291081799-RT.pdf

PROJECT SPECIFIC PROCEDURE

C12-001/PSP/QAQC- 004

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Page 2 of 8 TABLE OF CONTENTS

SECTION

DESCRIPTION

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PURPOSE

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SCOPE

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REFERENCES........................................................... REFERENCES.................................... .......................

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DEFINITIONS

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PROCEDURES .......................................................... ........................... ............................... 5.1 Radiography Equipment................................. 5.2 Equipment Strength / Capacity....................... 5.3 Source Size................................. Size..................................................... .................... 5.4 Thickness Range............................................ 5.5 Source to Film Distance.................................. 5.6 Surface Preparation............................ Preparation........................................ ............ 5.7 Film Type..................................... Type........................................................ ................... 5.8 Intensifying Screen......................................... 5.9 Radiographs Technique......................... Technique................................. ........ 5.10 Quality of Radiographs............................... Radiographs................................... .... 5.11 Location Markers........................................... 5.12 Radiograph Identification............................... 5.13 Density............................... Density........................................................... ............................ 5.14 Image Quality Indicator (IQI).......................... 5.15 Sensitivity.................................. Sensitivity....................................................... ..................... 5.16 Back-Scatter Radiations................................ 5.17 Film Processing............................................. 5.18 Storage of Film..................................... Film............................................... .......... 5.19 Interpretation of Radiograph.......................... 5.20 Acceptance Criteria....................................... 5.21 Qualification of Personnel............................. 5.22 Radiographs Viewing Facilities..................... 5.23 Reports...................................... Reports.......................................................... ....................

5 5 5 5 5. 5 6 6 6 9 11 11 11 11 11 13 14 14 16 16 16 17 17 17

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SPECIAL REQUIREMENT...................................... REQUIREMENT........................................... .....

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RECORD

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.......................................................... ........................ ....................................... .....

APPENDICES Attachment 1: Radiographic Testing Report Format……….19 Attachment 2: Location Markers……………….....................20 Markers……………….....................20


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Page 3 of 8 1.0

PURPOSE This procedure outline the requirements for radiographic testing of structural welds to detect surface, sub-surface and internal discontinuities in materials, welds and fabricated parts or components.

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SCOPE This procedure covers the personnel qualification, safety, equipment, materials, technique, methods, film processing and quality of radiograph for radiographic examination.

3.0

REFERENCES The following codes and standards shall form parts of the requirements of this procedure: AWS D1.1 ASTM E 94 ASTM E 1032 ASME V

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Structural Welding Code (2008) Guide for Radiographic Radiographic Testing. Method for Radiographic Method Radiographic Examination of Weldment Non Destructive Examination Article 2 (2007 Edition).

DEFINITIONS RT NDT PCN ASNT ASTM ASME CSWIP AWS PTW

: : : : : : : : :

Radiographic Testing Non-destructive Testing Personnel Certification in Non-Destructive Testing American Society for Non-Destructive Testing American Society for Testing and Materials American Society of Mechanical Engineer Certification Scheme of Welding and Inspection Personnel American Welding Society Permit To Work


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Page 4 of 8 5.0

PROCEDURE 5.1

Radiography Equipment The Radiography equipment used shall cover the following model where applicable:a)

5.2

Equipment Strength/Capacity a) b)

5.3

Iridium 192 of source strength of maximum 25 curies and minimum of 12 curies. Gamma-Ray Equipment shall be selected in accordance with quality level/energy per ASME Sec. V T-272 and SE-94 Part 1.

Source Size a)

5.4

Gamma-Ray projector, Amertest Model 660 for Iridium 192 or equivalent. The projector shall be tested and certified by the manufacturer (leak test, drop test, fire test) and approved by LPTA.

2.7mm diameter x 1.45 mm long for Iridium 192.

Thickness Range This procedure shall cover for Butt Weld and Girth Weld of thickness range from 5mm up to 38 mm.

5.5

Source to Film Distance i)

The source to subject distance shall not be less than the total length of film being exposed in a single plane, and

ii)

The source to subject distance shall not less than seven (7) times the thickness of weld plus reinforcement and backing strip, and

iii)

The minimum source to film distance or different thickness of material shall be determined from the f ollowing derivation.

