COMPUTED RADIOGRAPHY KEY ELEMENTS for CONSIDERATION

AWS FABTECH Atlanta - 2010 Terry Plasek

Fujifilm NDT Systems

MANAGEMENT

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THE BOTTOM LINE

•   COST CONTAINMENT •   COST REDUCTION •   IMPROVED PRODUCTIVITY •  NEW TECHNOLOGY

•  COMPETITIVE EDGE •  WINNING •  BE PROFITABLE

THAT’S WHY WE’RE HERE!

The Role Of:

RADIOGRAPHY

HAS ALWAYS BEEN EXPENSIVE: •   FILM •   CHEMISTRY •   TIME •   STAFF •   HAZMAT

TIMES ARE CHANGING!

X-Ray Film Prices Have Been And Will Continue to Increase

One Solution is the Conversion to Computed Radiography

Radiographic Film:

Medical Imaging Is the Market Driver for New Technologies

Research Money

Fujifilm Research Budget

Entire USA Market

Fujifilm Investment: 12 Times the Total USA NDT FILM Market Potential

Just The Facts Please

Let’s Take a Look at: •  Myths •  Wrong Assumptions •  Actual Facts

MYTH 1: “It’s a Digital System”…………….Yes, BUT It is “CR” Not to be Confused with Other Systems

MYTH 2: “It’s Medical”…………………. Very Wrong it is an NDT System MYTH 3: “They are all the same”……… IN “CR” NAME ONLY

MYTHS and DISPELLING THEM

ASSUMPTIONS

ASSUMPTION 1 All CR Systems are the Same…………Wrong Assumption

ASSUMPTION 2 Smaller Laser Spots are Better………..Misconception

ASSUMPTION 3 Lowest Price Will Do………………….. Lowest Cost Does

Computed Radiography is the Oldest and Most Proven Digital Imaging RT Technology. It Is Still Evolving, and is a “True Film Replacement”

Fact 1

CR is a constantly Evolving Technology, based on Market Demands for Image Quality And System performance.

Fact 2

NDT CR” Systems are NOT Medical Imagers. They Utilize Specific Imaging Plates NDT Software

NDT Electronics NDT Capacity for Higher Dose

Fact 3

There is NO ONE PARTICULAR ELEMENT of a “CR SYSTEM” which Guarantees “ FILM QUALITY IMAGERY”. All SYSTEM ELEMENTS MUST FUNCTION IN UNISON. There are 4 Basic Elements, Integrated by One KEY CATALYST.

Fact 4

KEY ELEMENTS “CR” Has Always Consisted of Four Major Elements

1 2 3 4

Imaging Plates “IP’s”

Reader Unit “RU”

Software Workstation

FMSU CONFIDENTIAL - 13 September 2006

The Catalyst

The Well Trained Radiographic Inspector is the True Key to Successful Implementation of Digital NDT RT Technology.

THE CONVERSION:

Film Radiography Computed Radiography

ONE PITFALL

All NDT X-Ray Films Provided By All Manufacturers Are of Excellent Quality. Historically:" Buy the Ones Which Offer the “BEST PRICE”

THE ASSUMPTION

Film Radiography Computed Radiography

The “Best Priced” CR System is the Same as ALL Others

NOT THE CASE ALL CR SYSTEMS ARE NOT THE SAME

EARLY CR APPLICATIONS

•  Profile Exams •  Corrosion/Erosion

Important Tests, However for Code Work X-Ray Film Was Still Being Used Most CR Systems can Comply

THE LANDSCAPE HAS CHANGED

TODAY’S REQUIREMENTS

A Variety of Applications Requiring TRUE FILM REPLACEMENT

THE MANAGERIAL ROLE

The primary role of the Manager is to assure that Any decision made with regards to “CR” will make the Company, or Department more Profitable, with Improved Productivity, using Leading Edge Technology, resulting In a “LEG UP” on any Competition.

Management Concerns: •  Code Approvals •  ASTM Documents •  ASME Documents •  Ultimate Customer Approval and Acceptance •  The TRUE COST not the PRICE

FILM QUALITY IMAGES & RESULTS

FMSU CONFIDENTIAL - 13 September 2006

THE ELEMENTS OF THE IMAGE ITSELF 1 2 3

Spatial Resolution

Contrast Resolution

Signal to Noise Ratio (SNR)

TO ACHIEVE FILM QUALITY We Must Examine:

FMSU CONFIDENTIAL - 13 September 2006

Spatial Resolution

TO ACHIEVE FILM QUALITY We Will Address

How Is IT Achieved?

What Key Elements are Needed?

