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PROCEDUREFOR RADIOGRAPHIC
EXAMINATIONOF CASTINGS
USEDFOR VALVES AND BOILERS.

Reviewed&Approved B

M,MANIfTIOHAN R.J.PARDIKAR
DY.MANAGER AGM
LEVELII $T.LEVELlll
NDT

EFFECTIVEFROM 18.04-2009

CONTROLLED/ INFORMATIONCOPY
ISSUED
TO ISSUEDON CONTROL ISSUEDBY
NO.
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BHARAT HEAVY ELECTRICALS LIMITED ax

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RECORDOF REVISION H

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Rev Revision Revision of Details
Date C
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No
05 01-06-1993 Revisedin its entirety

06 12-06-1997 ProcedureBHE:NDT:V:RT:9 Rev.0lmergedwith this procedure

And revisedto its entirety.
07 18-04-2009 2 . 0 , 5 . 1 , 8 . 1 . 1 , 1 3 1. 15,. 1, 1 8 . 1 ,A n n e x u r eA , B , C , D , E , F -
Revised.
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1.1 This procedure describes the testing method and acceptance standard for the A Y ( - A

radiographic examination of steel castings of materials ASTM A 216 - WCB, WCC, A 217 t'ti :
-WC6, WCg, ASTM A351 Gr.- CF8M, Components covered under API 6A, thickness < c !
ranging up to 305mm and pertaining to conventional valves, TOA valves, Safety and !.1 lrl
'.1-

Safety Relief Valves, Oil Field Equipments,and Boiler Gomponents. -

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2.0 REFERENCES

2.1 ASME Boiler and PresserVessel code - Section-V/Vlll Div 11200712008Addenda

2.2 ASMEB 16.34I 2004

2.3 ASTME 94 I 2000

2.4 API-6AI 2005,6D/ 2008,16C

/ 1993,17DI 1992.

3.0 EQUIPMENT

3.1 Radiationsources

3.1.1 The radiationenergy (X-rays upto 6 Mev, lridium 192, Cobalt 60) employed for any
Radiographictechniqueshallachievethe Densityand lQl image requirements.

3.2 Films

3.2.1 Industrial Radiographic Film shall be used. Generally the following brands of film or
equivalentshall be used for radiography:
a) Agfa -Gevaert D7l(Laser DTllDSl(LaserD5)
b) Kodak Industrex A/AA 400/T/M

3.3 Screen

3.3.1 Lead intensifying Screens shall be used for radiography. Fluorescent screen shall not be
used. Minimum thickness of the Lead Screen shall be 0.10/0.15mm for 1r.192 and
0.2010.25mmfor Co.60.

4.0 SURFACECONDITION

4.1 The surface to be radiographed shall have a relatively even surface to allow proper
interpretation of the radiograph. All deep surface pits of casting shall be dressed
smoothly before radiography.Fettling operation shall be done before radiography.

5.0 RADIOGRAPHICSENSITIVITY

5.1 Radiography shall be performed with a technique to achieve the sensitivity of 2-27
Selection of lmage Quality lndictor (lal ) shall be based on the table 2 in Annexure -A .

5.2 lf ASTM Wire Type lQl is used, the set of wires used shall be identified with the material
with which the wire is made and their number. The set shall contain a wire equivalentto
2% ol the thickness being radiographed.

5.3 The material of the lQl shall be radiographicallysimilar to the object being radiographed.lf
this material is not available the lQl of the required dimensions, but of lower absorption
materialmay be used. lQl shall conform to RecommendedPractice SE 102515E747.

5.4 Placementof lQl

5.4.1 Wherever possible, the lQl shall be placed on the source side of the section being
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examined.For double wall single image technique, lQl may be placed on film side with ii>
identification 'F', if hand placementon source side is impracticable. o >
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6.0 N U M B E RO F I Q I - - l
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6.1 When one or more film holders are used for an exposure, at least one lQl image shall
appear on each radiograph except as outlined in 6.3 and 6.4. -
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6.2 lf the requirementof 14.0 is met by using more than one lQl, one shall be representativeof
the lightest area of interest and the other shall be of the darkest area of interest; the
interveningdensities on the radiographshall be considered as having acceptabledensity.

6.3 For cylindrical/spherical castings where the source is placed on the axis/centreof the
object for a single exposure, at least three lQl shall be placed spacing approximately
120degreeapart under the following conditions;

6.3.1 When a complete circumferenceis radiographedusing one or more film holders or

6.3.2 When a section or sections of the circumference,where the length between the ends of the
outermost sections span 240 or more degree is radiographed using one or more film
holders. Additional film locations may be required to obtain necessary penetrameter
spacing.

