COMET X-RAY insight

The Magazine of Industrial X-Ray

TECHNICAL CUSTOMER SERVICES

A reliable, professional team Innovative paper production

#1 | 2014

MEASURING WITH X-RAYS

CONTENTS

COMET SPIRIT An interview with the Technical Services X-ray team: “The moment of truth” 04 COMET INSIDE The motto at Bosello High Technology is “think different” 10 Innovative paper production thanks to x-ray technology

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For the good of the environment

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EXPERTISE BAM: The Federal Institute for Materials Research and Testing (BAM) in Berlin tests new x-ray methods 20 PRODUCTS & NEWS New facilitiy of the US subsidiary of Industrial X-Ray in in Shelton

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Imprint Issuer: COMET AG, Flamatt (Switzerland).

Project management: Flavia Nicolai, VP Marketing& Business Communications Industrial X-Ray. Production and editing: Denon Publizistik AG, Rapperswil-Jona (Switzerland), Daliah Kremer, Fabrizio Milano.

Photos: Nick Veasey (cover), Gaëtan Bally (pp. 2, 4–7, 9–11, 13), Bosello HT (pp. 11, 13, 23), Magnatek (p. 16), Applus RTD (p. 18), BAM (p. 22), istockphoto (pp. 12, 15, 17, 20).

Translation and proofreading: Apostroph AG, Lucerne (Switzerland).

Lithography: Küenzi & Partner/mediacheck, Langnau a. A. (Switzerland).

Printed by: Rub Media AG, Wabern (Switzerland).

Print run: 700 copies each, German and English

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EDITORIAL

Stephan Haferl, General Manager Industrial X-Ray Dear reader, As an OEM supplier, technical service is, under normal circumstances, not a frontline business at the end-customer‘s operation. Nevertheless, Comet Industrial X-Ray proudly features a global service organisation with a highly skilled and devoted technical staff operating from the United States, Switzerland and China.

Whereas originally the primary objective of COMET‘s technical service team was to repair x-ray tubes, coolers and high-voltage generators, a distinct shift has emerged into more sales and customer supportrelated activities, such as product training, commissioning training, consultancy for new system designs and forensics on damaged products.

COVER The cover shows an image created by x-ray artist Nick Veasey. www.nickveasey.com

The Magazine of Industrial X-Ray

Customer benefits: Low lifetime cost Higher throughput than micro-focus sources Low maintenance thanks to sealed tube technnology Reliability and Swiss quality

TECHNICAL CUSTOMER SERVICES

A reliable, professional team MEASURING WITH X-RAYS

Innovative paper production

#1 | 2014

The novel solutions HP-Technology and Variable Focal spots demonstrate COMET’s continuous commitment and investment in delivering added value to our global customer base.

COMET – Market leader with more than 65 years of experience

COMET connected Our magazine is available online: www.comet-xray.com (PDF and Issuu).

These services have become an ever important connection between you, our valued customer, and other departments within COMET, such as R&D, Sales and Production. When operating extremely demanding technical equipment such as x-ray modules, every piece of information and advice is valuable in order to maintain products, extend lifetime and design the next generation of improved products. By inter-facing with you, technical services is making an important contribution to this cycle with you helping us as the information source. Thank you!

In nearly all applications that employ x-rays the ultimate result is information. Be it information about the mechanical integrity of welding seams and casting parts or process parameters in the manufacturing of everyday items such as paper. Commercial and technical advances snd the availability of industrial grade photon-counting detectors have the potential to take your, our industry on the next level in terms of generating ever better information for your customer. BAM in Berlin has taken on the role of a forerunner in this field and we‘re all looking forward to new possibilities in the future. A path we‘ll happily travel along with you, our customers.

Questions, feedback, suggestions?

Drop us a line: magazine@comet-xray.com “X-Ray insight” 2/2014 The next issue will be available in September 2014.

Stephan Haferl

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COMET SPIRIT

Analyzing and solving problems: Working together is essential for the COMET service team in Flamatt.

