Document No: RUSL-PADMA-2016-06

Employer: Gas Transmission Company Limited

(GTCL)

Contractor: China Petroleum Pipeline Bureau

(CPP)
Sub-Contractor: The Royal Utilisation Services

(Pvt.) Ltd. (RUSL)

Radiographic Test Procedure
for

Construction of 30 OD High Pressure Natural Gas Pipeline by

Horizontal Directional Drilling (HDD) method across the PADMA
River under Hatikumrul Bheramara Gas Transmission Pipeline
Project on Design, Installation, Testing, Tie-in & Commissioning
basis

Submitted by:
THE ROYAL UTILISATION SERVICES (PVT.)
LTD.

CONTENTS
1.0

Scope.........................................................................................................................2

2.0 General.........................................................................................................................2
4.0 Image Quality Indicators............................................................................................5

5.0 Radiographic Film......................................................................................................6

6.0 Radiographic Makings...............................................................................................7
7.0 Radiographic Makings...............................................................................................7
8.0 Diagnostic Film Length..............................................................................................7
9.0 Film Processing..........................................................................................................8
10.0 Personnel Qualification...........................................................................................8
11.0 Acceptance Criteria for Welds.................................................................................9
12.0 Test of Rework or Replacement Material.............................................................10
13.0 Reports....................................................................................................................10
14.0 Records....................................................................................................................11
15.0 Radiation Safety......................................................................................................11
APPENDIX-A.....................................................................................................................12

1.1 Scope
1.2 This procedure provides methods, equipment, materials and acceptance
standards for the radiographic examination of weldments of Installation of 30 OD High
Pressure Natural Gas pipeline by Horizontal Directional Drilling (HDD) Method across
the Padma River on Design, Supply, Installation and commissioning on Turnkey Basis
Contract NO. 28.14.0000.165.038.03.15.2948 DATE: 12-01-2016 of CPP. It conforms to
the requirements of ASME Section V, ANSI B31.1 thru B31.7 and API1104.Qualified
personnel shall perform examination.
1.3

This procedure will be utilized to examine steel, copper alloys, high nickel
alloys of 15.9mm or above of martial thickness.

1.3

Alternative specifications to the above may be used when so requested by the customer. If
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alternative specifications are used, the radiographic procedure will be performed in

accordance with that specification.

2.0 General
2.1

Radiographic examination provides for the detection of cracks, voids, porosity, inclusions,
inadequate penetration and lack of fusion beneath the surface of a weld.

2.2

The number of areas or parts to be radio graphed shall be specified by contract and
related drawings

2.3

Quality level for radiographic test shall be at least 2% unless the client agrees upon a
higher or lower quality.

2.4

Radio graphing double walled parts such as piping, ducts, with a radiation source outside
the pipe, the pentameter/IQI shall be placed where practicable, on the outside of the
pipe nearest the source of radiation, however where the placement of IQI on the
source side is impracticable, a IQI will be placed on the film side and a lead letter F
shall be placed adjacent to the IQI.

2.5

Radiographic personnel shall be certified in accordance with section X of this procedure.

2.6

Radiographic personnel performing radiography will comply with local

Radiation Safety Regulations.

2.7

Radiation sources will be radioactive isotopes for repair, Ti-in and WQT, X-ray machine
will be used for main pipe line welding.

2.8

Complete records of technique details for each pipe size shall be approved by client and
maintained by MIX as permanent record for use on production radiographs.

3.0 Inspection Requirement

3.1

Condition of Material: As per API 5L X60(PSL-2)

3.1.1 Irregularities the area to be examined shall be free of any of irregularities, which could
interfere with interpretation. Weld ripples; edges, or weld surface irregularities are
allowable to the extend that, they do not mask defective areas or interfere with the
radiographic interpretation; weld edge will be blend smoothly into the base flush with the
base metal or may have a reasonably uniform crown not to exceed the following
thickness:
Thickness of Base Metal
Up to 12.5mm
Over 12.5to 25.4mm
3.2

Thickness of Reinforcement
1.58mm
2.38mm

Radiographic Technique Qualification

Radiographic supervisor/NDT Engineer shall qualify each technique by submitting to the
clients engineer a production radiograph or technique shot to demonstrate their ability to
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meet the sensitivity and film quality levels for each technique.
3.3

Film and Image Quality Indicator (I.Q.I)

