w

x ME FEATURE

The Transition from

imaging From Materials Evaluation, Vol. 67, No. 5, pp: 499-506.
Copyright © 2009 The American Society for Nondestructive Testing, Inc.

Conventional Introduction

Radiography to
D
igital radiography is earning its place in the NDT market, as special-
ists determine that this technology surpasses film and film replace-

Digital Radiography ment technologies. This article reviews various applications and
the particular benefits the NDT operator enjoys when working with
this digital format. The article will focus on nondestructive testing with a
by Ron Pincu and Ofra Kleinberger
portable amorphous silicon flat panel based digital radiography system.
The article will show NDT conducted in a laboratory and in a refinery with
a portable amorphous silicon flat panel combined with an Ir-192 source and a
pulsed 270 kV X-ray source. The examples will show that exposure time has
been shortened tenfold and inspector safety is increased. Plant shutdown is
reduced and testing is conducted in minimal time. Various software tools for
immediate onsite analysis will be demonstrated, with examples from the
petrochemical and pipes industry, aerospace industry and in the service of
art.
Portable digital radiography is the ideal combination between nearly real-
time results and sophisticated analysis software tools, enabling NDT
personnel to work in the laboratory and onsite with the same equipment,
achieving results quickly and efficiently and being able to increase the level of
analysis while reducing working time and costs, thus enlarging the profits of
NDT service providers.

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The external setting and the thickness (approximately 6 mm [0.24 in.] total wall
thickness), welded in a V shape. The external setting

X-ray shot parameters are and the X-ray shot parameters are recorded, as are the
conditions and time of X-ray. Measurements of the

recorded, as are the conditions pipe diameter and wall thickness are also recorded as
(removable) annotations on the image. Exposure time

and time of X-ray. was 3.54 s (53 pulses). Focal detector distance was
500 mm (19.7 in.) and the “shooting” angle 90°. Wire
type IQI EN13FE was used to verify 2% sensitivity. A
Digital Radiography in the Laboratory steel block was placed for this test as a measurement
A large NDT provider from France commissioned a reference. The discontinuities in the weld are clearly
major research project in 2008 in order to investigate visible.
the capability of digital radiography systems in the In Figure 2, lack of root penetration is clearly seen
field of pipe NDT. The provider serves refineries in on the top of the weld. On the bottom left of the weld
Europe and wanted to determine the relevancy of one can discern porosity, and on the lower right slag
digital radiography technology to their work in this and undercutting are visible. The pipe is made of
application. The system used in the investigation was carbon steel and has an 88.9 mm (3.5 in.) outer
a portable X-ray testing system, containing a flat diameter with 3.2 mm (0.13 in.) wall thickness (total
amorphous silicon panel with 14 bit (16 384 gray wall thickness 6.4 mm [0.25 in.]).
levels) dynamic range and 3.5 lp/mm resolution. In Figure 3 shows a T-shaped carbon steel pipe with
the investigation, a 270 kV pulsed X-ray source was 60 mm (2.36 in.) outer diameter and 2.9 mm
deployed. Several pipe welding samples with inten- (0.11 in.) wall thickness (total wall thickness to
tional discontinuities such as slag, undercutting, penetrate in X-ray, approximately 6 mm [0.24 in.]). The
corrosion, porosity and cracks were tested. Criteria for exposure was just 4.3 s and the distance between the
the success of the investigation were the time taken to detector and the source 500 mm (19.7 in.). The angle
achieve an image and the visibility of the discontinu- was 90° and the IQI used was EN10FE, to verify 2%
ities and the IQI wires. sensitivity. Slag and lack of root penetration are clearly
Figure 1 shows carbon steel pipe with a 60.3 mm visible in the top left of the welding, as are the IQI
(2.38 in.) outer diameter and 2.9 mm (0.11 in.) wall wires in the center.

2.87 mm

Porosity 59.50 mm
Slag

Crack

(a) (b)

Figure 1. Carbon steel 60.3 mm (2.37 in.) pipe investigation: (a) set-up; (b) test X-ray.

500 MATERIALS EVALUATION • MAY 2009

Digital Radiography in the Field with a digital radiography system onsite using a
gamma ray source (Ir-192 isotope). Once again the
The second phase of the commissioned research portable X-ray amorphous silicon flat panel based
included onsite NDT. This phase was recently system was used. Criteria for the success of the test
conducted in a French refinery. The test set out to included time for onsite set-up of the detector and
understand the advantages and efficiency of working source, time to take a good image, the quality of

Undercut

Porosity

Slag

(a) (b)

Figure 2. Weld ellipse in pipe investigation: (a) set-up; (b) test X-ray.

Undercut

Slag

(a) (b)

Figure 3. Carbon steel 60 mm (2.36 in.) pipe investigation: (a) set-up; (b) test X-ray.

