How to Build Your Own Use Case for a Conformable DR Detector

At Carestream NDT we want to share not only our technological developments and product portfolio, but also the knowledge and practical experience that our staff obtains by working shoulder-to-shoulder with customers like you. We aim to share this knowledge and experience in a straightforward fashion so that our readers may find practical applications in their everyday activities.

This series is directed but not limited to NDE professionals in the following industries: Oil & Gas, Nuclear, Construction, Foundry and Castings, Energy Generation, Aerospace, Transportation, Automotive, Military and Defense, Agriculture, Art Restoration & Museum Artifacts, and NDE Services Companies.

Introduction – Ecosystems and Platforms

Since the momentous discovery of x-rays made by Röntgen in November of 1895, imaging processes have enhanced our senses allowing us humans not only to see inside ourselves in health- related imaging processes but also have granted us the power to see inside individual objects and complex assemblies that constitute the remarkably diverse type of assets that surround us.

Industries such as oil and gas, nuclear, construction, foundry and castings, energy generation, aerospace, NDE services companies, transportation, automotive, military and defense, or even non-industrial activities such as art restoration and museum artifacts make ample use of a very diverse palette of radiographic, ultrasonic, infrared and eddy current imaging capabilities.

This richness of imaging capabilities not only contributes to assure the quality and safety of the associated assets but also provides essential information and knowledge to support substantially important decision-making processes at all hierarchical levels in key stakeholders in the asset’s ecosystem such as designers, manufacturing and construction companies, operators, owners and regulatory bodies.

Radiographic Film, Imaging Plates (IPs) for Computed Radiography (CR), and Digital Detectors Arrays (DDAs) for Digital Radiography (DR) and Computed Tomography (CT) offer a rich palette of imaging capabilities that range from the carefully controlled environment of a R&D laboratory to the harsh, and often hostile, environmental conditions of field applications in an off-shore platform.

Competitive and sustainable imaging operations must have not only a clear perspective of the constituents of its imaging ecosystem, as is shown in Figure 2, but also of the role that any supporting imaging software platform should have to streamline the capture, analysis, transmission, storage and preservation of trustworthy images. A vendor-independent DICONDE-compliant imaging platform shall ensure technological advancements in imaging media, hardware, and software create a positive syngenetic effect on the rest of the constituents of the imaging ecosystem; here the importance of establishing a proper alignment between the adoption of advancements in recording media technology, imaging platforms, and the technical requirements integrated into codes and regulations.

WHY does a Bendable Detector should exist – The importance of conformability and intimate contact.

Radiographic image formation principles advise, that whenever is feasible, the distance between the subject and the recording media, regardless if it is film, IPs or DDAs, should be maintained as minimal as it is possible to minimize distortion and unsharpness effects on the resulting image. This image formation principle is replicated in the radiographic inspection requirements contained within an ample spectrum of manufacturing and construction codes worldwide.

Codes such as the ASME BPVC for boilers and pressure vessels or AWS D1.1/D1.1M in steel construction, specifications such as API 6A and standards such as ASME B31.1, ASME B31.3 or API 1104 have as a common trait that they embrace this imaging principle not only for the inspection of welds on pipes or tubular components, but also integrate it in the radiographic inspection requirements for castings, rolled products, forges. pipes, tubing or other manufactured components formed with round surfaces.

Single-wall exposure / single-wall viewing (SWE/SWV) as is shown in Figure 3, double-wall exposure / single-wall viewing (DWE/SWV) as is shown in Figure 5, and double-wall exposure for double-wall viewing (DWE/DWV) techniques as is shown in Figure 6 constitute the fundamental repertoire of radiographers around the world regardless of the industrial sector where they participate.

Specific applications based on the shape of the inspected assets, such as panoramic expositions (See Figure 6) in pressure vessels, large diameter pipes or tanks, constitute clear variations of these fundamental techniques.

What manufacturing codes exactly demand:

Table 1 provides a glimpse of the technical requirements related to radiographic techniques very diverse set of industries where radiographic standards emphasize and prioritize the use of flexible radiographic media.