Industrial X-Ray: An interview with the Technical Services X-ray team

Service – the moment of truth A technical fault in an x-ray system or a broken x-ray tube can happen out of the blue. In such situations, fast, reliable and professional service is crucial.

Roland Vonlanthen, Director Technical Services X-ray, and his global service team are dedicated to satisfying the needs of their customers. We talked to him about how they achieve this goal.

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COMET SPIRIT

COMET Technical Services – a well-organized team: Urs Brügger, Manuel Oetterli, Roland Vonlanthen, Mario Obi, Don Brennan and Walter Soltermann (from left to right).

What do you regard as good service?

Roland Vonlanthen: Regardless of the sector, good service is when people respond to the customer and think and act with the bigger picture in mind. Take a visit to a restaurant, for example. It’s not all about what you eat and drink, but about how you are welcomed and looked after as a guest. A friendly smile, responding to the needs of your guests, being proactive and showing that you enjoy your work – that’s what really matters. The motivation to be completely at the service of the customer has to come from within.

How is this service philosophy practiced at COMET Industrial X-Ray? Roland Vonlanthen: It’s important to spend as much time as possible at the customer company and deal with them on a personal level. The best way of seeing how you can help the customer and offer the support they need most is to see the system in action – nowhere will you get a more honest response than here. If something is not working correctly, the customer is under pressure and things can quickly get emotional. Then you see the unvarnished reality of what the customer needs. For this reason, we invest a

COMET Technical Services Comprising five employees, the Technical Services X-ray team in Flamatt has been led by Roland Vonlanthen since 2005.

Walter Soltermann has worked in the COMET workshop formore than 40 years; his experience in precision engineering is highly valued in the team.

Urs Brügger deals with service issues relating to x-ray tubes, while Mario Obi specializes in generators.

Junior service technician Manuel Oetterli, who joined the COMET team this year, is responsible for monoblocks and generators.

In the event of problems, the customer will receive an initial answer within 24 hours. In most cases, customers call their contact partner directly.

Cases that cannot be assigned clearly in the first instance are handled

by Roland Vonlanthen before being passed on to the responsible team member.

Service center: service.xray@comet.ch

Manuel Oetterli, Junior member, HSM monoblocks “I learn something new about our products every day and I’m always keen to improve my basic knowledge. Discovering why damage has occurred is the exciting part of my job. This is a very varied and complex process as you have to collect all the information required – only then am I able to find out more. As a junior member of the Technical Services X-ray team, I was made to feel at home right away.“

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COMET SPIRIT

Urs Brügger, Service employee, tubes “In service, it is important to stay flexible. I’m often working on several tricky tasks at the same time. To pinpoint and resolve faults, though, you also need to remain calm and apply your technical experience and people skills. I listen carefully to the customer and we try to find the cause of the problem together. If something doesn’t work as planned, then honesty on our part is usually what counts. Doing a good job is not enough for me, I also have to maintain good relationships with our customers.”

lot of time and effort in a well-managed, dedicated after-sales service.

How is the department organized to offer customers a professional service?

Roland Vonlanthen: Our qualified service staff work closely with customers on their premises. We are an international organization and closely connected to each other within the company. We optimize all our service processes on a regular basis and across all our international offices.

There are five of us at the headquarters in Switzerland, four in the USA and a small team in China. We offer a very traditional form of technical service. The customer

“It is critically important that we pass on results and findings internally when carrying out a fault analysis.”

Roland Vonlanthen

puts their new product into operation and notices that something is missing, or they are having difficulties and need help with technical issues. They contact us, we answer their questions and try to resolve the cause of the problem. Our clients are original equipment manufacturers, or OEMs, who build the x-ray inspection systems that are delivered to the end customer.

We provide the so-called noble parts – the heart of the system – to the OEM. These are XRS modules comprising the x-ray tubes, generators, coolers and cables. The 06

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service we offer includes on-site commissioning, maintenance, the procurement of spare parts, repairs, testing and even intensive product training.

What usually happens when your team is called for?