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images in comparison with known images of the images, shortest time to image and superior propri-
tested objects (procured with film), and analysis tools etary software for onsite analysis of results. The
available on site. software is user friendly and enables the use of
The source used was an Ir-192, 481 GBq (16 Ci) advanced image enhancement tools to facilitate the
gamma source. The distance between the detector highest level of immediate onsite analysis. The
and the source was 500 mm (19.7 in.) — the same software tools most commonly used for onsite
distance used when conducting testing with film. analysis are: window leveling, sharpening, embossing,
Exposure time ranged between 8 to 16 s. The images overlaying, wall thickness measurement and
appeared on the screen in real time, without the need averaging. With these tools, the level of analysis the
for development or scanning. If an image was not operator can conduct on site is significantly increased.
good enough, the test was immediately repeated and This gives the operator the tools to make a correct and
a new image was once again available in seconds. immediate decision regarding the quality of the image
There was no need to compromise on image quality as and the information obtained.
good images were achieved on site.
The system is fully portable and carried in one rugged Window Leveling
case to any location in the refinery. Set-up of the imager The window leveling tool is a software feature that
was conducted with the help of a tripod and cables. allows the NDT operator to make the most of the infor-
mation created by the digital radiography system. The
Digital Radiography Software for Onsite portable flat imager offers a 14 bit dynamic range
Analysis image, which means 16 384 gray levels of informa-
The portable digital radiography system used tion. A computer screen normally shows only 256 gray
throughout offers a combination of the highest quality levels. The window leveling tool allows the operator to
lighten or darken an image, examining a particular
spectrum of gray levels each time, allowing visibility of
more specific information on an 8 bit screen.
Figure 4 shows the window leveling tool in action.
An X-ray image of an aircraft wing rib (made of
aluminum casting) is viewed in the range that brings
to light both the discontinuities around the bolt hole
on the thin end (Figure 4a) and the crack on its thick
end (Figure 4b).

Sharpening
The sharpening tool is a sophisticated algorithm that
Discontinuity Bolt sharpens the image with minimal added noise. The
Thin End sharpening tool comes in handy especially when
(a) using the Ir-192 source, which shoots its rays in
every direction and therefore has a large focal spot
that causes unsharpness in the images. This feature
can help bring out details of discontinuities in an
image.

Emboss
The emboss algorithm translates the gray-level scale
into depth, creating a 3D effect and making the image
appear as if stamped in metal. This makes it easier to
detect discontinuities such as corrosion and porosity
Crack Around Drill in pipes.
(Thick End) Figure 5 illustrates how the emboss effect brings
(b)
out the sunken materials in an 88.9 mm (3.5 in.) outer
diameter carbon steel pipe and makes them much
Figure 4. The window leveling tool, demonstrating its ability to bring different easier to see. With a click of a button, the image is
indications to light: (a) focusing on discontinuities around bolt hole; (b) focusing immediately transformed on the screen for convenient
on crack on thick end. analysis.

502 MATERIALS EVALUATION • MAY 2009

 Sunken Material
Appears Lighter Emboss Effect
in Regular X-ray Enlightens
Sunken Material

(a) (b)

Figure 5. The emboss algorithm in action: (a) X-ray; (b) with emboss effect.

Overlay In Figure 6, the differences between the materials

The overlay mode combines two images, one on top of of the pipe and its insulation make it difficult to see all
the other. This mode is most useful when different the details with just one exposure. Two images are
parts of the X-rayed object require different exposure taken, the first exposure being 10 s long and the
times. This allows viewing different thicknesses and second just 3 s. Then the images are automatically
materials in one image. laid exactly on top of each other using the overlay

Both Pipe and its

Insulation are
Pipe
Clearly Visible in
Overlay Mode

Insulation

(a) (b)

Figure 6. Overlay mode: (a) set-up; (b) overlaid images.

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there was no need to shut down the

plant and the quality of the images
was known immediately
mode. Now all the details can be viewed in one image averaging function averages a number of images (as
for clear analysis. In addition, the external set-up spot set in advance by the user) by taking consecutive
is recorded in the database with an external image. images one after another and then displaying one
Repeating this set-up for future maintenance testing is image that is the result of averaging the consecutive
easy. images. The result is a cleaner image due to reduction
of noise, and will show finer details.
Wall Thickness Measurement
The software also enables the use of a convenient wall A Combined Test
thickness measurement tool. This tool is mostly useful A piece of pipe was brought to the laboratory from
in measuring the pipe wall thickness to ensure that no the refinery for a comparison between the pulsed
erosion has taken place. X-ray source and the gamma ray source. Figure 7
shows that the pulsed X-ray source was able to
Averaging achieve sharper results in minimal exposure time.
The averaging function combines two or more images Just one exposure with the pulsed 270 kV source
by averaging their values at every pixel. The automatic gave a high quality image that surpassed even the

Cracks Seen
More Clearly

Porosity
Visible
First Time

(a) (b) (c)

Figure 7. Image comparisons: (a) single Ir-192 exposure; (b) six averaged images with Ir-192; (c) pulsed 270 kV X-ray source images.

