HDRTR (High Definition Real Time Radiography) Advances in Technology
HDRTRHDRTR (High Definition Real Time Radiography)(High Definition Real Time Radiography)
Advances in Technology Advances in Technology
API 2010 Winter Standards MeetingNew Orleans, LA January 28, 2010
Steve MorrisonSteve Morrison
Shaw Pipeline Shaw Pipeline ServicesServices
Gamma Radiographic Inspection Gamma Radiographic Inspection HistoryHistory
0.1 Ci of Ra-226 1930s-1940s
Photos courtesy of: NUREG/BR-0024 Working Safely in Gamma Radiography.Morrison, A. Radiography with Cobalt-60. Nucleonics December 1949. Pages 19-32.
Fishpole method for pulling through a long Pipe.
PresenterPresentation NotesThis is an example of an industrial radiography source of the type used in the 1930s and 1940s. Sometimes referred to as a plumbbob, it would have contained approximately 0.1 Ci of Ra-226. Although expensive, radium was used because no other radionuclides were then available of sufficient strength. After World War II, Ir-192 and Co-60 quickly became the radionuclides of choice and the use of radium was abandoned. When used, the radiography source would be placed on one side of the weld or metal casting being "x-rayed," while a sheet of photographic film was placed on the other side. Exposure times were quite long, e.g., one hour to as much as four days. The source was either handled with a long pole ("fishpole") or tied to a cord. The latter method, for example, would allow it to be pulled through a long pipe. The above B & W photos are from NUREG/BR-0024 Working Safely in Gamma Radiography. In the picture on the left, the source is being removed from its shield ("pig"). The photo on the right shows the source being held at the end of a fishpole. The long exposure time and an unsteady hand often resulted in a blurry x-ray image. The radium (usually radium sulphate) was packed into a cylindrical silver container, which was then placed inside a larger outer capsule. There were two general types of radium capsules: the aluminum type shown at the top of the page, and a steel type. The latter, manipulated at the end of a magnetic handling rod, had two parts: an hexagonal base with a flat bottom (ca. 1" diameter and 1" long) and a short conical cap.
Pipeline XPipeline X--Ray HistoryRay History
Pipeline X-Ray Machine 1968
PresenterPresentation NotesAn example of an X-Ray rig circ 1968, these low KV X-ray or termed Automatic x-ray macines were not that automatic, they did a reasonable good job on light wall piping and at that time were state of the art. They were bulky, heavy and slow compared to todays equipment and requirements for production. Notice also how safety requirements have changed since 1968.
Pipeline Pipeline XX--Ray HistoryRay History
In 1960s, most pipeline radiography was conducted using low kilovoltage x-ray machines (170 kV to 225 kV) with a combination of fluorescent (calcium tungstate) screens and high speed, light sensitive film.
Iridium 192 Gamma sources and lead foil screens were used primarily for weld inspection on fabrication (elbows, flange welds, etc.).
In the years following, as the pipe wall thickness and diameters increased, it became necessary to increase the X-Ray kilovoltage which in turn was detrimental to the quality of the radiograph when using fluorescent screens.
New techniques were developed such as using a combination of fluorescent screen on front and lead on back, and also a special screen material manufactured using lead screen impregnated with calcium tungstate. Both techniques produced radiographs much faster than lead screens, but had less desirable results when using higher kV radiation. As a result, a combination of gamma ray sources and lead foil screens replaced x-ray machines for most double wall exposures.
HDRTR HISTORY & BACKGROUND
In 2005 SPS independently funded the development of a 2nd Generation RTR system specifically designed for pipe weld inspection using new components & software to facilitate inspections particularly geared for a high resolution and high production demanding environment both On and Offshore.
2005 SPS Acquired XTEK developers of the RTR Technology to further develop the
RTR technologies, GEN I
2008 Performed HDRTR Offshore Market Lay Barge (Tyrihans) Norway (HDRTRSW-1)
GEN II
2009 Introduced HDRTR to the landline market (HDRTRSW-1/ HDRTRDW-1) GEN
III
2009 Performed HDRTR Offshore Market Lay Barge (Pluto) Australia (HDRTRSW-1)
PRODUCT DEVELOPMENT PRODUCT DEVELOPMENT New for 2009New for 2009
Ruggedized LandRuggedized Land--Line and Laybarge Cooled Dual Head System using Line and Laybarge Cooled Dual Head System using components developed in components developed in tietie--inin program, covering 10program, covering 10 to 30to 30 pipe pipe diameters (SW2)diameters (SW2)
TieTie--In version for fully external (DW1) XIn version for fully external (DW1) X--ray inspection of 16ray inspection of 16 to 36to 36 pipeline girth welds using 300kV CP Highly Directional Xpipeline girth welds using 300kV CP Highly Directional X--ray Source ray Source and single head, cooled detectorand single head, cooled detector
High Resolution (24 micron) detector also variant for thin wall High Resolution (24 micron) detector also variant for thin wall tubes tubes
General DescriptionThe Hi-Res HDRTR detector has been developed for critical welds on pipelines. It has twice the resolution of the original RTR product and its combined electronics and CCD into the same package increases the overall signal to noise ratio. The detector produces results exceeding that of D4 film used with typical gamma sources. Applications also include thin wall pipes/tubes, fuel lines, aerospace engine components, laser and electron beam welds.