6.4 For cylindrical/Sphericalcastings of the circumference of a cylindrical/spherical casting

is radiographed placing source at the axis/centre of the component for a single
exposure, at least three lQl's shall be placed at each end of the span of the
circumference radiographedand one in the approximatecentre of the span,

6.4.1 When a section of the circumference,the length of which is greater than 120 degree and
less than 240 degree is radiographedusing just one film holder, or

6.4.2 When a section or sections of the circumference,where the length between the ends of
outermost sections span less than 240 degree is radiographed using more than one film
holder.

6.5 In order to maintain the continuity of records involving subsequent exposures, all
radiograph exhibiting lQl which qualify the techniques permitted in accordance with 6.3
and 6.4 shall be retained.

When an array of objects in a circle is radiographed,at least one lQl shall be seen on each
object image.

7.0 RADIOGRAPHY
COVERAGE

7.1 The castings sections to be radiographed shall be as per the sketches shown in
Annexure F. However all the sample castings shall be radiographed for the entire
accessibleregion.

8.0 GEOMETRICAL (pn)

UNSHARPNESS

8.1.1 When required by the referencingcode section, Geometric Un-sharpnessof the radiograph
shall not exceed the following and source to film distance shall be selected accordingly.
T A B L E. 1
MATERIALTHICKNESS po Max.
Under50.0mm 0.51mm
Over 50.0to 75.0mm 0.76mm
Over 75.0to 100.0mm 1 . 0 2m m
'Greater
than 100.0mm 1 . 7 8m m
Materialthickness is the thickness on which lQl is based.
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8.2 For other cases, source to film distance shall be selected such that Geometric Un- E >
sharpnessshall not exceed 1.78mm. o >
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8.3 Final acceptanceof the radiographshall be based on the achievementof requisite m

sensitivity. <cD
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9.0 LOCATIONMARKER -
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9.1 Location markerc which are to appear as radiographic images on the film, shall be
placed on the psrt, not on the exposure holder/cassette. Their location shall be
permanentlymarked on the surface of the part being radiographedwhen permitted or on a
map in a manner permitting the area of interest on a radiograph to be accurately
traceable to its location on the part for the required retention period of the radiograph.
Evidence also shall be provided on the radiograph that the required coverage of the
region being examined has been obtained.

9.2 Location markers shall be placed as in Annexure F

1O.O EXAMINATION

10.1 Radiographic technique: A single wall exposure technique shall be used whenever
practical.When it is not practicalto use a single wall technique a double wall technique
shall be used (for cylindrical/sphericalcastings where outside diameter is less than g0
mm). An adequate number of exposures shall be made to demonstrate that the required
coverage has been obtained.

10.2 For double wall viewing, only a source side lQl shall be used.

11.0 INFORMATION
ON RADIOGRAPH

11.1 The following information shall appear on the radiograph as a permanent image.

11.1.1 Job Number i.e. serial number given for the part as per radiographic details register.

11.1.2 Segment number as per the shooting sketch of the part.

11.1.3 lmage Quality Indicators

11.1.4 Date of Radiography.

11.1.5 Nameof the company/BHEl

11.1.6 lf the radiograph is taken after any local repair revealed in the original radiograph, letters
R1, R2 etc. shall be kept after the job number to indicate that the radiograph is after the
repair and the suffix 1,2 etc. will specify the number of times repair is carried out. The
radiographs taken after repair shall be submitted along with original. The repaired area
shall be identified by placing lead arrows. Radiographicidentificationand lQl shall not be
placed on the repaired region.

12.0 QUALITYOF RADIOGRAPHS

12.1 All radiographsshall be free from mechanical,chemical or other blemishes

'B', of 13.0mmin
12.2 ScatteredRadiation: To check the back scattered radiation, a lead symbol
height and 1.6mm in thickness shall be attachedto the back of each film holder.