•   Imaging Plate Cross Section

X-Ray Thicker Phosphor Coatings in IP’s:

•  Higher “QDE” •  More Internal Scatter

Element 1 The Imaging Plate

There are Currently FIVE Types of Imaging Plates Available

•   4 X-Ray, Gamma, Linac Various Grain Size Various Speed

•   1 Neutron

FMSU CONFIDENTIAL - 13 September 2006

Element 2 The “CR” Reader

The Reader Excites the IP with Laser Light, Extracts The Latent Image, Erases the IP, Converts “A” to “D”

FMSU CONFIDENTIAL - 13 September 2006

Element 2 The “CR” Reader

The Laser --------------------------

25 Micron 50 Micron 100 Micron XXX Micron

Is the Size Of the Laser NOT The System Resolution

Systems with Selectable Laser Spot Size: Done with Software

FMSU CONFIDENTIAL - 13 September 2006

Element 2 The “CR” Reader

Laser Spot Size

Pixel Dimension 1

Sampling Rate

Pixel Size File Size 14” x 17”

50 Micron 0.002”

50 Micron 0.002”

20 Pixels/mm 0.002” x 0.002”

135 MB

64 MP

100 Micron 0.004”

100 Micron 0.004”

10 Pixels/mm 0.004” x 0.004”

35 MB

16MP 200 Micron 0.008”

200 Micron 0.008”

5 Pixels/mm

0.008” x 0.008”

15 MB

8 MP

THE CORRECT PROCESS

FMSU CONFIDENTIAL - 13 September 2006

Element 2 The “CR” Reader Conversion to DIGITAL

Pixels are “THREE DIMENSIONAL

FMSU CONFIDENTIAL - 13 September 2006

Element 2 The “CR” Reader

THE PROCESS: Which Determines Image Quality

Laser Scanning “X’ Direction: Main Scan

Pixel Sampling Along Main Scan Direction

Laser Indexing (Translational Movement)

…………………… …………………… ……………………

Imaging Plate

PIXEL HEIGHT

PIXEL WIDTH

NEXT LINE

FMSU CONFIDENTIAL - 13 September 2006

Element 2 The “CR” Reader

The Laser Spot Size Determines ONLY One Dimension Of The Pixel Size

FMSU CONFIDENTIAL - 13 September 2006

Element 2 The “CR” Reader

The Sampling Rate Along that Line Determines The Second Dimension of the PIXEL

……………..

ONLY ONE LINE!

FMSU CONFIDENTIAL - 13 September 2006

Element 2 The “CR” Reader

Translational Movement is as Critical

INDEXING

LINE TO LINE

FMSU CONFIDENTIAL - 13 September 2006

Element 2 The “CR” Reader

The Translation Along the Axis 90 Degrees to the Laser Scan Direction is Equally as Critical.

UNIFORM PIXEL MATRIX!

“CR” E2444-05 Stability Document ASTM: That is WHY the ASTM Gage Exists

Laser Jitter

Transport Slippage Sharp Edge (Spatial Check)

Exposure Homogeneity

Linearity Check

Element 3 Software

There are Two Software Activities Associated with A “Production” CR System.

System Controller Software

Workstation or Imaging Software

Element 3 Software

System Controller Software

•  Controls the System •  User Interface •  Demographics Entry •  Applies Pre-Processes •  Enables QA Functions •  Directs Exporting Images •  Re-Processes Raw Data •  Data Entry

Element 3 Software

System Controller Software

This Terminal Allows Inspection Personnel to Easily Use The System. It is Menu Driven.

Element 3 Software : System Controller

Close up: Vendor Supplied or User Generated

The Purpose of the Menu is an Assurance that all Images of any Particular Study Have Been CONSISTANT and Not ARBITRARY

Element 3 Software

System Controller Software

•  Controls the System •  User Interface •  Demographics Entry

•  Applies Pre-Processes •  Enables QA Functions •  Directs Exporting Images •  Re-Processes Raw Data •  Data Entry •  Demographics entry

Besides Applying those Gray Scale and Edge Treatment Values Associated with the “READ” Menu.

HISTOGRAM NORMALIZATION Exposure Data Recognizer

Exposure Data Recognition Immediately Starts Correcting The Image by generating a Histogram Analysis of the Image Data and extracts only the information needed for output, securing the Gray Scale data, and creating an Optimized FILM QUALITY Image,

Element 3 Software

Some Images are Displayed in a linear Fashion, where Gray scales are Displayed as a direct Function of Dose, displaying Both Underexposed And “D-Max” Pixel values.