Ug

= Fd/D

Ug F d D

= Geometric unsharpness = Source size: the maximum projected dimension of the radiating source = Distance from source side of weld or object being radiograph to the film = Distance from source of radiation to object being radiographed Geometric unsharpness of radiograph shall not exceed Table 5.5


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Page 5 of 8 Table 5.5: Geometric Unsharpness

5.6

Material Thickness (inch)

Ug Maximum (inch)

Under 2 2 through 3

0.020 0.030

Surface Preparation Component to be radiography shall satisfy following requirement. 5.6.1

5.6.2

5.7

Weld ripples or other weld irregularities on both the inside and outside of the weld which would mask or be confused with image of unacceptable imperfection shall be removed by grinding to an extent which permits satisfactory interpretation of the radiograph. Heat Affected Zone (HAZ) should free from spatter or other irregularities which would mask or be confused with image appear in the radiograph.

Film Type Radiographic film used shall be ASTM Class II Film. (example: Agfa Geavert D7 or Fuji 100, or Equivalent) However ASTM Class 1 Films shall be used for material stainless steel, duplex stainless steel and when required sensitivity could not be achieved using ASTM Class II film or for Radiography performed after PWHT. (example: Agfa Geavert D4 or Fuji 80, 50 or Equivalent)

5.8

Intensifying Screen 5.8.1

Lead Intensifying Screens used shall be 0.125 mm thick lead for both front and back. Leads Screen shall be free from scratches, dirt, dent, moisture and periodically checked and replaced whenever there is scratch or deep impression, in order not to affect film interpretation.

5.8.2

The use of fluorescent screen shall not be permitted.


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Page 6 of 8 5.9

Radiographic Technique 5.9.1

Radiographic Testing of Groove Weld in Butt Joints –Plate Structure Radiographs shall be made with Single Wall Single Image (SWSI) Technique. This technique, the radiation passes through one (1) wall of the weld (material), which is viewed for acceptance on the radiograph. Arrangements of source and film placement are illustrated in Fig 5.9.1a, 5.9.1b, 5.9.1c & 5.9.1d. IQI placement

Weldment

Length less than 225mm Fig 5.9.1a: Radiographic Test on welded plate, Length of interest is 225mm or lesser


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IQI placement

Length 225mm and greater Fig 5.9.1b: Radiographic Test on Welded Plate, Length of interest greater than 225mm

Film

IQI Placement I-Beam

Source

Fig 5.9.1c:

Radiographic Test on Welded I-Beam structure - Bottom / Top plate


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SFD > L

Overlapping min 25mm Source L one (1) exposure multiple film

IQI Placement

Film

Fig 5.9.1d : Radiographic Test on Welded I-Beam Structure – Web Plate

5.9.2

Radiographic Test of groove weld in Butt Joint – Tubular Connectors The technique used to radiograph circumferential butt joints shall be capable of covering the entire circumference. The technique shall preferably be Single Wall Single Image (SWSI). Where accessibility or pipe size prohibits this, the technique may be double-wall exposure technique. 5.9.2.1

Single Wall Single Image The source of radiation is placed inside the pipe and the film on the outside of the pipe (see figure 5.9.2a). For pipe diameter more than 14 in (350 mm), panaromic exposure may be m ade if the source-to-object requirements are satisfied; if not, a minimum of three exposures shall be made. The IQI may be selected and placed on the source side of the pipe. If not practicable due to safety issue / concern , it may be placed on the film side of the pipe.

5.9.2.2

Double Wall Single Image Where access or geometrical conditions prohibit single wall exposure, the source may be placed on the outside of the pipe and film on the opposite wall outside the pipe. See figure 5.9.2b. A minimum of three exposures is required to cover the complete circumference. The IQI may be selected and placed on the film side of the pipe.


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5.9.2.3

Double-Wall Exposure/Double-Wall View When the outside diameter of the pipe is 3 1 / 2 in (89mm) or less, both the source side and film side weld may be projected onto the film and both walls viewed for acceptance. The source of radiation is offset from the pipe by a distance that is at least seven times the outside diameter. The radiation beam shall be offset from the plane of the weld centreline at an angle sufficient to separate the images of the source side and film side welds. There shall be no overlap of the two zone interpreted. A minimum of two exposures 90º to each other is required (see figure 5.9.2c) The weld may also be radiographed by superimposing the two welds, in which case there shall be a minimum of three exposures 60º to each other (see figure 5.9.2d). In each of these two techniques, the IQI shall be placed on the source side of the pipe.

