuwait International Industrial Laboratory & Inspection
Services. (KIL)
RADIOGRAPHIC INSPECTION
QCP-KIL-04 Rev.0

1. SCOPE

This procedure specifies the minimum requirements for radiography of welds, employing
radiographic techniques for MEW shutdown job at Mina Az zour Power station.

2. PURPOSE

The purpose of this Quality Control Procedure is to address clause 4.9 “Process Control ” of
ISO 9002: 1994 and covers the requirements, performance and documentation of radiographic
examination of weld seams in plates, pipes and branches in carbon and stainless steel.

3. REFERENCES

3.1 Testing Procedure

1. ASME B & PV Code Section V: Non-Destructive Examination Articles 2 and

22.1
2. ASTM E114-86: Standard Method for Determining the Focal Size.
3. ASME SE 999: Guide For Controlling The Quality Of Industrial Radiographic
Film.
4. AWS D1.1 Structural Welding Code
5. ASME B31.1 ,Power Piping Latest edition.
6. Project Specification :.
4. DEFINITIONS

I.Q.I.: Image Quality Indicator: Area of Interest: The area of interest shall include the
weld plus a minimum of 1/8in of adjacent base metal.

5. RESPONSIBILITIES

5.1 The Radiographer shall be responsible for carrying out radiographic work in a safe and
responsible manner, having due regard for his own safety and the safety of other
personnel.

5.2 The Radiographic supervisor shall be responsible for ensuring that all boundary markings,
signs, available warnings and warning lights are in place and operating, and that the area is
clear prior to exposing the radiographic source.

5.3 The clients Safety Engineer is responsible for the emergency procedures in the event of
equipment malfunction presenting a potential radiation hazard.

5.4 The NDT Controller shall be responsible to coordinate the activities of the
including:
1

QCP-KIL-08 RT Procedure
 Kuwait International Industrial Laboratory & Inspection
Services. (KIL)
RADIOGRAPHIC INSPECTION
QCP-KIL-04 Rev.0

Issuing of requests for radiography.

Receiving corresponding reports.

Physical location/identification of welds for radiography.

Arrange scaffolding, lighting, access to the welds..

6. PROCEDURE

6.1 Personnel Qualifications

All personnel shall be qualified and certified in accordance with the written practice of the
company contracted to perform radiographic examination, and shall meet SNT-TC-1A.
Interpretation shall be performed by personnel qualified to level II, minimum, of the
above mentioned specification.

The certification of personnel shall be checked by the Quality Control Department prior to
work commencement.

6.2 Surface Preparation

Weld ripples or weld surface irregulations on both the inside (where accessible) and
outside shall be removed (if necessary) by any suitable process such that the radiographic
image of any irregularities cannot interface with radiographic interpretation.

6.3 Radiation Sources

The minimum recommended thickness limitation for Iridium 192 Isotope as per ASME V
Para T-272.2 may be reduced when the radiographic technique used demonstrates that the
required radiographic sensitivity has been obtained.

6.4 Source-Weld-Film-Arrangements

6.4.1 The arrangements are shown in Attachment 7.1 sheets 1 to 3. Single wall exposure
technique takes a preference. If this is not feasible double wall exposure techniques
shall be used.
6.4.2 Single-Wall Viewing

This is a double wall exposure technique with single wall viewing whereas the
radiation passes through both walls of the component but only the weld on the film
side is viewed for acceptance. For this case adequate number of exposures shall be
made to demonstrate that the required coverage has been obtained. When complete

coverage is required for circumferential welds a minimum of three exposures taken

approximately at 120 deg. to each other shall be made.

6.4.3 Double-Wall Viewing

QCP-KIL-08 RT Procedure
 Kuwait International Industrial Laboratory & Inspection
Services. (KIL)
RADIOGRAPHIC INSPECTION
QCP-KIL-04 Rev.0

This is a double wall exposure technique with double wall viewing which means
that radiation passes through both walls and in the film both walls are evaluated for
acceptance.

 For welded pipes having a nominal diameter of 3½“ (89mm) or less, a

technique may be used in which the radiation passes through two walls and the
weld (material) in both walls is viewed for acceptance on the same radiograph.
For double-wall viewing, only a source side pentameter shall be used. Care
should be exercised to ensure that the required geometric unsharpness is not
exceeded. If the geometric unsharpness requirement cannot be met, then
single-wall viewing shall be used, if possible.

