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SPECIFICATION

PP E - 2356NUCLEAR POWER CORPORATION OF

INDIA LIMITED

PROCEDURE FOR RADIOGRAPHIC

EXAMINATION OF WELDS

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Specification No:PP - E - 2356 Rev 0 June 2007

DIRECTORATE OF QUALITY ASSURANCE

SPECIFICATION

NO.: PP E - 2356 REV. NO. 0

TITLE : PROCEDURE FOR RADIOGRAPHY EXAMINATION OFWELDS

NOTE: This specification supersedes PP-E-1212, Specification for RadiographicExamination of Welds issued by Quality Assurance Directorate of NPCIL on

31.03.1992.

Revision No. 0

DATE OF ISSUE

(MONTH/YEAR)

JUNE 2007

TOTAL NO OFPAGES (Including

cover sheet)

41

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REVISION CONTROL SHEET

SPECIFICATION

NO: PP E - 2356 REV. NO. 0

TITLE: PROCEDURE FOR RADIOGRAPHIC EXAMINATION OF WELDS

REV. NO. &

DATE

DESCRIPTION

OF REVISION

REVISED BY

SIGN &

DATE

REVIEWED

BY SIGN &

DATE

APPROVED

BY SIGN &

DATE

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1.0 SCOPE:

This specification describes general procedure and requirements to be followed andacceptance criteria for the examination of welds for internal discontinuities using

Radiographic techniques.

This specification applies to all welded material parts, components and repairs when

radiographic examination is required by NPCIL Specifications. The term Radiographic

Techniques shall include both X-Ray and Gamma Ray techniques.

CONTENTS:

The requirements of this specification are presented under the following sections:

Section

Scope 1Applicable Documents and Standards 2

Qualification of Radiographic Examination Personnel 3

Safety Precautions 4General Requirements 5

Material and Equipments 6

Calibration 7Examination Procedure 8

Evaluation 9

Interpretation 10Documentation 11

Radiographic Acceptance Standard 12

Tables, Charts, and Figures.

2.0 APPLICABLE DOCUMENTS AND STANDARDS:

The following documents and standards of the issue in effect, form a part of this specificationto the extent specified herein.

ASME Sec. III Division I. - Boiler and Pressure Vessel Code for NuclearEquipments.

ASME Sec. V Article 2 - Non-destructive examination Code.

ASME Sec. VIII Div . 1 - Boiler and Pressure Vessel Code.

ASME Standard SE 94 - Latest Edition

ASTM Standard E 1032 - Latest Edition

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3.0 QUALIFICATION OF RADIOGRAPHIC EXAMINATION PERSONNEL:

All the personnel performing radiographic examination shall be qualified in accordance with

recommended guideline SNT-TC-1A of ASNT/IS-13805/ISO 9712-3.

Radiography shall be performed by personnel qualified to RT level I or II. The test results

shall be evaluated by either level II or level III qualified personnel.

4.0 SAFETY PRECAUTIONS:

All the precautions with regards to radiation safety shall be observed strictly as per the

guidelines of AERB/BARC/National Codes and Guides.

The radiography examination involves use of ionizing radiations (X-Ray & Gamma). For the

potential risk associated with acute radiation exposure and health hazard, all the personnelengaged in radiography examination, handling of equipments and people working around the

job shall be made aware of the necessary protective measure as recommended in above safety

Codes/Guides.

5.0 GENERAL REQUIREMENTS:

Radiographic examination is employed for detection of internal discontinuities such as cracks,

voids, porosity, inclusions, inadequate penetration, lack of fusion etc.

The manufacturer, of a product to which this specification is applicable, shall provide for and

perform all the inspection and testing specified herein which is appropriated to the product or

is demanded by the controlling product specifications, purchase order or drawing. The

radiography examination shall be conducted in accordance with written procedure and shall besubjected to approval by Nuclear Power Corporation of India Limited (NPCIL).

5.1 PROCEDURE REQUIREMENTS:

The written procedure shall contain, as a minimum, the following technique variables:

Material and thickness range Isotope used or maximum X-Ray voltage Minimum source to film distance Maximum source size Film brand or designation Screen used

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Demonstration of density and penetrameter image requirements of the written procedure onproduction radiographs or technique radiographs shall be considered a satisfactory compliance

of the procedure.

5.2 SURFACE PREPERATION:

5.2.1 WELDS:

The weld ripples or the weld irregularities on both inside (accessible area) and outside shall be

removed by any suitable process to such a degree that resulting radiographic image due to any

irregularities cannot mask or be confused with the image of any discontinuity.

5.2.2 SURFACE FINISH:

The finished surfaces of all the butt-welded joints may be flush with the base material or may

have any reasonably uniform crowns. The weld reinforcement shall not exceed the specified

limits of the referencing code.

5.3 BACK SCATTERED RADIATION CHECK:

A lead screen of adequate thickness is placed behind the part under radiography to reduce

back scattered radiation. As a check on back scattered radiation a lead symbol B with

minimum dimension of inch (13 mm) in height and 1/8 inch (3 mm) in thickness shall beattached to the back of each film holder during exposure. If a light image of the lead letter B

appears on the radiograph, it indicates that more back scatter protection is necessary. The

appearance of a dark image of the lead letter B should be disregarded, unless the dark imagecould mask or be confused with rejectable weld defects.