Specification:
CCD Size: 1024 x 128 pixels at 24 micron pitch Resolution: >18 line pairs per mm Sensitivity (IQI): better than 2% on 2.5mm thick plate/pipe Active size: 24.6 mm length x 3.07mm TDI width Scan speed: up to 35mm/second Energy Range: 20 to 300 kV Output: 16 Bit USB2
HiHi--ResRes HDRTRHDRTR
HDRTRHDRTR HardwareHardware
HDRTR EquipmentHDRTR Equipment 2 Systems for targeted applications
HDRTRSW1
Extremely Fast Production applications
Lay Barge/ Landline production welding
Fabrication and Spooling
HDRTRDW1
Tie-In Welds
HDRTRHDRTR--SW2SW2 General Description
The HDRTR-SW2 (Land-Line) girth weld system has been designed for operation from a vehicle in the field, used in conjunction with an X-ray crawler. It is also suited for offshore, lay-barge HDRTR where high production is required.
This new water cooled, twin head system inspects girth welds without the use of film. The X- rays source is an SPS panoramic x-ray crawler placed inside the pipe. The system inspects pipes from 10 to 30 diameter and shares the same major components as the Tie-In system.
Twin water cooled and Peltier chilled HDRTR detection heads Water cooled electronics module, motor control and USB to Ethernet adapter Miniature closed loop pumped water chillers' Weight reduced orbiting scanner (
SPS X-ray tube crawler system
HDRTR-SW2 Land-Line & Lay- Barge Production Version
3D CAD Model
HDRTRHDRTR--SW2SW2
HDRTRHDRTR SW2SW2
From 10 inch to 30 inch diameter currentlyFrom 10 inch to 30 inch diameter currently
HDRTR-SW2 Land- Line & Lay-Barge RTRfor 10 to 30 Diameter
Pipe
HDRTRHDRTR--SW2SW2
Twin head cooled HDRTR- SW2 Detection Head on 16
pipe
HDRTRHDRTR--SW2SW2
HDRTRHDRTR SW3SW3--LDLD
Large Diameter Piping Large Diameter Piping up to 48 inch up to 48 inch diameter expected to diameter expected to be released 2nd Q be released 2nd Q 20102010
The The HDRTRHDRTR Inspection ProcessInspection Process Single Wall ScannerSingle Wall Scanner
HDRTRHDRTR--SW2 (LandSW2 (Land--Line): Line): Estimated/Actual Inspection TimesEstimated/Actual Inspection Times.750 wall thickness API pipe, 1.6% Wire IQI Sensitivity (source side)300kV/3mA CP Internal Panoramic 300kV/3mA CP Internal Panoramic
PipePipeDiameterDiameter
DistanceDistancemmmm
OverlapOverlap10%10%
Scan Scan SpeedSpeed
mm/secmm/secScan TimeScan Time
secondssecondsScan TimeScan Time
minutesminutes
1010 800800 877877 1212 4040 0.70.71616 12771277 14191419 1212 6060 1.01.02424 19101910 21282128 1010 106106 1.81.83030 23932393 26602660 88 212212 3.53.5
HDRTR-DW1 (Tie-In )3D CAD Model of finalized production system on pipe band
HDRTRHDRTR--DW1 DW1 (Tie(Tie--In) In)
System DiagramSystem Diagram
Single Head HDRTR-DW1 Tie-In X-ray detector with e-box, cooler & extended width scanner/band
HDRTRHDRTR--DW1DW1 ScannerScanner
HDRTR HDRTR DW1 (TieDW1 (TieIn)In) SystemSystem
General DescriptionThe Tie-In HDRTR system inspects girth welds totally externally to the pipeline (DWSI) using a light/compact orbiting detection head (
X-ray tube on extended width bug & band
HDRTRHDRTR DW1DW1
Up to 30 inch diameter currentlyUp to 30 inch diameter currently
HDRTRDW1HDRTRDW1
TieTie--in weld on 20in weld on 20 OD Pipeline Road CrossingOD Pipeline Road Crossing
HDRTRDW1HDRTRDW1
Typical Double wall setup Typical Double wall setup
HDRTRHDRTR--DW1 (TieDW1 (Tie--in inspection times:in inspection times:.600 wall thickness API pipe, 1.8% Wire IQI Sensitivity .600 wall thickness API pipe, 1.8% Wire IQI Sensitivity (source side)(source side)
