BerlinBAM
Perspectives on Digital IndustrialPerspectives on Digital Industrial Radiology
t@b d
Uwe Ewert
April 2012,Ewert et al. Essential Parameters in Radiology
1
Outline Digital Radiology is replacing Film Radiography in analogy to digital photography,
which has replaced film photography almost completely. Computed Radiography with imaging plates and Radiography with Digital Detector
Arrays (DDA) are the upcoming new technologies. Special calibration procedures of DDAs yield higher image quality than X-ray film Spec a ca b at o p ocedu es o s y e d g e age qua ty t a ay
radiography (high contrast sensitivity technique) and reduced exposure times. New digital measurement tools allow the exact measurement of object dimension
and functionalityand functionality. Corrosion and wall thickness lost can be measured exactly in industrial plants. Digital detectors with a central hole allow the endoscopic application for inspection
f h t hof heat exchangers. X-ray back scatter technologies and dual energy radiography can be applied in
industrial NDT, additionally to the security applications. Modeling of digital radiography supports training and film replacement. Computed Tomography with DDA becomes a routine industrial application for flaw
detection and measurement of inner dimensions
April 2012,Ewert et al. Essential Parameters in Radiology
detection and measurement of inner dimensions.
Filmless Radiographyg y
Computed Radiography withPhosphor Imaging Plates
April 2012,Ewert et al. Essential Parameters in Radiology
Classic Radiographyg p y
Our roots: Experiences in Fil R di hFilm Radiography
since 1933 at BAM
April 2012,Ewert et al. Essential Parameters in Radiology
Digital Industrial Radiology: Techniques
ReportingImagingPl t
Data TransmissionScannerfor Imaging Plates p g
Plates Plates
Archive
NetworkingFilm Digitizer
Real Time Hard CopReal TimeDetector
Hard CopyGrayscalePrinter Agfa
April 2012,Ewert et al. Essential Parameters in Radiology
Motivation for Film Replacement by Computed Radiography and DDA‘sComputed Radiography and DDA‘s
• Shorter test and interpretation time
• New application areas by higher inspection quality and wall Film (D4)thickness range
• No chemicals and dangerous
( )
• No chemicals and dangerous waste
• Less consumablesFlachdetektor (Hamamatsu)
April 2012,Ewert et al. Essential Parameters in Radiology
( )
Filmless Radiographyg y
Computed Radiography withPhosphor Imaging Plates
April 2012,Ewert et al. Essential Parameters in Radiology
The Imaging Plate Cycle
Scanning the IP, Digitising and Erasing the residual Image
Exposure of Imaging Plate
Imaging Cassette
Erasing the residual Image
Plate
Lead filter
Exposure
Processing Station
April 2012,Ewert et al. Essential Parameters in Radiology
High Definition CR Systems for Welding
Systems available down to• 12 µm pixel pitch and • < 40 µm unsharpness
• “weld quality”
BAM 5: 8 mm steel
HD CR:„VistaScan“, of Duerr, Germany
FUJI IP‘s, light blue
April 2012,Ewert et al. Essential Parameters in Radiology
Digital Radiography for Pipeline Testing
•36 inch 12.7 mm Wall thickness Pipe Weld (SWSI-panoramic exposure )
FilmFree meeting17.04.2007
April 2012,Ewert et al. Essential Parameters in Radiology
Corrosion and Wall Thickness Measurement
f = film focus distancer = outer pipe radiusR = outer radius of insulationw = projection of wall thickness
w on the detector planeVEBA-OEL 2000
p
April 2012,Ewert et al. Essential Parameters in Radiology
Wall Thickness MeasurementTutorial at 11.12.2007
Tangential RadiographicRadiographic Technique(TRT)
April 2012,Ewert et al. Essential Parameters in Radiology
(TRT)
X-Ray Inspection in Lieu of Manual Maintenance Check of Large Componentsg p
April 2012,Ewert et al. Essential Parameters in Radiology
X-Ray Inspection in Lieu of Manual Maintenance Check of Large Componentsg p
Pseudo plast filter (relief)
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Filmless RadiographyFilmless Radiography
Digital Detector Arrays(Flat Panel Detectors)(Flat Panel Detectors)
and the newHi h C t t S iti it T h iHigh Contrast Sensitivity Technique
HCS-RT
April 2012,Ewert et al. Essential Parameters in Radiology
New Digital Detector Array Technology
Spahn 97
April 2012,Ewert et al. Essential Parameters in Radiology
Film and Flat Panel Detector for the BAM 5 Weld.
