THE ENVIRONMENTAL TECHNOLOGY VERIFICATION
PROGRAM
tal Protection Ago
Balteiie
The Btisiiiess o} Innovation
TECHNOLOGY TYPE: ALTERNATIVE TECHNOLOGY FOR SEALED
SOURCE RADIOGRAPHY CAMERAS
APPLICATION:
PIPELINE INSPECTION
TECHNOLOGY NAME: IXS High Frequency Integrated X-Ray Generator
COMPANY: VJ Technologies, Inc.
ADDRESS: 89 Carlouh Rd PHONE: 800.858.9729
WEB SITE:
E-MAIL:
89 Carlough Rd
Bohemia, NY 11716
http://www.vjt.com
mross@vjt.com
ETV Joint Verification Statement
The U.S. Environmental Protection Agency (EPA) has established the Environmental Technology Verification
(ETV) Program to facilitate the deployment of innovative or improved environmental technologies through
performance verification and dissemination of information. The goal of the ETV Program is to further
environmental protection by accelerating the acceptance and use of improved and cost-effective technologies.
ETV seeks to achieve this goal by providing high-quality, peer-reviewed data on technology performance to
those involved in the design, distribution, financing, permitting, purchase, and use of environmental
technologies. Information and ETV documents are available at www.epa.gov/etv.
ETV works in partnership with recognized standards and testing organizations, with stakeholder groups
(consisting of buyers, vendor organizations, and permitters), and with individual technology developers. The
program evaluates the performance of innovative technologies by developing test plans that are responsive to
the needs of stakeholders, conducting field and laboratory tests (as appropriate), collecting and analyzing data,
and preparing peer-reviewed reports. All evaluations are conducted in accordance with rigorous quality
assurance (QA) protocols to ensure that data of known and adequate quality are generated and that the results
are defensible.
The Advanced Monitoring Systems (AMS) Center, one of six verification centers under ETV, is operated by
Battelle in cooperation with EPA's National Risk Management Research Laboratory. The AMS Center
evaluated the performance of an alternative technology for sealed source radiography cameras in gas and oil
industry pipeline inspections. This verification statement provides a summary of the test results for VJ
Technologies, Inc. IXS High Frequency Integrated X-Ray Generator.
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VERIFICATION TEST DESCRIPTION
This verification test evaluated the ability of a technology with a non-radioactive source, VJ Technologies IXS
High Frequency Integrated X-Ray Generator, to determine defects in pipeline similar to that found in an oil and
gas industry refinery. Testing was designed in particular to identify defects through pipeline insulation. Test
results were compared to results from a reference technology, the commonly used radiography camera with a
Selenium-75 sealed source. Subsections of two pipes were examined by both the VJ Technologies FXS High
Frequency Integrated X-Ray Generator and the radiography camera. Testing was conducted outdoors on June 1,
4, 5, and July 8, 2010 at Battelle's Pipeline Facility in West Jefferson, Ohio.
Pipe Sample 1 was a seam-welded carbon steel pipe approximately 35 feet in length and 8 inches in diameter.
The wall thickness was 0.188 inches. To simulate the refinery environment, a portion of Pipe Sample 1 was
insulated with calcium silicate material and jacketed with aluminum sheet metal. Four simulated corrosion
defects (named Pl-1, Pl-7, Pl-18, and Pl-23), one natural corrosion defect (Pl-9), and the weld next to the
selected natural corrosion region were assessed on Pipe Sample 1. All areas of interest (defined as 'patches')
were under the insulation placed on Pipe Sample 1, except for defect Pl-1. Each patch on Pipe Sample 1 was a
specific area of general corrosion with defined pits within it. Two images were taken 90 degrees to the centerline
of the pipe for each patch. Pipe Sample 2 was a stainless steel alloy approximately 52 inches in length and 8
inches in diameter. The wall thickness was 0.515 inches. Three holes of varying diameter and depth were drilled
into the pipe using handheld tools. A contact image and two images taken 90 degrees from the centerline of the
pipe were collected for the defects on Pipe Sample 2. Physical measurements were collected for the drilled holes
on Pipe Sample 2. The defects on Pipe Sample 1 were thoroughly characterized at the time of their creation, prior
to the development of this verification test.
