This content provides you with a example Radiographic Testing Procedure. This is a general and sample RT procedure and you need to modify it to meet your project specifications.
1. SCOPE:
1.1–This Procedure describes the general requirements for radiography examination (RT) according to related approved weld map for the metallic welding and casting as may be required by the specification or under which component is being designed and manufactured.
1.2-This radiographic testing procedure provides the material, equipment, calibration, personnel qualification, examination process, evaluation, records and acceptance standards for XXX Project which will be fabricated in YYY.
2. SURFACE CONDITION
According to T.222.2, the weld ripples or weld surface irregularities on the both the inside (where accessible) and out side shall be removed by any suitable process to such a degree that the resulting radiographic testing image due to any surface irregularities cannot mask or be confused with the image of any discontinuity. the finished surface of all butt welded joints mat be flush with the base material or may have reasonably uniform crowns, with reinforcement not to exceed that specified in the referencing code section.
3. RADIATION SOURCE
3.1- X-Radiation:
The radiography testing techniques shall demonstrate that the required radiography sensitivity has been obtained. Maximum x-ray voltage is 300 KV.
3.2- Gamma radiation:
The recommended minimum thickness for which Radio-active isotopes may be used as follow:
Table – 3.2
| Material | Iridium192 | Cobalt 60 |
|---|---|---|
| Steel | 0.75 in | 1.50 in |
| Copper or high nickel copper | 0.65 in | 1.30 in |
| Aluminum | 2.50 in | — |
The maximum thickness for the use of radioactive isotopes is primarily dictated by exposure time, therefore; upper limits are not shown. The minimum Recommended thickness limitation may be reduced when the radiography techniques are used to demonstrate that the required radiographic testing sensitivity have been obtained, by purchaser approval.
4. RADIGRAPHIC FILMS
Any commercially available industrial radiography films may be used in accordance with SE 1815(ASTM) standard test method for film system in industrial radiography. Radiography film shall be fine grain high definition, high contrast film (Kodak type AA 400, FUJI 100 or AGFA D7).
5. SCREENS
Any commercially available intensifying screen, except those of the fluorescent type, may be used. Intensifying screen for x-ray or Gama ray method divided in two categories: 1-front screen 2-back screen. Commonly lead screens use with 27 micron thickness. (Front screen)
6. PENETRAMETER (I.Q.I)
Penetrameters shall be either the whole type or the wire type and shall be manufactured and identified in accordance with the requirements or alternatives allowed in SE 142 or SE 1025 (for whole type) and SE-747 (for wire type), and appending. ASME V 2007 ED & ASME Sec VIII Div I ED 2007.
Penetrameters shall consist of those in table 233.1 for hole type and those in table 233.2 for wire type. (Wire type IQI shall be used for welds.)
7. SELECTION OF PENETRAMETER (I.Q.I)
7.1. Material. IQIs shall be selected from either the same alloy material group or grade as identified inSE-1025, or SE-747, as applicable, or from an alloy material Group or grade with less radiation absorption than the material being radiographed.
7.2 Size. The designated hole IQI or essential wire listed in Table T-276 provided an equivalent IQI sensitivity is maintained. See T-283.2.shall be as specified in Table T-276. A thinner or thicker hole-type IQI may be substituted for any section thickness
(a) Welds With Reinforcements. The thickness on which the IQI is based is the nominal single-wall thickness plus the estimated weld reinforcement not to exceed the maximum permitted by the referencing Code Section. Backing rings or strips shall not be considered as part of the thickness in IQI selection. The actual measurement of the weld reinforcement is not required.
(b) Welds Without Reinforcements. The thickness on which the IQI is based is the nominal single-wall thickness. Backing rings or strips shall not be considered as part of the weld thickness in IQI selection.
7.3 Welds Joining Dissimilar Materials or Welds with Dissimilar Filler Metal.When the weld metal is of an alloy group or grade that has a radiation attenuation that differs from the base material, the IQI material selection shall be based on the weld metal and be in accordance with T-276.1. When the density limits of T-282.2 cannot be met with one IQI and the exceptional density area is at the interface of the weld metal and the base metal, the material selection for the additional IQIs shall be based on the base material and is in accordance with T-276.1
8. PLACEMENT OF RADIOGRAPHIC TESTING PENETRAMETER (I.Q.I)
8.1- Source side penetrameters:
The penetrameters shall be placed on the source side of the part being examined, except for the condition described in chapter 8.2.