 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 overlap of the areas to be interpreted. When
complete coverage is required, a minimum of two exposures taken 90 degrees
to each other shall be made for each joint.

 As an 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 degrees
or 120 degrees to each other shall be made for each joint.

6.5 Geometric Conditions

6.5.1 Geometric Unsharpness.

The geometric unsharpness shall be calculated using the following equation.

Ug = F x d
D
where:

Ug = geometric unsharpness.

F = source size: the maximum projected dimension of the radiating

source (or effective focal spot) in the plane perpendicular to the
distance D from the weld or object being radiographed in.

d = distance from the source side of the weld being radiographed to the
film (in).

D = distance from the source of radiation to the weld being

radiographed (in).

As long as “Ug” does not exceed the limit for the thickness range the minimum sfd
(D + d) can be that which meets “Ug” requirements.
QCP-KIL-08 RT Procedure
 Kuwait International Industrial Laboratory & Inspection
Services. (KIL)
RADIOGRAPHIC INSPECTION
QCP-KIL-04 Rev.0

The geometric unsharpness Ug of a radiograph should not exceed the following:

Material Thickness (in) Ug Maximum (in)

Under 2 0.020

Over 2 through 3 0.030

Over 3 through 4 0.040

Greater than 4 0.070

Note: Material thickness is the thickness on which the penetrameter is based.

6.5.2 Focal Spot Size

The Focal Spot Size “F” shall be the largest dimension of the optically effective
focal spot as indicated by the manufacturer of the source.

6.6 Films

6.6.1 Radiographs, shall be produced using films of type 1 or type 2.

Film type 1: KODAK INDUSTRIES, AA 400 or equivalent.

Film type 2: KODAK INDUSTRIES MX 125.

6.6.2 Screens

Lead screens of appropriate thickness should be used whenever they improve

radiographic quality or IQI sensitivity or both and to prevent excessive back scatter0A
radiation. The lead screens must be placed in intimate contact with the film during
exposure. Screen thicknesses must be as follows:

Front Screen 0.01 in

Back Screen 0.020 in

Fluorescent screens are not allowed.

6.6.3 Weld coverage

Where more than one film is used to cover one weld, then the films will have at
least 25mm overlap to ensure full coverage of the weld area.

QCP-KIL-08 RT Procedure
 Kuwait International Industrial Laboratory & Inspection
Services. (KIL)
RADIOGRAPHIC INSPECTION
QCP-KIL-04 Rev.0

6.7 Identification of Films

6.7.1 Film Identification

Films shall be adequately identified to maintain full traceability to the weld being 0A
radiographed. The following information shall appear on each radiographic film:

 Date

 “O” Location

 Welder No.

 Isometric/Spool Number

 Weld No.

 Project No.

 Base metal Thickness

To identify repair welds, the letter “R1” will be used to identify first repair, and
“R2” second repair. For the case of rework (cut-out) this is going to be identified
as “RW” and additionally for the case of reshoot the alphanumeric RS followed by
the serial number of reshoot shall be used (RSI, RS2, etc.) For example if we are
dealing with weld No. 001 the following apply:

W001 R1 First weld repair of weld No. 001

W001 R2 Second weld repair of weld No. 001

W001 RW1 First reweld (cut-out) of weld No. 001

W001 RW2 Second reweld (cut-out) of weld No. 001

W001 RS1 First reshoot (e.g. because of debris) of weld No. 001

W001 RS2 Second reshoot of weld No. 001

This identification shall be of a permanent film nature.

6.7.2 Film Markings

To maintain traceability of the defects in a weld for repair purposes, adequate

markings shall be provided. These markings shall not be moved during
radiography of the weld. A zero “O” marker shall identify the starting point on the
weld and shall be marked with a permanent marker (chloride free marker forC
QCP-KIL-08 RT Procedure
 Kuwait International Industrial Laboratory & Inspection
Services. (KIL)
RADIOGRAPHIC INSPECTION
QCP-KIL-04 Rev.0

stainless steel) on the pipe surface as well as the film. Marker images shall not
appear in the area of interest on the radiograph. Two types of identification are
required based on the pipe weld diameter:

a) Pipe welds having nominal diameter above 3½“ shall have a continuous marker
band (metric) wrapped around the circumference of the pipe. The spacing of the
distance markers of the band shall not exceed 50mm.
b) Films for pipe welds with nominal diameter 3½“ or less, shall be identified with
letters such as “A” for the first film, “B” for the second and so on. The markers
shall be lead type with approximate dimensions of 6mm in height and 1.5mm
thick. Markers should also be used on 3½“ or less [as in a) above]
6.7.3 Scattered Radiation

