1.

Module Details

Module name
INDUSTRIAL RADIOGRAPHY
Nominal duration 3 modules

It is anticipated that a learner holding the prescribed entry level
skills will achieve the module purpose in 105 to 120 hours

Module Codes EA610
Discipline Code Non-destructive testing (Code to be allocated)

2. Module Purpose
To provide learners with knowledge of the principles, procedures
and applications of radiographic testing, to develop the competency
to undertake radiographic testing of materials in accordance with
the requirements of national and international codes and
specifications, and to interpret the results of such tests

3. Prerequisites
Radiography and Radiation Safety - EA612

4. Relationship to
competency
standards
This module, in association with the module Radiography and
Radiation Safety, meets the training requirements for Level 2
qualification in radiographic testing under AS3998-1992 "Non-
destructive Testing - Qualification and Certification of Personnel -
General Engineering" and AS-3669-1989 "Non-Destructive Testing
- Qualification and Registration of Personnel - Aerospace".

Currently no national competency standards have been established
at national level. However, the learning outcomes in this course
relate to ASF level 5-6.

5. Content
X-ray Equipment
Electron source, beam focusing, electron acceleration.
Equipment design, roentgen output, duty cycle, focal spot size, heel
effect, tube efficiency.
Mono and bipolar tubes.
Rod anode, rotating anode, fine and dual focus tubes.
Glass and metal/ceramic tubes.
X-ray circuits, self rectified, half wave rectified Greinacher, Graetz,
Villard, constant potential.
Tube windows - Beryllium and glass window.
Control equipment. Effect of voltage and current.
Intro to special equipment eg. Linear Accelerators,
Betatron, Van de Graaf.
Gamma Ray Sources
Spectra, activities, decay factors, energies of principal
lines, advantages, limitations, applications of Ir192, Co60,
Yb169.
Comparison on X-ray and gamma ray sources on basis of energy
and intensity.
Radio-isotope containers, types, construction, materials, ancillary
equipment, operation, safety.
Shielding Thickness
Shielding theory. Properties of shield materials.
Camera types and design and accessories.
Handling isotope cameras.
Safe working distance for X-ray & Gamma ray exposures -
calculation.
Photographic Aspects
Principles of image formation.
Film types, emulsions, classes, properties. Film selection.
Film density, characteristic curves, gradient, film gamma,
film contrast, exposure latitude.
Inherent unsharpness
Intensifying screens - lead, fluorescent, fluorometallic
Processing chemicals - developer, stop bath, fixer, wash
Effect of time and temperature. Tropical processing.
Need for washing. Requirements for archival storage.
Dark room control and layout.
Chemical processes for intensification and reduction
of films. Effect on quality.
Film artefacts - source, appearance, avoidance.
Radiographic Sensitivity
Radiographic contrast - effect of energy, material,
scatter, film.
Definition - Geometric, film and total unsharpness,
geometric factors, film factors. Determination.
Radiographic sensitivity - definition.
Radiographic undercut - use of screens and masking.
Assessing Sensitivity
Image quality indicators - types, applications.
Calculation of IQI sensitivity.
Relevance to flaw sensitivity.
Undercut comparator shims.
Exposure calculations
Set-up procedures.
Effect of X-ray & gamma ray energy.
Effect of tube current and source activity
Determining exposure geometry.
Control of geometric unsharpness.
Relationship of source size, distance and object/film distance.
Reciprocity Law.
Choice of films, screens, cassettes.
Preparation and use of exposure charts, radiographic equivalence
charts. Use of distance squared law and characteristic curves.
Exposure calculations taking into account all variables.
Preparation of exposure charts and characteristic curves.
Exposure Techniques
Selecting the views - number of exposures, minimising use.
General and local views, beam centring, Directional and
panoramic exposures.
Identification of radiographs - overlap, markers, job
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Module: EA610 - Industrial Radiography - May, 1998
(correlation) numbers, numbering of joints.
Image distortion, object/focus/film distance, section
equalisation.
Choice of source/energy, film, screens.
Use and placement of IQI's.
Preparation and use of sensitivity charts.
Viewing and Interpretation
Viewing radiographs - Equipment types, determination of
brightness with photographic exposure meter.
Background lighting, operator factors.
Preliminary assessment - artefacts, IQI sensitivity.
Recording and reporting.
Acceptance codes, standards.
Radiography of Welds
Welding processes (revision only).
Defects in welds - appearance, cause, significance.
X-ray and gamma ray techniques - Code requirements.
Radiography of Castings
Foundry processes (revision only).
Defects in castings - appearance, cause, effect.
X-ray and gamma ray techniques -Code requirements.
Radiography of aircraft parts
Aircraft structures (revision only).
Defects in aircraft
X-ray and gamma ray techniques, codes, ANO's, ANR's
Radiography of other Materials
Assemblies - electrical, mechanical. Effect of beam
divergence
Plastics, ceramics, graphite, foods, wood
Autoradiography of radioactive materials
Site Radiography
Specific problems of radiography at a field site
Equipment required
Safety aspects
Special Radiographic Techniques
Depth location using double exposures.
Two exposures at right angles, stereo radiography.
Multi film techniques for section equalisation.
Enlargement and projection.