5.4 RADIOGRAPHIC IDENTIFICATION AND MARKING:

a) A system of positive identification of the film shall be provided. As a minimum, thefollowing shall appear on the radiograph; the name or symbol of company performing

radiography, the date and the weld identification numbers traceable to part and contract.

b) Exact location of area of interest should be marked and hard punched on the surface of thepart/weld seam for permanent identification during and after radiographic examination.Location markers or letters made of lead or high atomic number metal should be placed on

the part under examination and not on the film holder. Their images shall clearly appearon the radiograph.

c) Utmost care shall be taken that identification letter do not interfere in the evaluations ofresults and provide sufficient evidence on the radiograph that complete coverage of the

area being radiographed has been obtained with following exceptions:

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i) The method of marking identification letters shall not be injurious to thecomponent.

ii) In case, where permanent stamping is impractical or prohibited a temporarymarking on the surface of the component or part shall be made. It is important

that in such cases, an accurate sketch clearly showing all the temporary

marking shall be maintained until satisfactory examination of the part isestablished.

iii) Repaired area shall be identified with the letter R-1 for the first repair andR-2 for the second repair and complete identification shall appear on theradiograph. The radiographs taken after repair shall be presented for evaluation

along with original radiographs.

5.5 MONITORING DENSITY LIMITATION OF RADIOGRAPHS:Either a step wedge comparison film or a densitometer shall be used for judging film density.A calibrated step wedge film traceable to a national standard shall be used to calibrate a

densitometer.

5.6 EXTENT OF EXAMINATION:

Unless otherwise specified by purchaser and supplier agreement, the extent of radiographyshall include the 100% of the volume of the weld.

6.0 MATERIAL AND EQUIPMENT:

6.1 RADIOGRAPHY APPARATUS:

Radiation source (X-Ray or Gamma Ray):Selection of the appropriate source is dependentupon variables regarding the weld being examined (material composition and thickness). The

suitability of source shall be demonstrated by attainment of the required IQI sensitivity and

compliance with all other requirements such as film density, area of interest densitytolerances.

6.2 FILM

6.2.1 SELECTION:

Radiographs shall be made using good quality industrial radiographic films meeting the image

quality requirements of this specification or as specified in purchaser and supplier agreement.

Various industrial radiographic films are manufactured to meet quality level and production

needs. Test method ASTM E-1815 provides a method for film manufacturer classification of

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Film System. A Film System consists of the film and associated film processing system. Achoice of film class can be made as provided in test method ASTM E-1815.

Following are some of the commercially available industrial radiography films which may beused for performing radiography of welds as per this specification provided sensitivity

requirements are met (Films of equivalent class of other manufacturers may also be used

provided radiographic sensitivity meets the specified requirements):

FILM CODESr

No.

CLASS

KODAK LASER AGFA FUJI1. Special (Ultra fine

grain, very high

contrast used for

highest qualityradiographs).

DR50

-

D2 IX25

2 I (Extra fine grain, very

high contrast used for

highest qualityradiographs).

M100,

MX125 &

T200

NDT 3,

NDT 4,

NDT 5

D3, D4 &

D5

IX50 &

IX80

3. II (Fine grain, high

contrast suitable forlight metals with low

energy).

AA400 NDT 7 D7 IX100

6.2.2 FILM CARE:

Radiographic film shall be free from blemishes. Unexposed film shall be stored in such a

manner that they are not exposed to light, pressure, radiation, excessive humidity, heat or

chemical contamination.

6.2.3 FILM PROCESSING:

For film processing main Equipments & Chemical required are developer, stop bath, fixer,washing agent and drying equipment. Method of processing and selection of chemical shall be

as per recommendations laid by the manufacturer of film. Chemical processing baths such as

developer, stop bath and fixer shall be maintained in the fresh or repleshnished condition.Processing Tanks shall be made of stainless steel material.

The object of film processing is to transform the invisible latent image produced on the film

by X-Rays or Gamma Rays to a visible and permanent image. Following are the main steps

involved in film processing:

a. Developmentb. Stop bath

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c. Fixationd. Washinge. Drying

Automatic or Manual film processing method may be selected for processing the radiography

films. The film Image Quality will vary with the processing variables such as chemistry,

temperature, time and method of processing (Manual or Automatic). The film processingrequirements shall be in accordance with Guide ASTM E-999.

6.3

SCREENS:

6.3.1 Lead foil screensshould be used in direct contact with the films in all gamma radiographyduring exposure. Lead foil screens of appropriate thickness should be used whenever they

improve the quality of radiography or penetrameter sensitivity or both. The thickness of thefront lead screens should be selected with care to avoid excessive filtration in the radiography

of thin or light alloy materials.

For radiography using gamma sources the thickness of the front lead screen should be 0.13

mm for Ir-192 and 0.13 mm to 0.25 mm for Co-60. Minimum thickness of the back lead

screen shall be 0.13 mm for Ir-192 and 0.25 mm for Co-60. fluorescent screens shall not be

used for radiography.

6.3.2 Screen care- All screens should be handled carefully to avoid dents and scratches, dirt, orgrease on active surfaces. Grease and lint may be removed from lead screens with a solvent.

The screens showing evidence of physical damage should be discarded.

6.4 IMAGE QUALITY INDICATOR (IQI):

IQI shall be either the hole type or the wire type. IQI design, manufacture and material

grouping shall be as per ASTM E-747 and ASTM E-1025 for wire type and hole typerespectively. ASME standard hole penetrameters shall consist of those as specified in table-1.

6.5 VIEWING ROOM AND FACILITIES FOR VIEWING OF RADIOGRAPHS:

The radiographs shall be viewed in a room illuminated by subdued back ground lighting.

Room illumination must be arranged in such a manner that will not cause reflections,shadows, or glare on the radiographs. Equipment used to view radiographs shall provide a

light source sufficient for the essentitial penetrameter hole to be visible for the specifieddensity range and shall permit the viewing of the radiographs with an optical density of 4.0.

7.0 CALIBRATION

7.1 SOURCE SIZE:

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7.1.1 VERIFICATION OF SOURCE SIZE:

Equipment manufacturers publications such as technical manuals, decay curves or written

statements documenting the actual or maximum source size or focal spot shall be acceptableas verification of source size.