A lead symbol “B”, with a minimum dimensions of 1/2” (13mm) in height and 1/16
“(1.5mm) in thickness, shall be attached to the back of each film holder. If a light
image of the “B” appears on a darker background of the radiograph, protection
from back scatter is insufficient and the radiographed protection from back scatter
is insufficient and the radiograph shall be considered unacceptable. A dark image
of the “B on a lighter background is not the cause for rejection

6.8 Image Quality Indicators (penetrameters)

6.8.1 Image quality indicators (IQI’s) shall be used to ensure that the required sensitivity
is achieved. IQI’s shall be in accordance with ASMEV and their selection will be
on the basis of the material thickness and type. Table No 1 provides IQI wire
designation and wire diameters in inches.

QCP-KIL-08 RT Procedure
 Kuwait International Industrial Laboratory & Inspection
Services. (KIL)
RADIOGRAPHIC INSPECTION
QCP-KIL-04 Rev.0

TABLE 1
WIRE IQI DESIGNATION AND WIRE
DIAMETERS, in.
ASTM Wire
Set Diameter, in
0.0032
0.004
A 0.005
0.0063
0.008
0.010
0.013
B 0.016
0.020
0.025
0.032
0.040
0.050
C 0.063
0.080
0.100
0.126
0.160
D 0.200
0.250
0.320
Note: The material of penetrameters shall be of a similar radiographic density to
that of the material being radiographed.

For components where one or more film holders are used at least one penetrameter
image shall appear on each radiograph.

For panoramic exposures where the source is placed on the axis of a cylindrical
vessel at least three (3) penetrameters shall be placed approximately 120 deg apart.

If a section of a circumfercutial weld is radiographed and four or more film holders

are used, one pentrameter shall be placed at the approximate centre of this section
being radiographed and one at each end. If the section exceeds 240º of the
circumference then 3 penetrameters placed approximately 120 deg apart shall be
used.

6.8.2 IQI’s shall be placed on/or adjacent to the weld (max. ¾“). The identification
number(s) and the lead letter “F”, when used, shall not be in the area under
examination. Wire penetrameters shall be placed on the weld such that the length
of the wires is perpendicular to the weld axis.
QCP-KIL-08 RT Procedure
 Kuwait International Industrial Laboratory & Inspection
Services. (KIL)
RADIOGRAPHIC INSPECTION
QCP-KIL-04 Rev.0

IQI’s shall be located on the source side of the weld. Where inaccessibility
prevents placing penetrameters on the source side then, the IQI will be placed on
the film side. In this case, a lead marker “F” will be placed adjacent to the
indicator.

6.9 Film Processing

Care shall be taken to ensure that films do not get in touch with each other. A minimum
separation of 13mm shall be observed when films are being processed. The following
bath temperatures and dwell times are recommended:

FOR GUIDANCE ONLY

Bath Temperature Dwell time

Development 20Oc 5-8 min.
Interim. Washing 20oC 2 min.
Fixation 20oC 5-15 min.
Final washing 16 oC - 30oC >=20 min.
Wetting bath 30 sec.
Drying 20oC -60oC
Additionally all the film manufacturer’s instructions must be observed and followed.
Mixing of materials of different families of manufactures is not permitted.
Manufacturer of processing material shall be AGFA .


Proper Bath Temperatures - Dwell times a well as bath replenishment procedures, must be
experimentally established and maintained.

6.10Evaluation of Films and Documentation

6.10.1 Viewing Requirements

The minimum density for films made with gamma ray source shall be 2.0.
minimum and 3.5max for the weld area of interest. Films shall be examined using
suitable film viewers. Dimmed lighting, rather than total darkness, is preferable in
the viewing room. Room illumination must be arranged so that there are no
reflections from the surface of the film under examination. The viewer shall give
illumination sufficient to view films with density requirements as stated in section
6.10.3.

The minimum value required of illuminator brightness is:

 For film density 2.0; 3,000 cd/m².

 For film density 3.5; 30,000 cd/m².