IQI Film Source

3 IQI at 120 deg

One exposure (panaromic)

Note: Pipe diameter more than 14 in (350mm) Source

IQI

Film

Note: Whenever is practical, IQI shall always be placed on source side Fig 5.9.2a: Single Wall Single Image - Minimum Three Exposures


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Page 10 of 8

Note: Whenever is practical, IQI shall always be placed on source side. Fig 5.9.2b: Double Wall Exposure - Minimum Three Exposures Source

Source

Offset 7Dmin

IQI

Weld D

Film

Fig 5.9.2c: Double Wall Double Image (Elliptical Image)

Weld


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IQI

7D min

Centreline Axis of weld

Source

Source

Weld

D

Film

Fig 5.9.2d – Double Wall Double Image (SUPER IMPOSE) 5.10

Quality of Radiographs All radiographs shall be free from mechanical, chemical 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. Such blemishes include, but are not limited to: a) Fogging; b) Processing defects such as streaks, watermarks, or chemical stains; c) Scratches, finger marks, crimps, dirtiness, static marks, smudges or tears; d) False indications due to defective screens, cassettes or internal faults (artifacts).

5.11

Location Markers The image of the location markers for the coordination of the part with the film shall appear on the film without interfering with the interpretation, with such an arrangement that it is evident that complete coverage was obtained. These marker positions shall be marked on the part at 1” (25.4mm) form the edge of the film and its position shall be maintained on the part during radiography. Suggested location of markers for the various techniques are shown in Attachment II


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Page 12 of 8 5.12

Radiograph Identification. 5.12.1

Each Radiograph must be properly identified for permanent correlation between the part being radiographed and the film. The minimum identification shall include the following: a) b) c) d) e) f) g)

5.13

Contract No./Project name Component Weld or part no. Contractor name Date radiograph Welder ID Repair (R1, R2)

Density The transmitted film density through the radiographic image of the body of the required IQI 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 gamma-ray source. For composite viewing of double film exposure, the minimum density shall be 2.6. Each radiograph of a composite set shall have a minimum density of 1.3. The maximum density shall be 4.0 for either single or composite viewing. A calibrated densitometer or step wedge film comparison shall be used for judging film density with a max tolerance of 0.05.

5.14

Image Quality Indicator (IQI) IQI or Image Quality Indicator of ASTM wire-tyres shall be used for determination of radiographic film sensitivity. 5.14.1

Placement of Penetrameter (IQI) The penetrameter shall be placed on the source side at the part being examined except where in accessibility prevent to hand placing the penetrameter on the source side. When the part being examined is not accessible, the penetrameter shall be placed on the film side in contrast with part being examined. A lead letter ‘F’ shall be place adjacent for or on penetrameter. The penetrameter of wire type should be placed on the weld so that length of the wire is perpendicular to the length of the weld.

5.14.2

Number of Penetrameter For component where one (1) film holder is used for an exposure which the length of interest is 9” (225mm) or less, one (1) penetrameter shall be used and to be placed at the centre on the length radiograph. (see fig 5.9.1a).


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Page 13 of 8

For component where one (1) or more film holder is used for each exposure which the length of interest is more than 9” (225mm), two (2) penetrameters shall be used. The penetrameter shall be placed at the end of radiograph, see figure 13.1b (i.e 25mm from end or section marking which the thinnest wire facing outwards). The tubular component where the source is placed on the exist of the object and are used for a single exposure (panaromic) of a complete circumference at least three (3) penetrameter shall be placed approximately 120 degree apart. 6 WIRES EQUALLY SPACED

ASTM FOR SETS A & B, THE MINIMUM DISTANCE BETWEEN THE AXIS OF WIRES IS NOT LESS THAN 3 TIMES THE WIRE DIAMETER AND NOT MORE THAN 5MM (0.2IN.) FOR SETS C & D, THE MINIMUM DISTANCE BETWEEN THE AXIS OF WIRES IS NOT LESS THAN 3 TIMES THE WIRE DIAMETER AND NOT MORE THAN 19MM (0.75

Minimum 25mm (1in.) for sets A & B. Minimum 51mm (2 in.) for sets C & D.