EN 462 2 Step HoleASTM E747 / EN 462-2Fe 13 Wire Penetrameter
EN 462-2 Step Hole Type IQI „H1“
ASTM E1025 InconelASTM E2002 duplex wire
ASTM E1025 Inconel 5 Hole Penetrameter
BAM 5 is a hand welded steel plate (St 35) 8 mm thick, the welding seam is max. 10 mm thick. It t i ll t f ldi fl i ll i k t th f f th ldi
April 2012,Ewert et al. Essential Parameters in Radiology
It contains all types of welding flaws, especially nice cracks at the surface of the welding seam.
BAM 5, 8mm steel
Fuji IX25SNRnorm~ 265
DDA Technology provides betterprovides better image quality than film with a
Best (slowest) NDT filmt a
special calibration procedure!
Images high pass filtered for better presentation
PerkinElmer 1620
presentation
April 2012,Ewert et al. Essential Parameters in Radiology
SNRnorm~ 1500Magn. = 3.5DDA exposure
F t T t f H t E hFast Test of Heat Exchangerswith
Tiled DDA
April 2012,Ewert et al. Essential Parameters in Radiology
RT-testing of tube-to-tube-sheet jointsGammat B3
Possible tube dimensions: 12*1.5 up to 76.1*4 (diameter*thickness)Materials: carbon and stainless steel, Ni-alloys, Zr, (Ti, Ta)Joint design shall be consideredJoint design shall be considered
Ir 192, Radiator: 1 x 0.5 mm²
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WLE/AD - Plant Inspection, Welding Engineering; PVT Meeting Freeport 2004 14
X-ray tube Warrikhoff MCTS 130A-0,6 and CdTe-Detector Ajat DIC100THTesting of Heat Exchanger Welds
with a specialisedwith a specialised Digital Detector ArrayThrough the Detector
Practice test:
Alekseychuk Zscherpel RostAlekseychuk, Zscherpel, Rost
April 2012,Ewert et al. Essential Parameters in Radiology
D4 film with 130 kV:1 min (1mm Sn filter)
X-Ray tube with DIC100TH detector75 kV, 0,5 mA, 10s
Research-Project BASF/Ajat/BAM since 2006, first results on test weld
April 2012,Ewert et al. Essential Parameters in Radiology
Research Project BASF/Ajat/BAM since 2006, first results on test weld
Imaging andImaging and Materials Characterisation with
Dual Energy Technique
April 2012,Ewert et al. Essential Parameters in Radiology
Explosive Detection by Dual-Energy-Radiology
Typical device for explosive detection of baggage and fin postal ser ice
Fan beams at two different energies
Baggage-
fin postal service
(Smiths Heimann)Baggage-transport
L-line detectors
Smiths Heimann
April 2012,Ewert et al. Essential Parameters in Radiology
Dual-Energy-Technique for Plastics and Composite Pipes
Inspection of a multi layer pipe, made from different plastics and with partial glass fibre reinforcement for chemical industry
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chemical industry
X-Ray Back Scatter Techniqueforfor
Security and Aircraft Industry
April 2012,Ewert et al. Essential Parameters in Radiology
X-Ray B k S tt T h iBack Scatter Techniquewith Single Sided Access
AS&E
April 2012,Ewert et al. Essential Parameters in Radiology
X-Ray Back Scatter TechniqueFlying Spot Unit
X-Ray Back Scatter Techniquewith Single Sided Access
Organic materials are visible with high contrast
AS&E
April 2012,Ewert et al. Essential Parameters in Radiology
X-Ray Back Scatter Technique with Single Sided Access
April 2012,Ewert et al. Essential Parameters in Radiology
Source: http://www.as-e.com Accepted e.g. in UK on voluntary basis
X-Ray Back Scatter Technique with Single Sided Access
Backscatter image of a person
N t t d i G d t R di ti S f t R l ti
Accepted e.g. in UK on voluntary basis
April 2012,Ewert et al. Essential Parameters in Radiology
Not accepted in Germany due to Radiation Safety Regulations
X-Ray Back Scatter Technique with Single Sided Access
DiaphragmX-ray tube
Imaging plate/
Shielding box
Imaging plate/Detector Array
Camera
Osterloh01/2007
April 2012,Ewert et al. Essential Parameters in Radiology
Fast Back Scatter Technique with Specialized Diaphragm
Water in Honeycomb
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Water in Honeycomb-Structures
Radiograph
Back scatter image
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Comparison of Back Scatter vs. Penetration Techniquep q
X-ray penetration image X-ray back scatter image
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y p g y g
X R M d li fX-Ray Modeling for- Film replacement
- Training
- Planning of testing
- POD
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Simulation-Example Complex Geometry: Rail
Pore
April 2012,Ewert et al. Essential Parameters in Radiology
Computed TomographyComputed Tomographyfor
Nuclear Power Plants and
Ai ft I d tAircraft Industry
April 2012,Ewert et al.
