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GE Measurement & Control Solutions
Digital Radiography
Steven Wissels
Product Sales Manager X-Ray Products
Latin America
The Use of digital radiography in the Oil & Gas Industry.
• Timeline
• Systems used • X-Ray tubes
• Film Digitizing (FS) solution
• CR based solution
• DDA based solution
• Pro´s & Con´s
• Software tools
• Standards & Recommendations
• Using Digital Radiography
3 GE Inspection Technologies
Digital Radiography: History
1973 Patent issue covering method & workflow of CR (US3859527 (Eastman Kodak) George W. Luckey)
No storage phosphor available yet that time
1980 1st commercial (powder) storage phosphor composition patented (BaFBr:Eu2+) EP0044516 Nishimura & Kotera
Covers until today >90% of all CR solutions
1983 Fuji introduces the first medical CR system
1985-1995 More medical CR systems commercially available: AGFA, Kodak, Konica
Acceptance of CR for general radiography
1996-2000 First use of CR for NDT pioneered by BAM-Berlin (Prof. Uwe Ewert)
Dedicated CR systems for NDT available from AGFA followed by Fuji, Lumisys
1994-2000 Development and emergence of amorphous silicon digital detector arrays mainly for medical applications
(Dupont, GE, Xerox, Philips, Siemens, Thompson… )
>2000 Other players producing DDA’s and CR equipment enter the NDT market
2004 First release of ASTM DICONDE standard,
GE to acquire AGFA NDT division
2005 First CR Standards: EN 14784-1 and -2, ASME V Code Case 2476
2009 CR in HOIS JIP (Joint Industry Project) forum
2010 Aerospace MAI on CR/DR
2013 Release ISO 17636-1 and -2
X-Ray Tubes
4
5 GE Inspection Technologies
Radiography Basics: X-ray Tubes & Generators
Portable ERESCO generators
o 160 - 300 kV
o Directional and Panoramic units
o Intuitive and ergonomically Control Module MF4
o Application specific accessories
o Robust design
Mobile ISOVOLT mobile 160 System
o 160kV HV generator
o Compact and easy to handle
o Supports different X-ray tubes
o Ruggedized design
5
6 GE Inspection Technologies
Radiography Basics: X-ray Tubes & Generators Stationary ISOVOLT TITAN E System
o 160 – 450 kV
o High stability and accuracy
o High dose rate output
o Supports >50 X-ray tubes
o Supports different coolers / chillers and safety mechanism
o Simple system integration
o Reliable operation
o Maintenance Free High Voltage option for 450kV
6
7 GE Inspection Technologies
Radiography Basics: X-Ray Tubes & Generators
Next generation Stationary X-ray System: ISOVOLT Lynx
o 160 – 320 – (450 – 600) kV
o State-of-the-art High Voltage and Power Electronics
o Fast controller and high performance computing power
o On-line monitoring
o Maintenance Free High Voltage Connections
7
Film Digitizing (FS)
8
9 GE Inspection Technologies
Film Digitizing: FS50 (B)
Converts radiographic film to a digital format.
Extracts more information than light box viewing.
Contrast Sensitivity: Δ0.02 between 0 and 4.5 OD.
Film digitizing up to 50µ.
50µ pixel pitch: 9 lp/mm resolution.
FS50: 0-4.3 OD, EN14096 Class DB (SN. 2071xxx).
FS50B: 0-4.7 OD, EN14096 Class DS (SN. 2075xxx).
9
Systems used: CR based solution
11 GE Inspection Technologies
X-Ray
A B
Red laser beam
Blue emittedlight
Principle of CR explained in the Atom Shell Model (= shell like structure of electron cloud)
X & Gamma radiation => phosphor electrons excited and trapped in a semi-stable state [LATENT IMAGE]
Laser energy releases electrons => light emitted & captured by PMT [start of DIGITAL IMAGE]
Principle of Storage Phosphor
12 GE Inspection Technologies
rotating mirror
PMT
light-guide
Laserdiode
storage phosphor plate
Computed Radiography: Scanner Principle
Reflecting mirrors
13 GE Inspection Technologies
• Scanners for Computed Radiography (all are BAM certified)
– High Resolution Weld scanner, exclusively for GE, combining highest resolution with high throughput: CRxVision
– Cassette based, HR daylight system designed specifically for NDT applications, with long IP lifetime: CRxFlex
– Portable Scanner (flexible & compact system for on- and off-shore applications) CRx25p
• Reusable Phosphor Imaging Plates and Cassettes
– Superior image quality specifically designed for dedicated NDT applications: IPC2, IPS2, IPU.