5mm

1 A

O 1

MATERIAL GRADE NUMBER LARGEST WIRE NUMBER SET IDENTIFICATION LETTER


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Page 14 of 8 Wire diameter In (mm) Set A

Set B

0.0032 (0.08) 0.004 (0.1) 0.005 (0.13) 0.0063 (0.16) 0.008 (0.2) 0.010 (0.25)

Set C

0.010 (0.25) 0.013 (0.33) 0.016 (0.4) 0.020 (0.51) 0.025 (0.64) 0.032 (0.81)

0.032 ( 0.81) 0.040 (1.02) 0.050 (1.27) 0.063 (1.6) 0.080 (2.03) 0.100 (2.5)

Set D

0.10 (2.5) 0.126 (3.2) 0.160 (4.06) 0.20 (5.1) 0.25 (6.4) 0.32( 8)

T- 233.2: Image Quality Indicator (wire penetrameter) sizes

Nominal Material Thickness Range, in Up to 0.25 incl Over 0.25 to 0.375 Over 0.375 to 0.625

Over 0.50 to 0.75 Over 0.75 to 1.50 Over 1.50 to 2.00 Over 2.00 to 2.50 Over 2.50 to 4.00 Over 4.00 to 6.00 Over 6.00 to 8.00

Nominal Material Thickness Range, mm Up to 6 incl Over 6 to 10 Over 10 to 16 Over 16 to 20 Over 20 to 38 Over 38 to 50 Over 50 to 65 Over 65 to 100 Over 100 to 150 Over 150 to 200

Source Side Maximum Wire Diameter in mm 0.010 0.013 0.016 0.020 0.025 0.032 0.040 0.050 0.063 0.100

0.25 0.33 0.41 0.51 0.63 0.81 1.02 1.27 1.60 2.54

Film Side Maximum Wire Diameter in mm 0.008 0.010 0.013 0.016 0.020 0.025 0.032 0.040 0.050 0.063

0.20 0.25 0.33 0.41 0.51 0.63 0.81 1.02 1.27 1.60

Notes : 1. Single-wall radiographics thickness (for tubulars) 2. Applicable to tubular structures only. WS D1.1 Table 6.5: Wire IQI Requirements

5.15

Sensitivity The radiographic sensitivity shall be judged base on wire image quality indicators (IQI). Proper radiographic technique and equipment employed shall provide sufficient sensitivity to be achieved. Table 6.5 AWS D1.1 above provide guide to achieve the required sensitivity.


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Page 15 of 8 For double-wall exposures and double viewing technique, the diameter of wires employed shall be based on the nominal double-wall thickness of the specimen including weld reinforcement. For double-wall exposure and single–wall viewing technique, the diameter of the wire shall be based on the nominal single-wall thickness of the specimen including reinforcement. Steel backing strip shall not be considered of the weld or weld reinforcement for sensitivity determination. 5.16

Back-Scatter Radiations Back-scatter radiations results in the scattering of radiation from walls, grounds or obstructions which might affect film appearance. The adequacy of protection from back scattering shall be checked with lead letter ‘B’ of size ½” height and 1/16” thick being attached at the back of film holder. If a light image of letter ”B” appears on a darker background of the radiograph, the radiograph shall be rejected due to insufficient protection of back scatter.

5.17

Film Processing Processing of film shall be done in air-conditioned dark-room with normal processing. Dilution or mixture of chemicals shall be in accordance to manufacturer’s recommendation. 5.17.1

Preparation Exposed film shall be unloaded in a suitable darkroom with filtered illumination (safe light) onto film holders or hangers. Temperature of processing chemical should be within 20 ~ 25 °C or as per manufacturer’s recommendation.

5.17.2

Developer •

Developers Agfa G 150 are used by dilution in water accordance to the mixing instruction (for new solution) as follows : 5 litres Agfa G 150 (16.7%) + 25 litres Water (83.3%) Developers Solutions

•

The solutions must be thoroughly stirred with a paddle or plunger type agitator to make sure that they are mixed thoroughly.

•

For old solution, checked the solution levels and ensure that the solutions completely cover the film and replenisher added to the proper solution, if needed.


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Page 16 of 8

•

Replenisher mixer shall be in accordance as follows: 5 litres Agfa G 150 (25%) + 15 litres Water (75%) Replenisher

•

Measure the temperature of the developer solution. Take the reading after the thermometer is immersed in the developer for 2 minutes.

•

Determined the development time in accordance to the table 5.16.2.

Table 5.16.2 - Temperature vs Time (Agfa G150 Solutions) Temperature Degree C Development Time (Mins)

18

19

20

21

22

23

24

25

26

27

28

6.0

5.5

5.0

4.5

4.0

3.75

3.5

3.25

3.0

2.75

2.5

•

5.17.3

Immerse film completely in developer solution and simultaneously start the timer. The film shall be continuous agitated for the first 30 seconds. Then for every 1 minute agitates the film 5 second until the development time is completed.

Stop Bath or Rinse After the development is completed, the film should be immersed in the stop-bath acid or by rinsing with vigorous agitation in clear water to discontinue the activity of the developer that remained in the emulsion for at least 30 seconds.

