At the beginning of 2024, we had an interesting project to upgrade and optimize the radiography testing process in a huge pipe mill in Abu Dhabi (UAE). We used the SCANRAY 1230 complex with a non-magnetic mechanical system to fix the digital detector on the control object and the constant-potential X-ray generator with anode voltage up to 225 kV. The inspected pipes were from 2 to 24 inches with a wall thickness ranging from 4 to 32 mm.

Our optimization process results for this project showed that the average productivity of direct digital radiography (DR) was at least 3 times as high as when using conventional RT with film.

The total NDT time of the original procedure with the film included the following: the pure time to install the marking signs, position the film on the joint, obtain one image and, subsequently, obtain a full image of one joint, bring the film to the dark room, develop it and wait it dry, and, finally, evaluate the results. Moreover, there was always a risk of exposition mistakes leading to reshooting. Ir-192 was used with the film.

The SCANRAY system gave the absolute advantage that the inspection result was visible immediately after shooting. The detector positioning was performed in three movements (unscrew the bracket, turn it and fix), the use of digital marking signs eliminated the need to spend time on their installation, the exposition time was much faster than that used on the film.

On that project, it was important that the pipe movement through the entire production conveyor was not delayed at the flaw detection stage. The traditional method using X-ray film gave a delay of more than one day, while DR allowed the pipe to be sent for painting or repair literally instantly after receiving the images.

The number of joints per shift varied depending on diameters and wall thickness, as well as the convenience of exposition. On average, a team of 2 operators with the guidance of our technical expert has reached productivity from 50 to 80 joints per shift.

It is also crucial to mention that the result depends strongly on the experience and motivation of the employees. A motivated professional will always show higher productivity than a non-motivated beginner, the difference can be times. However, despite the initial lack of skills and few communication difficulties, our technical expert succeeded in training local personnel on how to work with DR, explained the main exposition parameters and physics behind the process, shared some special tricks on how to achieve the best image quality and enhanced the testing procedures in general. No doubt that gaining working experience by operators will increase productivity even further.

During the time of optimization, the software, SCANRAY 1230 system and X-ray generator worked well and stably, and the team did not experience any problems in training and control.

In conclusion, it is important to note that the use of specialized accessories and tailored solutions can also boost the inspection effectiveness drastically. Upon completion of the project, it was recommended to purchase of unique magnetic holder for the SCANRAY systems to eliminate the detector installation/dismantling time, as well as consider the use of automatic annular weld control complex XPRESS-SCAN DW for pipes of 10 inches and more.