Computed Radiography
Systems used: DDA based solution
15 GE Inspection Technologies
GE Digital Panel Technology
Cesium iodide scintillator
absorbs X-Ray photons
and converts them to light.
Low-noise photodiode array
absorbs light and converts it
into an electronic charge.
Each photodiode represents a pixel or picture element.
Low- noise electronics
digitally read out charge
at each pixel
Cesium Iodide (CsI)
Light
Amorphous Silicon Panel
(Photodiode/Transistor Array)
Photons
DE
TEC
TOR
Digital Data
Electrons
Read Out Electronics
High Efficiency Technology
• Reduces required photons per image
• Reduces non-relevant signal noise
Valuable Benefits
• Increases capacity – extreme short exposure time
• Increases resolution - sharper image
16 GE Inspection Technologies
Direct Radiography (DDA) Digital acquisition of radiographs using DDA technology
- extremely high image quality even in a harsh production environment
- static & fully automated inspection systems for various applications:
• Medium / High Resolution Detectors
• Real Time Detectors
- 1st generation Portable Detectors for Field Radiography (Erosion/Corrosion Monitoring, Weld inspection)
• Value Line (GOS) / Premium Line (CsI)
- 2nd generation Portable Detectors (wireless & battery operation)
17 GE Inspection Technologies
Scope of inspection:
o 18 refinery images (elbows, valves and T-s) with Ir192 and Co60
o Completed with both a CR scanner and DXR250V detector
Results:
o Estimated exp. time film: +15 hrs. / 2 full shifts
o Total exp. time CR: 3.78 hours / 0,5 shift
o Total exp. time DXR250V: 7.03 min
Direct Radiography: Example of Exposure Time Gain
17
Pro´s and Con´s
19 GE Inspection Technologies
Return On Investment: Why Digital Radiography
Re-Work
Film
CR
Eliminated Process
Improved Process
DR
Chemical
Disposal Report to
Customer File Film Film Review Develop Film Inspection
Prepare
Workplace
Prepare
Worklist
Purchase
Film &
Chemicals
Inspection Prepare
Workplace
Prepare
Worklist
Au
to A
rch
ive
Image
Analysis
Sca
n
Report to
Customer
Insp
ecti
on
Prepare
Workplace
Prepare
Worklist A
uto
Arc
hiv
e
Image
Analysis
Report to
Customer
19
20 GE Inspection Technologies
Computed Radiography: Pro´s & Con´s
Lower dose required as film
No variable costs (chemistry, darkroom)
Higher dynamic range - less reshoot
High SNR and BSR
Flexible detector
Reusable
Zero environmental impact
ROI: 12 – 18 mnths
Less typo’s (info need to be entered only once)
SW: consistent results & evaluations
Easy sharing of data, worldwide
Pro Con
Weld Image quality slightly less than film with gamma
More sensitive to scatter (adding filter)
Higher initial investment cost, but quite short ROI
Recent released Weld Standard, customers need to understand and adapt
20
21 GE Inspection Technologies
Direct Radiography: Pro´s & Con´s
Very low dose /very short exposures
No variable costs (chemistry, darkroom)
Image quality better than film
Higher dynamic range - less reshoot
Immediate results & reusable
Standard BSR and very high SNR
Zero environmental impact
ROI: 18 – 24 mnths
Less typo’s (info need to be entered only once)
SW: consistent results & evaluations
Easy sharing data, worldwide
Pro Con
Non-flexible detector
DWSI requires (min. 1) image more for pipes smaller than 20” vs. film
Slightly higher investment cost vs. CR
Recent released Weld Standard, customers need to understand and adapt
