AMMTIAC Quarterly, Vol. 2, No. 2 - Advanced Materials ...

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Informational inspections have been performed on various submarine and ship components, and informational verification of defect removal has been performed on various welds. In these informational inspections, image quality is not the defining criterion that it is for production inspections. Initial work experience suggests that future time and cost savings from using CR should be substantial. In many cases it is not logistically feasible to use conventional radiography methods to inspect ship components because of the time required for the inspections while the ship is in dry dock. In one example, the ship components required multiple radiographic inspections, ultimately ending up with 56 images being taken. If film were used, each image would have required a 23-minute exposure time for a total exposure time of more than 21 hours. Another logistical issue posed by the prolonged exposure times is protecting the operator and ensuring compliance with ALARA, which extends the overall inspection time. Given the available dry dock time for the inspections, this number of conventional radiographic shots for each of these components would not have been possible. Using CR for these inspections reduced exposure time to 3.5 minutes per exposure, saving roughly 18 hours in exposure time alone. In addition to the ALARA-associated benefits of the reduced exposure, the CR technique allowed operators to quickly read the image plate instead of processing the film. This eliminated retakes, which also saved a considerable amount of time. Informational CR inspections have already yielded cost and time savings and with continued effort and research, CNRNW activities will be at the forefront for implementing this new technology for inspecting welds and castings. By performing both a film-based and a CR exposure on the same item, operators demonstrated that the digital images were of the same or better image quality. In addition to comparable image quality, operators welcomed the safety benefits associated with the CR process. They cited the benefits of reducing radiation exposure, eliminating film-development chemicals, and no longer needing to dispose of hazardous waste products. The annual savings for the first CR system have been calculated to be $194,000. This figure is based upon several factors, including: • A 500 to 2000 exposure-lifespan for the IP • Eliminating hazardous waste disposal expenses and the associated cost for silver reclamation • Saving water by eliminating film rinsing and eliminating climate controls for chemicals • Reduced personnel costs due to reduced exposure times. In early 2006, the most recent CR system within CNRNW was installed and manufacturer training was provided; how ever, the system has yet to be fully utilized. This is a different CR system from that used at the other activities, and it includes updated components as well as a selection of three different sizes of IPs. The new system was installed within an existing radiography facility, which has spatial limitations that influenced the system’s configuration. Because the radiography operation is divided between two floors, the radiographic equipment and scanners were set up on the first floor while the viewing (reader) stations were placed on the second floor, and the system components are linked by Ethernet. Similar to the results from the first two CR systems, CNRNW anticipates several environmental and workload benefits from the implementation of the new CR system. Eliminating chemicals from traditional film development will help meet the waste reduction requirements under the Resource Conservation and Recovery Act (RCRA) and Executive Order 13148. In addition, digital imaging will help Navy Region Northwest reduce its reporting requirements under Superfund Amendment Reauthorization Act (SARA) Title III. Average annual savings for the newest CR system are projected to be $689,000 based on the facility’s return on investment analysis. Obstacles to Implementation Regrettably, the Pacific Northwest Navy facilities are not yet able to fully utilize their CR systems. For these activities, the use of CR is restricted to the informational type “in-process” inspections rather than final acceptance inspections. Several factors contribute to this limitation. The first factor is the reliability of weld defect indications. Currently users have not consistently achieved the same sensitivity to weld defect indications with CR as with traditional film techniques. Process reliability is of paramount importance. The capacity to certify that individual components are capable of providing a baseline of information has yet to be established. Related to this is the frequency of certification and calibration. Procedures for system certification (including frequency of calibration) have yet to be finalized. The issuance of standards and authorization depends upon the completion of two separate studies to examine the present and future capabilities of CR technology in order to ultimately determine the requirements and procedures for CR inspections. One study is focused on ensuring that the results obtained through CR are compatible with those obtained through traditional film processing. The existing operating practices for technicians are for film-based radiography and are not directly applicable to CR because of the major technical differences between the two techniques. Any settings alterations under CR affect which discontinuities and anomalies are detected. The goal is to have a set of procedures that ensure reliable and consistent detection and evaluation results, regardless of the operator. The second study is focused on ensuring that the test results cannot be altered. It is critical that the original data in the digital image files is not able to be modified. In addition to Navy authorization, CNRNW activities face their own obstacles to implementing and using CR. Consolidation of inspection processes among the activities is the primary obstacle. In addition, once a determination is made on the lead activity for implementing CR training the two sites will benefit from standardization. Computed radiography offers several advantages over filmbased techniques, but issues about implementation remain. As the Navy studies CR applications and requirements in other settings, Navy Region Northwest will offer its extensive experience to the evaluation. 14 The AMMTIAC Quarterly, Volume 2, Number 2
AMMTIAC Directory TECHNICAL MANAGER/COR Dr. Lewis E. Sloter II Associate Director, Materials & Structures ODUSD(S&T)/Weapons Systems 1777 North Kent Street, Ste 9030 Arlington, VA 22209-2110 703.588.7400, Fax: 703.696.2230 Email: lewis.sloter@osd.mil DEFENSE TECHNICAL INFORMATION CENTER (DTIC) POC Melinda Rozga, DTIC-I 8725 John J. Kingman Road, Ste 0944 Ft. Belvoir, VA 22060-6218 703.767.9122, Fax: 703.767.9119 Email: mrozga@dtic.mil AMMTIAC DIRECTOR Micheal J. Morgan 201 Mill Street Rome, NY 13440-6916 937.431.9322 x103, Fax: 315.339.7107 Email: mmorgan@alionscience.com AMMTIAC DEPUTY DIRECTOR Christian E. Grethlein, P.E. 201 Mill Street Rome, NY 13440-6916 315.339.7009, Fax: 315.339.7107 Email: cgrethlein@alionscience.com MATERIALS TECHNICAL DIRECTOR Jeffrey D. Guthrie 201 Mill Street Rome, NY 13440-6916 315.339.7058, Fax: 315.339.7107 Email: jguthrie@alionscience.com CONTRACTS MANAGER David J. Brumbaugh 201 Mill Street Rome, NY 13440-6916 315.339.7113, Fax: 315.339.7107 Email: dbrumbaugh@alionscience.com MANUFACTURING TECHNICAL DIRECTOR Christian E. Grethlein, P.E. 201 Mill Street Rome, NY 13440-6916 315.339.7009, Fax: 315.339.7107 Email: cgrethlein@alionscience.com TECHNICAL INQUIRY SERVICES MANAGER Richard A. Lane 201 Mill Street Rome, NY 13440-6916 315.339.7097, Fax: 315.339.7107 Email: rlane@alionscience.com NON-DESTRUCTIVE EVALUATION AND TESTING TECHNICAL DIRECTOR Dr. George A. Matzkanin 3096 Stevens Circle South Erie, CO 80516 303.926.0582, Fax: 303.774.0652 Email: gmatzkanin@tri-austin.com For a listing of upcoming materials, manufacturing & testing related events, please visit our website: http://ammtiac.alionscience.com/calendar AMMTIAC answers materials, manufacturing, and testing questions CALL: 315.339.7090 EMAIL: ammtiac@alionscience.com OR VISIT: http://ammtiac.alionscience.com/experts http://ammtiac.alionscience.com The AMMTIAC Quarterly, Volume 2, Number 2 15
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