TPT March 2017

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AR T I C L E
VisiConsult X-ray Systems & Solutions GmbH
MARCH 2017 91
VisiConsult X-ray Systems &
Solutions GmbH – Germany
Tel: +49 451 290 286 0
Fax: +49 451 290 286 22
Email:
Website:
Commercial view
The change from film to digital technique is mainly driven
by the aim to reduce the cycle time and labour costs, while
eliminating the film consumables and chemicals. The sum of
higher throughput, less labour costs and less consumables is
a significant cost factor.
The above table provides a sample calculation of three
different setups. Assumption: 12m LSAW pipe with 15mm wall
thickness. The gate is open and the bunker is empty. Quality
standards require a 100 per cent test of the weld. 300 working
days per year. €50 per hour labour costs and €5 per 48cm film
including development.
Conclusion
The simplified example calculation shows clearly the benefit
of moving from film to a digital solution. A brand-new pipe
inspection system including bunker and doors poses an
investment of around €1,500,000. Compared to the costs for
the film and the necessary manpower the user can estimate a
return on investment (ROI) in less than two years of operation.
Beside the cost savings, the manufacturer gets many other
benefits:
• Higher inspection quality
• Faster feedback of identified defect inside the weld
• Protection of the environment
• Better reputation on the market because of better results
• Access to “high-end demanding” customers, because of
improved inspection quality
• Increased process safety and inspection coverage
Step Film 6* 48cm Digital Radiography: Off-line Digital Radiography: In-line
Move pipe in 60 sec 60 sec 60 sec
Close Gate 25 sec 25 sec 25 sec
Placing the film 120 sec - -
X-ray On 3 sec 3 sec 3 sec
Total exposure time 900 sec (30 shots, 30 sec) 208 sec (52 shots, 4 sec) 208 sec (52 shots, 4 sec)
Move to Position 90 sec (30 shots, 3 sec) 104 sec (52 shots, 2 sec) 104 sec (52 shots, 2 sec)
X-ray Off 3 sec 3 sec 3 sec
Open Gate 25 sec 25 sec 25 sec
Move pipe Out 60 sec 60 sec 60 sec
Move pipe to Wait position 60 60 sec -
Cycle time 22 min 9 min 8 min
Throughput 2.5 pipes / hour
20 pipes / shift
6 pipes / hour
48 pipes / shift
7-8 pipes / hour
60 pipes / shift
Costs for consumables
Costs for labour
(1,200/40) x 20 x 5 = €3,000
2 x 8h x €50 = €800
€0
1 x 8h x €50 = €400
€0
1 x 8h x €50 = €400
Costs per shift €3800 €400 €400
Costs per year (single shift) €1,140,000 / year €120,000 / year €120,000 / year
Raw costs per pipe €190 €8.33 €6.66
Investment costs €0 €1,500,000 €2,000,000
Return of Investment - 1.5 years 2 years (more throughput!)
• Easier archiving and delivery of inspection results
• Scalable and automated setup
• Reduction of required manpower
• Easy certification of inspection process
• Higher prices for sold products