7.1.2 DETERMINATION OF SOURCE SIZE:When manufacturers or suppliers publications are not available, source size may be

determined as follows:

a) X-Ray Machines: For X-Ray machines operating at 500 KV and less, the focal spot

size may determined by the Pin-Hole method, in accordance with ASME SE-1165,

Standard Test Method for Measurement of Focal Spot of Industrial X-Ray Tubes byPin Hole Imaging.

b) Iridium-192 Sources: For Iridium -192 the source size may be determined in accordancewith ASME SE-1114, Standard Test Method for Determining the Focal Size of

Iridium-192 Industrial Radiography Sources.

8.0 EXAMINATION PROCEDURE:

Radiography shall be performed according to a radiographic shooting sketch showing sourcelocation, film position, and location of the penetrameter. The radiographic shooting sketch

shall be annexed to the written procedure for approval by NPCIL.

8.1 RADIOGRAPHIC TECHINQUE:8.1.1 SINGLE-WALL TECHNIQUE: Refer Fig.1

Radiography, regardless of the configuration of the product, shall be performed using a single

wall radiographic technique whenever practicable. The radiation passes through only one wall

of the weld (Material) which is viewed for acceptance on the radiograph. An adequate numberof exposures shall be made to demonstrate that the required coverage is obtained.

8.1.2 DOUBLE-WALL TECHNIQUE: Refer Fig.2

Whenever single wall technique is not practical, one of the following double wall techniquesshall be employed.

A) SINGLE-WALL VIEWING:Radiography of circumferential butt welds shall be performed with single-wall

viewing only; the radiation passes through the both walls. The weld/material on the

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film side wall is only viewed for examination. When complete coverage is required forcircumferential welds and for materials, a minimum three exposures 120

0apart shall

be taken.

B) DOUBLE-WALL VIEWING: Refer Fig.2

(1)Unless otherwise specified, for material and welds in pipe and tube 3.5 inch (89mm) or less in nominal outside diameter, radiography may be done using a

technique in which radiation passes through two walls and the weld in both walls

is viewed for acceptance on the same radiograph.

(2)The radiation beam may be off set from the plane of the weld centre line at anangle 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 completecoverage is required, a minimum of two exposures taken at 90

0to each other shall

be made for each weld joint. This technique is also known as elliptical technique.

(3)As an alternative, the weld may be radiographed with the radiation beampositioned so that the images of both walls are super imposed, in which case a

minimum of three exposures shall be taken at 600 at each other.

(4)For double wall viewing only source side penetrameters shall be used and selectionmade from table-2 shall be based on single wall thickness.

8.2 SELECTION OF ENERGY OF RADIATION8.2.1 X RAY RADIATION:

The maximum voltage used in the radiographic examination shall not exceed the value that is

shown in Figure 3 for steel, Figure 4 for alloys of copper and/or high nickel, Figure 5 foraluminum and aluminum alloys. For materials other than shown in Figure 3, 4 and 5 the

voltage selected shall be in accordance with the procedure qualification and demonstration.

8.2.2 GAMMA RADIATION:

The recommended minimum thickness for which radioactive isotopes may be used is asfollows:

Minimum Thickness

Radiation SourceMaterial

Iridium 192 Cobalt 60

Steel 0.75 inch (19 mm) 1.50 inch (38 mm)

Copper or high nickel 0.65 inch (17 mm) 1.30 inch (33 mm)

Aluminum 2.5 inch (64 mm) -

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The maximum thickness which can be radiographed with above radioactive isotopes is

primarily dictated by exposure time, hence upper limits are not shown. It is recommended that

minimum thickness limitation may be reduced and radiographic techniques used shalldemonstrate that the required penetrameter sensitivity is obtained.

8.3 RADIOGRAPHIC TECHNIQUE CONTROL:

a) Each cassette or film holder shall be placed on the surface to be radiographed in a

secured manner so that there is a minimum gap between the surface of interest and the

cassette. When film cassettes are overlapped the minimum overlap shall not be lessthan one inch from each end of the cassette. When practical, the film shall be shaped

to the contour of the object.

b) As a check on the radiographic technique employed penetrameters shall be used in a

manner as described to determine whether the requirements are met. All radiographic

examination performed shall be proved by actual demonstration.

c) The source to object distance shall be selected in such a way that a sharp image is

produced.

8.4 DIRECTION OF RADIATION:

The direction of central beam of radiation should be centered on the area of interest whenever

practical.

8.5 GEOMETRIC UNSHARPNESS:

Geometric Unsharpness of the radiograph (Ug) shall be determined in accordance with:

Ug = Fd/D

Where

F = Source size, i.e. the maximum projected dimension of the radiating source (orfocal spot) in the plane perpendicular to the distance D from the weld or object

being radiographed.

D = distance from source of radiation to weld or object being radiographed.

d = distance from source side of weld or object being radiographed to the film.

Note: Refer to recommended practice ASME Sec. V-SE-94 for a method of determininggeometric Unsharpness. Alternatively Nomogram as shown in recommended practice

ASME Sec. VSE-94 may be used. Nomogram as shown in Fig. No. 7 of this

specification can also be used which are reproduction of ASME Sec VSE-94.

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8.6.3 MAPPING THE PLACEMENT OF LOCATION MARKERS:When inaccessibility or other limitation, prevent the placement of markers as stipulated in

clauses 8.6.1 and 8.6.2, a dimensional map of the actual markers placement shall accompanythe radiographs and shall show that full coverage has been obtained.

