The cleaner used for the surface cleaning will be an organic chemical such as Acetone or

Trichloro-ethylene.
Developer- Non-aqueous suspendable type.technicalhrd@gmail.com
Sulphur content in Penetrant materials for Nickel base alloys testing shall be less than 1% of
the residue by weight.
Chlorine plus Fluorine content shall not exceed 1% of the residue by weight in Penetrant
materials when used for testing of Stainless steel or Titanium.
For Lower temperature range from 5 C to 10 C, the Dwell time shall be two times the time
listed in the table.
Final interpretation begins as soon as a wet developer coating is dry. The minimum
developing time shall be 10 minutes and maximum time 60 minutes.
A minimum light intensity of 100 foot candle (1000 lux) is required to ensure adequate
sensitivity during the examination and evaluation of indications, which can be achieved by a
hand lamp or torch light positioning at a distance of 200 mm.
The temperature of the wet particle suspension and the surface of the part being examined
shall not exceed 57C.
METHOD OF EXAMINATION
Examination shall be made by continuous method.
Dry continuous magnetization method
TECHNIQUES
One of the following magnetization techniques shall be used.
Circular Magnetization-Prod Technique
Longitudinal Magnetization- Yoke Technique
TYPE OF CURRENT FOR MAGNETISATION
Single phase half-wave rectified Direct Current shall be employed for testing with prod
techniques.
The amperage required with single-phase Half-wave rectified current shall be verified
by measuring the average current during the conducting half cycle only.
For yokes, the current shall be either AC or HWAC.
Each alternating current electromagnetic yoke shall have a lifting power of at least 4.5 kg
and each direct current / permanent magnetic yoke shall have a lifting power of 18.0 kg, at
the maximum pole spacing that will be used. Or the pole distance shall be the spacing at
which the yoke lifts the stipulated weight.

Magnetizing Current
The current shall be 100 to 125 (maximum) amperes / 25 mm of prod spacing for sections
19 mm thick or greater.
For sections less than 19 mm thick, the current shall be 90 to 110 amperes/25 mm of prod
spacing.
Prod Spacing
Prod spacing shall not be less than 75 mm nor exceed a maximum of 200 mm.
YOKE TECHNIQUE
The pole spacing shall be between 100 mm to 150 mm. The field indicator will be
used to check the direction of the part magnetization.
LIGHTING
Visible Light Intensity
The examination and evaluation of indications shall be performed under minimum light
intensity of 1000 lux (100 fc) at a height of 200 mm using a torch light or Hand lamp.
Black Light
Black light intensity at the examination surface shall be not less than 1000 micro watt/cm
square at a height of 200 mm. The black light intensity shall be measured at least once
every 8 hr. and whenever the work station is changed.
The examiner shall be in the darkened area for at least 5 minutes prior to performing the
examination for eye adaptation.
Visible Light Intensity
An intensity of 500 lux is adequate.
Black Light
Black light intensity at the examination surface shall be not less than 1000 micro
watt/cm.
The black light shall be warmed up for a minimum period of 5 minutes prior to use or
measurement of the intensity.
One exposure shall be made for Hancock Welds (Double wall double image technique).

SELECTION OF IQI

IQI shall be selected from either the same material group or grade as identified in SE - 1025
or from a material group or grade with less radiation absorption than the material being
radiographed.
PLACEMENT OF IQI
Source Side IQI

Wherever possible, the IQI shall be placed on the source side of the part being examined.
Film Side IQI

Where inaccessibility prevents hand placing the IQI(s) on the source side, the IQI shall be
placed on the film side in contact with the part being examined. A lead letter 'F' shall be
placed adjacent to the IQI(s) but shall not mask the essential hole
Radiographic density

