Safety Assessment with NDT Digital Radiography /Radioscopy

Corrosion Assessment with NDT digital radiography

Mr S.C.Sood, Chairman/ Managing Director
CEng, MIERE, MIEEE, M.TECH, B.TECH
Computerised Information Technology Limited
20 Potters Lane, Kiln Farm, Milton Keynes, United Kingdom
Tel: 01908 260082, Fax: 01908 260084, Email: scsood@cituk.com

Operational risks associated with oil, gas, and power

stations, petrochemical plants commence from the
date the production plants are built. The wear and
tear due to corrosion and erosion begins during
construction under the useful life of the production
plants.
Like
any
manufactured
equipment
serviceability and maintenance is the only key factor
to ensure safe operation. This requires routine
program of managed maintenance. Statistics prove
that predictive maintenance process is the only key
factor that is cost effective. This predictive method
requires the asset maintenance team to get on
stream information on the condition of the plant for
them to take appropriate action. Worldwide several
methods have emerged. Each of them deploying
some form of NDT from which assessments are being
made. With the advent of the dedicated computing
technology majority of the information captured in
the form of the data sets is held on the system from
which intelligent reports are processed and some
form of risk based inspection decisions are taken.
Further this information is globalised throughout the
world with the assistance of remote access. All this is
very constructive. The validity of the information is as
accurate as the measuring device and the
inspection method mode and its reporting standards.
The accuracy of the information is dependent upon
the physical area under examination and the
number of dataset readings taken and objectives use
of the interpretation of the datasets. Ultrasonic, Eddy
currents, Magnetic particles, acoustic emission all
generate point data on these details, while film
radiograph and digital radiography generate a
pictorial image of the region under examination.
The introduction of Digital Radiography can result in
economic benefits and reduced costs of NDE. This
presentation describes the technology, method and
regulatory
acceptance.
CITs
technology
incorporates radiographic image acquisition, image
management, product traceability and audit trail. CIT
Digital Radiography Systems provide high quality
images with radiography unsharpness that meets with
a majority of acceptance criterias. The Systems are
used in NDT departments, site radiography for
corrosion and condition management and weld
casting inspection.
Introduction
Corrosion or erosion of material due to chemical
reactions result in material loss. This material loss
eventually results in leakage and accidents, which
are expensive and thus must be avoided. Regular
condition monitoring eliminates this catastrophe, as
appropriate action can be taken prior to major

damage occurring. There are several methods for

accessing these losses.
Conventional film radiography based upon Iridium
source radiography has been used in the field for the
last 20 to 30 years. As the picture tells a thousand
words hence, the radiographic material is extremely
powerful further added by the fact that one can look
at internal composition of the material. Traditionally
the technology lends its self with the following with
some constraints.

Iridium Source: 5 curie to 26 curies with the maximum limit set

by the H & SE due to ionisation radiation of
each.

Xray Film: AGFA/ FUJI/ KODAX and film processing

chemicals.

Radiation Safety: Containment area, which had to set up prior

to radiography being carried out.

Typical exposure Times: Timing may vary from 4 minutes up to 2 hours

and for heavy wall up to 3 hours.

Reports: Manual reports generated by Inspectors and

radiographs measured with the aid of scales.

Reports / Results throughput: Results may be generated in 2 to 12 hours

Due to the above there is a general reluctance to use

conventional film radiography, although the
information and results are more comforting and the
confidence factor is much higher than any other
alternative methods. Measurements are more
accurate with the radiography method.
Digital Radiography based upon flexible imaging
plates in conjunction with the flexible radiation
shielding has emerged as a technology that has
eliminated the short falls of conventional radiography
for instance digital radiography requires: Iridium Sources/
SE75/ X-rays: -

From 2 curie to 8 curie

(It operates with higher
curries up to 26 curries) but
reduced dosage is actually
required. This prolongs the
useful lifespan of the Isotope
for radiography.

Safety Assessment with NDT Digital Radiography/Radioscopy

Xray Radiographs: -

Uses reusable flexible digital

imaging plate technology
and digital radiography.

Radiation Safety: -

Due to the lower radiation

activity shorter exposure
time are required saving of
80 90% exposure for
corrosion.
Hence
the
controlled area protected
by flexible radiation shielding
can work effectively for set
up and exposures.

Exposure Times: -

Usually from 30 seconds to 2

minutes heavy wall up to 100
mm will take 40 minutes as a
typical case.

Reports: -

Electronic reporting with

archiving is accomplished
with
electronic
measurements.

Reports/Throughput: -

Results can be generated in

10 minutes to 15 minutes
from the time of exposure to
end result.

