Crown Hollander International Inc.

Description

The X-ray system supplied by Byard is known as Real-time X-ray or Fluoroscopy. This is a system which displays live the image of a weld directly onto a TV monitor and records the image onto a video tape or a CD. Hard copies (photographs) of the image can also be made.

The X-ray station has the following components;
1 LIFTING AND LOWERING STATION
2 PIPE TROLLEY
3 X-RAY EQUIPMENT
4 X-RAY CHAMBER
5 CONTROL ROOM
6 SAFETY SYSTEMS

These are summarized below;

1. LIFTING AND LOWERING STATION
The pipe is taken by conveyor and placed on racks in the x-ray area. The pipe is rolled into a position over the x-ray trolley. The pipe is then lowered by the pipe lifters onto the rotators on the x-ray trolley.

2. PIPE X-RAY TROLLEY
The pipe x-ray trolley is a long structural steel frame, with four steel wheels, mounted on steel rails. Two of the wheels have a variable speed electric motor drive.

On top of the frame are two pairs of rotators to support and rotate the pipe. The rotators have steel rollers with tyres of polyurethane. One roller in each pair is driven by a variable speed electric motor drive. The rollers are bolted to slides and can be spaced apart by means of a screw jack, manually operated.

An encoder, attached to the axle of the long travel drive, is used to monitor and record the longitudinal position of the pipe.

3. X-RAY EQUIPMENT
The x-ray unit, which is supplied by either Phillips or Agfa/Siefert, is enclosed in an x-ray chamber. A pipe can go through the chamber. The operator is situated and works remotely from a control room using video cameras and remote controls.

The x-ray tube and a spray marker (to mark faults) are fixed to one end of a long (as long as the pipe) cantilevered boom which is fixed, at the other end, to the factory floor. The x-ray tube is positioned about 100mm from the pipe surface, inside the pipe. The Transformers which power the x-ray tube, the chiller/cooler and a small compressor are positioned on the factory floor near the base of the boom. The high voltage cables, chiller/cooler circulation tube and compressed air pipe run along the boom to the live end.

Also on the factory floor is an uninterruptible power supply (UPS), which serves as a backup power supply for the chiller/cooler in case of a power failure whilst the x-ray unit is running and requires cooling after de-energising. The UPS also powers the image processing system and console computer.

Outside the pipe is the image intensifier. The intensifier is mounted on a miniature gantry which is powered to enable the operator to position the image intensifier to suit the pipe diameter.

The x-ray image of the weld is formed on the output window of the image intensifier tube, and the image size is controlled by the image intensifier shutter controller. The image intensifier body contains a sensitive CCTV camera, which transmits the image to the image processing unit. The image processor sends the signal to a printer and to a CD writer or a video cassette recorder.

Thus as the weld passes between the x-ray tube and the intensifier the operator observes the live image of the weld on the monitor.

4. X-RAY CHAMBER
The operator moves the pipe on the trolley along the track into the x-ray chamber. When it is clear (by observation of a separate TV monitor linked to a small camera focused on the space between the tube and the intensifier) that the pipe end is in position, the encoder (giving the longitudinal position) is zeroed and the pipe is rotated until the weld is seen in the middle of the monitor screen.

The operator then ogores to the pipes and attaches a penatrameter, which is required in order to determine the quality and sensitivity of the x-ray system.

The operator returns to the control room and after video scanning of the chamber and starting the warning siren, the x-raying is started.

The pipe number, pipe length, pipe size, etc is displayed on the screen and the operator concentrates on the inspection process. An experienced operator can observe the image of the weld on the screen at a rate of up to 2m per minute.

If no defects are found the operator reverses the pipe on the trolley, at a high speed (in about 4 minutes for 19m).

If possible defects are observed by the operator, the pipe movement is stopped, and the image is digitally magnified and enhanced. The operator measures the suspected defect and if it is greater than the specified tolerances, the defect is marked and a hard copy for the repair welder is made.

The marking of a defect is done remotely using a paint spray system operated from the control room by push button.

5. CONTROL CHAMBER
The control room contains the control panel and the operator.
The control panel has two monitors for the video cameras and another for the visual display of the x-rayed weld. The operators console contains the key board, the computer and the variable speed controller for the pipe movements. The key board is used to input in all the pipe statistics.

6. SAFETY SYSTEMS
The x-ray tube is enclosed in a lead shield, with an aperture for the focus on the enhancer. The chamber has thick concrete walls to contain, as far as possible, stray x-rays. The area around the x-ray station is fenced off from the factory, with gates controlled by limit switches.

When x-raying is about to commence a siren is sounded as a warning and when x-raying is in progress a flashing red light operates.

7. RANGE AND OPERATING CAPACITY OF BYARD REAL TIME X-RAY MACHINE
Pipe diameter range…………………………………………………………. 500 to 3200 mm
Wall thickness………………………………………………………………………. 5 to 25 mm
Pipe length………………………………………… 19 m standard can be modified for 24m
Pipe weight………………………………………………………………………… up to 32 tons
Seam examination speed……………………………………………………….. up to 2m/min
Pipe trolley rotation speed……………………………………………………….. 0 to 3m/min
Pipe trolley long travel speed…………………………………………………. 0 to 6,3m/min
Electrical power supply…………………………………………………………………… 30 KW

8. DELIVERY OF REAL TIME X-RAY MACHINE
The Real-Time X-Ray machine can be supplied ex-works within 4 months from receipt of Order.

9. INSTALLATION
Once on site the X-Ray machine will be installed within 2-3 weeks by experienced technicians. On site training and safety will be provided once the pipe factory is ready to be commissioned.

10. EXCLUSIONS
All civil engineering and building works including foundations, X-Ray chamber, X-Ray Operators Office and associated works are excluded. Byard will however provide detailed engineering drawings for the construction of the civil and building works required.

As for costs the following is the current price for this equipment. Supply of all technology as described on the specification including all X-ray systems, mechanical control and process equipment (rotators/boom/etc) hydraulic and electrical systems and control and pc equipment but excluding civil works for concrete barriers etc.

X-Ray Inspection