Saferad Procedure

TestEx
Mechanical Integrity System Manual

Author: Yusoff B Ismail
Page 1 of 19
Doc No.:
MI-30570
TESB-INSP-10001
MIIST
Approved by
Issue (Rev.) 3
JANUARY 15, 2010 (a)
CLIENT
Title:
SAFERAD PROCEDURE
SAFERAD
PROCEDURE
TABLE OF CONTENTS
SECTION
DESCRIPTION
1.0
PURPOSE
2.0
SCOPE
Printed on Monday, August 17, 2015
TestEx

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Title:
SAFERAD PROCEDURE
3.0
RESPONSIBILITY
4.0
DEFINITION
5.0
SAFETY
6.0
PERSONNEL
7.0
PREPARATION
8.0
TOOLS & EQUIPMENT
9.0
PROCEDURE
10.0
ACCEPTANCE CRITERIA
11.0
DOCUMENTATION
12.0
REFERENCES
13.0
ATTACHMENTS
CLIENT
TestEx

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Title:
SAFERAD PROCEDURE
1.0
PURPOSE
This procedure describes the proper method of carrying out Saferad Testing as described in
Article 2 for examination of materials including castings and welds shall be used together
with Article 1.
2.0 SCOPE
This procedure describes the radiographic methods to be employed by Testex (M) Sdn Bhd
for the Radiographic Inspection of butt welds in accordance with ASME Section V.
3.0 RESPONSIBILITY
3.1
The NDT Supervisor shall possess minimum of Level II in Radiography Testing.

He/she shall be the focal person and will assume total responsibility of the companys
performance during execution of the WORKS. He will also double-up his function as
to oversee and manage the Safety and Quality aspects of the WORKS and Companys
resources.
3.2
The NDT Level II Operators is responsible for performing the activity, preparing the
Activity Report, and evaluate the results.
4.0 DEFINITION
Client Company or organization for whom Testex (M) Sdn Bhd performing the work.
LPTA
Lembaga Periesenan Tenaga Atom, Malaysia (Atomic Energy

Licensing Board)
NDT
Non-Destructive Testing
ASNT
American Society for Non-Destructive Testing
MLVK
Majlis Latihan Vokasional Kebangsaan,Malaysia(National Vocational Training

Council)
PCN
Personnel Certification Scheme for Non-Destructive Testing
CSWIP
Certification Scheme for Weld Inspection Personnel
IQI
Image Quality Indicator
TestEx

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Title:
SAFERAD PROCEDURE
5.0
SAFETY
5.1
All Radiographic work shall be carried out in accordance with Statutory Safety
Requirements (AELB), Testex (M) Sdn. Bhds Radiation Protection Program/Safety
Standing Instructions that was approved by AELB and Client Regulations. Adherence
to these regulations is mandatory.
5.2 Special precautions must be taken to protect personnel from radiation hazards. The
assigned person performing the examination must be aware of the special precautions,
including barricading of the exposure area.
5.3
The detail work procedures in this program require that all inspection activities be
conducted such that all risks to safety health and the environments are minimized to
an acceptable level. Therefore the following requirement should be met;
i.
Job Safety Analysis (JSA) be undertaken for all inspection work procedures
(Refer to JSA attached).
ii.
Safe work procedures shall be documented for inspection procedures. These

should clearly cover permit requirement, protective equipments and
requirements for working at heights and in confine space areas.
6.0 QUALIFICATION OF PERSONNEL

Radiographic Inspection work shall be carried our by two Radiographers. The technicians
shall be required to hold the followings;
a) Radiographer
A Valid LPTA Radiographer Operator License and a current

Certificate Proficiency in Radiography Level II to a recognize
qualification and certification scheme.
b) 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 scheme may be used for the purpose
of qualification and certification of personnel:a) ASNT (in accordance with the companys written practice)
b) MLVK
c) PCN/CSWIP
Alternative qualifications shall only be acceptable with the prior consent of the Client and
Companys Level III
.
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Title:
SAFERAD PROCEDURE
7.0
PREPARATION
Saferad (Radiography) Inspection shall only be carried out on welds which has visually
inspected and any remedial work necessary is completed and accepted by the
Client In addition, the Radiographer inspects the weld surface for any
irregularities that may mask or confuse interpretation of the final radiograph.
8.0
RADIOGRAPHIC TOOLS & EQUIPMENT