8.7 IQI SELECTION:a) IQI shall be selected from either the same alloy group or grade as identified in ASME SE

1025 (for hole type) and ASME SE 747 (for wire type) or from an alloy material or grade

with less radiation absorption than the material being radiographed.

b) The quality level required for radiography shall be atleast 2% (2-2T) unless a higher orlower quality level is contractually agreed upon. The essential hole size and designatedpenetrameters shall be as specified in Table 2 as applicable. A smaller hole in a thicker

penetrameter or a larger hole in a thinner penetrameter may be substituted for any section

thickness listed in Table 2 provided equivalent penetrameter sensitivity (EPS) is maintainedand all other requirements for radiography are met. EPS is to be calculated as specified in

ASME SE 1025

c) For welds made in accordance with ASME boiler and pressure vessel code Sec. III,penetrameter selection shall be based on Table 3 for class I ASME Sec. III (Sub Section

NB) and class II (Sub Section NC) components.

d) Selection of penetrameters shall be made from Table 2 for radiographic examination forclass III components fabricated in accordance with ASME Sec. III Sub section ND andASME Sec. VIII. Div. 1.

e) For welds with reinforcement: The thickness on which the penetrameter is based is thenominal single wall thickness plus the reinforcement permitted by the referencing code.Backing rings or strips are not to be considered as part of the weld or reinforcement

thickness in penetrameter selection.

f) Welds without reinforcement: when welds made without reinforcements, thepenetrameter selection is based on nominal single wall thickness. Backing rings or strips

are not to be considered as a part of the weld thickness in penetrameter selection.

8.7.1 USE OF PENETRAMETERS TO MONITOR RADIOGRAPHIC EXAMINATION

8.7.1.1 PLACEMENT OF PENETRAMETERS:

a) SOURCE SIDE PENETRAMETERS(S):

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The penetrameter (s) shall be placed on the source side of the part being radiographed,

except as described in (b) below.

b) FILM SIDE PENETRAMETER(S):

Where inaccessibility prevents hand placing of the penetrameter on the source side itshall be placed on the film side of the part under radiography and a lead letter F

atleast as high as identification number(s) shall be placed adjacent to or on the

penetrameter(s). In no case the letter F shall mask the essential hole where hole

penetrameters are used.

c) PENETRAMETER LOCATION FOR WELDS Hole Penetrameter

The penetrameter(s) may be placed adjacent to or on the weld. The identification

numbers and the letter F, when used, shall not be in the area of interest. The

identification numbers and lead letter F may be placed in the area of interest with thefollowing exceptions;

1) When geometric configuration makes it impractical.2) When the weld metal is not radiographically similar to the base material.

d) PENETRAMETER LOCATION FOR WELDS Wire Penetrameter

The penetrameters shall be placed on the weld in such a manner that the length of thewires is perpendicular to the length of the weld. The identification numbers and lead

letter, when used shall not be in the area of interest, except for the conditions outlined

in clause 8.7.1.1 (c) (1) or (2).

e) When performing radiography of welds, penetrameter(s) shall be placed on the parent

material approximately 1/8 inch (3 mm) from the edge of the weld seam.

f) ALTERNATIVE LOCATION FOR PENETRAMETER(S):

When the configuration or size prohibits placing the penetrameter on the object beingradiographed, the penetrameter may be placed on a separate block radiographically

similar. The block shall be placed as close as possible to the material beingradiographed.

In any case the position of the penetrameter shall not interfere with the interpretationof the area of interest shall be placed on the source side.

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g) When examining double walled parts such as piping or duct, with source positionedoutside the pipe, the penetrameter shall be placed, where practicable, on the outside of

the pipe along side the weld.

h). Where placement of penetrameter on the source side is impracticable, use of film side

penetrameter is permitted provided the following conditions are met:

1) The radiographic technique shall be demonstrated with the applicable penetrameterplaced on the source side and a continuous series of penetrameters placed on the

film side of a like pipe section. The series of penetrameters shall range in thickness

from 2% to 0.5% of the material thickness.

2) If the required sensitivity of source side penetrameter is achieved, the image ofsmall penetrameter hole visible on the film side shall be used to determinepenetrameter and penetrameter hole, which shall be used for production

radiographs.

8.7.1.2 NUMBER OF PENETRAMETERS:

a) Except as provided in 8.7.1.2 (c) one penetrameter shall be used for each radiograph.Each penetrameter shall represent an area of essentially uniform radiographic density

as judged by a densitometer. If the density of the radiograph anywhere through the

area of interest varies more than minus 15% or plus 30% from the density that adjacentto penetrameter then an additional penetrameter shall be used for each exceptional area

or areas. In each case acceptable sensitivity shall be achieved.

b) For those sections where the thickness varies sufficiently to cause difficulty in meetingrequirements of 9.2.1 with one penetrameter, two penetrameters shall be used

representing the thinnest and the thickest section in the area of interest and the

intervening densities on the radiograph shall be considered as having acceptabledensities.

c) SPECIAL CASE:1. For cylindrical vessels or flat products where one or more film

holders/cassettes are used for a single exposure, a penetrameter image on eachradiograph shall appear. Where the source is placed on the axis of the object

and a complete circumference using one or more film holders/cassettes isradiographed with a single exposure atleast three penetrameters approximately

1200apart shall be used.

2. Where sections of longitudinal welds adjoining the circumferential welds areradiographed simultaneously with the circumferential weld an additional

penetrameter shall be placed on each longitudinal weld at the end of each

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section most remote from the junction with a circumferential weld beingradiographed.

3. For cylindrical vessels where the source is placed on the axis of the object andfour or more film holders are required to radiograph a single section of the

circumference, atleast three penetrameters shall be used. One penetrameter

shall be placed approximately in the centre of the section exposed and one ateach end. Otherwise atleast one penetrameter image shall appear on each

radiograph when the section of the circumference exposed exceeds 2400; rules

of (1) and (2) shall apply.

4. For spherical vessels where the source is located at the centre of the vessel andone or more film holders are exposed for a complete circumference a minimum

of three penetrameters shall be spaced approx 1200 apart. For other welds,

radiographed simultaneously, one additional penetrameter shall be placed on

each other weld.

5. When segments of spherical vessel are radiographed in a single exposure,source located at the centre of the vessel using four or more film holders for an

exposure of circumferential weld, atleast three penetrameters shall be used tokeeping one penetrameter in the approximate centre of the portion exposed and

one at each end. When the portion exposed exceeds 2400; the rules of (4) above

apply. In each case additional film locations may be required to establishproper penetrameter spacing, otherwise atleast one penetrameter image shall

appeared on each radiograph.