12.3 Excessive Scatter: lf the light image of 'B' appears on the darker background of the
radiograph, protection from back scatter is insufficient and the radiograph shall be
considered unacceptable. A dark image of 'B' on a lighter background is not a cause for
rejection.
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13.0 RADIOGRAPHICDENSITY t >
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13.1 The transmitted film density through the radiographic image of the body of the -Al) =
Y
appropriatelQl's and the area of interest shall be H

for single film viewing- 1.8 minimum and 4.0 maximum {co
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For Super imposed viewing of double film F.l

each film shall have 1.00 minimum and 2.5 maximum and with double film 4.0 maximum C
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13.2 Either a densitometer or a step wedge comparison film shall be used for density
measurements

14.0 DENSITYVARIATION

14.1 lf the density of the radiograph anywhere through the area of interest varies by more than
-15% or +30% from the density through the body of lQl, within the minimum/maximum
allowable density ranges specified in 13.1, then an additionallQl shall be used foreach
exceptional area or areas and the radiograph retaken. When calculating the allowable
variation in density, the calculation may be rounded off to the nearest 0.1 within the
rangespecified in 13.1.

15.0 ACCEPTANCESTANDARDS

15.1 Evatuationof defects shall be carried-outas per ASTM E446 for Steel Castings upto 50mm
thickness, as per ASTM E-l86 for steel castings - heavy walled (50mm to 115mm) and as
per ASTM E-280for heavy walled steel castings, wall thickness 11Smmthrough 305mm.

15.2 Acceptance standards for various components are given in annexure B to D.

16.0 N D EP E R S O N N E L

16.1 Radiographyshall be performed by personnel qualified as minimum level I and

Evaluationby Level ll / lll in accordance with ProcedureBHE:NDT:G:CRT.

17.0 RECORDINGAND UP KEEPINGOF THE RADIOGRAPHS

REPORTING,

17.1 Results of radiographic examinationshall be reported in formats approved by Head/NDTL-

BHEL.

17.2 All the radiographs shall be clearly identified with serial numbers which can be linked
up with, the casting which bears the same serial number as that of radiographs.

17.3 The radiograph number shall be punched just betow the heat numbers and encirciedwith
white paint and the location number shall be legibly painted on the castings with white
paint.

17.4 Radiographsof castings pertainingto API 6A - PSL 3 and 4 and of welds pertainingto API
6 A - P S L 2 , 3 a n d 4 c l a s s i f i c a t i o ns h a l lb e r e t a i n e d f o r a p e r i o d o f m i n i m u m 5 y e a r s .
Other radiographswill be retainedtill the manufacturing is completed or up to 3 years.
from the date of radiography,whichever is earlier.

18.0 SAFETY

18.1 Applicable safety precautions shall be followed in accordance with Procedure

BHE:NDT:G:SFT
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ANNEXURE-A -ii >

Table-2 o>
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MaterialThickness, lQl designationsand Essentialhole/ Wirediameter. (^ r-,

NominalSinglewall lmage Quality Indicator r n i

thickness range (mm) Sourceside Film side
Fl trr

Desgn Essl. Wire Desgn Essl. Wire -

i.

Hole No Dia(mm) Hole No Dia(mm) C

a
Up to 6.4 incl. 12 2T 5 0.20 10 2T 4 0.16
Over 6.4 throuqh 9.5 15 2T 6 0.25 12 2T 5 0.20
Over 9.5 throush 12.7 17 2T 7 0.33 15 2T 6 0.25
Over 12.7 throuqh 19.0 20 2T I 0.41 17 2T 7 0.33
Over 19.0 throuqh 25.4 25 2T 9 0.51 20 2T I 0.41
Over 25.4 throuqh 38.1 30 2T 10 0.64 25 2T 9 0.51
Over 38.1 throuqh 50.8 35 2T 11 0.81 30 2T 10 0.64
Over 50.8 throuqh 63.5 40 2T 12 1.02 35 2T 11 0.81
Over 63.5 throuqh 101.6 50 2T 13 1.27 40 2T 12 1.02
Over 101.6throuqh 152.4 60 2T 14 1.60 50 2T 13 1.27
Over 152.4throuqh 203.2 80 2T 15 2.03 60 2T 14 1.60
Over 203.2throuqh 254.0 100 2T 16 2.54 80 2T 15 2.03
Over 254.0throuqh 304.8 120 2T 17 3.20 100 2T 16 2.54

ANNEXURE.B
RADIOGRAPHIC
ACCEPTANCESTANDARDS
FORCASTINGSOF CONVENTIONAL
VALVES,
TOADESTGN
VALVESANDBOTLER (ASPERASME B 16.34)
CASTTNGS.