For Saferad (Radiography) work, Se-75 Saferad or equivalent Containers and remote
Control Wind outs will be used8.1
LOCATION OF DATUM
All welds 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:
For horizontal and inclined tubular structure, the datum is the highest point in the
joint when viewed from the lower numbered joint
For vertical tubular structure, the datum is north, when the join is viewed vertically
downwards.
In all cases the datum shall be indelibly marked on the welds. A meter band
incorporating lead numerals along the weld shall be utilized to allow positive
location of any discontinuity.
8.2
CASSETTES
Flexible envelope cassettes shall be used unless specifically stated otherwise.
Ensure close Film-To-Screen and Cassette-To-Object Contact
The use of pre-pack film with integral metal screens may be used with written
agreement from the client
TestEx
CLIENT
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SAFERAD PROCEDURE
8.3
FILM
8.3.1
Type of Film
Radiographs shall be made using industrial radiographic film and shall be
selected from Table I below.
Table 1: Selection of Radiographic Film
Class of Film
Brand
Type
Size of Film used
I
(high sensitive film)
Dupond
Agfa
Kodak
NDT55
D4
MX
4 x 10
4 x 15
14 x 17
II
(sensitive film)
Dupond
Agfa
Kodak
NDT70
D7
CX
4 x 10
4 x 15
14 x 17
Films shall have sufficient length and shall be placed to produced at least 13 mm of film
expose to direct radiation beyond each edge where the weld is terminated
8.3.2
Overlap
If more than one film is required in single exposure, overlapping cassettes
shall be used. Radiographs shall have 25 mm 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 overlap.
8.4
SCREENS
Lead intensifying screens shall be used. The front screen thickness shall normally be
0.125 mm and rear will normally be 0.125 mm.
Screen shall be examined and cleaned on a regular basis (every time before film
loading) for dirt or blemishes that may transfer onto the film thus confusion with and
masking of defect images.
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Title:
SAFERAD PROCEDURE
8.5 GAMMA RAY SOURCE
The Selenium-75, an artificial isotope with a half-life of 119.8 days shall be used.
9.0
8.5.1
Source Size
The size of Se-75 source shall be as per stated in the suppliers decay curves
i.e diameter 3.0 mm, length 3.0 mm and diagonal 4.24 mm
8.5.2
Source Strength
For safety reasons the maximum source strength in every container is limit to
80 curies (3 Tbq)
RADIOGRAPHIC PROCEDURE.
9.1
Radiographic Inspection techniques

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 radiography whenever practical.
When it is not practical to use a single-wall 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.
9.1.1
Single-Wall Technique
In the single-wall technique, the radiation passes through on one wall of the
weld (material), which is viewed for acceptance on the radiograph.
9.1.2
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 3 1/2 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 doublewall viewing, only a source-side IQI shall be used. Care should be
exercised to ensure that the required geometric un-sharpness is not
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Title:
SAFERAD PROCEDURE
exceeded. If the geometric un-sharpness requirement cannot be met,
then single-wall viewing shall be used.
9.3
i.
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.
ii.
As an alternative, the weld may be radiograph 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.
iii.
Additional exposures shall be made if the required

radiographic coverage cannot be obtained using the minimum
number of exposures indicated in (i) or (ii) above.
GEOMETRIC RELATIONSHIPS
9.3.1 The geometric un-sharpness of the radiograph shall be determined in
accordance in accordance with:Geometric un-sharpness,
Ug = Fd/(S-d)
Where Ug - geometric un-sharpness

F - focal spot size of source size
d - object to film distance
S - focal spot-to-film distance (x-ray) or source-to-film distance
(Gamma Ray)
9.3.2
Geometric Un-sharpness of the radiograph shall not exceed the Ug value in

table 2 below and the value of geometric un-sharpness shall be recorded in the
report.
Table 2: Maximum Geometric Un-sharpness
Material Thickness, mm
Under 50.8
50.8 through 76.2
Over 76.2 through 101.6
Greater than 101.6
Ug Maximum, mm
0.51
0.76
1.02
1.78
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SAFERAD PROCEDURE
Material thickness is the thickness on which the IQI 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.
9.4
IMAGE QUALITY INDICATORS (IQI)

9.4.1
Selection of IQI
The IQI provides a guide to the quality of radiographs produced and shall
be appropriately chosen from one of the types recommended in ASME
Section V Article 2 (As per Table 3 & 3a below).
Table 3: Wire IQI Designation, Wire Diameter And Wire Identity