5.17.4

Fixing •

Fixer Agfa G354 are used by dilution in water accordance to the mixing instruction as follows

Step 1 5 litres Agfa G 354 (20%) + 15 litres Water (60%) Solution A Step 2 5 litres water (20%) + Solution A

Fixer Solution


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•

5.17.5

Fixing shall be done for at least twice the clearing time but not more than 15 minutes in fixer solution. The film shall completely immersed and agitate vigorously at the beginning of fixing step about 10 seconds and at least a two minute intervals afterward to assure uniform action of the chemicals on the film emulsion.

Washing The films shall be immersed in clean water and rinsed for at least 10 minutes to ensure complete removal of the fixer that may remain in the emulsion. The films may de dip in wetting agent for approximately 30 seconds to facilitate quick and even dry.

5.17.6

Drying The film may be hung in the dark room and dry at room temperature or in dry oven for quick drying. Drying temperature must not exceed 55 °C.

5.18

Storage of Films 5.18.1

Unexposed films will be stored in an air-conditioned room and will also be protected form the effects of light, pressure, excessive heat, humidity, damaging vapours or penetrating radiation.

5.18.2

All RT films, after interpretation/reviewed one duplicate RT report shall be wrapped on the RT films and keep in the original RT film boxes.

5.18.3

The Project Number, RT report Number and discipline (Structural/Piping) shall be written on the RT films box for easy retrieval and traceability.


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Page 18 of 8 5.19

Interpretation of Radiograph 5.19.1 Interpretation film shall be used intensity illuminator (viewer). The viewer shall have sufficient capacity to illuminate radiograph with H&D density if 4.0. Film view shall be done in darkroom (subdued light area) 5.19.2 All radiographs shall be examined and interpreted by qualified personnel and approved by client. The interpreter shall be qualified and certified to CSWIP 3.4 /PCN Level II radiographer interpreter. 5.19.3 The interpreter shall have at least two (2) years experience in interpretation of industry radiograph.

5.20

Acceptance Criteria Limitation of imperfections shall be evaluated as in the following codes and standards which are applicable in contract specification/client’s acceptance criteria as applicable: AWS D1.1:

6.12.1

6.12.2

Acceptance Criteria for statically Loaded Non Tubular and Statically or Cyclically Loaded Tubular Connections. Acceptance Criteria for Cyclically Loaded Non Tubular Structure

All parties should follow the above acceptance criteria on the interpretation and evaluation of radiographs.

5.21

Qualifications of Personnel 5.21.1

All NDT personnel performing Radiographic Testing shall be qualified and certified in accordance with NDT Sub –Contractor Written Practice and ASNT-TC-1A or equivalent. The task and responsibility for each certified level as follows: NDT Practitioner Level 1 – He shall perform Radiography testing with under supervision of Level II only. NDT Practitioner Level II - He shall responsible to perform Radiography Testing, supervise and guidance NDT Level I personnel.

5.21.2

Personnel’s utilizing radiographic equipments shall be qualified NDT Level II and practice all safety requirements laid down by the company in accordance to Act 304, Atomic Energy


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Page 19 of 8 Licensing Board. All personnel involved in radiographic work shall be registered with AELB. Level III to provide refreshment course for the personnel prior commence of the project. 5.22

5.23

Radiographs Viewing Facilities 5.22.1

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 light source sufficient for the essential designated sensitivity to be visible for the specified density range. The equipment illumination shall be capable to provide even lighting intensity over the viewing area for density up to 4.0.

5.22.2

Sufficient time shall be allowed for the interpreter’s eyes to become adapted to the lighting condition, and he shall also have his eyes tested for ability to observe the smallest details at normal film viewing distance.

Reports 5.23.1

All reports shall be prepared and completed by the interpreter and also be counter-signed by authorized representatives.

5.23.2

The report format used shall be as enclosed.


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Page 20 of 8 6.0

SPECIAL REQUIREMENTS 6.1

7.0

Prior to any radiography work, a PTW shall be obtained from the Kencana HL Safety Department.

RECORDS 7.1

All radiography test reports shall be prepared and completed by the interpreter and submitted together with the film for review within 24 hours after completion of radiography.

7.2

The records of all objects radiographed including those of rejected welds, repairs and reshoots shall be properly catalogued and filed for easy retrieval during and after construction.


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Page 21 of 8 Attachment I – Radiographic Testing Report Format


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Page 22 of 8

ATTACHMENT 2 : LOCATION OF MARKERS

291081799-RT.pdf

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