Element 3 Software

Optimum Image Quality is Obtained when Information is Displayed in the form of the Sensitometry Curves as achieved in Film Radiography…..when TRUE FILM REPLACEMENT is required.

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Element 3 Software

EXPOSURE FEEDBACK

As there is no way to determine Film Density, there has to be a Method to assist in establishing Correct Exposure Parameters.

One method is to Display the “Dose” of Radiation Impinged On the Imaging Plate Itself,

•  Linear •  Feedback to Erasure Process

Element 3 Software

If the Correct Menu and Functions are Used: Inspector Intervention Should be Limited to Simple Zooming, Scrolling, and Slight Window And Leveling.

WITHOUT These Automated Features the CR Process Can be very SLOW. Adjusting Each Image is Simply Not COST EFFECTIVE. CR Becomes a Lab Tool, Not an Inspection System

Element 4 The Workstation

Most Utilize Flat Panel Displays

2 Mega-Pixel 3 mega-Pixel 4 Mega-Pixel 5 Mega-Pixel ETC. Etc.

Select the Display That Meets your Needs. A Higher Resolution Display Is Worthless When Viewing A Lower Resolution Image

Element 4 The Workstation

Most Utilize Flat Panel Displays

2 Mega-Pixel 3 mega-Pixel 4 Mega-Pixel 5 Mega-Pixel ETC. Etc.

All Workstations Should have Networking Capability and Image Storage Options of Resident and remote Storage

Computed Radiography Approvals

•  E 2007-08 Standard Guide for CR •  E 2033-99 Standard Practice for CR •  E 2445-05 Qualification and Long Term Stability Document •  E 2422-05 Digital Reference Images (Al) •  E2446-05 Classification of Computed Radiography Systems •  E 2339-08 DICONDE A version of DICOM--- Modified for NDT Use

ASTM:

Computed Radiography Approvals

•  ASME ASME Section V Article 2 Mandatory Appendix VIII

Radiography Using Phosphor Imaging Plate

THE KEY ELEMENTS

ACTION PLAN AS MANAGEMENT

•  CUTOMER REQUIREMENTS •  PURCHASE SPECIFICATIONS

CUSTOMERS HAVE ALWAYS REQUIRED THE SUBMITTAL OF AN RT TECHNIQUE:

•  RADIATION ENERGY •  GEOMETRY •  PENETAMETER SENSITIVITY •  FILM TYPE* •  PROCESSING PARAMETERS

THE KEY ELEMENTS

*As There is no Film: •  Imaging Plate Type •  System Classification (ASTM) •  Algorithms: •  Contrast, an Absolute Value •  Gray Scale (Absolute Value Range) •  Curve Applied, Absolute Value •  Edge Treatment Brightness, Absolute Value •  Edge Treatment Width, Absolute Value •  Level and Degree of Histogram Normalization •  Dose value

Simply Adjusting the Contrast and Gray Level on Each Obtained Image Without Displaying and Documenting Absolute Values Will Not Be Acceptable.

THE KEY ELEMENTS

Simply Adjusting the Contrast and Gray Level on Each Obtained Image Without Displaying and Documenting Absolute Values Will Not Be Acceptable.

Every Image has to be Traceable with Regards to the Algorithms Applied, in Defined Quantitative Values.

The Days of Manually Adjusting Each Image to the Preference of the Interpreter are Gone. Each Image Has to be Permanently Stored, as Interpreted with A Traceable Record of the Method of Which the Image was Generated, in a DICONDE (DICOM) Format, with True Backwards and Forward Compatibility.

THE KEY ELEMENTS •  PURCHASE SPECIFICATIONS

•  Type of Imaging Plate Speed, Grain Size, Sizes •  Type of Imaging Plate Transport •  Method of Demographics Entry •  Method of Applying “Read Software” •  Type of Erasure Sub-System •  Method of Determining Adequate Erasure •  Method of Avoiding Latent Image and •  Double Exposure •  Dust and Artifact Control Methods •  Ease of Operation •  Speed of System (Images per Hour)

THE KEY ELEMENTS •  PURCHASE SPECIFICATIONS

•  Type of Laser •  Laser Sampling Rate •  Laser Jitter •  Transport Slippage •  TRUE SYSTEM SPATIAL RESOLUTION Not JUST LASER SPOT SIZE •  ASTM Classification •  Method of Applying Software •  Software Quantitative Values •  Storage and Retrieval of Software Values •  Ability to Re-Process Image Files W/O Re-shot •  Method of Determining Correct Exposure

A NEW AGE

We Have Entered A New Age of More Demanding Customer Requirements.

CR and Digital RT Are a Part of Those Requirements

Thank You

Fujifilm NDT Systems