6. When an array of objects in a circle is radiographed atleast one penetrametershall show on each object image.

8.7.1.3 SHIMS UNDER HOLE PENETRAMETERS:

a) A shim of material radiographically similar to the weld metal shall be placed under thepenetrameter in case weld reinforcement and or backing strip/rings are not removed.

b) The shim thickness atleast should be the same as the total weld thickness includingany reinforcement plus backing strip/ring thickness. The shim dimensions shall exceedthe penetrameter dimensions by atleast 1/8 inch (3 mm) on all sides. The shimmed

penetrameter shall not overlap the backing strip or ring. The outline of atleast threesides of the penetrameter images shall be visible in the radiograph.

c) Where shims are used under the penetrameter the radiographic density throughout thearea of interest shall not more than minus 15% from (lighter than) the radiographic

density through the penetrameter throughout the area of interest.

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8.8 TIME OF EXAMINATION:

8.8.1 Unless otherwise specified by applicable job order or contract, radiography may be performed

prior to heat treatment.

8.8.2 For weld joints of components where referencing code is ASME-Sec III NB or ASME Sec III

NC radiography examination shall be performed after and intermediate or final Post WeldHeat Treatment (PWHT), when required, except as provided in (a) and (b) below:

a) Radiographic examination of welds in piping, pumps and valves fabricated of P.No. 1material may be performed prior to any required PWHT.

b) Radiographic examination of welds in vessels fabricated of P.No.1 materials and all weldsin components fabricated of P.No.3 materials may be performed prior to an intermediateor final (PWHT) provided the welds are ultrasonically examined after an intermediate or

final Post Weld Heat Treatment.

Note: An intermediate PWHT for examination is defined as a PWHT on a weld within a

temperature range to which the weld shall be subjected during the final PWHT.

9.0 EVALUATION

9.1 QUALITY OF RADIOGRAPH:

a) All the radiographs shall be free from chemical, mechanical handling related or other

blemishes which could interfere with proper interpretation of the radiograph.

b) Each radiograph shall be examined for processing defects and shall be considered not

interpretable when one or combination of the following defects are seen on radiograph:

- fogging

- processing defects such as streaks, water marks

- damage to emulsion, scratches, crimps, static marks- discoloration due to improper fixing or washing

- loss of detail due to poor screen to film contact

- strain marks

9.2 RADIOGRAPHIC DENSITY:

9.2.1 DENSITY LIMITATION:

The transmitted film density through the radiographic image of the body of the appropriate

penetrameter and the area of interest shall be 1.8 minimum for single film viewing for

radiographs made with an X-Ray source and 2.0 minimum for radiographs made with a

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gamma ray source. For composite viewing of multifilm exposures, each film of composite setshall have a minimum density of 1.3. The maximum density shall be 4.0 for either single or

composite viewing. A tolerance of 0.05 in density is allowed for variations between

densitometer readings.

9.2.2 DENSITY VARIATION:

a) General If the density of the radiograph anywhere through the area of interest varies bymore than minus 15% or plus 30% from the density through the body of the whole

penetrameter or adjacent to designated wire of a wire type penetrameter, within

minimum/maximum allowable density range is specified in 9.2.1, then an additionalpenetrameter shall be used for each exceptional area or areas and the radiograph retaken.

The allowable variation in density may be rounded to the nearest 0.1 within the range

specified in 9.2.1.

b) With Shims When shims are used the plus 30% density restriction of 9.2.2 (a) may beexceeded, provided the required penetrameter sensitivity is displayed and the densitylimitations of 9.2.1 are not exceeded.

9.3 IMAGE QUALITY INDICATORS (PENETRAMETERS) SENSITIVITY:

Radiography shall be performed with a technique of sufficient sensitivity to display the

penetrameter image and the specified hole of plate type penetrameter or required wire of wiretype penetrameter. The images of the identifying numbers, penetrameters image and specified

hole are essential indications of the image quality and shall appear on the radiograph. As far

as possible the penetrameter shall be placed perpendicular to the radiation beam, if therequired penetrameter image and specified hole do not show on any film in a multifilm

technique but do show in composite film viewing, interpretation shall be permitted only by

composite film viewing.

9.4 EXCESSIVE SCATTER:

If the image of symbol B specified in clause 5.3 appears on the radiograph as a lighterdensity than background, it is an indication that the protection from back scatter is insufficient

and the radiograph shall be considered unacceptable. A dark image of the symbol B on a

lighter background is not a cause for rejection.

9.5 GEOMETRIC UNSHARPNESS LIMITATION :

Geometric Unsharpness (Ug) determined as per clause 8.5 of this specification shall be within

following limits:

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Material Thicknessinch (mm)

Ug maximum

inch (mm)

Under 1 (25.4) 0.010 (0.254)

1 (25.4) through 2 (50.8) 0.020 (0.508)

Over 2 (50.8) through 3 (76.2) 0.030 (0.762)

Over 3 (76.2) through 4 (101.6) 0.040 (1.016)

Greater than 4 (101.6) 0.070 (1.778)

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

10.0 INTERPRETATION:

All the final radiographs shall be submitted to the purchaser or his authorized representativefor evaluation and acceptance. The radiographs shall be evaluated and interpreted by the

manufacturers Level II or Level III qualified personnel prior to offering for interpretation to

Quality Assurance Engineers of NPCIL. The interpreted results of each radiograph anddisposition of material examined shall be recorded by the manufacturer in the examination

report and the same shall be available with the radiographs at the time of evaluation and

interpretation by NPCIL.

Discontinuities revealed in welds shall be interpreted to the appropriate degree of defects in

accordance with the norms of acceptance laid down in Para 12 of this specification. However

final acceptance criteria shall be governed by the controlling product Specification,

Purchase Order or Drawing.

