HCC-DSD-VNR Consortium Management System

RADIOGRAPHIC TESTING PROCEDURE

HCC P 097 17 03

Table of Contents

Sl.
Description Page No.
No.

1 Purpose 4
2 Scope 4
3 Cross Reference 4
4 General requirements 4
5 Responsibility 4
6 Principle of operation 4
7 Equipment 5
8 Weld surface preparation 6
9 Radiographic technique 6
10 Identification of radiographs 6
11 Location of markers 6
12 Film processing 7
13 Film density 7
14 Interpretation 7
15 Radiographs viewing facilities 7
16 Safety 7
17 Radiograph quality requirements 8
18 Test report 8

Revision No.: 0, Revision date: 31.10.12 Page 2 of 9

 HCC-DSD-VNR Consortium Management System
RADIOGRAPHIC TESTING PROCEDURE
HCC P 097 17 03

History of Revisions

Revision Chapter/clause
Revision
issue date no. & text Reason for revision
No.
affected

0 31.10.12 - First Issue

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 HCC-DSD-VNR Consortium Management System
RADIOGRAPHIC TESTING PROCEDURE
HCC P 097 17 03

1.0 PURPOSE

Investigation of butt welded joints through gamma rays isotopic radiation.

2.0 SCOPE

The scope is limited to Bogibeel Rail-Cum-Road Bridge Project and covers the radiographic
examination of butt welds for carbon steel plates in a thickness range of 10mm to 63mm.

3.0 CROSS REFERENCES

• Contract Agreement no.: CON/Bogibeel-Super-str./180 dated 28.02.2012;

• BS EN ISO 1090-2: Execution of steel structures and aluminum structure
• EN 1435/1997 + A1, 2002 and ISO 17636, 2003.
• EN 473, Non-destructive testing - Qualification & certification of personnel – General
Principles.
• ISO 17635, Non-destructive of welds – general rules for fusion welds in metallic materials.

• ISO 5817, Welding – Fusion welded joints in steel – Quality levels of imperfections.

4.0 GENERAL REQUIREMENTS

Radiographic testing of welded joints will be performed by personnel qualified as `Certified

Radiographer’ by BARC in presence of `Site-In-Charge’, who is passed IRG-1 or RT-II course
from BARC, Mumbai, and the competent authority in this regard. The Radiographs should be
interpreted by the Site-In-Charge / Sr. Radiographer (ASNT – II)

4.1 RESPONSIBILITY

Approved third party NDT agency for execution & reporting.

Manager / Engineer – Quality Assurance for supervising.

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 HCC-DSD-VNR Consortium Management System
RADIOGRAPHIC TESTING PROCEDURE
HCC P 097 17 03

4.2 Principle of Operation

This method includes the use of isotopic gamma radiation generally Iridium 192 which
penetrates the welded joint or the part to be tested. This method indicates defect by virtue of
difference in densities of normal area and defective area. This is recorded in the form of an
image which is developed in dark room to get a permanent record known as radiograph.

4.3 Equipment

a) Radiation Sources: Gamma Ray Source (Ir-192) loaded in remote operated Camera.

b) Films

The films confirm with class 1 of EN – 1435: 1997 + A1: 2002 - Standards practice for
Radiography Testing.

(KODAK – AA 400 OR EQUIVALENT)

c) Screens

Generally intensifying lead screens will be used. Screens will be free from surface streaks of
lower atomic number materials and from wrinkles, dirt grease, lint and scratches. Screens
showing evidence of physical damage will be discarded.

Screens will be in close contact with both sides of the film (front screen has a thickness of 0.1
mm to 0.15 mm and back screen 0.2 mm enclosed in light proof cassettes.

d) Image Quality Indicators

To determine Radiography quality level, image, Quality Indicators (Penetrameter) will be used.
Penetrameter of DIN-62-FE 10-1SO-16 (Wire) type will be used.

6 –ISO-12, 10-ISO-16 and 1- ISO – 7.The Penetrameter will be placed on the source side

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 HCC-DSD-VNR Consortium Management System
RADIOGRAPHIC TESTING PROCEDURE
HCC P 097 17 03

e) Calculation of sensitivity :
For calculation of sensitivity of penetrameter the diameter of visible wire is divided by material
thickness. Following table shows the values of wire diameters.

PENETRAMETER WIRE DIAMETER mm

1-ISO-7 3.2 2.5 2.0 1.6 1.25 1.0 0.8

6-ISO-12 1.0 0.8 0.62 0.5 0.4 0.32 0.25

10-ISO-16 0.40 0.32 0.25 0.20 0.16 0.125 0.10

Sensitivity Requirements: Sensitivity of 2.5 % (approx.) will be maintained.

Placement of Penetrameter

The penetrameter (wire type) will be placed across the weld so that the plane of the
penetrameter is normal to be radiation beam.

5.0 Weld Surface Condition

The weld ripples or weld surface irregularities on both the inside and outside where accessible
shall be removed by any suitable mechanical process to such a degree that the resulting
radiographic image due to any irregularities and not mask or confused with the image of any
discontinuity.

5.1 Radiographic Technique

Following techniques shall be used:

Technique : Single wall single image.