6.10.2 Film Quality

QCP-KIL-08 RT Procedure
 Kuwait International Industrial Laboratory & Inspection
Services. (KIL)
RADIOGRAPHIC INSPECTION
QCP-KIL-04 Rev.0

All radiographs shall be free from mechanical, chemical or other artifacts to the
extent that they cannot mask or be confused with the image of any discontinuity in
the object being radiographed. Such artifacts 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 detail due to poor film contact.
e) False indications due to defective screens.
In case that any of the above artifacts are present the film(s) shall not be reviewed.
Measures to eliminate the problem(s) must be taken and a new radiograph must be
obtained as appropriate.

6.10.3 Density Requirements

The transmitted film density through the radiographic image of the body of the
appropriate IQI and the area of interest shall be 3.0 minimum for single film
viewing for radiographs made with a gamma ray source. For composite viewing of
multiple film exposures, each film of the composite set shall have a minimum
density of 1.3. The maximum density shall be 3.5 for either single or composite
viewing. Either a calibrated densitometer or step wedge comparison film shall be
used for determining the film density. The density of step wedge comparison films
and densitometer calibration shall be verified with a step wedge film traceable to a
national standard.

Calibration interval of densitometer is 3 months. Calibration method is according

to manufacturers instructions. In lieu of these instructions procedure ASME VSE
1079 can be used as applicable. Calibration records, signed and dated as
appropriate, must be maintained.

The density of the radiograph anywhere through the area of interest shall not vary
more than -15% or +30% from the density adjacent to the designated wire of a wire
penetrameter.

6.10.4 Sensitivity Requirements

The minimum sensitivity required is provided by Table 2.

The thinnest wire of the IQI must be located in the outer most position of the film
and must be perpendicular to the weld axis.

The penetrameter selection shall be based on the nominal wall thickness of the base
material plus the reinforcement Internal protrusions of single bevel welds, backing
ring strips etc. shall be disregarded in the selection of the required penetrameter

QCP-KIL-08 RT Procedure
 Kuwait International Industrial Laboratory & Inspection
Services. (KIL)
RADIOGRAPHIC INSPECTION
QCP-KIL-04 Rev.0

wire size. Reinforcement value shall be based on the allowable by the code one and
not on actual measurement.

In general the following shall apply.:

Panoramic Single Wall-Single Image, Double Wall-Single Image, Double Wall-

Double Image (Elliptical and Superimposed) Techniques.

The required wire size shall be based on the nominal single wall thickness plus one
reinforcement where such reinforcement is not ground off.

Note: For welds without reinforcement the required wire size shall be based on
the nominal single wall thickness

Table 2 provides the ASME V IQI selection criteria.

TABLE 2
IQI SELECTION
______________________________________________________________________________
Penetrameter
Nominal Source Side Film Side
Single-Wall
Material Thickness
Range, in. Wire Diameter, in Wire Diameter, in
Up to 0.25, incl.. 0.008 0.006
Over 0.25 through 0.375 0.010 0.008
Over 0.375 through 0.50 0.013 0.010
Over 0.50 through 0.75 0.016 0.013
Over 0.75 through 1.00 0.020 0.016
Over 1.00 through 1.50 0.025 0.020
Over 1.50 through 2.00 0.032 0.025
Over 2.00 through 2.50 0.040 0.032
Over 2.50 through 4.00 0.050 0.040
Over 4.00 through 6.00 0.063 0.050
Over 6.00 through 8.00 0.100 0.063
Over 8.00 through 10.00 0.126 0.100
Over 10.00 through 12.00 0.160 0.126
Over 12.00 through 16.00 0.250 0.160
Over 16.00 through 20.00 0.320 0.250

6.10.5 Documentation

The evaluation of the films and the classification of the examined weld seams shall
be recorded on the Radiographic Inspection Report (see Attachment 7.2).

QCP-KIL-08 RT Procedure
 Kuwait International Industrial Laboratory & Inspection
Services. (KIL)
RADIOGRAPHIC INSPECTION
QCP-KIL-04 Rev.0

6.10.6 Acceptance Criteria

Acceptance criteria of weld defects shall be as specified in ASME B31.3

6.11 Viewing

When radiographic evaluation is performed by subcontractor the following applies:

6.11.1 Radiographs will first be evaluated by the KIL film interpreter. Then
CONTRACTOR will verify the evaluation and sign the report. COMPANY will
then make an evaluation and sign the report if satisfied with the report findings.

6.11.2 Major differences in evaluation may be raised at a joint meeting between the above
parties.

7. ATTACHMENTS

7.1 Radiographic Examination Report

QCP-KIL-08 RT Procedure