8.2- film side penetrameters:
Sensitivity:
The sensitivity required using wire type IQI shall be 2%.
Sensitivity:(Diameter of thinnest wire visible on radiograph / Part thickness at IQI location) x 100
Where inaccessibility prevents hand placing the penetrameter (s) on the source side, it shall be placed on the film side in contact with the part being examined. A lead letter “F” shall be placed adjacent to or on the penetrameter (s).
9. NUMBER OF PENETRAMETER (I.Q.I)
When one or more film holders are used for an exposure, ate least one penetrameter imager shall appear on each radiograph.
If the requirements of T-282 are met by using more than one penetrameter, one shall be representative of the lightest area of interest and the other the darkest area of interest.
The intervening densities, on the radiograph, shall be considered as having acceptable density.
Number of I.Q.I shall be according to ASME SEC V.T.277.2.
10. RADIOGRAPHIC TESTING TECHNIQUE
A single-wall exposure technique shall be used for radiography whenever practical. When it is not practical to use a single-wall radiographic testing technique, a double-wall technique shall be used. An adequate number of exposures shall be made to demonstrate that the required coverage has been obtained.
10.1 Single-Wall Technique. In the single-wall radiographic testing technique, the radiation passes through only one wall of the weld (material), which is viewed for acceptance on the radiograph.
10.2 Double-Wall Technique. When it is not practical to use a single-wall technique, one of the following double-wall techniques shall be used.
(a) Single-Wall Viewing. For materials and for welds in components, a technique may be used in which the radiation passes through two walls and only the weld (material) on the film-side wall is viewed for acceptance on the radiograph. When complete coverage is required for circumferential welds (materials), a minimum of three exposures taken 120 deg to each other shall be made.
(b) Double-Wall Viewing. For materials and for welds in components 31⁄2 in. (89 mm) or less in nominal outside diameter, a technique may 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 IQI shall be used. Care should be exercised to ensure that the required geometric unsharpness is not exceeded. If the geometric unsharpness requirement cannot be met, then single-wall viewing shall be used.
(1) For welds, the radiation beam may 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 complete coverage is required, a minimum of two exposures taken 90 deg to each other shall be made for each joint.
(2) As an alternative, the weld may be radio graphed with the radiation beam positioned so that the images of both walls are superimposed. When complete coverage is required, a minimum of three exposures taken at either 60 deg or 120 deg to each other shall be made for each joint.
11. SOURCE TO OBJECT AND OBJECT TO FILM DISTANCE (SOD & OFD)
According to geometric unsharpness formula (Ug = f *OFD/FOD) for minimizing the Ug value, OFD value shall be minimizing therefore object to film distance shall be minimum.
Source to object distance (SOD) shall be set according radiographic technique, object shape and strength of source.
12. RADIOGRAPHIC TESTING IDENTIFICATION SYSTEM
The method shall be used to produce permanent identification to the radiographies traceable to the contract, components, welds or weld seams, or part numbers, as appropriate. This identification mark shall not obscure the area of interest.
13. RADIOGRAPHIC TESTING ACCEPTANCE STANDARD
Refer to ASME Sec VIII, Div. I
a) Butt welded joints surfaces shall be sufficiently free from coarse ripples ,grooves , overlaps and abrupt ridges and valleys to permit proper interpretation of radiographic and the required non-destructive examinations.
If there is a question regarding the surface condition of the weld when interpreting a radiographic film, the film shall be compared to the actual weld surface for determination of acceptability.
b) Indications shown on the radiographies of welds and characterized as imperfections are un-acceptable under the following condition:
1) Any indications characterized as a crack or zone of incomplete fusion or penetration.
2) Any other elongated indication at radiography, which has length greater than:
(a) 1/4 in. (6mm) for t up to 3/4 in. (19mm)
(b) 1/3 t for t from 3/4 in. (19mm) to 2 1/4 in. (57mm)
(c) 3/4 t (19mm) for t over 2 1/4 in. (57mm)
Where: t= thickness of weld excluding any allowable reinforcement.