Both the radiography camera and the vendor collected analog images on General Electric (GE) phosphor imaging
plates. After exposure, each imaging plate was placed into a Virtual Media Integration (VMI) 5100 computed
radiography scanner where the image was retrieved using laser light scanning, and stored as a digital file.
The VJ Technologies IXS High Frequency Integrated X-Ray Generator was verified by evaluating the following
parameters:
Qualitative Detection of Defects - Qualitative results of defect detection were determined by viewing the
image(s) of the defect, and assessing if the technology discovered a defect of appropriate size and shape in the
appointed area. These results were then compared to those from the radiography camera.
Percent Error - Quantitative results of defect detection were determined by performing percent error
calculations on measurements from the images obtained by the radiography camera and the VJ Technologies
device, then comparing these results to physical measurements of the defects.
Percent Difference - Quantitative results of defect detection were determined by comparing the difference
between measurements from the images obtained by the radiography camera and the VJ Technologies IXS
High Frequency Integrated X-Ray Generator.
Operational Factors - These included sustainability metrics such as maintenance needs, power needs,
calibration frequency, data output, consumables used, ease of use, repair requirements, training and
certification requirements, safety requirements, and image throughput.
QA oversight of verification testing was provided by Battelle and EPA. Battelle and EPA QA staff conducted
technical systems audits of the testing, and Battelle QA staff conducted a data quality audit of at least 25% of the
test data. This verification statement, the full report on which it is based, and the test/QA plan for this verification
test are available at www.epa.gov/etv/centers/centerl.html.
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TECHNOLOGY DESCRIPTION
The following is a description of the VJ Technologies IXS High Frequency Integrated X-Ray Generator
technology, based on information provided by the vendor. The information provided was not verified in this test.
The IXS technology is a compact, portable, x-ray generator. It integrates a high voltage (HV) power supply, an x-
ray tube, and a filament supply into one single module. The product comes with a HV module connecting to a
control module. The control module is powered by 110 volts (V) or 220 V of alternating current. The control
interface uses a RS232 cable between the control module and a computer via a graphic user interface. The digital
interface provides the ability to program and monitor the output voltage and current, monitor any fault conditions,
and operate the interlock for the x-ray generator. The IXS series x-ray systems are designed to be used for a wide
range of non-destructive testing applications including: industrial radiography, baggage security inspection,
medical radiography and fluoroscopy, food and package inspection, and electronic component inspection. The
product offers output power from 10 kilovolts (kV) to 160 kV, and up to 500 watts continuous output, with higher
wattages available for pulsing applications. The IXS High Frequency Integrated X-Ray Generator is 16 inches
long by 5.6 inches wide by 15 inches high. It weighs 59 pounds. The list price for a 500 watt (160 kV at 3.12
milliamp [mA]) model is $15,000. A computer, imaging plates, and image processing equipment are not included
with the unit and must be purchased separately.
VERIFICATION RESULTS
Qualitative Detection of Defects. The VJ Technologies IXS High Frequency Integrated X-Ray Generator
showed the patches with defects, natural corrosion, and the weld under the insulation, as well as the patch with
defects on the uninsulated pipe. Raw images were comparable in quality to the radiography camera images for
non-contact images. Both the radiography camera and the x-ray device had difficulties detecting the interior pipe
wall on the images collected. This often led to an inability to make depth measurements on the defects for both
the radiography camera and the x-ray technology. Detailed comparisons between images captured by the vendor
and reference technology are provided in the verification report.
Percent Error and Percent Difference. Average percent differences were calculated for each defect
characteristic (e.g., patch width and pit length) across all defects and ranged from 14% for all patch width
measurements to 40% for all pit length measurements. Standard deviations were similar for patch width and
length measurements.
Average percent errors for the radiography camera ranged from 13% for all patch width measurements to more
than twice that with 28% and 30% errors for all pit length and width measurements, respectively. Standard
deviations for the radiography camera average percent errors were similar across the different measurement
categories such as patch width and pit length. The average percent error range for the results from the VJ
Technologies IXS High Frequency Integrated X-Ray Generator was wider than the radiography camera, ranging
from 2% to 38%. Pit dimension measurements from the VJ Technologies IXS High Frequency Integrated X-Ray
Generator images were similar across all defects, and similar to the average percent errors for the radiography
camera. This result indicates that measurements were derived from images from both technologies with similar
accuracy. The average percent error for all patch dimensions based on images from the VJ Technologies IXS
High Frequency Integrated X-Ray Generator was two to seven times lower than those for the radiography camera.