Document	Requirement	Excerpt	Scope of application
ASME Boiler  and Pressure  Vessels Code  2023 edition  [7]	Section V  Article 2  Paragraph T-271  Radiographic  Technique	“A single-wall exposure  technique shall be used for  radiography whenever practical.  When it is not practical to use a  single-wall technique, a double wall technique shall be used. An  adequate number of exposures  shall be made to demonstrate  that the required coverage has  been obtained.”	Since 1914 ASME  BPVC have been  considered an  essential reference  within a wide  spectrum of  industries such as  nuclear, electric  power-generation,  petrochemical, and  transportation,  among others.
ASME B31.1  – 2022 Power  Piping [8]	Chapter VI Inspection,  Examination,  and Testing,  Paragraph  136.4.5  Radiography	“(a) When required by this  Chapter (see Table 136.4.1-1),  radiographic examination shall  be performed in accordance with  the requirements of ASME BPVC,  Section V, Article 2, except that  the requirements of T-274 are  to be used as a guide but not  for the rejection of radiographs  unless the geometrical  unsharpness exceeds 0.07 in.  (2.0 mm).”	This standard  prescribes  requirements for  piping systems  typically found  in electric power  generating stations,  industrial and  institutional plants,  geothermal heating  systems, and central  and district heating  and cooling systems.
ASME  B31.3 -2022  Process  Piping [9]	Chapter VI Inspection,  Examination,  and Testing,  Paragraph 344.5  Radiographic  Examination	“344.5.1 Method.  (…) Radiography of welds and of  components other than castings  shall be performed in accordance  with ASME BPVC, Section V,  Article 2.”	This standard contains  requirements for  piping typically  found in petroleum  refineries; chemical,  pharmaceutical,  textile, paper,  semiconductor, and  cryogenic plants; and  related processing  plants and terminals.
API  Specification  6A, 21st  Edition –  Specification  for Wellhead and Tree  Equipment  [10]	10.4.2.16 Weld  NDE-Volumetric Paragraph  10.4.2.16.2  Test Method Radiographic  Examination	“Radiographic examinations shall  be performed in accordance  with the procedures specified in  ASME BPVC Section V, Article 2  (or equivalent) with a minimum  sensitivity of 2%(2-2T).”	This specification  identifies  requirements for  wellhead and tree  equipment for use in  the petroleum and  natural gas industries.
API Standard  1104, 22nd  Edition –  Welding  Pipelines  and Related  Facilities [11]	Section 11.1*  Radiographic  Test Methods,  Subsection  11.1.2.3 Other  Imaging Media,  paragraph  f) Exposure  geometry * Section 11.1  presents the  requirements  for producing  radiographic  images on film  or other media  through the use  of X- rays or  gamma rays.	“Whether single-wall exposure  for single-wall viewing (SWE/ SWV), double-wall exposure  for single-wall viewing (DWE/ SWV), or double-wall exposure  for double-wall viewing (DWE/ DWV);” whether in motion  or still imaging; the scanning  speed for in motion imaging;  the distance from the source  or focal spot to the imager  surface; the relative positions  of the imager surface, weld,  source, IQIs, and the intervals or  reference markers; the amount  of geometric magnification;  the total magnification used  for viewing; and the number of  images required for radiography  of a complete weld”.	This standard provides  requirements for gas  and arc welding used  in the construction  and in-service  repair of pipes and  components for  the compression,  pumping and pipeline  transmission of  crude oil, petroleum  products, fuel gases,  carbon dioxide and  nitrogen.
AWS D1.1/ D1.1M:2020 Structural  Welding  Code —  Steel [12]	Clause 10  – Tubular  Structures  Section 10.28  Supplementary  RT Requirements  for Tubular  Connections Paragraph  10.28.1  Circumferential  Groove Welds in  Butt Joints.	“The technique used to  radiograph circumferential butt  joints shall be capable of covering  the entire circumference. The  technique shall preferably be  single-wall exposure/ single-wall  view. Where accessibility or pipe  size prohibits this, the technique  may be double-wall exposure/  single-wall view or double-wall  exposure/double-wall view.”	This code contains  the requirements  for fabricating and  erecting welded  steel structures for  a very diverse set of  construction sectors.  Clause 10 covers  butt joints between  tubulars, T-, Y-.  K- connections of  tubulars to tubulars,  or tubulars welded  to flat plates or flat  elements of other  members.

All the technical references listed above, and their equivalents codes, specifications, and standards  in other regions of the world such as Europe, Asia or Africa, have in common that they emphasize  the importance of direct contact of the radiographic detector with the inspected zone, whenever this  condition is technically feasible but until today, only film and computed radiography (CR) imaging  plates (IPs) could satisfy that requirement. 