SFD : Calculated Value as per Dimension

Type of Film : Class I (KODAK – AA 400 or EQUIVALENT)

Penetrameter : Source Side Placement

Location Marker : Film Side

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 HCC-DSD-VNR Consortium Management System
RADIOGRAPHIC TESTING PROCEDURE
HCC P 097 17 03

5.2 Identification of Radiographs

A radiograph identification mark and two locations identification marks will be placed on the
parent metal at each radiograph location. A corresponding radiograph, identification mark and
location mark and two location identification marks, all of which will show in the radiograph,
will be produced by placing lead numbers and/or letters over each of the identical identification
and location marks made on the parent metal to provide a means for matching the developed
radiograph to the weld.

5.3 Location Markers:

The start position shall be marked in such a manner permitting the area of interest on the
radiograph to be accurately located. Location Markers which are to appear as radiographic
images on film will be placed on part and not on the exposure holder. Cassette and their
locations will be marked on the surface of the part being radio graphed. It also provides
evidence on the radiograph that the required coverage of the region being examined has been
obtained. All location markers will be made of lead letters or nos. Joint will be marked by
crayon, painting, etching etc. for future identification.

6.0 Film Processing

All films shall be processed in accordance with part – Clause No. 6.9 of EN – 1435: 1997 +
A1: 2002
There are five main stages in film processing

a) Development - Creation of visible image (developing time is 5 min. at 20° C)

b) Stop – bath - To stop developer action (Usually 30 Sec. In 2 % acetic acid).
or Rinse
c) Fixing - Removal of unexposed emulsion (usually 8-10 min.)
d) Washing - Removal of unwanted excess fixer solution (usually 15 min. in
running water)
e) Drying - Removal of unwanted water.

Film should be continuously stirred in developer and fixer solution for at least 1-2 minutes in
the beginning.

7.0 Film Density

Process film density shall be within 2 to 3 H & D.

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 HCC-DSD-VNR Consortium Management System
RADIOGRAPHIC TESTING PROCEDURE
HCC P 097 17 03

8.0 Interpretation

Interpretation and assessment of radiograph will be always carried out with the aid of
specification and standard reference radiographs by ASNT/ISNT Level-2 / Sr. Radiographer.

9.0 Radiographs Viewing Facilities

Viewing facilities is constructed as to provide sufficient lighting and exclude background lighting
of an intensity that may cause reflection of the radiographic film. Equipment used to view films
for radiographic interpretation shall provide a high intensity light source such that the specified
quality level shall be readily visible for the specified density range. The extraneous light from the
illuminator shall be masked. Densitometers or comparison step wedge films shall be provided
for assuring compliance with film density requirements.

10.0 Safety

In Field

There will be one radiation monitoring equipment (Survey meter) to measure the radiation
hazard and CV Tong, Lead Sheets, Lead Pot for accidental measures.

With Radiation Worker

Everyone directly or indirectly involved in radiography job at radiation hazard area will use TLD
badges and the person, who will operate the camera, will use the pocket dosimeter for personal
monitoring.

For Non- Radiation workers/ General Public

Certain area around the source will be cordoned off using ropes and radiation warning symbol
(“RADIATION DANGER – KEEP AWAY” in English as well as in local language) would be
posted around the cordon. The radiation level outside the cordoned area will be monitored and
within the dose limit for non-radiation workers.

11.0 Radiograph quality Requirements

All radiographs shall be free from mechanical, chemical or other blemishes to the extent that
they cannot mask or be confused with the image of any discontinuity in the area or interest of
the object being radio graphed. Such blemishes include but are not limited to:

a) Fogging
b) Processing defects such as streaks, water marks or chemical stains.
c) Scratches, finger marks, crimps, dirtiness, static marks or tears.
d) Loss of detail due to poor screen to film contact.

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 HCC-DSD-VNR Consortium Management System
RADIOGRAPHIC TESTING PROCEDURE
HCC P 097 17 03

e) False indications due to defective screens or internal faults.

12.0 Test Report

The test report will be used as per the format for RT HCC F 097 14 36 Rev.0 dated 26-10-12.

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 HCC-DSD-VNR Consortium Management System
BOGIBEEL RAIL-CUM-ROAD BRIDGE
BOGIBEEL, ASSAM
RADIOGRAPHIC TEST REPORT
PROJECT : CONSTRUCTION OF SUPER STRUCTURE FOR BOGIBEEL RAIL-CUM-ROAD BRIDGE
CONTRACTOR: HCC-DSD-VNR CONSORTIUM Report No. :
CLIENT : NF RAILWAY Date :
Film Type: AGFA D-7 / KODAK / OTHER Film Density :
Radiographic Technique: SWSI / DWSI / DWDI Source strength:
SFD (Inch): Acceptance Standard :
Penetrameter: Wire type/ Hole Type Sensitivity :
Location of penetrameter (Source side / Film side):
Location of Markers (Source side / Film side):
Source Isotope: Gamma Ray Ir 192
Quality Level: EN ISO 5817, Quality level B for Butt Welds
Reference Doc.: EN ISO 17635
Acceptance Level: ISO 10675-1 or 10675-2

Sr. Welding completion Type of

Drawing No. Joint No. Welder No. Results Remarks
No. date & time Weld & joint

Inspection parties PERFORMER HCC-DSD-VNR TPI AGENCY (IRS) NF RAILWAY

Signature
Name
Date
Format No. HCC F 097 14 36, Revision No. 0, Revision Date: 26.10.12 Page 1 of 1