On the basis of the type of technology deployed and

the accuracies required the appropriate technologies
might be selected. CITs opinion is to use a higher
resolution system to achieve the required accuracy
for this purpose. Specially for thin and medium wall
material loss assessments.
The accuracy of material wall loss may be
dependant upon the genetical magnification of say
the pipe wall to the film.
CITs GammaGauge calibration devices are a
significant step forward in enabling measurements
that can be made with the device. This is a block,
which has as magnetic grip to aid fixing to the steel
pipes and has an instant grid that enables visibility of
the radiograph film and the image. This is used as a
calibration device for the distance measurements.
The radiography below depicts the use of the block.

The calibration gauge is as follows: -

What it really means is that from the tests conducted

worldwide in various petrochemical plants and
power stations, CITs digital radiography is being a
serious alternative to the end customer from the asset
management.

This gauge is a
two
material
thickness
to
enable visibility
at any one level.

Performance
Material loss accuracies are dictated by the
radiographic unsharpness of the system, contrast
sensitivity, the type of imaging plate and what
resolution it is scanned and displayed.
With CITs technology the following results have been
achieved: -

CIT DR1000

CIT DR1000

254 DPI
100
Microns
200 x 380
512 DPI
50
Microns
200 x 300

Correspondi
ng
unsharpness

Wire Dia
&
Spacing,
mm

11th pair of
duplex IE 462
wire

0.16

0.080
mm

12th pair of
duplex IE 462
wire

0.13

0.063
mm

0.13

0.063
mm

0.16

0.080
mm

0.26

0.130
mm

12th Pair of
duplex IE 462
wire
11th Pair of
duplex IE 462
wire
9th Pair of
duplex IE 462
wire

CIT DR1200

600 DPI
200 x 430

CIT DR1200

300 DPI
200 x 430

CIT DR1200

150 DPI
200 x 430

CIT DR2000

508 DPI
50
Microns
70
Microns
350 s 430

11th Pair of
duplex IE 462
wire

0.16

0.080
mm

CIT DR1700
Medical
i l t

165 DPI
350 x 430

8th /9th Pair of

duplex IE 462
i

0.32

0.160
mm

The BS EN latest standards are being developed also

specifying that the duplex wire IE 462 be used in all
radiography so that the system performance may be
assessed for every image.
Digital Radiography Process
The basic radiographic technique is similar to the
conventional film technique apart from reduction of
dosage and exposure times with the digital imaging
plate. For completeness a Corrosion Assessment
method Statement is generated for inspection of the
various components under examination. This takes
into consideration the practical set up, jigs and
radiation shielding that may be required.
Insp ectio n
proced u re

E xpo se
C o m p on en t

Isoto pe
D IP

D R S ca nn ed
R e a de r

A rch ived
D a ta

R ad ia tion
S he ild in g

B a ck up
C e n tre

M e asure
In fo rm ation

G e ne rate
rep o rt

RBI

Safety Assessment with NDT Digital Radiography/Radioscopy

The Digital imaging plates are exposed as per the
method statement and scanned in the digital
Digital Radiography Process

Erased Imaging
Plate is
inserted into
the jacket and
exposed to
radiation

the QA technique. The various measurements can be

measured and displayed on the computer screen
and the tables. This can be printed and saved and
the set up activated for future review.

Imaging plate is
mounted onto the drum

Advanced
Radiograph
Analysis

21/05/2003

Image is displayed
on the screen with
product profile and
techniques

Copyright CIT Ltd Version 1.0

Imaging plate is
scanned using
DR1000 Software

30

Radiography scanner. The scanned image is given

the title based upon the selected product profile and
the radiography technique. The raw radiograph
image generated is then archived and available to
the inspector for interpretation and a report written
on the screen and information archived along with
the radiograph image and its complementary data.
Digital Radioscopy /Digital Radiography Processes
Complementary Data
Product Profile
definition

Radiography
Exposure of
Product under
Examination
Based upon
Iri 192
Ytb 169
X-ray

Radiographic
technique

Radiograph
Display System
User data/
Profiles
Electronic Archives
NDE Reference data

Raw Data

Densitometer

Distance
Measurements

Defect sizing

Product
Raw Data/ Scanning Prestine
Data (Legal data)

Complmentary data

This method is accurate to the pixel level and to the

scanning resolution. Hence higher resolution provides
more accurate readings then those offered by lower
resolution scanning devices. This technique is used for
profile radiography for material wall loss estimation.
The calibration enables the wall loss at a point of the
place located by the GammaGauge.
The CIT system allows the supervisor to enter his notes
prior to authorising the image in accordance with the
image authorising process. This image and the
associated data are retrieved again for future
reference.
Line profile Measuring Method

Automated
reports

NDE Raw Product data

User Security and data protection

This completes the process of acquisition, capture

and automated storage in to the disk drive. The
operator and supervisor are trained to enable the
above work to be achieved in accordance with the
QA requirements. The data captured may be
uploaded via modem or satellite link to the central
management system where the entire image and
data is saved ready for the RBI to take charge over
the reported details.
Distance Measurement
The ability to measure physical distances from within
the images is the greatest virtue that has been
provided by the image processing technology. The
radiographic images have to be calibrated against a
known size item from within the image and in this
typical case this device is in the GammaGauge
scale. The measurement units can be specified by

Radiographic density profile measurement of flawing

material loss is more accurate assessment than point
and click distance measurement. This line profile
enables the inspectors to assess the percentage of
material loss at the edges and in the middle of the
components. Also in areas where local material loss
such as pitting has taken place.