Film density through acceptable weld metal shall be 2.0 minimum for a single viewing and
2.6 minimum for composite viewing of double film exposures, each film shall be 3.0
densitometer shall be calibrated using certified step wedge calibration film weekly. The
IQI density shall not be greater than 15% more than the lightest film density of the area
of interest. When the thickness of different speeds as employed during technique
approval may be submitted for interpretation either as a single or super-imposed film,
which is better suited for interpretation of any area covered by the exposure. An
additional I.Q.I will be required for the area or areas when density varies more than
minus 15% or plus 30% from the density through the I.Q.I

3.4

Film Quality

3.5

Radiographs presents for interpretation shall be free blemishes of film defects that might
mask or be confused with defects in the material being examined. If doubt exists
concerning the true nature of an indication in the film, the radiograph shall be rejected.
Typical blemishes are as follows: Fogging, mechanical processing defects, pressure or
lead marks, scratches, gouges and crimp marks.
Darkroom Facility
Darkroom facilities shall be capable of producing uniform, blemish free, radiographic
negatives. Film viewer, densitometer, transparent scale, magnifying glass will be
provided to clients dark room.

3.6

Film Viewing Facility

Viewing facility shall be so constructed as to afford the exclusion of objectionable
background lighting of an intensity that may cause reflection on the film.

3.6

Viewing Light
A viewing light will be provided such intensity and be suitably controlled to allow the
selection of optimum intensities for viewing film. The viewing light will be cooled to the
extend that film emulsion will not be damaged during the viewing.

3.8

Radiation Source
Either X-Ray internal crawler contains a X-ray generator which will emit a Panoramic
beam of radiation, Max volt-200Kv, Max. Current-3mA,(Fig bellow)or Gamma Ray(IR192)Isotope will be used for carrying out main pipe line welds Tie-ins and repair.
Radiographic examination with Ir-192,curie strengths up to 100 curies will be used on
thickness of 6.3 to 63.5mm.Physical source size will be a maximum 3.13.1mm.

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3.9

Screen and Filters

Front and back lead foil intensifying screens with a minimum thickness of 0.10mm and
0.125mm respectively shall be used for low energy radiography. Complete contact
between screen and film shall be maintained. Screen shall be free from dents,
scratches, grease, dirt and other foreign material.

3.10 Back-Scatter
A back-scatter condition is not acceptable. To establish existence of back-scatter, affixed
to the back of each cassette shall be a lead letter B if this is visible on processed film,
a new exposure must be made with adequate lead shielding. A 3.17mm lead filter shall
be placed behind the film holder to prevent fogging of film by scattered radiation.

4.0

Image Quality Indicators

4.1

Requirements
Image Quality Indicator(I.Q.I)shall conforms the requirement of API 1104, i.e.; ASTM
E747(wire type).Selection of Particular IQI to be used shall be per API 1104 clause no.
11.1.6.1 to meet requirement of 15.9mm thick wall thickness of pipe.

4.2

Number
As per API 1104 clause no.11.1.6.1, when a complete weld is radio graphed in a single
exposure using a source inside the piping, at least four pentameters placed parallel to
the weld and spaced approximately equally around the circumference shall be used.

4.3

Configuration
IQI thickness shall be 2% of the subject material and shall be of radiographically similar
material to the object being examined.

4.4

Identification
Image Quality Indicator (IQI)s shall bear standard applicable identification as ASTM-1A,
ASTM-1B,DIN 10-16,DIN 6-12 etc.

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4.5

Placement of IQIs
The wire type IQIs shall be placed on the source side, across the weld so that the wires are
at the 90to the seam, with the thinnest wire away from the central beam of radiation
where in accessibility prevents placement IQIs on the source side, a film side IQI may
be used and a letter F shall be placed adjacent to the IQIs.
For multiple exposures for complete inspection of the world, and where the length of film to
be interpreted is greater than 5 in.(130mm), two pentameters placed parallel to the
weld and located on the film side shall be used. One shall be within 1 in (25mm) of the
end of the film length to be interpreted and the other shall be at the center of the film.
When the film length to be interpreted is 5 in. (130mm) or less, one pentameter shall be
placed on the film side, parallel to the weld is radiographed, at least one pentameter
shall be placed adjacent to each repaired area.

4.6

Alternative Placement
If the IQIs can not by physically placed on the component to be radiographed, then either
of two alternatives lists below are acceptable.

4.7

Separate Block
The I.Q.I may be placed on a separate block of a radio graphically similar, placed as closed
as possible to the area being radiographed. The film density of the block shall be within
plus or minus 10% of the film density in the area of interest of the radiographed being
examined.