3) Any group of aligned indications that have an aggregate length greater than t in a length of 12t , except when the distance between the successive imperfections exceed 6L where L is the length of the longest imperfection in the group.
4) Rounded indications in excess of that specified by the acceptance standards given in ASME sec. VIII, DIV I, appendix 4 fig. 4-2 to 4-8
Note: spot RT shall be done as per ASME Sec. VIII, Div. 1 UW-52; however the acceptance criteria shall be according to UW-51 (as specification).
14. DEFECT REMOVAL
Repair area shall be located on the weld line after evaluation & interpretation of radiograph .defects shall be removed by suitable method such as grinding, chipping or gouging (if permitted).welding of the repair area shall meet the requirement of related WPS,PQR.
15. CERTIFICATION AND PERSONNEL QUALIFICATION IN RADIOGRAPHIC TESTING.
Personnel performing radiography examination to this procedure shall be qualified and certified by XXX also shall meet the requirements of ASNT-SNT-TC-1A-2001 EDITION at least level II and on ASNT-SNT-TC-IA for code section I and sec VII div 2. Film interpreter shall have level II as a minimum.
Executive Summary & Industrial Inspection Scope
In demanding industrial environments across Oil, Gas, Petrochemical, Offshore, and Heavy Process Infrastructure, rigorous compliance with ISO 9001 / ASME / API is essential to ensure operational integrity, personnel safety, and compliance with statutory regulatory frameworks. This technical specification provides QA/QC managers, procurement engineers, welding inspectors, and third-party inspection (TPI) agencies with an authoritative, field-tested guideline for “Radiographic Testing Procedure”.
Ensuring compliance regarding radiographic testing procedure minimizes the risk of catastrophic asset failures, costly unscheduled shutdowns, and supplier non-conformances. The following technical sections delineate the scope of inspection, mandatory verification protocols, acceptance criteria, documentation deliverables, and root cause mitigation strategies.
Governing International Engineering Codes & Specifications
Verification and validation of Radiographic Testing Procedure must strictly conform to the latest editions of the following international engineering codes and project specifications:
• **Primary Standard Reference:** ISO 9001 / ASME / API
• **Quality Management & Inspection Systems:** ISO 9001:2015 & ISO/IEC 17020 (Requirements for the operation of various types of bodies performing inspection)
• **Material Compliance & Traceability:** EN 10204 Type 3.1 / 3.2 Inspection Certificates for metallic and non-metallic pressure-retaining components
• **Personnel Qualification:** ASNT SNT-TC-1A / ISO 9712 for NDT personnel, CSWIP 3.1 / AWS CWI for welding inspection, and NACE / AMPP Level 2/3 for coating and corrosion personnel
• **Statutory & Health Safety Directives:** ASME Boiler & Pressure Vessel Code (BPVC), API Standards, OSHA, and regional local authority regulations.
Step-by-Step Quality Control & Inspection Procedure
The execution of quality surveillance for Radiographic Testing Procedure is structured across four progressive QA/QC intervention phases:
Stage 1: Pre-Inspection & Engineering Document Review (Review Point – R)
Prior to commencement of any physical activities or manufacturing operations related to Radiographic Testing Procedure, the contractor or vendor must submit all technical submittals to the Owner or TPI agency for formal review and approval.
- Verification of approved Inspection and Test Plan (ITP) identifying all Hold (H), Witness (W), Review (R), and Surveillance (S) intervention points.
- Cross-examination of Material Test Reports (MTR / Mill Certificates) against standard design specifications (ISO 9001 / ASME / API).
- Review and approval of specific Procedure Qualification Records (PQR), Welding Procedure Specifications (WPS), or calibration certificates.
- Verification that all measurement instruments, gauges, and NDT equipment hold valid calibration certificates from ISO/IEC 17025 accredited calibration laboratories (within 6 to 12 months validity).
Stage 2: In-Process Witnessing & Fabrication Control (Witness / Hold Point – W/H)
During the active execution phase, the certified inspector performs physical surveillance to ensure strict adherence to certified drawings, manufacturing procedures, and code tolerances.
- Verification of material traceability (heat number, heat treatment lot, plate number) transferred accurately onto fabricated components.
- Dimensional verification and visual inspection using calibrated gauges, micrometer depth dials, or laser alignment systems.
