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PROCEDURE FOR
RADIOGRAPHIC TESTING OF WELDS IN
STRUCTURAL STEEL FABRICATION

as per

AWS D1.1

REV. NO. DATE APPROVED BY : APPROVED BY : APPROVED BY :

LEVEL III
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PROCEDURE FOR RADIOGRAPHIC TESTING

OF WELDS IN STRUCTURAL STEEL FABRICATION
(AWS D1.1)

TABLE OF CONTENTS

Description Page No.

1.0 Scope 4 of 35

2.0 Reference 4 of 35

3.0 Definition 4 of 35

4.0 Personnel Qualification 5 of 35

5.0 Radiographic Equipment 6 of 35

6.0 Preparation 6 of 35

7.0 Location of Datum 6 of 35

8.0 Cassettes 7 of 35

9.0 Film 7 of 35

10.0 Screens 8 of 35

11.0 Geometric Relationship 8 of 35

12.0 Image Quality Indicator 9 of 35

13.0 Sensitivity 11 of 35

14.0 Film Density 11 of 35

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TABLE OF CONTENTS CONT’D

Description Page No.

15.0 Scattered Radiation 11 of 35

16.0 Radiographic Procedure 12 of 35

17.0 Film Processing 14 of 35

18.0 Film Identification 14 of 35

19.0 Viewing Conditions 14 of 35

20.0 Interpretation of Radiographs 15 of 35

21.0 Radiographic Reports 15 of 35

22.0 Safety 15 of 35
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1.0 SCOPE

This procedure describes the radiographic method to be employed by the company

for the Radiographic Inspection of butt welds in accordance with AWS D1.1.

2.0 REFERENCES

AWS D1.1 Section 6

DIN 54109 - Wire Type Image Quality Indicators

3.0 DEFINITION

a. Client Company or organization for whom Global

Inspection Services performing the work.

ASNT The American Society for Non Destructive

Testing

PCN Personnel Certification for Non Destructive Testing

CSWIP Certification Scheme for Weld Inspection Personnel

IQI Image Quality Indicator

3.0 PERSONNEL QUALIFICATION

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Radiographic Inspection work shall be carried out by at least one Radiographer

and one Assistant Radiographer. Each technician shall be required to hold the
following:-

a) Radiographer A valid LPTA Radiographic Operator

License
and a current Certificate of Proficiency in
Radiography Level II to a recognized
qualification and certification scheme.

b) Assistant Radiographer Registration with LPTA as a Radiation

Worker and a current Certificate of Proficiency in
Radiography Level I or Level II to a
recognized qualification and certification
scheme.

c) Radiographic Interpreter A current Certificate of Proficiency in

Radiography Level II, Level III or Radiographic
Interpreter to a recognized qualification and
certification scheme.

The following recognized qualification and certification schemes may be used for
the purpose of qualification and certification of personnel:-

a. ASNT (in accordance with the company’s Written Practice).

PCN / CSWIP

5.0 RADIOGRAPHIC EQUIPMENT

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For Gamma Ray work, Tech Ops 660 or equivalent containers and remote control
windout will be used.

6.0 PREPARATION

Radiographic Inspection shall only be carried out on weldment which has visually
inspected and any remedial work necessary is completed and accepted by the
cistomer. In addition, the Radiographer inspects the weld surface for any
irregularities that may mask or confuse interpretation of the final radiograph.

7.0 LOCATION OF DATUM

All weld will be positively marked datum and each portion under examination
shall be positively identified by marking along the length of the weld.

This may be achieved by taking measurements along the length of the weld from
an agreed datum. For tubular structure, the ‘clock face’ method shall be employed
and the datum line shall be positioned, as follows:-

a) For horizontal and inclined tubular structure, the datum is the

highest point in the joint when viewed from the lower numbered
joint.

b) For vertical tubular structure, the datum is north when the joint is
viewed vertically downwards.

In all cases the datum shall be indelibly marked on the welds. A meter band
incorporating lead numerals along the welds shall be utilized to allow positive
location of any discontinuity.

8.0 CASSETTES
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Flexible envelope cassettes shall be used unless specifically stated otherwise.

Ensure close film to screen and cassette to object contract.

The use of pre-pack film with integral metal screens may be used with written
agreement from the Client.

9.0 FILM

9.1 Type of Film

Radiographs shall be made using industrial radiographic film and shall be

selected from Table 1 below.

Table 1 : Selection of Radiographic Film

Class of Film Brand Type

I Dupond NDT 55
(high sensitive film) Agfa D4
Kodak MX
II Dupond NDT 70
(sensitive film) Agfa D7
Kodak CX

Films shall have sufficient length and shall be placed to produce at least
13mm of film exposed to direct radiation beyond each free edge where the
weld is terminated.