Non shielded electronics can be affected by long term high-energy radiation (Co60)
21
22 GE Inspection Technologies
OD & WT vs. used energy for CUI (courtesy EDF)
26,0 153 161 169 184 197 210 222 233
25,0 140 150 158 166 180 194 206 218 229
24,0 137 147 155 163 177 190 202 214 225
23,0 128 135 145 152 160 173 186 198 209 220
22,0 116 125 132 142 149 156 170 182 194 205 216
21,0 114 123 129 139 146 153 166 178 190 201 211
20,0 102 111 120 126 136 143 150 162 174 185 196 206
19,0 100 109 117 124 132 139 146 159 170 181 191 201
18,0 88 97 106 114 121 129 136 142 155 166 176 186 196
17,0 80 86 95 104 112 117 126 132 139 150 161 172 181 190
16,0 78 84 93 101 109 114 122 129 135 146 157 167 176 185
15,0 62 67 75 81 90 98 105 111 119 125 131 142 152 162 171 179
14,0 61 65 73 79 87 95 102 107 115 121 127 137 147 156 165 173
13,0 54 59 63 71 76 84 92 99 104 111 117 122 132 142 151 159 167
12,0 53 57 61 69 74 81 88 95 100 107 112 118 127 136 145 153 161
11,0 46 51 55 59 66 71 78 85 91 96 103 108 113 122 131 139 147 154
10,0 40 45 49 53 57 63 68 75 81 87 92 98 103 108 117 125 133 140 147
9,0 33 38 43 47 51 54 60 65 71 77 83 87 93 98 102 111 119 126 133 140
8,0 32 37 41 45 48 51 57 61 67 73 78 82 88 92 97 105 112 119 125 132
7,0 30 35 39 42 45 48 54 57 63 69 74 77 82 87 91 98 105 111 117 123
6,0 29 32 36 39 42 45 50 53 59 64 68 72 77 80 84 91 97 103 109 114
5,0 26 30 33 36 39 41 46 49 54 58 62 66 70 73 77 83 89 94 99 104
4,0 24 27 30 32 35 37 41 44 48 52 56 59 63 66 69 74 80 84
3,0 21 24 26 28 30 32 36 38 42 45 49 51 54 57
2,0 17 20 22 23 25 27 29 31 34 37
40 50 60 70 80 90 110 125 150 175 200 220 250 275 300 350 400 450 500 550
Thickness (mm)
X-Ray tube 250 kv
Diameter (mm)
X-Ray tube 400 kv
Selenium 75
Iridium 192
Cobal 60
Out of range
• The DICONDE Standard
• Flash! filter
• Wall Thickness Measurement tool
• Advanced Report Generator
• Archive
Tools designed for NDT
24 GE Inspection Technologies
DICOM Standard: History
Digital Imaging and COmmunication in Medicine.
ASTM Standard for Medical, defining image format & sharing protocol.
From many equipment suppliers, all with their own propriety format to one worldwide standard!
ACR-NEMA Standards Publications No. 300 was first published in 1985.
These standards provided a platform including: o Communication of digital image information regardless of manufacturer o Command support for display devices o New hierarchy for image identification o More data elements to allow more detailed descriptions of an image o Facilitated the use of picture archiving and communication systems (PACS) o Extending communications to a network environment o Specifies levels of conformance o Introduces explicit Information Objects for studies, reports, etc. o Establishes techniques for uniquely identifying any Information Object
24
25 GE Inspection Technologies
DICONDE Standard: History
Digital Imaging and COmmunication for Non-Destructive Evaluation.
Modalities like Magnetic Resonance (MR) and Nuclear Medicine are not common for NDE.
Similarly, NDE modalities such as Eddy Current (EC), Immersion Testing (IT), and Thermography are not used in the Healthcare. The DICOM standard has been perfected to create a standard for NDE, called DICONDE.
Original tags containing Patient Name, ID, Sex, Age, … are replaced by DICONDE tags with Component Name, ID, Part Thickness, Size Dimensions, etc.