Set A
Set B
Set C
Set D
Wire
Diameter,
in
Mm
Wire
Identity
Wire
Diameter,
in
mm
Wire
Identity
Wire
Diameter,
in
mm
Wire
Identity
Wire
Diameter,
in
mm
Wire
Identity
0.0032
0.004
0.005
0.0063
0.008
0.010
0.08
0.01
0.13
0.16
0.20
0.25
1
2
3
4
5
6
0.010
0.013
0.016
0.020
0.025
0.032
0.25
0.33
0.41
0.51
0.64
0.81
6
7
8
9
10
11
0.032
0.040
0.050
0.063
0.080
0.100
0.81
1.02
1.27
1.60
2.03
2.54
11
12
13
14
15
16
0.100
0.126
0.160
0.200
0.250
0.320
2.54
3.20
4.06
5.08
6.35
8.13
16
17
18
19
20
21
Table 3a: IQI Selection

________________________________________________________________________________
_
IQI
Source Side
Material Thickness Range
In.
mm
Hole-Type
Designation
Wire-Type
Essential
Film Side
Hole-Type
Designation
Wire-Type
Essential Wire
Up to 0.25, incl.
Up to 6.4, incl.
12
5
10
4
15
6
12
5
17
7
15
6
20
8
17
7
25
9
20
8
30
10
25
9
35
11
30
10
40
12
35
11
50
13
40
12
60
14
50
13
80
16
60
14
100
17
80
16
120
18
100
17
160
20
120
18
200
21
160
20
_________________________________________________________________________________________________________________________
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a)
Source Side IQI(s)

The IQI(s) shall be placed on the source side of the part being examined, except in the
condition described in 12.2 b.
b)
Film Side IQI(s)

Where inaccessibility prevents hand placing the IQI(s) on the source side it shall be
placed on the film side in contact with the part being examined. A lead letter 'F at
least as high as the IQI identification numbers) shall be paced adjacent the IQI(s).
Radiography shall be performed with a technique of sufficient sensitivity to display the IQI 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.
9.4.2
Number of Image Quality Indicator (IQI)

IQI shall show clearly on each radiograph. For a radiograph represents 255
mm or greater of weld length, two IQIs 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 lQI(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 Image Quality Indicator (IQI)
shall be spaced approximately 120 apart
b)
Where the source is placed at the center of the component (SingleWall Single-Image Viewing) and four or more film holders are used
for a single exposure of a section of the circumference, at least three
Image Quality Indicator (IQI) shall be used. One IQI shall be placed at
the center of the section exposed and one each at the 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 Image Quality
Indicator (IQI) shall be used. One IQI shall be in the approximate
center of the section exposed and one at each end.
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9.5
SENSITIVITY
The required sensitivity for each radiograph shall be based on ASME Standard as in
Table 3a Wire Type IQI. Radiography shall be performed with a technique of
sufficient sensitivity to display the designated the essential wire of a wire IQI. The
radiographs shall also display the IQI identifying numbers and letters
9.6
FILM DENSITY
For each radiograph made, film Density will be measured adjacent to the designated
wire of a wire 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 a gamma ray source. The maximum density shall be 4.0 for either single of
composite viewing.
9.7
EXCESSIVE BACKSCATTER
A lead symbol B with dimensions of in. (13 mm) in height and 1/16 in. (1.6 mm)
in thickness, shall be attached to the back of each film holder during each exposure to
determine if backscatter radiation is exposing the film. If a light image of the B,
appears on a darker background of the radiograph, protection from backscatter is
insufficient and the radiograph shall be considered unacceptable. A dark image of the
B on a background is not cause for rejection.
9.8
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 recommendationsThe performance of the processing will be checked daily using control strips of X-ray
film exposed to a known 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 that would interfere with interpretation.
TestEx
CLIENT
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9.8.1
Developing Time/Temperature
Time and temperature are important factors in development. Typically, a
temperature of 68 oF (20 oC) is used with a development time of between 5
and 8 minutes. As the temperature of the solution is increased, the speed at
which the alkali penetrates is also increased. The details of developing time is
as tabulated in Table 4.
Table 4:
Developer Temperature
(oC )
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
9.9
Standard Developing Time