4.8

Technique Exposure
Technique exposure will be provided upon request of the QA Manager. IQI type will be as
per ASME Section V code.

4.9

I.Q.I Sensitivity
Radiographic sensitivity shall be as per the requirement of ASME V. Calculation of
sensitivity for DWSI shall be based on the thickness of one wall
only, whereas calculation for DWDI shall based on the combined thickness of
both walls.

5.0

Radiographic Film

5.1

The film used conform to ASTM E94 classor.Depending upon application to obtain the
quality and sensitivity all film shall be dated and be utilized prior to the self-life expiry
date. Film types to use shall be limited to the following:
a)
b)
c)
d)

Agfa-Gevaert Structurix types D7

Indux-R7 industrial X-ray Film
Kodak Types AA-400
Fuji 100

Film size will be 70mm wide and approx.40 inch length for panoramic exposure.
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5.2

Identification and Marking of Films and Objects

Lead identification marker shall be placed on all sections being radiographed .Markers shall
be placed on the source side of the object being radiographed except as otherwise
approved by the quality Assurance Manager and placed in such a manner that all
overlapped to be placed on the film side, the technique shall be such that sufficient film
overlap is provided to ensure complete coverage of the full section thickness due to
angularity. There shall also be an identification on each film showing the contract
number, vendors name or symbol, date, seam, weld, or par number of the component
being radiographed. Letter R plus repair number shall identify repair.

6.0 Radiographic Makings

6.1

Component Permanent Marking

The location of identification markers shall be accurately made n each component tested,
by permanent marking on the base meta, adjacent to the weld but outside the heat
affected zone, by one of the following methods:
a. Electro-chemical etch
b. Vibro-tools
c. Interrupted dot-low stress stamps
d. Waterproof indelible crayon or dye markings

7.0 Radiographic Makings

7.1

Single wall Radiograph-Open en component

When the diameter of and access to the component is such that, the source of radiation
can be located inside, without deviating from good source to film distance and
sharpness practices, the cassettes shall be placed at the outer
surface of the pipe component.

7.2

Radiography without Access Hole

When no access hole is provided, nor otherwise available in a component, the source of
radiation shall be placed outside the component and the technique shall be in
conformance with the requirement for Double Wall radiography Single wall viewing.

7.3

Double Wall Radiograph-Components Less than three inch Diameter

Double wall exposures for double wall image viewing(DWDI) may be employed for
component diameters less than three inch, this technique will be used in which radiation
passed through two walls and the weld in both walls s viewed for acceptance in same
radiograph .For DWDI technique only a source side IQI shall be used, The radiation
beam offset from the place of the weld will be at an angle approximately of 30.When a
complete coverage is required two exposures will be taken at 90 to each other.

8.0 Diagnostic Film Length

8.1

The length of component under examination at each exposure shall be such that, the
thickness of the material penetrated at the extremities of the readable area, measured
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in the direction of the incident beam at that point, generally does not exceed by more
than 10%.The actual thickness where the beam is aligned normal to the part, with the
exception of DWDI technique.
8.2

Number of exposures

8.3

a) SWSI (Panoramic) Technique: One exposure with film overlap to be at least1

b) SWSI (Off-set) Technique: At least 3 equidistantly spaced exposures with minimum
overlap of coverage to be 1

8.4

Double Wall Single Image (DWSI) Techniques number of exposures will be

as follows:
a) For wall thickness schedules up to 100 a minimum 3 equidistantly spaced
requires, with minimum overlap of coverage in the diagnostic area to be 12.5mm.
b) For wall thickness schedule over 100 a minimum of 4 equidistantly
spaced exposures required, with minimum overlap of coverage in the diagnostic area to
be 12.5mm.
Double Wall Double Image (DWDI) Elliptical: minimum no of exposures
will be 2, at 90to each other.

8.5
8.6

Double Wall Double Image (DWDI) superimposed: Minimum number of exposures to be 3

at 60apart.

9.0 Film Processing

9.1

All exposed films shall be developed utilizing the rapid manual processing technique.
Developing time to be 4-5 minutes in a temperature range of 18-22 .
Film shall be agitated for 10 seconds each minute during development. This will help film
develop evenly.

9.2

Following Development, the activity of developer in emulsion shall be neutralized by an

acetic acid stop bath for maximum 1 minute agitation for first 10 seconds

9.3

Films will be fixed for at least twice the clearing time with an agitation for 10 seconds and
again at the end of first minute.