DICONDE follows exactly the same protocols as DICOM, except for changes to handle different modalities and the parts.
25
26 GE Inspection Technologies
DICONDE Standard: Benefits
DICOM/DICONDE compliant: o Ensures data integrity (NO manipulation of raw data) o Ensures customers not to be “locked in” to propriety form. o Eliminates data conversion issues customers face today o Simplifies integration NDT information into other systems
TIFF represents just an image: a small header + image pixel values. It does not typically inform the user
o Of where the image was taken, o Who took the image, o From which modality it is, etc.
DICONDE is much more than an image : o The image is a complete report in itself o Extra info like all Technique data, all Component data, … o An Standard providing common platform for users dealing with NDT images.
Interoperability of the DICONDE platform enables data-sharing between systems,
locations, and/or customers.
Component & technique data, operator name,
date, …
26
27 GE Inspection Technologies
The “ Digital Age” of NDT -”Adopt to Opt imize”
AQUIRE DATA o RT - Radiography o UT – Ultrasonic o CT – Computed Tomography o RT - Remote visual inspection o EM - Electromagnetic o TM - Testing machines
o Data management software
REVIEW DATA o QA/QC o Level II or Level III o Remote Collaboration
SHARE DATA o Remote Collaboration
o Automated Workflow o Convert data into actionable
information o Measure the health of the asset
by product, region and channel o Find growth opportunities via
data mining
ARCHIVE - REPORT DATA o 100 % DICONDE/ASME CODE - Non Propriety Data Format o Measure the health of the asset o Find quality and verification opportunities via data mining o Traceability
o Data Integrity/Data Management
DICONDE Standard: Turning Information Into Intelligence
28 GE Inspection Technologies
Statement It is the intent of this document to confirm that the GEIT Rhythm applications are in compliance
with and are following the DICONDE 11 specification for data formatting. The GEIT team has been an integral part of the ASTM E07.11 subcommittee and participated heavily in guiding the team to the creation of the DICONDE 11 specification.
GE DICONDE Conformance Statement
Tools designed for NDT
Flash! Filter ...
a new era in digital imaging ….
30 GE Inspection Technologies
Flash! Filter
A unique image enhancement software tool based upon innovative technology bringing NDT inspection to an advanced level.
Why:
o A raw image is not optimal for reading and interpretation.
o Image processing visualizes the essential information which is embedded in the raw image without creating indications!
Benefits:
o Higher productivity with more reading comfort
o Faster & consistent results
o less retakes & shorter exposure times, lower labor cost / job
31 GE Inspection Technologies
Conventional Cast! Filter
See also the 2T holes below!
32 GE Inspection Technologies
Conventional Flash! Filter
Wall thickness Corrosion
33 GE Inspection Technologies
Conventional Flash! Filter
Corrosion
34 GE Inspection Technologies
Conventional Flash! Filter
Valve
joint
35 GE Inspection Technologies
Conventional Flash! Filter
Corrosion under insulation
36 GE Inspection Technologies
Conventional
Flash! Filter
Copper on steel weld
Wall Thickness Measurement tool
Tools designed for NDT
38 GE Inspection Technologies
Wall Thickness Measurement Tool
An automated measurement software for pipe wall inspection and documentation.
A unique – patented – mathematical algorithm developed by BAM Germany for GE.
Correct visual wall edge determination is impossible: o Visible edge is optical illusion
o Mathematical determination of outer wall is needed
Computer based evaluation algorithms: o higher precision of measurement
o more consistent results, operator independent
o digital archiving, direct exchange into reports,
o Import & export measurements into pipe data managing system (e.g Pipecad)
Benefits: o Higher productivity with faster & consistent results
39 GE Inspection Technologies
Calblock Calblock with Flash!
Fully automatic WTM tool
Validation and Certification of the mathematical algorithm by independent certification body required for end-users!