81.0 Acceptanceof pressurecontainingcastingsup to and including600 PSI(g)or40 atm.

primary service ratingshall be basedon the following:

81.1 Wallthicknesslessthan 50 mm.

Thefolfowingcomparativeplatesof ASTME 446defineacceptableindicationsas foltows:-

Discontinuitv type Acceptablecomparative plate

Category Level
Gas A A2
Sand B B3
Shrink Type-l c cA2
Shrink Type-2 c c83
Shrink Tvpe-3 c cc3
Shrink Tvpe4 G cD3
Hot tear& Cracks D&E None
Inserts(chills,chaplets) F None
Mottling G ReferencePurposeonlv

B1.2 The following comparative plates of ASTM E 186 shall be acceptablefor Wall thickness
f r o m 5 0 m m u p t o l l 5 m m a n d o f A S T M E 2 8 0 s h a l l b e a c c e p t a b l e f o r w a l lt h i c k n e s sf r o m
1 1 5m mth 305mm.
Discontinuitytvpe Acceptablecomparative plate
Gateqory Level
Gas porositv A A3
Sand and slaq inclusions B B3
Shrink Type-l c cA3
Shrink Tvpe-2 c c83
Shrink Type-3 c cc3
Gracks D None
Hot tear E None
lnserts F None
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82.0 ACCEPTANCEOF PRESSURECONTAININGCASTINGSOVER 600 PSI(G) (40 atm) C >
PRIMARYSERVICEPRESSURERATINGSHALL BE BASED ON THE FOLLOWING: =7

82.1 Wall thickness less than 51mm. €co

The following comparative plates of ASTM E 446 define acceptabteindications as Fl trr

follows:- -
i
Discontinuitytype Acceptable comparative plate
Category Level
Gas A A1
Sand B 82
Shrink Tvpe-1 c cA1
Shrink Tvpe-2 c cB2
Shrink Tvpe-3 G cc2
Hot tear & Gracks D&E None
lnserts (chills, chaplets) F None
Mottling G ReferencePurpose
onlv

B.2.2 The following comparative plates of ASTM E 186 shall be acceptablefor Wall thickness
from 51mm upto 115mm and of ASTM E 280 shall be acceptablefor wall thickness from
11Smmthrough 305mm.

Discontinuitytype Acceptable comparative plate

Category Level
Gas porositv A A2
Sand and slaq inclusions B 82
Shrink Tvpe-1 c cA2
Shrink Type-2 c cB2
Shrink Type-3 c cc2
Cracks D None
Hot tear E None
Inserts (chills, chaplets) F None

83.0 Butt welding ends shall be free from shrinkage and hot tear. Gas hole/porosity and
sand inclusion shall be limited to level A1 and 81 respectively.

84.0 The acceptance Standard for yoke, yoke clamp and wedge/Disc shall be level-lll of
E4461E186/E280.No crack, hot tear or unfused chapleUinsert is permitted.

85.0 Acceptance of weld repairs of steel casting shall be as follows:-

Weld repair portions of castings that are shown by radiography to have any of the following
type of discontinuities shall be unacceptable.

A) Any type of crack or zone of incompletefusion or incomplete penetration.

B) Any other elongated indication which has a length greater than

i) 6.00mmfor't' upto 19mm inclusive

ii) 1/3tfor't'from 19mm to 57mm inclusive
iii) 19 mm for't' over 57mm where 't' is the thickness of the repairedportion.
't'
C) Any group of indications in line that have an aggregate length greater than in a
length ol 12t except when the distance betweenthe successive indication exceeds6 L
where 'L' is the length of the longest indication in the group.

D) Rounded indication in excess of that shown as acceptable in rounded indication

chart given in annexure4 of ASME SectionVlll, Division 1
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C1.0 Radiographic acceptance standard for area marked as critical in the respective { w
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casting drawing shall be as follows:- F.l
'T.
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C1.1 Thefollowing comparative plates of ASTM E446 forthickness upto 51mm and ASTM-E186
for thickness from 51mm to 11Smmshall define the acceptableindication as mentioned
below:
Discontinuitvtvpe Acceptablecomparative plate
Category Level
Gas A A3
Sand B B3
Shrink Tvpe-l c cA3
Shrink Type-2 c cB3
Shrink Tvpe-3 c cc3
Shrink Tvpe4 c cD4
Hot tear & Cracks D&E None
lnserts (chills, F None
chaplets)
Mottlinq G Referencepurpose onlv
C1.2 Other areas shall be accepted against the comparative plate as indicated below depending
upon the thickness.
Discontinuity type Acceptablecomparative plate
Categor Levef (ASTM E446 / E 186
v
Gas porosity A A4IA4
Sand and slag B B4IB4
inclusions
Shrink Type-1 c cA4tcA4
Shrink Tvpe-2 c cB4tcB4
Shrink Tvpe-3 c cc4tcc4
Shrink Type4 c cD4t -
Hot tear & Gracks D&E None
'lnserts(chills, chaplets) F None
Mottlinq G Referencepurpose onlv
C2.0 Butt weldingendsshall be freefrom shrinkageand Hot Tear.Gas Hole/Porosity
and sand
inclusionshall be limitedto A1 and 81 respectively.