11.0 DOCUMENTATION:

11.1 EXAMINATION REPORT:

To aid in proper interpretation of radiography and to have a final status of acceptance ofradiographs, examination reports shall be prepared for each group of radiographs and

submitted for approval/acceptance.

The examination report shall at least include the following information: and the same shall be

filled.

a) Manufacturer Name, Job Number.b) Identification of part and weld seam.c) Identification of welderd) Thickness of radiographed area, diameter/size of the job.e)

Material type and grade.f) Applicable specification.

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g) Type and size of source (Isotope or max. X-Ray voltage used)h) Type of films and type of processing used.i) No. of films per cassette.j) Type, number and thickness of screen and filters used.k) No. of exposures.l) Exposure time.m) Single wall and double wall exposure and viewing.n) Type and designation of IQI and required sensitivity.o) Film density achieved.p) Sensitivity achieved.q) Interpretation of film results.r) Remarks for unusual occurrences.s) Date of examination and signature of evaluator.t) Qualification level of operator and personnel performing evaluation.

11.2 STORAGE OF PROCESSED RADIOGRAPHS:

The radiographs should be stored in such a manner that staining and fading of image is

prevented. The films should be protected from excessive heat and humidity. The envelopes

sealed at an edge with non-hygroscopic adhesive shall be stored in a safe place. For storage offilms, detailed instructions of the film manufacturer shall be followed. The system of storage

shall be so organized that when required, the radiograph of a pertinent joint of required

component can be easily withdrawn for reference.

11.2.1 RETENTION PERIOD OF PROCESSED RADIOGRAPHS:

A) LIFE TIME RECORDS:Final radiographs pertaining to ASME-Sec. III NB & NC components identified for

INSERVICE INSPECTION and INSERVICE TESTING shall be classified as lifetime records and shall be retained by NPCIL for the service life time of the component

or system. The radiographs shall be properly identified, packed and submitted to

NPCIL by manufacturer.

B) NON PERMANENT RECORDS:Final radiographs of ASME Sec. III NB and NC components which are not

identified for INSERVICE INSPECTION and INSERVICE TESTING shall beclassified as non-permanent records. Unless otherwise specified by job order or

contract, the manufacturer shall be responsible to retain final radiographs of

components manufactured in accordance with ASME Sec. III NB & NC & ND for aperiod of 10 years.

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11.3 DIGITALIZATION OF RADIOGRAPHS:Radiographs shall be digitalized in accordance with ASME Sec V Article 2 Mandatory

Appendix VI, if so required by the product specification or Purchase Order/Contract.

12.0 RADIOGRAPHIC ACCEPTANCE STANDARD:

12.1 FULL RADIOGRAPHY:

Acceptance standard for welds in accordance with ASME code, Sec. III Class 1, class 2 and

class 3 components and ASME. SEC. VIII DIVISION 1 components for full radiography shallbe as given below:

12.1.1 Following type of indications that are shown on radiographs of welds and characterized asimperfections are unacceptable.

a) Any type of cracks or a zone of incomplete fusion or penetration.b) Any other elongated indication which has a length greater than:

i) 1/4 inch (6.4 mm) for t up to 3/4 inch (19 mm) inclusive.ii) 1/3 t for from 3/4 inch to 2 1/4 inch (19 mm 57 mm) inclusiveiii) 3/4 inch (19 mm) for t over 2 1/4 inch (57 mm)Where t is thickness of thinner portion of weld.

c) Internal root weld conditions are acceptable when the density change as indicated inthe radiograph is not abrupt; elongated indications on the radiograph at either edge of

such conditions shall be unacceptable, as provided in 12.1.1 (b) above.

d) Any group of aligned indications having an aggregate length greater than t in a lengthof 12 t unless the minimum distance between successive indications exceeds 6L, in

which case the aggregate length is unlimited, L being the length of the largest

indication.e) Rounded indications in excess of that shown as acceptable as per clause number 12.4

of this specification.

12.2 ACCEPTANCE STANDARD FOR SPOT RADIOGRAPHY EXAMINATION FOR

ASME SEC. III ND AND ASME SEC. VIII DIV. I COMPONENTS:

12.2.1 Butt welded joints which are to be spot radiographed shall be judged by the following

acceptance standards.

a. Welds in which the radiograph shows any type of cracks or zone of incomplete fusion orpenetration shall be unacceptable.

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b. Welds in which the radiographs show slag inclusions or cavities shall be unacceptable ifthe length of any such imperfection is greater than 2/3 t where t is the thickness of the

thinner plate welded. If several imperfections within the above limitations exist in line, theweld shall be judged acceptable if the some of the longest dimensions of all such

imperfections is not more than t in a length of 6t or proportionately for radiograph shorter

than 6t and if the longest imperfections considered or separated by atleast 3L of acceptableweld metal, where L is the length of the longest imperfection. The maximum length of

acceptable imperfection shall be 3/4 inch (19 mm). Any such imperfections shorter than

1/4 inch (6 mm) shall be acceptable for any plate thickness.

c. Rounded indications are not a factor in the acceptability of welds not required to be fullyradiographed.

12.3 ACCEPTANCE STANDARD FOR COMPONENT SUPPORTS- ASME SEC. III

SUBSECTION NF:

Acceptance criteria of weld joints shall be as per para 12.1.1 (a) to 12.1.1 (d). Rounded

indications are not a factor in the acceptability of welds that are radiographed.

12.4 ACCEPTANCE STANDARDS FOR RADIOGRAPHICALLY DETERMINED

ROUNDED INDICATION IN WELDS

12.4.1 TERMINOLOGY:

a) ROUNDED INDICATION:

Indications with a maximum length of three times of width or less on the radiograph are

defined as rounded indications. These indications may be circular, elliptical, conical or

irregular in shape and may have tails. When evaluating the size of an indication the tailshall be included. The indication may be from any source in the weld, such as porosity,

slag and tungsten.

b) ALIGNED INDICATIONS:

A sequence of four or more rounded indications shall be considered to be aligned whenthey touch a line parallel to the length of the weld drawn through the centre of two outer

rounded indications.

c) THICKNESSt:

t is the thickness of the weld, of the pressure retaining material, or of thinner of the

sections being joined, whichever is least. If a full penetration weld includes a fillet weld,

the thickness of the fillet weld throat shall be included in t.

