DIGITAL RADIOGRAPHY TESTING (DRT)

Digital radiography is a form of radiography that uses x-ray–sensitive plates to directly capture data during the patient
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examination, immediately transferring it to a computer system without the use of an intermediate cassette. Advantages
include time efficiency through bypassing chemical processing and the ability to digitally transfer and enhance images. Also,
less radiation can be used to produce an image of similar contrast to conventional radiography.
Instead of X-ray film, digital radiography uses a digital image capture device. This gives advantages of immediate image
preview and availability; elimination of costly film processing steps; a wider dynamic range, which makes it more forgiving for
over- and under-exposure; as well as the ability to apply special image processing techniques that enhance overall display
quality of the image.

TYPES OF DRT EQUIPMENT

There are various types of DR Equipment all of which have same principle. Some of which include:-
 Vidisco Equipment
 Novo Equipment
 G.E Equipment

For the purpose of this note, the vidisco system will be used for training.

VIDISCO DRT EQUIPMENT

The vidisco equipment is a portable, Flat Panel X-ray Inspection System suitable for a wide range of tasks. Its applications
include field and laboratory NDT (Non-Destructive Testing) used in areas such as the Aerospace, Petro-Chemical, Casting,
Forging, Electronics and Security Industries, to name a few. The entire system is contained in a single ruggedized, waterproof
case. This ruggedized case is easily carried by a single operator and can be used in the field without the need for an AC power
supply.

The vidisco equipment typically contains five main components:-

 Imager (DDA)
 Control and Display Unit (CDU)
 Imager Control Unit (ICU)
 Radiation source
 Interface Box

A connected Vidisco system

Imager: - The fox-rayzor images are obtained with the amorphous silicon panel imager. This imager offers an imaging area of
(9”x8.5”).
CDU (Control and Display Unit):- It rests on the Operational Shelf in the carrying case. The CDU is a laptop computer that
runs the unique and sophiscated fox-rayzor software. The software is used to operate the imager, to display and enhance the
obtained X-ray images and to manage the image database.

ICU (Imager Control Unit):- The heart of the fox-rayzor system, the ICU serves as the interface between the imager and the
CDU. The ICU receives and translates commands from the CDU to operate the X-ray source and imager. It processes the data
obtained by the imager and transmit it back to the CDU. In addition, the ICU is responsible for the management of the power
supply to the imager. The ICU is connected to the CDU by a single 50m lightweight cable coiled on a reel with external power
running through the lines

Interface Box: - The interface box, mounted on the CDU shelf allows for the quick connection of the CDU to Imager and is the
interface for both data and power including the charging of the unit via the ICU/CDU Connecting Cable
Radiation Source: - A radiation source is a tool that is used to generate radiation. The common source generator for vidisco
equipment is the XRS-4 radiation source. The xrs4 is an industrial type open beam xray generator intedned to radiograph
inanimate objects. The XRS4 is a pulsed x-ray device that produces x-ray pulses of very short duration (10 nanoseconds).

SET-UP CONFIGURATION
The entire system along side its component is moved to site in its pelican box. The imager is position as close as possible to
the objected to be inspected; the radiation source is position in front of the objected to be inspected (depending on the kind of
inspection). Connection cables are now used to connect the entire system. The imager cable is used to connect the imager to
the ICU, the source cable is used to connect the radiation source to the ICU and finally the 50m cable is used to connect the
CDU to the ICU through the interface box. The CDU is then powered to confirm the entire system and its component is properly
seen by the CDU.

PROCEDURE FOR PROFILE RADIOGRAPHY

Profile radiography has to do with the measurement of the remaining wall thickness of a test piece. The pelican box or case (Fig
1) is taken to the work location; the DDA is placed behind the area of interest.
N/B:- the imager should be placed as close as possible to the object or test piece to be inspected.
The X-Ray source is then placed directly in front of the inspected object at a distance between 30cm to 180cm.
The cable connections are then carried out. The imager cable connecting the imager to the ICU, source cable connecting the
source to the ICU. The 50m cable from the pelican box is reeled and connected to the ICU. The Ethernet and USB cable from
the interface box on the pelican box is then connected to their respective ports on the CDU (Laptop).
The vidisco xpro software is then lunched. The operator checks for the status of all connections on the laptop and then
proceeds to image capture.
Prior to capturing, the operator has to choose the desired source intensity (pulse) this is usually dependent on the thickness
and size of the test piece. For pipe size of ¾ - 1’’ a source intensity (pulse) of 10 – 15 pulses can be used to avoid burning the
image. If the captured image is burnt, the pulse can be further reduced. For pipe size of 1.5 – 4’’ a source intensity of 20-25
pulses can be used but this is also dependent on the thickness of the line inspected.
After selection of source intensity, command is given to the system to acquire the image. If the image captured is good, the
image is saved and the equipment setup is carried out on the next test point or location as already described above. If the
image captured is not good, adjustments are done on either the source or imager to get a better image.