Developer Temperature
(oF )
61
63
64
66
68
70
72
73
75
77
79
81
82
84
86
88
90
91
93
Developer Time
(minutes)
7.0
6.5
6.0
5.5
5.0
4.5
4.0
3.8
3.5
3.3
3.0
2.8
2.5
2.3
2.0
1.8
1.5
1.3
1.0
FILM IDENTIFICATION
Each film will be identified by the use of lead symbols to indicate the following
minimum information:a)
The job or work-piece
b)
The joint
c)
The section of the joint
d)
The date of the test
e)
The welder identification
9.10
.
VIEWING CONDITION
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SAFERAD PROCEDURE
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.
9.11INTERPRETATION 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 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 Densitometers.
Indication from defects shall be assessed in accordance with the requirements of the
latest edition Referencing Code section.
10.0
11.0
ACCEPTANCE CRITERIA
10.1
For the Pressure Vessel, the Acceptance criteria shall be in accordance to ASME VIII
Division 1 Appendix 4. Rounded indications charts acceptance standard for
radiographically determined rounded indications in welds.
10.2
For piping, the acceptance criteria shall be in accordance to ANSI B31.3 Table
341.3.2.
DOCUMENTATION/RADIOGRAPHIC REPORT
11.1
Written reports shall be prepared giving the results of all performed using the Testex
(M) Sdn Bhd Radiographic Form.
11.2The findings shall be reported in the Report format supported with the sketch shows the
defect location and depth (if any). The reports shall be submitted to the Client's
Inspector for approval.
12.0
.
REFERENCES.
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ASME Section V Article 2

SNT-TC-1A- Qualification of personnel
Atomic Energy Licensing Act, Malaysia, 1984.
Ionizing Radiation Regulation (licensing) Malaysia, 1986
Ionizing Radiation Regulation (Basic Safety Standard) Malaysia, 1988
Ionizing Radiation Regulation (Transportation) Malaysia, 1989
13.0
ATTACHMENTS
13.1
Appendices
13.2
Inspection and Testing Activity Report Form
13.3
Revision History (If any)
CLIENT
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ISSUE AND REVISION STATUS

.
CLIENT
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Revision Status
Text Amended
Revision 0
Original Text
15.04.1999
Yusoff Ismail
Revision 1
Add Para 3.0, 5.0 &

9.0
15.06.2003
Yusoff Ismail
Revision 2
Para 5.0, 8.0 & 9.0
15.09.2003
Yusoff Ismail
Revision 3
Para 8.0
15.01.2010
Yusoff Ismail
Date
Authorized

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TestEx

Mechanical Integrity System Manual

JANUARY 15, 2010 (a)

Printed on Monday, August 17, 2015

Mechanical Integrity System Manual

JANUARY 15, 2010 (a)

TOOLS & EQUIPMENT

Printed on Monday, August 17, 2015

Mechanical Integrity System Manual

JANUARY 15, 2010 (a)

The NDT Supervisor shall possess minimum of Level II in Radiography Testing.

Lembaga Periesenan Tenaga Atom, Malaysia (Atomic Energy

American Society for Non-Destructive Testing

Majlis Latihan Vokasional Kebangsaan,Malaysia(National Vocational Training

Personnel Certification Scheme for Non-Destructive Testing

Certification Scheme for Weld Inspection Personnel

Image Quality Indicator

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Mechanical Integrity System Manual

JANUARY 15, 2010 (a)

Safe work procedures shall be documented for inspection procedures. These

6.0 QUALIFICATION OF PERSONNEL

A Valid LPTA Radiographer Operator License and a current

A current Certificate of Proficiency in Radiography Level II,

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Mechanical Integrity System Manual

JANUARY 15, 2010 (a)

RADIOGRAPHIC TOOLS & EQUIPMENT

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Mechanical Integrity System Manual

Author: Yusoff B Ismail

JANUARY 15, 2010 (a)

Size of Film used

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Mechanical Integrity System Manual

JANUARY 15, 2010 (a)

Radiographic Inspection techniques

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Mechanical Integrity System Manual

JANUARY 15, 2010 (a)

As an alternative, the weld may be radiograph with the

Additional exposures shall be made if the required

Where Ug - geometric un-sharpness

Geometric Un-sharpness of the radiograph shall not exceed the Ug value in

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Mechanical Integrity System Manual

Author: Yusoff B Ismail

JANUARY 15, 2010 (a)

IMAGE QUALITY INDICATORS (IQI)

Table 3: Wire IQI Designation, Wire Diameter And Wire Identity

Table 3a: IQI Selection

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Mechanical Integrity System Manual

JANUARY 15, 2010 (a)

Source Side IQI(s)

Film Side IQI(s)

Number of Image Quality Indicator (IQI)

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

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Mechanical Integrity System Manual

JANUARY 15, 2010 (a)

Printed on Monday, August 17, 2015

Mechanical Integrity System Manual

Author: Yusoff B Ismail