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12.4.2 ACCEPTANCE CRITERIA

a) IMAGE DENSITY:

Density within the image of indication may vary and is not a criterion for acceptance

or rejection.

b) RELEVANT INDICATIONS (REFER TABLE-A FOR EXAMPLES):

Only those rounded indications which exceed the following dimensions shall be

considered relevant:

1/10 t for t less than 1/8 inch (3 mm)

1/64 inch (0.4 mm) for t equal to 1/8 1/4 inch (3 6 mm) inclusive1/32 inch (0.8 mm) for t greater than 1/4-2 inch (6 50 mm) inclusive

1/16 inch (1.5 mm) for t greater than 2 inch (50 mm)

c) MAXIMUM SIZE OF ROUNDED INDICATION (REFER TABLE-A FOR

EXAMPLES):

The maximum permissible size of any indication shall be 1/4 t or 5/32 inch (4 mm)

whichever is less; except that an isolated indication separated from an adjacent

indication by 1 inch (25 mm) or more may be 1/3 t or 1/4 inch (6 mm) whichever isless. For t greater than 2 inch (50 mm) the maximum permissible size of an isolated

indication shall be increased 3/8 inch (10 mm)

d) ALIGNED ROUNDED INDICATIONS:

Aligned rounded indications are acceptable when the summation of the diameters of

the indications is less than t in a length of 12t (fig.8). The length of groups of alignedrounded indications and the spacing between the groups shall meet the requirements of

Fig. 9.

e) SPACING:

The distance between adjacent rounded indications is not a factor in determiningacceptance or rejection, except as required for isolated indications or groups of aligned

indications.

f) ROUNDED INDICATION CHARTS:

(Ref fig. 10 to 15, these figs. as attached in this specification are for illustration only,

for actual size APPENDIX 4 of ASME Sec VIII Div 1 is to be referred).

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1. The rounded indications as determined from the radiographic film shall notexceed that shown in the charts.

2. The charts illustrate various types of assorted, randomly dispersed and clusteredrounded indication for different weld thickness greater than 1/8 inch (3 mm).

These charts represent the maximum acceptable concentration limits for rounded

indications.

3. The chart for each thickness range represents full-scale 6 inch (150 mm)

radiographs and shall not be enlarged or reduced. The distributions shown are

not necessarily the patterns that may appear on the radiograph, but are typical ofthe concentration and size of indications permitted.

g) WELD THICKNESS t LESS THAN 1/8 IN (3 mm):

For t less than 1/8 inch (3 mm) the maximum number of rounded indications shall not

exceed 12 numbers in a 6 inch (150 mm) length of weld. A proportionally fewernumber of indications shall be permitted in welds less than 6 inch (150 mm) in length.

h) CLUSTERED INDICATIONS:

The illustrations for clustered indications show up to four times as many indications in

a local area as that shown in the illustrations for random indications. The length of anacceptable cluster shall not exceed the lesser of 1 inch (25 mm) or 2 t. Where more

than one cluster is present, the sum of the lengths of the cluster shall not exceed 1 inch

(25 mm) in a 6 inch (150 mm) length of weld.

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TABLE 1

(Reference: TABLE T-233.1 ASME Sec, V Article 2)

HOLE TYPE IQI DESIGNATION, THICKNESS, AND HOLE DIAMETERS

IQI Designation IQI Thickness, T

inch (mm)

1T Hole Diameter,

inch (mm)

2T Hole Diameter,

inch (mm)

4T Hole Diameter,

inch (mm)

5 0.005 (0.13) 0.010 (0.25) 0.020 (0.51) 0.040 (1.02)

7 0.0075 (0.19) 0.010 (0.25) 0.020 (0.51) 0.040 (1.02)

10 0.10 (0.25) 0.010 (0.25) 0.020 (0.51) 0.040 (1.02)

12 0.0125 (0.32) 0.0125 (0.32) 0.025 (0.64) 0.050 (1.27)15 0.015 (0.38) 0.015 (0.38) 0.030 (0.76) 0.060 (1.52)

17 0.0175 (0.44) 0.0175 (0.44) 0.035 (0.89) 0.070 (1.78)

20 0.020 (0.51) 0.020 (0.51) 0.040 (1.02) 0.080 (2.03)

25 0.025 (0.64) 0.025 (0.64) 0.050 (1.27) 0.100 (2.54)

30 0.030 (0.76) 0.030 (0.76) 0.060 (1.52) 0.120 (3.05)

35 0.035 (0.89) 0.035 (0.89) 0.070 (1.78) 0.140 (3.56)

40 0.040 (1.02) 0.040 (1.02) 0.080 (2.03) 0.160 (4.06)

45 0.045 (1.14) 0.045 (1.14) 0.090 (2.29) 0.180 (4.57)

50 0.050 (1.27) 0.050 (1.27) 0.100 (2.54) 0.200 (5.08)

60 0.060 (1.52) 0.060 (1.52) 0.120 (3.05) 0.240 (6.10)

70 0.070 (1.78) 0.070 (1.78) 0.140 (3.56) 0.280 (7.11)

80 0.080 (2.03) 0.080 (2.03) 0.160 (4.06) 0.320 (8.16)

100 0.100 (2.54) 0.100 (2.54) 0.200 (5.08) 0.400 (10.16)120 0.120 (3.05) 0.120 (3.05) 0.240 (6.10) 0.480 (12.19)

140 0.140 (3.56) 0.140 (3.56) 0.280 (7.11) 0.560 (14.22)