- Monitoring ambient environmental parameters (relative humidity, dew point, substrate temperature) when applying surface treatments, welding preheat, or pressure testing.
- Witnessing non-destructive examination (RT, UT, MT, PT, PMI) at specified percentages according to project critical rating and code requirements.
Stage 3: Final Acceptance, Pressure/Performance Testing & Marking (Hold Point – H)
The culminating milestone where the fully assembled or completed item is subjected to definitive acceptance tests in the presence of the Owner’s Third-Party Inspector (TPI).
- Execution of pressure proof tests (Hydrostatic at 1.3x to 1.5x MAWP or Pneumatic test) with dual calibrated pressure gauges and temperature recorders.
- Full visual inspection of completed surfaces, welds, protective coatings, and flange contact faces for absence of mechanical damage or code defects.
- Validation of permanent stamping, low-stress die markings, nameplate data verification, and barcoding in strict conformity with project specs.
- Clearing all open punch-list items, non-conformance reports (NCRs), and concession requests prior to issuance of the release note.
Stage 4: Packing, Preservation & Inspection Release (Inspection Release Certificate – IRC)
Ensuring the inspected equipment is adequately protected against atmospheric corrosion, mechanical shock, and marine transit degradation.
- Inspection of rust preventative coatings, desiccant bags, flange face blind protectors, and vapor corrosion inhibitor (VCI) packaging.
- Verification of heavy-lift sea fastening lugs, center-of-gravity markings, and export crating compliance (ISPM 15 wooden crating).
- Compilation and signing of the final Inspection Release Certificate (IRC / Shipping Release) and manufacturer data dossier (MDR).
Technical Acceptance Criteria & Tolerances Matrix
All measurements and physical characteristics must comply with the engineering tolerances and acceptance thresholds tabulated below:
| Inspection Parameter / Test Item | Applicable Standard & Clause | Permissible Tolerance / Acceptance Limit | Verification Method | Intervention Type |
|---|---|---|---|---|
| Material Chemical & Mechanical Verification | ISO 9001 / ASME / API / EN 10204 3.1 | 100% compliance with minimum tensile, yield, elongation, and impact values (Charpy V-Notch at design temp) | Optical Emission Spectrometry (OES) / MTR Verification | Review (R) |
| Visual & Dimensional Tolerances | ISO 9001 / ASME / API / Project Specs | Zero cracks, lack of fusion, severe pitting; dimensional tolerances within ±1.0mm to ±3.0mm per code drawings | Calibrated Vernier, Bridge Cam, Depth Micrometer | Witness (W) |
| Non-Destructive Examination (NDT) | ASME Sec V / ASNT SNT-TC-1A | 100% compliant with code acceptance criteria; zero planar defects or unpermitted volumetric indications | Radiographic (RT) / Ultrasonic (UT) / Magnetic Particle (MT) | Hold (H) |
| Pressure / Proof Testing (Hydrostatic) | ISO 9001 / ASME / API / ASME Sec VIII | Test pressure maintained for minimum 30 to 60 mins; zero pressure drop, zero leakage or visible sweating | Dual calibrated Bourdon pressure gauges + Chart Recorder | Hold (H) |
| Surface Prep & Protective Coating Quality | SSPC-SP / NACE / ISO 8501 | Surface profile 50 – 75 µm; Dry Film Thickness (DFT) within 80/20 rule of specified nominal thickness | Replica Tape (ASTM D4417) & Magnetic Gauge (SSPC-PA 2) | Witness (W) |
| Nameplate & Final Preservation Verification | API / ASME / Client Specs | 316L SS nameplate securely affixed with correct design code, MAWP, design temp, and national board stamping | Physical visual check & VCI preservation verification | Hold (H) |
Mandatory QA/QC Dossier & Inspection Deliverables
Prior to the final issuance of the Inspection Release Certificate (IRC), the contractor and vendor must compile and submit the verified manufacturer data record containing:
- Approved Inspection & Test Plan (ITP) with sign-off stamps by Contractor, Client, and TPI.
- Material Test Reports (MTR / Mill Test Certificates EN 10204 Type 3.1 or 3.2).
- Certified Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), and Welder Performance Qualifications (WPQ).
- Calibration Certificates for all test instruments and measuring equipment (NABL / ISO 17025 accredited).