The transmitted film density through the radiographic image of the body of the IQI and the
area of interest shall be 1.8 minimum for radiographs made with an X-ray source and 2.0
minimum for radiographic made with a gamma ray source.
Any group of aligned indications that have an aggregate length greater thant in a length of
12t except when the distance between successive indication exceeds 6L where 'L' is the
longest indication in the group.
BACK SCATTER
A lead symbol B of 2 mm thick and 12mm height, shall be kept at the back of each film cassette to
check the back scattering effect and the radiograph is unacceptable if light image of the letter B
appears on a darker background of the radiograph. A dark image of B on a lighter background is not
a cause for rejection.
SYSTEM OF IDENTIFICATION
The following identifications shall be available in the radiograph.
Job Identification number/ Work order
Segment identification number
Date of RT,
Firm code No
Weld repair. / rework status details (R1, R2, R3 etc., RT, GRT or MRT) if applicable,
Location identification markers
Location marker identification shall be marked / stamped on the surface. These identification numbers
shall be placed 20mm away from the weld edge.

MATERIAL THICKNESS
Under 50.0 mm
Over 50.0 to 75.0 mm
Over 75.0 to 100.0mm
Greater than 100.0 mm
IMAGE QUALITY INDICATORS (IQI)
EQUIPMENT

g Max.
0.51 mm
0.76 mm
1.02 mm
1.78 mm

The equipment shall be of pulse - echo type that responds to frequencies 1 MHz to 6 MHz.
Rate of probe movement
The rate of probe movement for examination shall be less than 150 mm/sec.
Scanning sensitivity
The scanning shall be performed at a gain setting + 6 dB of the primary reference level.
Evaluation shall be performed with respect to primary reference level.
PROBES
The nominal frequency of the probe shall be 4 MHz for thickness less than or equivalent to 40 mm
and 2 MHz for thickness greater than 40 mm.
The crystal dimensions will be 8 x 9 mm or 20 x 22 mm and shall be appropriate to the examination
surfaces ensuring adequate contact for transmission of ultrasonic vibrations.
A square notch of size 1 mm x 1 mm shall be used to adjust the sensitivity for detection of flaws in the
root area and to furnish proof of form echoes in welds at root

DEMAGNETISATION OF MATERIALS
Method

: DEMAGNETISATION

Type of Magnetization

: LONGITUDINAL

Current Rating
specimen

: 1000 amps / 25 mm diameter of the

Type of Current

: AC

MATERIAL
STEEL,ALUMINUM,TITANIUM
AND HIGH TEMPARATURE
ALLOYS

FORM
CASTINGS AND
WELDS
FORGINGS,PLATES

DWELL TIME IN MINUTES

PENETRANT
DEVELOPER
5
10

10
10

Note: For temperatures range from 50F to 125F (10C to 52C). For
temperatures from 40F (5C) up to 50F (10C), minimum penetrant
dwell time shall be 2 times the value listed.
For straight beam technique, longitudinal wave probe of frequency 2MHz or 4 MHz with
contact face not exceeding 25mm (crystal dia.) shall be used.
For angle beam technique, shear wave probe of frequency 2 MHz or 4 MHz with contact
face not exceeding 20 x 20mm shall be used.
Glycerine, SAE 30 Servoway 68, Servo system 46 or Servo system 68 shall be used as
couplant.
Speed of scanning shall not exceed 150mm / second.

ACCEPTANCE STANDARD WELDS IN ALUMINUM RADIOGRAPHIC QUALITY

In general, the testing procedure shall be as per ASME, Section V, Article 2.
Radiation source x rays
Film ASTM class 1 or 2, such as Kodak C5, Agfa Gaevart D7,NDT 65, 70 or
equivalent.
Film density shall be between 1.8 to 3.0.
Radiographic Quality level shall be determined by using ASME Penetrameters or wire
penetrameters to DIN 54109 or IS 3657.
Note:
It is mentioned in ASME section VIII (1988) pare UL W 54

MINIMUM NDE REQUIREMENTS AS PER IBR

Boiler and Super heater Tubes (Regulation No.151 (h)):

Bore,

Percentage of NDE

Over 178

100%

Over 102 and upto 178

including
Below 102

10 % (Min. 2 welds per welder)

5% (Min. 1 weld per welder)

Pipelines NDE requirement:

Description
CLASS I PIPELINES
A Where the completed pipelines
are not subjected to hydraulic
test

Where the completed pipelines

are subjected to hydraulic test

Bore, mm

Over 102
Over 38 and
upto including
102
Below 38
Over 102
Over 38 and
upto including
102
Below 38

CLASS II PIPELINES
All pipes

All size

Percentage of
NDE for each
Welder
100%
5% (Min. 2
welds per
welder)
-10%(Min. 2
welds per
welder)
2% (Min. 1 weld
per welder)
--

Percentage of
cutout joints for
visual and bend
test for each
welder

2% (Note-1)

2% (Note-1)
2% (Note-1)

MINIMUM NDE REQUIREMENTS AS PER ASME B31.1 (POWER PIPING)

Piping service conditions: Temperature over 400 C and all pressures.
Type of weld

NDE

Butt welds

RT for over NPS 50

MT or PT for NPS 50 and less

Fillet, socket, attachment & seal welds

MT or PT for all sizes and thicknesses

Piping service conditions: Temperatures between 175 C inclusive and 400 C

inclusive with all pressures above 7100 kPa (gauge)
Type of weld

NDE

Butt welds

RT for over NPS 50 with thickness

over 19mm. Visual for others

Fillet, socket, attachment & seal welds

Visual for all sizes & thicknesses

Minimum NDE Requirements as per ASME SEC.I

(Table PW-11, Required Radiographic and Ultrasonic Examination of Welded butt
joints)
For drums and shells (excluding pipes, tubes, headers)
NPS exceeding 250mm or wall thickness > 29mm: All butt welds shall be radiographed or
ultrasonically tested.
For pipes, tubes and headers, radiography is not mandatory for the following
conditions:
For parts in flue gas path and subject to furnace radiant heat: NPS 100mm or wall
thickness 13 mm
For parts containing water: NPS 250 mm or wall thickness 29 mm
For parts containing steam: NPS 400 mm or wall thickness 41mm
Where radiography is to be performed and geometric un-sharpness cannot be within
1.8 mm, ultrasonic testing shall be performed.
Note: NPS - Nominal Pipe Size

PHASE DIAGRAMS AND THEIR IMPORTANT FEATURES

Phase is a constituent that is completely homogenous both physically and chemically,
seperated from the rest of the alloy by definite bounding s u r f a c e s .
Alloys can be classified as binary (two component elements), ternary (three component
elements), quaternary alloys (four component elements), and so forth.

DEFINITION OF ALLOYING
An alloy is a metallic material that contains two or more elements where at least one of
the major elements is a metal. Materials produced by alloying can have improved
corrosion resistance, physical, and mechanical properties.
Multiphase Materials - Eutectics
Two liquidus lines are apparent from the upper changes in the slopes of the cooling
curves. The intersection of these liquidus lines is called the Eutectic Point.
This point represents the lowest temperature at which the alloy remains
completely liquid.

equilibrium A state of balance between opposing forces.

homogeneous Uniform structure or composition throughout
liquids line The temperature at which each alloy composition starts to solidify.
solidus line The temperature at which each alloy composition has completely solidified.
CHARACTERISTICS OF THE PHASES IN THE PHASE DIAGRAM
Mild Steel
Mild steel (approximately 0.30 percent carbon) is a multiphase solid at ambient
temperature. Its microstructure contains the following:
Ferrite (body-centered cubic), an alloy of carbon dissolved in iron.
Pearlite, a mixture of ferrite and cementite (Fe3C) that exhibits a lamellar structure. Pearlite
is formed when an alloy containing about 0.83 percent carbon is cooled from slightly
above 722 C (1333 F).
Austenite, a solid solution of carbon in iron, is formed above 722 C (1333 F), and
has a face-centered cubic crystal structure.
Killed steels are normally specified when fabricating pressure vessels or heat
exchangers for petroleum or chemical service because the use of these materials
results in equipment of better quality, i.e., the base materials and welds generally
contain fewer defects.
Nonequilibrium Conditions (Rapid Cooling)
the martensite, are extremely hard and brittle. To obtain useful engineering properties, the
martensite and bainite must be tempered (reheated) or stress relieved to reduce hardness
and increase ductility. It is important to understand that both martensite and bainite are
formed under nonequilibrium cooling conditions, and consequently do not appear on the
phase diagram.
When used in post weld heat treatment in sections - W = 3 times the plate thickness.
For nozzle and other welded attachments - W must be wider than the nozzle or attachment
or 3 times the wall thickness.