Report Generator
Tools designed for NDT
41 GE Inspection Technologies
Releasing versatility in Reporting for Erosion & Corrosion applications
Date Date Date
4.2 0.1
General Remarks
Operator name/sign Interpreter name/sign Customer name/sign
Wall Thickness Wallthickness Tolerance
External corrosion
Exposure Time 0
Image Plate Size
Drawing Diagram/Measurement Setup (Tip: manually insert CAD diagram)
"Comments to Radiograph"
Wall Thickness Measurement (mm)
Customer Order # Position/Test Point
Radiography Setup:
Exposure Technique
Source
Strength
SDD 1300
Internal corrosion
Customer Ref # On Stream Inspection ISO Drawing #
Project # Line number
Customer Demo Images Radiograph creation date 12-09-05
RADIOGRAPHIC EXAMINATION REPORT
General Information: Radiograph Specific data:
o Fully flexible reporting system based on all the DICONDE data already available
o Including images and diagrams in the templates
o For Inspection Companies:
• streamlined reporting workflow,
• in a consistent & professional way
• eliminating time loss
42 GE Inspection Technologies
Benefits converting to Advanced Reporting:
Higher Productivity:
• Less steps involved in the report process
• Auto DICONDE data population
• Less time spent with final report output once generated
• Can now analyze, measure, and generate reports thru single Rhythm software platform
Flexibility & Customization:
• Promotes complete flexibility in design of the report template
• Report output format matches closely current report format that end-customers are using today
Archive
Tools designed for NDT
44 GE Inspection Technologies
Rhythm Archive
• Provides on-line and near-line storage of digital information (images and data), enabling
– Quicker access to information
– Simplified information sharing across the company
• Database capabilities provide the foundation for data mining
– Applications include identify correlation between defects and potential causes
• Data compression to share large image files across remote sites
• DICONDE standard ensures supplier independent long-term data utility and enables multi-system communication
• Next multi-modality platform manages all NDT information
Standards & Recommendations
• ASTM & ASME Digital X-ray Standards
• ASTM E07 Digital X-ray Standards
• ISO & EN Digital X-ray Standards
• HOIS recommendations
46 GE Inspection Technologies
ASTM & ASME Digital X-ray Standards
• ASME 2009b Section V, Article 2, Appendix VIII
“Radiography Using Phosphor Imaging Plate (CR)”
NOTE: This allows the usage of Computed Radiography (CR) for weld quality inspections.
• ASME 2009b Section V, Article 2, Appendix IX
“Application of Digital Radiography (DR)”
NOTE: This allows the usage of Flat Panel Digital Radiography (DDA) for weld quality inspections.
•Designation E-2007-08: Standard Guide for Computed Radiology (Photostimulable Luminescence (PSL) Method
•Designation: E 2033 –08: Standard Practice for Computed Radiology (Photostimulable Luminescence Method
•Designation: E 2445 –05: Standard Practice for Qualification and Long-Term Stability of Computed Radiology Systems
•Designation: E 2446 –05: Standard Practice for Classification of Computed Radiology Systems
–Article 2 Mandatory Appendix
–Article 2 Appendix VIII
ASME ASTM-ASME
47 GE Inspection Technologies
ASTM E07 Digital X-ray Standards
E2007 - “CR Guide”
E2033 - “CR Practice”
E2445 - “CR Qualification”
E2446 - “CR Classification”
E2597 - “DR/DDA Manufacturing Characterization”
E2698 - “DR/DDA Practice”
E2736 – “DR/DDA Guide”
E2737 – “DR/DDA Qualification and Long-Term Stability”
E2422 - “Aluminum Digital X-ray Reference Radiographs” (E155-analog)
E2660 - “Inconel/Steel Digital X-ray Reference Radiographs”(E192-analog)
E2669 - “Titanium Digital X-ray Reference Radiographs” (E1320-analog)
E2339 - “DICONDE”
48 GE Inspection Technologies
ISO & CEN Digital X-ray Standards
ISO 17636-1: NDT testing of welds – X- and Gamma-ray techniques with film.
ISO 17636-2: NDT testing of welds – X- and Gamma-ray techniques with digital detectors.