Safety Assessment with NDT Digital Radiography/Radioscopy

The process requires calibration against a known step
wedge or IQI (less preferable due to special nature)
The density change in the area of interest can be
measured and equated to establish the material to.
Advanced Line profile
The advanced line profile method is one step ahead
of the above. As one can take a reference line
profile and difference it against the line profile where
say pitting, material erosion has taken place. The
difference can be scaled or normalised to any
production parameter, hence the inspector can set
his limits to the acceptance level for estimation.

Report Page

Risk Based Inspection

Safety assessment of asset dictates that due to
economic constraints certain sections of the plant
assemblies are treated are more risk to failure than
others. These are required to be analysed and
monitored on regular basis so that accidents can be
avoided. Today existing risk based inspection
packages are based upon the text data only. The CIT
technology offers pictorial images, radiographs,
scanned documents and text. All these can be drilled
down to the raw data so that future prognosis and
trend setting capabilities on probability of failure can
be directed. Based upon the RBI factor allocated by
experts and design engineers, any remedial work can
be carried out on an urgent basis.
This Integrated approach improves workflow and
decision taking time on the basis of factual data. The
illustration below depicts the RBI report and data
entry screen, which enables the administration of the
RBI methodology. Customised reports may be
generated which can extract and highlighted with
details from the information base held. This on stream
strategic monitoring method is important feedback
required by the quality management. Future
development trends may interface live data to be
monitored. This will be the next area of the
implementation.

One of the major advantages of automated

reporting is that it saves time and the workflow
schedules are easy to track. Individual organisations
may require specific reports, but the CIT corrosion
report can consist of email transmissions of reports
and images. The CIT Digital Radiography incorporates
several reports with inspectors comments that can
be previewed as historical data from which
comparisons can be made.
A brief example of a report is illustrated below: -

In this report one can trace the operator, the

radiographic technique. Supervisor, inspectors and
auditors. This will also validate operators against their
qualification certifications. One important feature
integrated is electronic signatures as per FDA
electronic CFR21 part II requirement for electronic
data authorising and authentication. This raises the
documentation control to the quality code assurance
set up by each organisation

Safety Assessment with NDT Digital Radiography/Radioscopy

Configuration and Practice

Petrochemical, oil and gas processing can derive

benefits by adopting this technology today.

The CIT structured approach enables the archival

management as depicted below
Bibliography
NDE
Centralised
Management

Senior Board
level

Senior
Management
Level

Field
radiography
Scanning

Site and
remote
Location

Quality
manager

Prime/ sub
contractor
level reporting
workstation 1

Prime/ sub
contractor
level reporting
workstation 2

Remote
Station 3

Site Office
Digital
Radiography
Rooms

Site Office
Digital
Radiography
Rooms

Site Office
Digital
Radiography
Room

Radiography
team for
Exposing

Radiography
team for
Exposing

Radiography
team for
Exposing

1.
U. Ewert, H. Heidt, Current Status of European
Radiological Standards for NDT, ASNT spring
conference and IIW micro symposium, Orlando,
03/22-03/27, 1999, proceedings p. 171-173.
2.
U. Zscherpel, Internet page: Standardization
of fundamental
3.

Parameters of radiography digitisers at

http://trappist.kb.bam.de/CEN-NFD/cenahg3.html

4.
European Approach for Standardization of
X-Ray Film Digitisers and Computed Radiography
5.

Projection radiography by U. Ewert

Multi Team

The above structure can be at one site or scalable to

Multi sites. The main objective is to enable fast access
of information from the plant level to the managers
level so that predictive work may be scheduled at
short notice with proper notification. This in its self can
have a workflow advantage of how information can
disseminate. The above packages are all functional
and
developed
by
CIT
and
ready
for
implementation.
This
framework
dependency
improves evidenced based information which will
result in less operational risks, which is always the
target of the management for security purposes.
Summaries and Conclusion
The alternative radiography method based upon
digital radiography and flexible digital imaging
plates:
Can be used in a production environment.
The entire process generates results from start
of set up to results in a typical cycle time of 5
to 20 minutes.
The cost effective measurement tools that
enable precise position and qualitative
accurate assessments down to 0.08 or 0.100
mm.
The corrosion material loss assessments are
reported on the Risk Based Inspection
management system, which allows the entire
production facility to be monitored.
Multiple users can access the details from
local and remote sites.
The on stream information
significant cost and timesavings.

provided

Acknowledgement
The author would like to acknowledge Carole Colclough
and Jayshree Sood for their assistance in compiling and
proof reading this publication.