Density analysis for determining thickness of flaw.
Applications of low voltage and high voltage Radiography
Types of materials radiographed
Industrial applications
Set up procedures

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Module: EA610 - Industrial Radiography - May, 1998
6. Assessment
strategy
Competency based assessment applies. Assessment should be
carried out by gathering evidence using a variety of methods or
instruments that have validity according to the learning being
assessed.

Assessment method Multiple choice and short answer questions.
Written assignments and demonstrated competence through
assigned tasks.

Final assessment will be by a written examination and practical
examination as required by AS3998 for Level 2 Certification.

Conditions of assessment Assessment will be conducted by suitably qualified assessors, as
required by AS3998. The candidate will have access to any
equipment, materials and documentation as required for the
assessment.

7. Learning
outcome details
On completion of this module, the learner will be able to
8. Learning outcome
1
Describe the principal types of X-ray generator and the principal
radioisotopes used in industrial radiography, including the
important aspects of the radiation produced by each radiation
source, and the effect these factors have on radiographic quality

Assessment criteria 1.1 Describe the various X-ray tubes and generator circuits
used in industrial X-ray equipment, and the effect they have of
radiation output. Determine focal spot size and beam spread for an
X-ray tube.

1.2 Describe the principal radioisotopes used in industrial
radiography, their important properties, and the properties of the
radiation emitted by these radioisotopes. Select a suitable source for
particular applications.

1.3 Compare the outputs of X-ray and gamma ray sources on
the basis of energy and intensity of radiation.

1.4 Determine the shielding thicknesses and safe working
distances for X-ray and gamma ray radiography.
Learning outcome 2
Describe the photographic aspects of radiographic film exposure
and development.

Assessment criteria 2.1 Describe the different types of radiographic film and their
classifications.

2.2 Describe the factors that affect the exposure of radiographic
film.
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2.3 Describe the principal components of radiographic film
development chemicals and their purpose.

2.4 Select most suitable film/screen combinations for particular
circumstances.

2.5 Identify film artefacts and determine their source and cure.

2.6 Assess the effect of processing variables on film quality.

Learning outcome 3
Describe the factors that affect radiographic quality and apply these
principles in producing optimum quality radiographs.

Assessment criteria 3.1 Identify the primary and secondary factors that affect
radiographic sensitivity.

3.2 Identify the means available for assessing radiographic
sensitivity, and calculate sensitivity values using these devices.

Learning outcome 4
Describe the methods for setting up and producing a satisfactory
radiograph using X-ray and gamma ray sources.

Assessment criteria 4.1 Calculate radiographic exposures to achieve a specified
radiographic film density and sensitivity for a variety of industrial
applications taking into account the full range of factors that affect
quality of a radiograph..

4.2 Students will set up for various geometries and produce
radiographs to stated standards.

4.3 Describe the factors that affect radiographic sensitivity.

4.4 Determine required source/film geometry and number of
exposures necessary for a variety of industrial radiographic
applications.

4.5 Assess radiographic sensitivity using different types of IQI.

Learning outcome 5
Describe and set up the conditions necessary to view and interpret
radiographs.

Assessment criteria 5.1 State the conditions necessary to view and interpret
radiographs.

5.2 Design and/or set up a radiographic viewing facility.

5.3 View and report radiographs in accordance with published
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Module: EA610 - Industrial Radiography - May, 1998
codes and standards.