PROCEDURE FOR SEDIMENT CHECK

Sediment check involves the process of checking for blockage, debris or accumulation along a pipeline. This operation is
usually carried out to confirm the existence of foreign materials along a suspected section of a pipeline.
Procedure for set-up for sediment check is similar to that of profile radiography as this operation requires just image capture of
the area of interest.

PROCEDURE FOR WELD INSPECTION

Welds are reinforcement done to hold two materials in place. The status of this reinforcement is always concern and checks are
always done to ascertain the integrity of these reinforcements.
Set-up for weld inspection is almost similar to that of profile radiography with just a little twist in source positioning (this is
dependent on weld inspection method to be carried out).

Types of Weld Inspection Method:-

Double Wall Single Image: - For this method, the set-up is similar to the set-up for profile radiography. The technique is
generally used on pipes over 80mm in diameter.

Double Wall Double Image: - For this method, the source is not placed directly in front of the area of interest, but is placed at
0
an angle (45 ) to get an elliptical shot. This method is generally used only on pipes less than 75-80mm in diameter.
Gap Testing:- During the welding of a pipe to a socket or any other component other than a pipe, it is expected that the welder
gives an expansion gap of 1.6mm between the pipe and the shoulder of the socket. ASME B31.1 para. 127.3 Preparation for
Welding (E) Socket Weld Assembly says: In assembly of the joint before welding, the pipe or tube shall be inserted into
the socket to the maximum depth and then withdrawn approximately 1/16" (1.6 mm) away from contact between the
end of the pipe and the shoulder of the socket.

The gap test is carried out at the end of the welding process to check if the expansion gap is present and the size of the gap.
The set-up for gap testing is similar as that of profile radiography.

IMAGE ANALYSIS/INTERPRETATION

PROFILE RADIOGRAPHY
Profile radiography has to do with remaining wall thickness measurement for pipelines or metal plates. For image analysis and
thickness measurement to be done on a radiography image, the image is called up or re-opens from the image database.
Image profiling (thickness measurement) is unlikely for raw radiography image without some level of image enhancement done
on the image.
An essential tool for image enhancement and refingin prior to thickness measurement is the HISTOGRAM EQUALIZATION
TOOL. This helps lighten the image and make the thickness boundaries of the image more visible. Depending on the thickness
and size of the inspected material, the histogram equalization tool can be applied once or twice for proper clearly defined
boundaries of the line to be visible. After properly applying the histogram tool, the measurement tool is then used to check the
remaining wall thickness of the areas of interest (usually areas of wall loss). The desired font type, font size and color can be
edited. This is done by activating the edit mode, right clicking on the measurement to be edited and clicking properties. After all
necessary editing on the font type, style, size and color has been done click on APPLY.
After the image has been worked on, it has to be saved with all of its annotation inclusive in the directory (folder) of your choice.
This is done by checking file – save as – a dialogue box pops up.
Since this is a finished image which is ready to be exported to the final report we do not need to save in the software database
anymore. So we check NO and continue with the saving. The desired folder is selected, file name is typed and then the save as
type: is changed to Jpeg 24 including Permanent annotation. Then save button is clicked.

SEDIMENT CHECK:-
The process of image editing for sediment check is not so different from that of profile radiography; the only difference is the
absence of thickness measurement.
For sediment and debris check as the name implies is just to check for the presence of any foreign material in the internal of a
pipeline. The captured image which has been saved initially is re-opened from the database in a similar process as described in
profile radiography. It is difficult to see the presence of any accumulation/ deposit on the raw image until it has been worked on.
The histogram equalization tool helps makes accumulation (deposit if there’s any present) in the section of the line more visible.
The final image is then saved in jpg format for reporting. This is done as illustrated in profile radiography but for the save as
type, the image is saved as Jpeg 24 .
WELD ANALYSIS:-

Weld analysis is done to know the integrity of welds done. There are various kind of defect that are most likely to be associated
with a welding process and radiography inspection is used to detect and quantify these defects as accepted or not.
Some of the defects that are associated with welding process include:-
 Porosity
 Undercut
 Excess weld reinforcement
 Inadequate weld reinforcement etc
All of these defects have specific appearance on the radiography image and the interpreter have to be skilled to identify these
discontinuities and differentiate discontinuities that have similar appearance the radiography image.