Aiming to expand, enrich, and reinforce the imaging capabilities of our customers in a very diverse  set of industries, we have developed an amorphous silicon conformable digital detector array (DDA)  that is flexible and that allows the detector to be in direct contact with the inspected component.  This conformable detector can be bent repeatedly around pipe welds of varying diameters resulting in  significant image quality improvement, workflow time savings and productivity benefits for the static  capture of radiographic images on curved components. 

WHY does the use of a Bendable Detector make Business Sense – Optimized imaging workflow, reduced  image acquisition time and increased productivity. 

For field radiography applications the detector design should be portable, thin, flexible, easily  attached, and able to withstand harsh environments. Size, weight, scintillator type, pixel pitch,  bit depth, radiation shielding, load limits, temperature, moisture, atmospheric pressure, vibration  mitigation, drop resistance, and ingress protection are all additional considerations. High-quality digital  images can be obtained utilizing either tethered or wireless image acquisition modes. The improved  productivity obtained from bendable detectors relative to film and CR benefits not only the industrial  sectors listed in Table 1 but also to the constituents on their business ecosystem.  

As we have reviewed before, industrial radiography serves a wide variety of segments and  applications. More than half of the static two-dimensional exposures are accomplished with the use  of radioisotopes outside in field settings. Some field radiography exposures are done with portable  battery-powered pulse X-ray sources. Continuous X-ray exposures are typically done at a facility inside  a vault or cabinet. Conformable DDA’s are operated in the same way as rigid detectors. They do not  require a cassette like film or CR imaging plates. Multiple detector sizes are available to accommodate  different inspection areas and bend radii. The detector is repeatedly bent around components as part  of daily inspection operations. The manufacturer’s recommended bad pixel map process is utilized to  update the existing pixel map daily or prior to an inspection set. The detector may have a tether wire  to an access point interface box, whereby the interface box can communicate wirelessly or via tether  to a tablet or laptop. The image quality for digital radiography (DR) is superior to film and CR, and  image quality for single viewing is improved. The combination of both factors leads to a significant  and measurable image quality advantage. 

Conformable DDA’s also have a significant productivity advantage relative to film and CR. 

Why would you use conformable DR versus film or CR?
Productivity	Operational Savings	Health and Safety	Envirmonmental  Impact
• Instant Images  (no processing time  associated with film  development or IPs  Scanning)  • Labor flexibility  (complete twice as  much work in the  same time lapse)  • Reduce work  burden associated  with retakes	•Consumables  (including films and  chemicals or imaging  plates) • Inventory carryings  costs  • Chemical wastes  disposal costs  • Film scanning and  archiving  • Isotope replacement  costs	• Smaller exclusion  zones are possible • Reduce  radiographer’s  fatigue (associated  with running films  and imaging plates)	• Eliminate impacts  associated with  chemicals production,  distribution and  waste disposal.  • Eliminate water  consumption impact  associated with film  processing

Brian White, Research Scientist and Level III Radiographer at Carestream NDT, explains the practical  implications of the notions discussed in the present white paper in the following terms [8]:  

“Applications for conformable detectors include any curved exposure technique that requires single  viewing. The detectors may also be utilized flat for double viewing. We anticipate that conformable  detectors will be initially deployed into field radiography applications exposed with Iridium. In the  future, radiographers will find new ways to use these detectors in ways that we have not considered.  The primary industrial markets include oil and gas and inspection services. Other potential markets  include aerospace, defense, security, casting, and power. The industrial radiography industry will  benefit tremendously from conformable detector technology. The primary advantage is productivity,  the ability to get the inspection done quicker, which results in cost savings. In addition, digitization  and digital technology provide numerous benefits relative to analog processes. Digitization enables  digital transformation as part of the fourth industrial revolution.” 

An actionable approach for radiographic imaging professionals and business decision-makers – Building your  own use case for a conformable DR detector (Part I of III)

1. As an initial step in this stage, it will be interesting to make a list of the components and  assemblies within the scope of your work that require radiographic imaging processes based on the  options integrated in Figure 2. 
2. Next, for each component or assembly type make a list of the codes, specifications or standards  that describe the radiographical technique applicable to the components and assemblies already  included in your list.  
3. Then, for each codes, specifications or standards in your list validate if digital radiography using  DDAs is a feasible radiographic imaging processes.  
4. Finally (for this stage of analysis ), review either single-wall exposure for single-wall viewing (SWE/ SWV), panoramic, double-wall exposure for single-wall viewing (DWE/SWV), double-wall exposure for  double-wall viewing (DWE/DWV) or other exposure technique is applicable for each component or  assembly where digital radiography using DDAs is allowed.  