160 0.160 (4.06) 0.160 (4.06) 0.320 (8.13) 0.640 (16.26)

200 0.200 (5.08) 0.200 (5.08) 0.400 (10.16) -

240 0.240 (6.10) 0.240 (6.10) 0.480 (12.19) -

280 0.280 (7.11) 0.280 (7.11) 0.560 (14.22) -

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TABLE -2(Reference: TABLE T - 276 of ASME Sec, V Article 2)

IQI SELECTION

IQINominal Single Wall materialThickness Range Source Side Film Side

inch mm Hole typeDesignation

Wire-Type

Essential Wire

Hole typeDesignation

Wire-Type

Essential Wire

Up to 0.25, incl. Up to 6.4, incl. 12 5 10 4

Over 0.25through 0.375

Over 6.4through 9.5

15 6 12 5



17 7 15 6

Over 0.50

through 0.75

Over 12.7

through 19.0

20 8 17 7

Over 0.75

through 1.00

Over 19.0

through 25.4

25 9 20 8



30 10 25 9

Over 1.50

through 2.00

Over 38.1

through 50.8

35 11 30 10



40 12 35 11



50 13 40 12



60 14 50 13

Over 6.00

through 8.00

Over 152.4

through 203.2

80 16 60 14

Over 8.00

through 10.00

Over 203.2

through 254.0

100 17 80 16

Over 10.00

through 12.00

Over 254.0

through 304.8

120 18 100 17

Over 12.00

through 16.00

Over 304.8

through 406.4

160 20 120 18

Over 16.00

through 20.00

Over 406.4

through 508.0

200 21 160 20

Note: For hole type IQI essential hole is 2T for above table, where T is thickness of penetrameter.

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TABLE -3

(Reference: TABLE NB-5111-1 of ASME Sec, III div 1 - NB)

THICKNESS PENETRAMETER DESIGNATION AND ESSENTIAL HOLES AND WIRE

DIAMETERS

Penetrameters Hole or Wire Type

Source Side Film Side

Single WallmaterialThickness

Range,inch(mm)

Designation

Hole Sizeinch(mm)

Essential

Hole

Required wiredia-IQI,

inch(mm)

Designation

Hole Sizeinch(mm)

Essential

Hole

Required wiredia-IQI,

inch(mm)

Upto 0.25

(6) incl.

5 0.040

(1.02)

4T 0.006 (0.15) 5 0.040

(1.02)

4T 0.006 (0.15)

Over -3/8

(6-10)

7 0.040

(1.02)

4T 0.006 (0.15) 7 0.040

(1.02)

4T 0.006 (0.15)

Over 3/8-1/2(10-13)

10 0.040(1.02)

4T 0.010 (0.25) 10 0.040(1.02)

4T 0.010 (0.25)

Over -5/8

(13-16)

12 0.050

(1.27)

4T 0.013 (0.33) 12 0.050

(1.27)

4T 0.013 (0.33)

Over 5/8-3/4

(16-19)

15 0.060

(1.52)

4T 0.016 (0.41) 12 0.050

(1.27)

4T 0.013 (0.33)

Over -1

(19-25)

20 0.040

(1.02)

2T 0.016 (0.41) 17 0.035

(0.89)

2T 0.013 (0.33)

Over 1-1.25

(25-32)

25 0.050

(1.27)

2T 0.020 (0.51) 17 0.035

(0.89)

2T 0.013 (0.33)

Over 1.25-

1.5 (32-38)

30 0.060

(1.52)

2T 0.025 (0.64) 20 0.040

(1.02)

2T 0.016 (0.41)

Over 1.5-2(38-50)

35 0.070(1.78)

2T 0.032 (0.81) 25 0.050(1.27)

2T 0.020 (0.51)

Over 2-2.5

(50-64)

40 0.080

(2.03)

2T 0.040 (1.02) 30 0.060

(1.52)

2T 0.025 (0.64)

Over 2.5-3

(64-75)

45 0.090

(2.29)

2T 0.040 (1.02) 35 0.070

(1.78)

2T 0.032 (0.81)

Over 3-4

(75-100)

50 0.100

(2.54)

2T 0.050 (1.27) 40 0.080

(2.03)

2T 0.040 (1.02)

Over 4-6(100-150)

60 0.120(3.05)

2T 0.063 (1.60) 45 0.090(2.29)

2T 0.040 (1.02)

Over 6-8(150-200)

80 0.160(4.06)

2T 0.100 (2.54) 50 0.100(2.54)

2T 0.050 (1.27)

Over 8-10

(200-250)

100 0.200

(5.08)

2T 0.126 (3.20) 60 0.120

(3.05)

2T 0.063 (1.60)

Over 10-12

(250-300)

120 0.240

(6.10)

2T 0.160 (4.06) 80 0.160

(4.06)

2T 0.100 (2.54)

Over 12-16(300-400

160 0.320(8.13)

2T 0.250 (6.35) 100 0.200(5.08)

2T 0.126 (3.20)

Over 16-20

(400-500)

200 0.400

(10.16)

2T 0.320 (8.13) 120 0.240

(6.10)

2T 0.160 (4.06)

Note: In above table T is thickness of penetrameter.

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TABLE A

(Reference: TABLE VI-1132-1 of Mandatory Appendix VI, Article VI 1000 of ASME Sec III

Div 1 - Appendices and TABLE 4-1 of Appendix 4 of ASME Sec VIII Div 1)

MAXIMUM SIZE OF NON RELEVANT INDICATIONS AND ACCEPTABLE ROUNDED

INDICATIONS - EXAMPLES ONLY

Maximum size of Rounded Indication , inch

(mm)

Thickness t, inch (mm)

Random Isolated

Maximum Size of

Nonrelevent Indication, inch(mm)

< 1/8 (2 (>50) 0.156 (4.0) 0.375 (9.5) 0.063 (1.6)

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