The standard deviations for these average errors were also smaller for the VJ Technologies device, indicating that
patch dimensions were more accurately determined using images from the VJ Technologies IXS High Frequency
Integrated X-Ray Generator.
A variable sensitivity analysis of ASME Standard B31G, the method used to predict the remaining strength of
corroded pipe, shows that this method is more sensitive to wall thickness than to the length or width of defects.
The radiography camera was able to assess depth more often (four out of 12 pits) than the VJ Technologies IXS
High Frequency Integrated X-Ray Generator (two out of 12 pits). When both were able to measure depth, the
radiography camera was 50% more accurate. However, the interior pipe wall was not defined in images from
either technology, so depth measurements were not able to be made to the internal pipe wall, but were instead
based on the exterior wall. The ASME method is somewhat sensitive to errors in defect length estimations.
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Length errors that are on the order of a wall thickness or two are typically tolerable. For all length measurements
made, the radiography camera had one substantial measurement error, while the VJ Technologies IXS High
Frequency Integrated X-Ray Generator did not have any. The radiography camera error occurred with the
shallowest of the four patches tested. Quantification of the edges of shallow corrosion is often difficult, but these
anomalies usually do not affect structural performance of the pipe. The defect width estimate is the least
important parameter in corrosion characterization, and is often omitted by assessment methodologies.
Operational Factors. The VJ Technologies IXS High Frequency Integrated X-Ray Generator required the use of
a typical 110 V or 220 V power outlet to operate the technology. A connection to a computer was also required to
program the x-ray device for taking images, and to control the power output. The x-ray tube in the unit has a life-
span of six to eight years.
The exposure time used for this test was one minute. To determine an appropriate exposure time and source
power, initial images were taken and evaluated until the proper exposure situation was determined. This process
took approximately one hour. Preparation of the VJ Technologies IXS High Frequency Integrated X-Ray
Generator involved setting it up on a tripod stand, attaching the imaging plate and associated markers and image
quality indicators to the pipe, and inputting the correct parameters into the software. This process took
approximately 10-15 minutes for each image. Similar preparation times were noted for the radiography camera.
Positioning the VJ Technologies IXS High Frequency Integrated X-Ray Generator for images above the pipe
required the use of a platform to suspend the device. The x-ray device was placed 28 inches away from all
patches and defects (except for the contact image collected), and was operated at 3 mA and 160 kV. The
radiography camera was 32 inches away from the pipe, and used an exposure time of 1.5 minutes. These
parameters were determined by the camera operator to provide optimal images.
Significant ghosting was noted on the imaging plates when using the x-ray technology. These burned images did
not appear to impact the ability of the VJ Technologies IXS High Frequency Integrated X-Ray Generator to take
new images or interfere with the interpretation of any images. The cost of each phosphor imaging plate was
approximately $500.
The VJ Technologies IXS High Frequency Integrated X-Ray Generator produces x-ray radiation, though not from
a radioactive source. Thus, a technician must be licensed to operate this equipment safely. No maintenance or
calibration was needed for the VJ Technologies IXS High Frequency Integrated X-Ray Generator, although
techniques can be applied (such as the use of comparators and other image quality indicators) to determine image
quality and assist in image interpretation. There were no operational issues noted during the verification testing.
Signed by Tracy Stenner 12/1/10 Signed by Sally Gutierrez 12/20/10
Tracy Stenner Date Sally Gutierrez Date
Manager Director
Energy and Environmental Global Business National Risk Management Research Laboratory
Environment Solutions Product Line Office of Research and Development
Battelle U.S. Environmental Protection Agency
NOTICE: ETV verifications are based on an evaluation of technology performance under specific,
predetermined criteria and the appropriate quality assurance procedures. EPA and Battelle make no
expressed or implied warranties as to the performance of the technology and do not certify that a technology
will always operate as verified. The end user is solely responsible for complying with any and all applicable
federal, state, and local requirements. Mention of commercial product names does not imply endorsement.
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