C3.0 Acceptanceof weld repairsof steelcastingsshall be as follows:-

C3.1 Weldrepairportionsof castingsthat areshownby radiographyto haveany of the following

typeof discontinuityshall be unacceptable:

A. Any type of crackor zoneof incompletefusion or incompletepenetration.

B. Any other elongatedindicationwhich has a lengthgreaterthan

i) 6.00for't' upto 19mminclusive.

ii) 1/3t for't'from 19mmto 57mminclusive
iii) 19mmfor't' over 57mmwhere't' is the thicknessof the repairedportion.

C. Any group of indicationsin line that have an aggjregatelength greaterthan 't' in a

length 6t 12t' exceptwhenthe distancebetweenthe successiveindicationexceeds6L
where'L' is the lengthof the longest indicationin the group.

D. Roundedindicationin excessof that shownas acceptablein Appendix4 of ASME

SectionVlll,Division1.
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BHARAT HEAVY ELECTRICALS LIMITBD BHE:NDT:W:RT- 06
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ANNEXURE. D ti >
F 1
Dl.O ACCEPTANCESTANDARDSFOR OIL FIELDEQUIPMENTS o >
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D1.1 Castings m
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D1.1.1 The following comparative plate of ASTM E446 for thickness less than 51mm, ASTM E 186
-j .-,
'1.

for thicknessfrom 51mm to 114mmand ASTM E 280 for thicknessfrom 114 through 305 c-l
mm shall define the acceptablecriteria depending upon the section thickness being
examined.
Discontinuitv tvpe Acceptablecomparative plate
Gategory Level
Gas A 2
Sand B 2
Shrinkaqe(alltvpes) c 2
Hot tear D None
Grack E None
Inserts(chi lls, chaplets F None
Mottlinq G None

D1.2 Hot worked Parts of PSL-I ,2 , 3 and 3G

D1.2.1 No type of cracks, laps or bursts.

D1.2.2 No elongated indications with length exceeding

(a) 6.4 mm for thickness upto 19mm.

(b) 0.33 of thickness for thickness 19mm upto 57mm.
(c) 19mm for thickness over 57mm.

D1.2.3 No group of indications in a line that have an aggregatelength greater than the thickness
in a length of twelve times the thickness.

D1.3 Hot worked material of PSL4

D1.3.1 No type of cracks, laps or bursts.

D1.3.2 No elongatedindicationshaving length exceeding6.4mm.

D1.3.3 No more than 2 indications separated by less than 13.0mm.

D 1 . 4 W e l d s : P S L -, l2 , 3 a n d 3 G :

D1.4.1 No type of crack, zone of incompletefusion, or incomplete penetration.

D1.4.2 No elongated slag inclusion which has a length equal to or greaterthan

a) 6.4mm for weld thickness less than 19mm inclusive.

b) 1/3 times the thickness for weld thickness from 19mm to 57mm
c) 19mm for.weld thickness greater than 57mm.

D1.4.3 No group of slag inctusionsin a line having an aggregatedlength greaterthan the weld
thickness,'T',inany total weld length of l2T,exceptwhen the distance between
successive inclusion exceeds six times the length of the longest inclusion.

D1.4.4 No rounded indications in excess of that specified in rounded indication chart, Appendix
4 of ASME SectionVlll, Division 1.
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BHARAT HEAVY ELECTRICALS LIMITED 6x

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ANNEXUREE t >
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' Bonnet

GATEBODY(PRESSURE
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Y.PATTERNGLOBE BODY(PRESSURE
SEAL BONNET)

Section X-X and y-y

ANGLE BODY (PRESSURESEAL BONNET)

BONNETSAME AS Y.PATTERNGLOBE
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Saction X-X

ELBOWDOWN(PRESSURE
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Section X.X

GATEBODV(FLANGED
BONNET)

1 3 5d e g .

Section X-X Section I-Y

GLOBEBODY(FLANGED
BONNET)
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