504 MATERIALS EVALUATION • MAY 2009

 TABLE 1
Exposure time comparison
Item Tested Pipe Diameter Material Wall Thickness Liquid Digital Exposure Film Exposure
(mm) (mm) Content Time to Image Time*
Fire water hose 208 ST 35 7.2 none 30 s 3 min
Glass fiber profile 700 glass fiber  25 none  4.3 s (70 pulses) 30 s
Process water pipe 150 SS2343 total one wall = 6 water 20 s 15 min
Steam cooler 250 + insulation 10CrMo total one wall = 40 none 50 s 1h
Low pressure steam pipe 400 + insulation ST35 12 none 30 s  20 min
Fuel lye pipe 100/80 SS2343 6 lye 15 s 10 min
* no development

image created by averaging six images with Ir-192, object. The process is fully automated and user-
and was definitely better than a single exposure with friendly. Following are two examples from the NDT
Ir-192. fields of aerospace and art that show the uses of this
The emboss effect shows that new discontinuities innovative feature.
can be detected in the image created with the pulsed Figure 8 shows an aircraft aileron image stitched
X-ray source (Figure 7c). The image in Figure 7a was from 7 separate X-ray images. Each segment was X-
created with a 9 s exposure with Ir-192, Figure 7b is rayed separately. The separate images are X-rayed
an averaging of six such images (9  6 = 54 s consecutively. The stitched image provides the NDT
exposure with Ir-192) and Figure 7c is an image operator with an image of the entire aileron, just as if
taken with a 270 kV pulsed X-ray source, with 2.03 s it were X-rayed in one shot.
of exposure only. Not only are X-rays less dangerous
than the radioactive iridium, but its rays are more
focused and directional, and the exposure time is
shortened.

Exposure Time Comparison

Portable digital radiography testing systems have
been available to NDT operators for some years. To
complete the picture of the capabilities of pipe NDT
with portable digital radiography, here are results of
exposure times as obtained in daily field work of a
large NDT provider in Finland.
Table 1 details the time comparison of NDT of
pipes in several sizes that are made of various
materials. The table compares exposure times
required when using film with the exposure times
when using a portable digital radiography system. All
tests were conducted using a Ir-192 source.
(a)
Stitching
In addition to the already discussed software features,
a new proprietary tool has been recently been
developed. The stitching tool enables the stitching of a
few images into one large image for a complete view.
This is especially useful when X-raying a large object
(like a long pipe or aircraft aileron). The NDT personnel (b)
take images of different areas of the object, which can
be analyzed separately; the stitching tool, however,
allows them also to analyze the images while Figure 8. Stitching: (a) seven Images of aircraft aileron parts; (b) stitched image of
combined and assembled in one image of the entire complete aileron.

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4 1

5 2

6 3
(b)

(a) (c)

Figure 9. Stitched image of oil painting: (a) photograph of painting; (b) grid map of shots taken; (c) final stitched image.

Figure 9 shows an X-ray of an oil painting on than one day (including film development, but
canvas by Moshe Castel. “Synagogue on Saturday,” excluding analysis, which adds more time to the end
from the beginning of the 20th century, was X-rayed results of the test).
with a portable digital radiography amorphous silicon Not only was the testing time shortened, but there
flat panel based system in a visit to the Tel-Aviv Art was no need to shut down the plant and the quality of
Museum. The image was stitched together from six the images was known immediately. There was no
images that form a grid with overlapping parts. The need to return to conduct further testing because if a
darkened frame indicates the size of each image taken location mistake had been made, the operator could
(280 by 400 mm). The overlapping areas are indicated tell at once (because images are seen immediately on
with stripes. Each image was taken using the same screen) and correct it immediately – thus always
level of exposure. A 270 kV portable, pulsed X-ray achieving good images.
source was used with exposure time of approximately In laboratories, in museums and in aerospace
2.8 s (40 pulses) for each image. The source was facilities, portable X-ray makes analysis easier due to
located at 1.20 m away from the painting. The result sophisticated enhancement software. Results are
revealed a portrait of a woman under the painting. It is immediate and of the highest quality.
common practice for artists to reuse old canvases and Digital radiography systems offer the NDT provider
repaint them. an opportunity to achieve good results in less time
and to increase the quality of analysis. The service
Conclusion provided can therefore be improved and its cost
The portable amorphous silicon digital radiography reduced. Profitability and operator safety are increased
system has proven itself to be efficient because it significantly. w
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offers practical solutions to both laboratory uses of
NDT and also to conducting onsite testing. In the AUTHORS
refinery it took just 3 h for the operators of the Ron Pincu: Vidisco, Ltd., 32 Haharoshet St., Or-Yehuda
60375, Israel; 972 (3) 533-3001; fax 972 (3) 533-3002;
portable digital radiography system to conduct e-mail [email protected].
testing in 10 locations. A similar testing process Ofra Kleinberger: Vidisco, Ltd., 32 Haharoshet St. Or-
using film or film replacement technologies that Yehuda 60375, Israel; 972 (3) 533-3001; fax 972 (3) 533-
require scanning and development can take more 3002; e-mail [email protected].

506 MATERIALS EVALUATION • MAY 2009