A.- Component / Assembly	B.- Applicable Codes	C.- Is DR allowed?	D.- Applicable  Exposure	Next Stage is  available in the  second white paper  of this series
Circumferential Weld  in a Pressure Vesse	ASME BPVC, Section  VIII-1 UW-51 and  Section V Article 2.	Yes, ASME BPVC,  Section V, Article 2,  Mandatory Appendix  IX Radiography Using  Digital Detector  Systems.	Panoramic

At this stage, you should have consolidated into a single document: 

1. A comprehensive list of the most common components or assembles where you need to perform  radiographic imaging processes,  
2. Which of those radiographic imaging applications have the option to be performed with DR and 
3. Which are suitable to use a conformable DR detector. 

To move forward in the construction of your business case, we advise you to review other White Papers  in this series: 

Building Your Own Use Case for a Conformable DR Detector  

Part I – “The Why’s” Expanding, Enriching and Reinforcing Your Imaging Capabilities  (This White Paper) 

Part II – “The How’s” Proposing an actionable approach to a new set of imaging capabilities 

Part III – “The What’s” An Instructive Comparison of Conformable DDAs to Film and CR  Imaging Plates 

• For readers interested in exploring how digital radiography (DR) can be integrated into your  processes:  https://www.carestream.com/en/us/nondestructive-testing-ndt-solutions
• For readers interested in exploring supplementary white papers on practical application and  innovation on imaging processes:  https://www.carestream.com/en/us/nondestructive-testing-ndt-solutions/ndt-white-papers

Here are some supplementary information resources from Carestream NDT’s products and  services portfolio: 

Products 

• HPX ARC 1025 PH
• HPX ARC 1043 PH
• INDUSTREX Fieldview, Tablet
• INDUSTREX Digital Viewing Software
• Advanced Industrial Radiographic Training Academy
• ayData NDT Archive Solution
• Virtual NDT Showcase
• Resource Center
• NDT White Papers

Services – Training and Supplementary Resources: 

• Digital Detector Array Radiography – 40 Hour Online Course 
• Digital Imaging – 40 Hour Classroom Training

Resources from ASNT 

• Nondestructive Testing Handbook, fourth edition: Volume 3, Radiographic Testing

References: 

1. White, Brian S. “ Conformable Digital Detector Arrays for Nondestructive Evaluation,” 13th European Conference  on Nondestructive Testing, Lisbon, Portugal, 2024. 
2. White, Brian S. “ Conformable Digital Detector Arrays Compared to Film and Computed Radiography,” ASNT 2023  Annual Conference, Houston, Texas USA, 2023 
3. White, Brian S. “Exposure Factors for Film and Digital Detector Array Radiography,” 20th World Conference on  Nondestructive Testing, Incheon, South Korea, 2024. 
4. ASTM Standard E2736-17(2022), 2022, “Standard Guide for Digital Detector Array Radiography” ASTM  International, West Conshohocken, PA, 2022, www.astm.org. 
5. Sinek, Simon. Start with why: How great leaders inspire everyone to take action. Penguin, 2009. 
6. Bossi, R., Nondestructive Testing Handbook, fourth edition: Volume 3, Radiographic Testing, Columbus, OH,  American Society of Nondestructive Testing, 2019. 
7. ASME, Boiler and Pressure Vessel Code, Section V (Nondestructive Examination), American Society of Mechanical  Engineers, Boiler and Pressure Vessel Committee, New York., N.Y., 2023. 
8. ASME, “ASME B31.1-2022 Edition, Power Piping,” ASME Code for Pressure Piping, B31, An American National  Standard, The American Society of Mechanical Engineers, New York., NY., 2022 
9. ASME, “ASME B31.3-2022 Edition, Process Piping,” ASME Code for Pressure Piping, B31, An American National  Standard, The American Society of Mechanical Engineers, New York., NY., 2022 
10. API (American Petroleum Institute), Specification for Wellhead and Tree Equipment, 21st Edition, No. API 6A., 2018. 11. API (American Petroleum Institute), Welding Pipelines and Related Facilities, 22nd Edition, No. API 1104., 2018. 
11. AWS (American Welding Society), AWS D1.1/D1.1M:2020 Structural Welding Code – Steel, Miami: American  Welding Society (AWS), 2020.