9.2 Overlap

If more than one films is required in single exposure, overlapping cassettes

shall be used. Radiographs shall have 25mm overlap at each end to ensure
that no portion of the joint remains unexamined. There shall be a specific
lead marker visible on both radiographs in the area of overlap.

10.0 SCREENS
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Lead intensifying screens shall be used. The front screen thickness shall normally
be 0.125mm and the rear will normally be 0.125mm.

Screen shall be examined on a regular basis for dirt or blemishes which may
transfer onto the film thus causing confusion with and masking of defect images.

11.0 GEOMETRIC RELATIONSHIPS

11.1 The geometric unsharpness is calculated as folows:-

Geometric unsharpness, Ug = fxd

S-d

Where : f is the Focal Spot Size of Source Size

d is the Object-to-Film Distance
S is the Focal spot-to-Film Distance (X-ray) or source-to-
film distance (Gamma Ray).

11.2 Geometric Unsharpness of the radiograph shall not exceed the Ug value in
Table 2 below:-

Table 2 : Maximum Geometric Unsharpness

Material Thickness, mm Ug Maximum, mm

Under 50.8 0.51
50.8 through 76.2 0.76
50.9 Over 76.2 through 101.6 1.02
50.10 Greater than 101.6 1.78

Material thickness is the thickness on which the penetrameter is based. This

shall be the base metal or parent metal plus the maximum allowable
reinforcement. For welds at transition thickness, material thickness shall be
the thinner base metal.

12.0 IMAGE QUALITY INDICATORS

12.1 Selection of IQI

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The IQI provides a guide to the quality of radiographs produced and shall
be appropriately chosen from one of the types recommended in DIN 54109
(Table 3).

Table 3 : DIN 54109 Wire Type IQI Designation

Penetrameter Wire Number Wire Diameter, mm

Designation
1 3.200
2 2.500
3 2.000
1-7 4 1.600
5 1.250
6 1.000
7 0.800
6 1.000
7 0.800
8 0.6300
6 - 12 9 0.500
10 0.400
11 0.320
12 0.250
10 0.400
11 0.320
12 0.250
10 - 16 13 0.200
14 0.160
15 0.125
16 0.100

a) Source Side Penetrameter(s)

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

being examined, except in the condition described in 12.2b).

b) Film Side Penetrameter(s)

Where inaccessibility prevents hand placing the penetrameter(s) on

the source side it shall be placed on the film side in contact with the
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part being examined. A lead letter ‘F’ at least as high as the

penetrameter identification number(s) shall be placed adjascent to
the penetrameter(s).

Radiography shall be performed with a technique of sufficient sensitivity to

display the penetrameter image and the designated or smallest wire for
required sensitivity which are essential indications of the image quality of
the radiograph. The radiographs shall also display the identifying number
and letters.

12.2 Number of Penetrameters

IQI shall show clearly on each radiograph. For a radiograph represents

255mm or greater of weld length, two IQI shall be placed; one at each end
of the weld length. For radiograph represents less than 255mm of weld
length, one IQI shall be placed at any end of the weld length. IQI shall be
perpendicular to the joint with the smallest wire on the outer edge of the
area being radiographed.

Figure 1 and Figure 2 illustrate the arrangement of IQI(s) locations.

For tubular structure, the following exception minimum number and

required locations of IQI shall be followed:-

a) Where the source is located at the center of the tubular structure and
one or more film holders are used for a single exposure of complete
circumference (Panoramic Technique), at least three penetrameters
shall be spaced approximately 120 apart.

b) Where the source is placed at the center of the component (Single-

Wall Single-Image Viewing) and four or more film holders are
used for a single exposure of a section of the circumference, at least
three penetrameter shall be used. One penetrameter shall be in the
approximate center of the section exposed and one at each end.

c) Where the source is located on the axis of the object (Double-Wall

Single-Viewing Technique) and four or more film holders are used
for an exposure of a circumferential weld, at least three
penetrameters shall be used. One penetrameter shall be in the
approximate center of the section exposed and one at each end.
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13.0 SENSITIVITY

The required sensitivity for each radiograph using DIN 54109 Wire IQI is as per
ASME V Table T-276. DIN 54109 Wire Type IQI Sensitivity is calculated using
the following formula:-

IQI Sensitivity= Diameter of Thinnest Wire Visible on Radiographx 100%

Thickness of Penetrated Material In Same Region

14.0 FILM DENSITY

For each radiograph made, film Density will be measured in the area of interest
and shall be not less than 1.8 and not greater than 4.0 in density.