ISO 16371-1:2011 Industrial computed radiography with storage phosphor imaging plates - Part 1: Classification of systems
EN 14784-2 : Industrial CR with storage phosphor imaging plates - Part 2 : General principles for examination of metals using X-rays and gamma rays
Under development:
ISO/NP 16371-2: NDT - Industrial computed radiography with storage phosphor imaging plates - Part 2: General principles for testing of metallic materials using X-rays and gamma rays
prEN 16407-1, NDT - Radiographic inspection of corrosion and deposits in pipes by X- and gamma rays - Part 1: Tangential radiographic inspection
prEN 16407-2, NDT - Radiographic inspection of corrosion and deposits in pipes by X- and gamma rays - Part 2: Double Wall radiographic inspection
49 GE Inspection Technologies
HOIS recommendations
O&G industry forum, discussing inspection challenges & utilizing new technology for O&G applications
Achieve more reliable and cost effective NDT techniques in the O&G industry and hence improve operational safety.
Developing improved procedures and recommended practices:
o HOIS Recommended Practice for In-Service Computed Radiography of Pipes
o HOIS Recommended Practice on Weld Corrosion Inspection
o HOIS Recommended Practice for ISI of Offshore Composite Components
o Recommended Practice for non-intrusive inspection DNV-RP-G103
50 GE Inspection Technologies
Standards: important definitions
BSR or SRb: Basic Spatial resolution Indication of the smallest geometrical detail which can be resolved in a digital image. Measured with a Duplex IQI according to (EN462-5 or ASTM2002-03), not using any object on the detector!
This is the measured image sharpness, TOTALLY different from the image pixel size or selected scan resolution!
SNR : Signal-to-noise-ratio Noise can be generated in every step of the image creation (X-Ray tube, scattering, object, detector). The lower the SNR, the higher the noise in the image, the more ‘disturbing’ and the worse the defect recognition.
CNR: Contrast-to-noise-ratio
Both can be “normalised”: SNR N and CNR N. Normalised or linked to the actual SRb
Scan resolution: selected pixel size for building the digital image, e.g 50µ
Using Digital Radiography
52 GE Inspection Technologies
Where Digital Radiography can be used
Piping & Pressure Vessel • Refining • Petrochemical • Production • Pipeline • Oil Country Tubular Goods
• Mechanical Integrity • CUI • Wall thickness, corrosion, erosion • Weld quality • Pipe and tube quality • Heat exchangers
Subsea • Riser • Umbilicals • Flowlines
Midstream • Pipeline • LNG • Marine
Rotation Machinery • Turbine blade • Combustor • Gearboxes • Shafts and axles • Fan blade
53 GE Inspection Technologies
Environmental
Quality QA/QC
Production Safety
o ALARA (As Low As Reasonably Achievable). Implementing Digital
Radiography, with its short exposure times conforms to the ALARA principle.
o Fast or instant display of the image at the point of
inspection makes the need for re-shots virtually needless, eliminating extra exposures.
o Lower source strength may be employed.
o Consistent results and measurements, independent of operator.
o Flash! Improved inspection quality level
o Images & Software supplied for 3rd party review.
o Fully ASTM E 2339-04
(DICONDE) Compliant. o Radiographs from one
inspection program can be stored on one DVD.
o Faster throughput, shorter exposure times: lower cost/shot.
o Onsite results possible. o Production & safety go
hand in hand. o When production
increases, the risk of a safety incident also
increases. o Digital Radiography can
harmonize both increased production and safety with one system.
o No chemicals and water required anymore.
o ISO 14001:2004 – Environmental Management Systems - compliant.
Real Benefits-Value Chain Analysis
54 GE Inspection Technologies
Did you know …
• Corrosion Under Insulation
• High Temp Lines
• Control Valves up to 8” with Iridium-up to 150 Pound
• CML Tees
• Block Valves up to 6” with Iridium
• Heavy Wall Valves
• Boiler Tubes & Water Walls
• < 6 Inch STD Wall Piping
• < 3 Inch Heavy Wall Flow Control Valves
• < 3 Inch 900 PSI Series Control Valves
• < 6 Inch 150 PSI Series Block Valves
Applications - Iridium and Cobalt
Questions?