For Piping:
W = 3 times the wall thickness (of thickest part ) on each side from the centre of the weld
Thermocouples located at a distance of approximately 1.5 times of the wall thickness
about the center line of weld.
Maximum Heating Rate Above
300C

Thickness of Material

Maximum Cooling
Rate Upto 300C

25 mm

220C/hour

220C/hour

> 25 50 mm

110C/hour

110C/hour

> 50 75 mm

75C/hour

75C/hour

55C/hour

> 75mm

55C/hour *

* For structural - 65C/ hour (Max.)

Thermocouple Locations :
Minimum 2
d = 1.5 x t from weld centre
Heating Band = 6 x t
Insulation Band = 12 x t
Note 1 : For SA 106 Gr .C with less than 0.25 % carbon content .
Note 2 : Pre-heating is necessary for t >16mm.
Note 3 : Less than 0.15 % carbon content .
Note 4 : 9 Cr 1 Mo V Steel ( P-91, T-91 )
P1Gr 2

150

19 < t 5

Nil

25 < t 75

100

t > 75

150

Nil

Nil

620 - 650

for 2 hours
150
for 2 hours

620 - 650

150
Nil

620 - 650
Nil

Nil

620 -

Nil

650
P1 Gr 2
& SA 106 Gr C

>919

Nil

620 650

Nil

620650

Nil

620 650

>19

150

620650

150

620650

150

620 650

Nil
150
for 2

hrs

P1 + P3

- 620 to 650C

P1 + P4

- 640 to 670C

P4 + P5A

- 680 to 710C

(For other P Group combinations, refer to Engineering)

P NUMBER AND GROUP NUMBER FOR BASE MATERIALS

Grou
P.No p No. Common Name

Tubes
SA192

Carbon
Steels
P1

Pipes
SA106GRB

SA210GRA1

Plates
SA36

Forgings

Castings

SA266CL

SA216WC SA234

SA515GR55

SA352LC

SA515GR60

SA352LC

Fittings

SA515GR65
SA516GR55
SA516GR60
SA516GR65
SA210GRC

P1

P3

P3

P4

P5A
P15
E

1
2

Carbon Steels

Carbon-Moly
Steels

P8

SA213T2
1CrMo/
1CrMo Steels SA213T12/
SA213T11
2Cr1Mo Steels
SA213T22
9Cr1MoV Steels
SA213T91

SA515GR70 SA266CL

SA216WC SA105

SA516GR70

SA216WC SA234

SA299

SA352LC

SA335P1

SA217WC

SA335P2

SA387GR2

SA335P12

SA387GR12 SA182F1

SA217WC SA234

SA335P11

SA387GR11 SA182F1

SA234

SA335P22

SA387GR22 SA182F2

SA217WC SA234

SA335P91

SA387GR91 SA182F91

SA234
WP91

SA209T1

CrMo Steels

18Cr-8Ni Steels

P8

SA106GRC

25Cr-20Ni Steel
(Type 310)

SA213TP304

SA376TP304

SA240TP304 SA182F3

SA351CF

SA213TP304

SA376TP304H SA240TP321 SA182F3

SA351CF

SA213TP347

SA376TP321

SA240TP347 SA182F3

SA351CF

SA213TP347

SA376TP347

SA336F3

SA351CF

SA213TP321

SA376TP347H

SA336F3

SA351CF

SA336F3

SA351CF

SA240TP310 SA182F310 SA351CK

20

SA403

Note : IS1239 & API 5L GR B Pipes, IS2062 Plates may be treated as P No.1 Gr No.1
material.