- Non-Destructive Examination Reports (RT, UT, MT, PT, PMI, Ferrite Content) evaluated by Level II/III inspectors.
- Heat Treatment & PWHT Time-Temperature Recorder Charts with thermocouple layout drawings.
- Hydrostatic / Pneumatic Pressure Proof Test Certificate with calibrated chart recorder logs.
- Surface Preparation and Protective Coating Inspection Reports (Daily environmental log, blast profile, DFT summary).
- Non-Conformance Report (NCR) and Concession Disposition Closeout Log.
- Official Inspection Release Certificate (IRC / Shipping Release Note) permitting packing and dispatch.
Common Non-Conformances & Field Mitigation Strategies
Based on extensive third-party inspection field records in oil & gas projects, the following deviations require heightened surveillance:
Defect / Hazard: Material Grade Substitution & Lack of Heat Traceability
Root Cause: Uncontrolled workshop storage, missing color coding, or unverified supplier sub-tier procurement without EN 10204 3.1 documentation.
Preventative Action: Enforce strict 100% Positive Material Identification (PMI) prior to cutting, and mandatory material receiving inspection with physical stamping cross-referenced to original mill test certificates.
Defect / Hazard: Out-of-Tolerance Fit-Up & Alignment Mismatch
Root Cause: Poor thermal cutting, thermal distortion from excessive preheat, or inadequate jigging and tacking arrangements.
Preventative Action: Establish a mandatory Witness/Hold point at joint fit-up before root pass deposition. Use calibrated Hi-Lo gauges to verify bevel angle, root face, and root gap according to the qualified WPS.
Defect / Hazard: Premature Coating Delamination & Blistering Under Film
Root Cause: Excessive soluble salt contamination (>20 mg/m²) left on the substrate, blast cleaning below dew point (<3°C above dew point), or oil/moisture in the blasting compressor air line.
Preventative Action: Perform Blotter Test (ASTM D4285) daily on compressed air, enforce Bresle patch chloride testing, and apply primer within 4 hours of abrasive blasting before rust blooming initiates.
Defect / Hazard: Pressure Drop During Final Hydrostatic Proof Testing
Root Cause: Micro-leakage through temporary test flange gaskets, entrapped air pockets inside vessel high points, or inadequate temperature stabilization.
Preventative Action: Ensure thorough venting at all high-point vents until bubble-free fluid emerges, allow minimum 15-minute temperature stabilization between filling medium and ambient metal, and torque all blind flanges with calibrated torque wrenches.
Frequently Asked Questions (FAQ)
Q: What are the mandatory qualifications for inspectors verifying Radiographic Testing Procedure?
A: Inspectors must hold recognized international certifications applicable to the discipline. For welding and fabrication: CSWIP 3.1/3.2, AWS CWI, or API 510/570 Source Inspector. For NDT: ISO 9712 or ASNT SNT-TC-1A Level II minimum. For coatings: NACE / AMPP Level 2 or FROSIO Level III. Additionally, the inspection agency must operate under an ISO/IEC 17020 accredited quality management system.
Q: How does PtroTek resolve non-conformances (NCRs) encountered during vendor surveillance?
A: When a deviation from certified drawings or ISO 9001 / ASME / API is detected, the inspector issues a formal Non-Conformance Report (NCR) within 24 hours. The vendor must submit a Root Cause Analysis (RCA) and proposed disposition (Rework, Repair, or Concession). Work on the affected component is halted (Hold Point) until the Owner’s engineering authority approves the disposition and a re-inspection confirms full compliance.
Q: What is the difference between Witness (W) and Hold (H) points in an Inspection & Test Plan (ITP)?
A: A Hold Point (H) is a mandatory milestone where fabrication or testing CANNOT proceed without the physical presence of the designated client or third-party inspector. Written clearance or stamping is strictly required. A Witness Point (W) requires prior notification (typically 24 to 48 hours) to the inspector; however, if the inspector fails to attend at the scheduled time, fabrication or testing may proceed with subsequent review of the test records.
Q: Can international clients review inspection reports and photos in real time?
A: Yes. PtroTek provides comprehensive Flash Reports issued within 24 hours of inspection completion, followed by detailed formal inspection reports accompanied by high-resolution calibrated photographic evidence, dimension logs, and signed vendor test records for complete global transparency.
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