PipePipeDiameterDiameter
DistanceDistancemmmm
OverlapOverlap5%5%
Scan SpeedScan Speedmm/secmm/sec
Scan TimeScan Timeminutesminutes
EstimatedEstimatedCycle Time*Cycle Time*
1616 12771277 13401340 77 3.23.2 13.213.22424 19101910 20002000 3.53.5 9.59.5 19.519.52626 20752075 21802180 3.23.2 11.411.4 21.021.03030 23932393 25122512 2.52.5 16.816.8 26.826.83636 28732873 30163016 1.81.8 27.927.9 37.937.9
*6 minutes allowed to attach band, fit bugs/detector/x-ray tube , put up safety barrier, remove bus/band. 4 minutes to remove all equipment from band to vehicle
Inspection DataInspectionInspection DataData
HDRTRHDRTR SoftwareSoftware
HDRTRHDRTR Image ResultsImage Results
Incomplete Penetration due to Hi/Lo
HDRTR Image ResultsHDRTR Image Results
Incomplete Fusion on the cover pass
HDRTRHDRTR Image ResultsImage Results
Elongated Slag Inclusions
ConventionalConventional RT Image ResultsRT Image Results
HDRTR Image ResultsHDRTR Image Results Comparison with DComparison with D--44
HDRTR Image ResultsHDRTR Image Results
SummarySummary HDRTR BenefitsHDRTR BenefitsImmediate Results with capability exceeding that of film RadiogrImmediate Results with capability exceeding that of film Radiographyaphy Interpretation takes place while the system is acquiring data thInterpretation takes place while the system is acquiring data thus reducing us reducing overall inspection cycle time = overall inspection cycle time = No Wait Time for Film ProcessingNo Wait Time for Film Processing Time to weld disposition the weld significantly less than gamma Time to weld disposition the weld significantly less than gamma = $Savings= $Savings Data, Images and reports can be eData, Images and reports can be e--mailed for further analysismailed for further analysis Retakes are virtually eliminated Retakes are virtually eliminated
Enhanced interpretation of resultsEnhanced interpretation of results Capability for further automation of interpretationCapability for further automation of interpretation Sensitivity exceeds 1104 specifications and Gamma RadiographySensitivity exceeds 1104 specifications and Gamma Radiography
Safest form of Radiography Safest form of Radiography No Gamma Source requiredNo Gamma Source required No ChemicalsNo Chemicals Highly Collimated beam reducing exposure risk to personnel and oHighly Collimated beam reducing exposure risk to personnel and othersthers
Archives the weld image and disposition report digitallyArchives the weld image and disposition report digitally Results Archived electronically indefinitelyResults Archived electronically indefinitely
HDRTR(High Definition Real Time Radiography) Advances in Technology Gamma Radiographic Inspection HistoryPipeline X-Ray HistoryPipeline X-Ray HistoryHDRTR HISTORY & BACKGROUNDPRODUCT DEVELOPMENT New for 2009Hi-Res HDRTRHDRTR HardwareHDRTR Equipment2 Systems for targeted applicationsHDRTR-SW2Slide Number 11Slide Number 12HDRTR SW2Slide Number 14Twin head cooled HDRTR-SW2 Detection Head on 16 pipeHDRTR SW3-LDThe HDRTR Inspection ProcessSingle Wall ScannerSlide Number 18Slide Number 19HDRTR-DW1 (Tie-In) System DiagramSlide Number 21HDRTR DW1 (TieIn)SystemSlide Number 23HDRTR DW1HDRTRDW1HDRTRDW1Slide Number 27Slide Number 28HDRTR SoftwareHDRTR Image ResultsHDRTR Image ResultsHDRTR Image ResultsConventional RT Image ResultsHDRTR Image ResultsComparison with D-4HDRTR Image ResultsSummary HDRTR BenefitsSlide Number 37