15.0 SCATTERED RADIATION

Wherever necessary 6mm thick lead sheet shall be placed behind the film cassette
to prevent scattered radiation from fogging the film.

The cassette shall have a lead letter ‘B’ a minimum of 12.5mm high, fastened to
the back and if a light image of the letter appears on the film, additional backing
sheets are required. A light image of the letter ‘B’ shall be cause for rejection of
any radiographic film.

16.0 RADIOGRAPHIC PROCEDURE

Radiographic Inspection techniques shall be carried out in accordance with the

current edition of ASME Section V Article 2.

A single-wall exposure technique shall be used for used for radiography whenever
practical. When it is not practical to use a single-wall technique, a double wall
technique shall be used.

16.1 Single-Wall Technique

In the single-wall technique, the radiation passes through only one wall of
the weld (material), which is viewed for acceptance on the radiograph. An
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adequate number of exposure shall be made to demonstrate that the

coverage has been obtained.

Figure 3, Figure 5 and Figure 6 illustrate the single wall technique, one of
the following double wall technique shall be used.

16.2 Double-Wall Technique

When it is not practical to use a single wall technique, one of the following
double wall techniques shall be used.

16.2.1 Single-Wall Viewing

For material and for weld components, a technique will be used in

which the radiation passes through the two walls and only the weld
(material) on the film side wall is viewed for acceptance. An
adequate number shall be made to demonstrate that the required
coverage has been obtained.

Where complete coverage is required for circumferential welds

(material), a minimum of three exposures taken 120 to each other
shall be made.

Figure 7 illustrates the double-wall exposure single-wall viewing

set-ups that may be used.

6.2.2 Double-Wall Viewing

For materials and for welds in components 3-1/2 inch or less in

nominal outside diameter, a technique will be used in which the
radiation passes through two walls and the weld (material) in both
walls is viewed for acceptance on the same radiograph. For double
wall viewing only a source side penetrameter shall be used. Care
will be exercised to ensure that where the required geometric
unsharpness requirement cannot be met. Then the single wall
viewing shall be used.

a) For welds, the radiation beam will be offset from the plane
of the weld at an angle sufficient to separate the images of
the source side and film side portions of the weld so that
there is no overlap of the areas to be interpreted. When
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complete coverage is required, a minimum of two exposures

taken 90 to each other shall be made for each joint.

Figure 8 illustrates the double-wall exposure double-wall

viewing set-ups (ellipse) that may be used.

b) As an alternative, the welds, the radiation beam positioned

so that the images of both wall are superimposed. When
complete coverage is required a minimum of three
exposures taken at 60 or 120 to each other shall be made
for each joint.

Figure 9 illustrates the double-wall exposure double-wall

viewing set-ups (superimpose) that may be used.

c) Additional exposures shall be made if the required

radiographic coverage cannot be obtained using the
minimum number of exposures indicated in (a) or (b) above.

17.0 FILM PROCESSING

This shall be carried-out in accordance with the recognized good practice.

Processing shall be carried-out using the standard developer and fixer solutions
and shall be in accordance with manufacturers recommendations.

The performance of the processing will be checked daily using control strips of X-
ray film exposed to known density and processed. From the developed film, a
check is taken and any density change is marked on a process control chart. Upper
and lower limits are marked on the chart to provide controls against which the plot
can be monitored. The results are interpreted and corrective action taken if
necessary.

The radiographs will be free from imperfections due to processing or any other
defects which would interfere with interpretation.

18.0 FILM IDENTIFICATION

Each film will be identified by the use of lead symbols to indicate the following
minimum information:-
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a) The job or work piece

b) The joint
c) The section of the joint
d) The date of the test
e) The welders identification

19.0 VIEWING CONDITIONS

The radiographs shall be examined in a darkened room. The radiograph viewer

shall provide a light source sufficient for the essential IQI wire/hole to be visible
for the specific density range. The light from around the outer edges of the
radiographs will be masked.

20.0 INTERPERTATION OF RADIOGRAPHS

A calibrated densitometer or calibrated density strip will be kept in close

proximity to the viewer and a ‘spot’ high density illuminator will be available. All
comments with regard to film quality and interpretation will be recorded on the
film folder and on the radiographic report form.

The density of density strips and densitometer calibration shall be verified by

comparison with a calibrated step wedge film traceable to a national standard. The
densitometer shall be calibrated in accordance with paragraph 5 of ASTM E-1079,
Calibration of Transmission Referencing Code section.

21.0 RADIOGRAPHIC REPORT

Written reports shall be prepared giving the results of all the tests performed using
the companies Radiographic Form.

22.0 SAFETY

All radiographic work will be carried out in accordance with Statutory Safety
Requirements and with the companies Radiation Protection Program.