9.4

Washing will be for at least 10 minutes in running water.

9.5

Films shall be dipped in wetting agent for 1 minute.

9.6

Films shall be drained then hung and dried.

10.0 Personnel Qualification

10.1

Personnel performing and interpreting radiographic examinations shall be qualified in

accordance with ASNT-TC-1A or ISO standard

10.2

As a minimum all personnel conducting radiographic test shall be certified to Level-1

Radiographic test will be performed under supervision of level- or equivalently qualified

supervisor.
10.4 Interpretation of radiographs shall be carried out by Level- qualified personnel.
10.3

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10.5 All qualification certificates shall be current.

11.0 Acceptance Criteria for Welds

Radiographic films will be interpreted as per API-1104 and GTCL contract specification,
however where confusion may arise the following also be applied
11.1 Unacceptable Defects
Unless otherwise specified in materials specification or contractual documents, sections of
welds that are shown by Radiography to have any of the following types of defects are
unacceptable.
a. Any type of crack or zone of incomplete fusion or penetration.
b. Any elongated inclusion such as slag or tungsten, which has
c. Length greater than 6.3mm for t up to 19mm
1/3t for t from 19mm to 57mm
19mm for t over 57mm (where t is the thickness of the thinner part being welded)
11.2 Any group of inclusions in line that have an aggregate length greater than t in length of
1.2t, except when the distance between the successive imperfections exceeds 6L,
where L is the length of longest imperfection in the group.
11.3 Porosity in excess of that shown acceptable by the porosity standard given ASME Section
(Division 1).
11.4 Weld conditions Generally Unacceptable
a. Crater pits
b. Ark Strikes
c. Weld Splatter
d. Surface marking resulting from mishandling center punching
e. Incomplete insert melting
f. Burn-through
11.5
11.6

Acceptance Criteria employed for evaluation of welds in progress piping shall be as per
Table 341.3.2 of ASME B31.3 Normal fluid condition or severe cyclic condition depends
on operating condition
Acceptance Criteria employed for evaluation of welds as per ASME Sec Division-1
shall be as follows:
a. 100% Radiography-UW51
b. Spot Radiography-UW52

11.7

Acceptance Criteria employed for evaluation of welds of Steel structure shall be as

follows:
a. AWS D1.1.2004

11.8 Acceptance Criteria employed for evaluation of welds of Gas pipe line shall be as follow:
a. API 1104

12.0 Test of Rework or Replacement Material

12.1

Materials that are shown by the radiographic method of examination to be rejected and
subsequent rework or replacement shall be done again subject to the same approved
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radiographic testing in order to meet the acceptance requirements. A minimum amount

of overlap of 50mm beyond the repair edges shall be used.
12.2 Repairs
Unacceptable defects may, upon approval of clients authorized representative, be
repaired provided:
a. The minimum remaining wall thickness is not reduced below the minimum value
required by specification.
b. After the defect is removed and prior to making repairs, the area shall be reexamined and if no welding is required, the depression is blended into the surrounding
surface to avoid sharp notches, crevices or corners and should be to 4-1 taper.
c. After the area has been repaired and in the final heat treat conditions, the area shall
be re-examined by radiography and by all other NDT methods of examination that were
originally to detect the defect.

13.0 Reports
13.1 Written reports of all radiographic examinations shall include ,but not limited to the
following items:
a. Identification of parts, materials or area, wall thickness, diameter
b. The Radiographic Job number
c. The findings and disposition
d. Name of the radiographer
e. Name of the interpreter
f. Types of Radiation Source
g. Pentameter/IQI Type
h. Film Density
i. Film type
j. Technique used
Preliminary interpretation will be done by BIX and report will be handed over to cline for
final interpretation.
13.2 Report Form Enclosed as Appendix-A

14.0 Records
Radiographic reports shall be preserved and held for minimum, period of three years after
completion of the job. After films will be preserved of suitable atmosphere and handed
over to the cline after completion of the work.

15.0 Radiation Safety

Safety & Security
a. All technicians shall wear a TLD and a pocket dosimeter during radiation work
b. They should have a calibrated radiation survey meter.
c. The area where the radiation work is being performed shall be cordoned off to prevent
unauthorized entry.
d. After complete of work isotope should be kept at storage pit under lock & key
e. Collimator will be used specially where Radiography will be undertaken by gamma Ray.
f. All regulations and specifications approved by Bangladesh Atomic Energy commission
will be followed.

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