High Energy CT at BAM
Inspection of radioactive drums
LINACDrum
200 kV-12 MeVDetector > 500 µm1000 mm
Detector
X-ray tube
April 2012,Ewert et al.
J. Goebbels et al.
Quality Assurance of Radioactive WasteDrum with radioactive metallic stirrer in concreteDrum with radioactive metallic stirrer in concrete
200 l200 l
ironiron
hoophoop
drumdrum
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J. Goebbels et al.
Mobile CTin
Nuclear Power Plants andNuclear Power Plants and
in Aircraft IndustryMobile unitIllerhaus
April 2012,Ewert et al.
yIllerhaus
3D-Reconstruction of Weldments Metallography
Certification byEuropeanEuropeanNetwork ofInspection and
from outside to insidePlanar Tomography
Inspection andQualification.
Planar Tomography
8
April 2012,Ewert et al. Essential Parameters in Radiology
Planar Tomography as Reference for New Methods EvaluationEvaluation
EDISON WELDING INSTITUTE: DOT OPS ProgramEnhanced Defect Detection and Sizing Accuracy Using g y gMatrix Phased Array Ultrasonics Tools
Concept #1 - Girth Weld from OD
April 2012,Ewert et al. Essential Parameters in Radiology
X-Ray Tomographic Non Destructive Micrography
222Cross sections
345
222Cross sections
382572
772872
Top viewsilce 222Near center plane
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p
Electronic components
Sample Gas-filled capacitor
Aim Tightness of the gasket
Procedure
segmentation of different materials
evaluation of irregularities
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Planar Computed TomographyPlanar Computed Tomography for Inspection of
Large Flat Composite Structures ofLarge Flat Composite Structures of Aircrafts
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Moving Gantry CT Construction for Flexible Planar TomoCAR
Object dimensions
Yellow marked: regions to measure
Measurement positions: 87, witheach ROI: 17 x 17 cmeach ROI: 17 x 17 cm
inspected Stringer-length: 14 8 mlength: 14,8 m
April 2012,Ewert et al. Essential Parameters in Radiology
TomoCAR: Qualification by Comparison of C S ti d TCross Sections and Tomograms
Cross section cut from stringer Planar tomogramCross section, cut from stringer(micrograph)
Planar tomogram
April 2012,Ewert et al. Essential Parameters in Radiology
Summary:
Computed Radiography with Phosphor Imaging Plates is gaining more and more importance for mobile inspection and Film Replacement.
New High Definition CR (HD CR) systems allow the CR application for Weld and New High Definition CR (HD CR) systems allow the CR application for Weld and Casting inspection with low energy X-rays.
New calibration methods enable the High Contrast Sensitivity Technology (HCS RT) f di hi i ti Th t t iti it b h d bRT) for radiographic inspection. The contrast sensitivity can be enhanced by a factor of 10 in comparison to film.
New Digital Detector Arrays (DDA) are now available for stationary and mobile testing. They are also applied for automated defect recognition (ADR), CT, Back Scatter and Dual Energy Applications.
Back Scatter Techniques are increasingly applied for Security and NDTq g y pp y Numeric Radiographic Modelling is applied for Experiment Planning, Film
replacement, POD-calculations and training Computed Tomography gains importance for internal evaluation of flaws and Computed Tomography gains importance for internal evaluation of flaws and
dimensional measurements. Mobile and portable CT devices are suitable for non destructive cross sectioning
i l i d t d i ft li ti
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in nuclear power industry and aircraft applications
Acknowledgement
B. Redmer – BAM Berlin
A. Alekseychuk – BAM Berlin
B. Müller – BAM Berlin
A. Lange – BAM Berlin
K. Bavendiek – YXLON Hamburg
K. Osterloh – BAM Berlin
A. Kupsch – BAM Berlin
J. Beckmann – BAM Berlin
G.-R. Jaenisch – BAM Berlin
C. Bellon – BAM Berlin
Ch. Müller – BAM Berlin
S. Sood – CIT London
April 2012,Ewert et al. Essential Parameters in Radiology
J. Goebbels – BAM-Berlin B. Schillinger – TUM-Tech Munich
BAM-Berlin FG 8 3
Ende e-mail: [email protected]://www.bam.de
BAM-Berlin, FG 8.3Unter den Eichen 8712005 BerlinTel. (030) 81041830
April 2012,Ewert et al. Essential Parameters in Radiology
FAX (030) 81041839