Learning outcome 6
Discuss, describe and carry out radiography of welds, castings and
assemblies and non-metallic materials using standard procedures to
recognised standards, and interpret those radiographs in accordance
with acceptance codes and standards.

Assessment criteria 6.1 Satisfactorily set up and radiograph welds, castings,
assemblies and non-metallic specimens in accordance with national
standards.

6.2 Interpret and report radiographs of welds, castings,
assemblies and non-metallic specimens in accordance with national
acceptance codes and standards.

6.3 Demonstrate knowledge of requirements for site
radiography by setting up work using the appropriate code and
safety procedures to ensure the safety of themselves and the general
public.


Learning outcome 7

Discuss and describe specialised radiographic techniques,
including very high voltage and low voltage radiography, and
techniques for specialised applications.

Assessment criteria 7.1 Describe the theory, procedures and applications for high
voltage and low voltage radiography.

7.2 Describe the procedures for specialised radiographic
applications such as telegraph poles, assemblies, defect depth
determination and corrosion assessment in pipes.


7.3 Demonstrate methods for defect depth determinations,
apply section equalisation techniques, use density analysis for
determining flaw thickness and pit depth in accordance with
relevant standards and codes.

7.4 Set up and produce radiographs for specialised applications.

7. Delivery of the
module
This module may be taught by active participation, illustration,
demonstration and description. This module is practical in nature
and theoretically integrated to complement the acquisition of
practical skills.

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Module: EA610 - Industrial Radiography - May, 1998
Delivery strategy
This module may be taught and assessed on or off-the-job.

The module has a high practical content. Theory and practice will
be taught concurrently. There will be a range of learning activities
including modified lectures, practical work and project work.

Resource requirements
Human resources
trainer/teacher/mentor
Physical resources
appropriately equipped training room
relevant equipment and information
legislative and regulatory documents

Major texts and
references
RECOMMENDED TEXT

Radiographic Testing - P.A. Sheedy - NSW TAFECOM.

PRACTICAL TEXT

Practical Radiography - P.A. Sheedy

REFERENCES

1. Non-Destructive Testing Handbook, 2nd Edition, Vol. 3,
Radiographic Testing. ASNT, 1985.

2. Industrial Radiography, R. Halmshaw, 1982.

3. Radiographic NDT, G.L. Becker. Du Pont NDT Systems,
1990.

4. Industrial X-ray Interpretation, J.G. Schneeman. ASNT,
1985.

5. Industrial Radiography, Agfa Corporation.

6. NDE Characteristics of Pipe Weld Defects, EPRI, 1980.

7. Radiographs of Welds, IIW, 1982.

8. Radiographic Testing Classroom Handbook, ASNT.


STANDARDS

AS 1929 Non-Destructive Testing - Glossary of Terms.

AS 2177/1 Non-Destructive Testing - Radiography of welded
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Butt Joints in Metal - Methods of Test. (under review as DR91258)

As 2177/2 Non-Destructive Testing - Radiography of Welded
Butt Joints in Metal - Image Quality Indicators and
Recommendations for Their Use. (under review)

AS 2452/1 Non-Destructive Testing - Determination of Wall
Thickness of Pipe by use of Radiography.

AS 2452/2 Non-Destructive Testing - Determination of
Remaining Wall Thickness of Corroded Pipe by use of
Radiography.

AS 3507 Non-Destructive Testing - Radiography of Steel
Castings and Classification of Quality.

AS Z5/2 Welding Terms and Symbols - Fusion Weld
Imperfections.

ASTM E446 Reference Radiographs - Steel Castings up to 51
mm thick

ASTM E186 Reference Radiographs - Steel Castings 51 to 114
mm thick

ASTM E155 Reference Radiographs - Aluminium/Magnesium
Castings

ASTM E802 - reference radiographs - Gray Iron Castings up to 114
mm thick

NOTE: Reference should also be made to various structural, pipe
and pressure vessel codes and standards for defect limitations as
revealed by radiographic testing.

Occupational health and
safety requirements
Learners and/or employees undertaking this module should have
demonstrated competencies as defined in the Metal & Engineering
Industry Standards Unit No 1.2F - Apply principles of OH&S in the
work environment. This would apply in the classroom, practical
room or workplace.


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ACTRAC PRODUCTS
Module: EA610 - Industrial Radiography - May, 1998