Roland Vonlanthen: If a problem occurs on the x-ray system at an end customer company, the first port of call is the OEM as they know the complex system exactly.

This initial support is important as machine downtimes can quickly become expensive – a single hour out of service can cost a company as much as EUR100,000.

In which cases are the COMET team brought on board?

Roland Vonlanthen: After the OEM has successfully dealt with the initial problem and replaced the broken part at the customer company, that part is sent to the OEM-workshop for analysis. If they run into difficulties, they call us to work out why the damage occurred. Above all, we need to answer one question – what do we both have to do to stop the problem recurring? Pipes and generators are sent to our workshop at the company headquarters in Flamatt for detailed analysis.

So your team also works closely with other departments?

Roland Vonlanthen: Yes – it is critically important that we pass on results and findings internally when carrying out a fault analysis, from the development team to production, to sales and service and back again. The cycle has to work properly if we are all to improve in future. We carry

COMET SPIRIT

Technical experience and people skills are important when tracking down problems.

out repairs in close contact with specialists from the production, quality control, production technology and R&D departments. In the case of especially complex or specific problems, we link up with our colleagues abroad and help them on site.

The parts are repaired, tested and sent back to the customer, all within a very short time. Although x-ray tubes are often irreparable, it is still important to find out what led to the damage before the customer uses the new tube.

In other words, service technicians also analyze causes of damage that are not attributable to COMET products?

Roland Vonlanthen: Exactly. For example, if there is a malfunction in the cooling system, the tube overheats and eventually fails. Detailed fault analysis is essential.

We help the customer by installing the new tubes ourselves and checking that all other parts are synchronized and connected correctly, which means the customer also receives professional instruction on site. Our goal is to do everything in our

Mario Obi, XRS employee, generators “The best part of my job is taking a broken-down system or one with a complicated fault and getting it running again. This requires a skilled pair of hands, flexibility and reliability. Whether in Norway or Asia, I enjoy working with customers from different cultures. There’s a solution for everything, so I share the joy of the customer when their worries turn to happiness and gratitude.

That’s why I never give up or lose heart.“

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COMET SPIRIT

The sales and service team in China: Kunhai Cai, Sunday Li, Karen Li, David Chen (General Manager, Shanghai), Lisa Shan and Paul Lu (from left to right).

The service team in the USA: Paul Wade, Jeremy Simon (General Manager, USA), Neal Capizzano, Stephen Calderon and Paul Lukaniec (from left to right).

power to ensure the fault doesn’t occur again by offering intensive, personal after-sales service on site.

Are you also at the customer company for the commissioning of the system?

Roland Vonlanthen: Not in general, but this is recommended for a variety of reasons. Most mistakes are made the first time you do anything. That includes relatively banal issues, such as whether the cable should be inserted on the left or right. There is always something missing, a lamp or a switch, and we have these small parts to hand so that installation can be completed. Our strength is being proactive.

Are there any limits on what is feasible?

Roland Vonlanthen: There are no discussions where personal safety is at stake.

If radiation protection is missing, for instance, the system will not be put into operation. If other equipment could be 08

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damaged, the extent of the risk must be assessed before proceeding.

Is every system unique or do they become familiar with them over time?

Roland Vonlanthen: After two years, you know virtually everything on the technical side. Technical experience is not the only thing that’s needed, though – a sound instinct for the needs of the customer is also essential. The customer expects professional service and we have to meet those expectations. Let’s go back to the service in a restaurant. Does the dish I ordered meet my expectations in every way? Fulfilling the wish is the moment of truth, when you actually get what was promised and your expectations are even exceeded.

What skills must a member of your team have to satisfy customers?

Roland Vonlanthen: A positive attitude is important, not just at work but for life

COMET SPIRIT

Walter Soltermann, Workshop employee, tubes “I have worked at COMET for 40 years, and I’ve been with the IXT service team for the past 12 years. I look forward to the new challenges every day brings. I am very familiar with our tubes, but curiosity and resilience are more important in day-to-day service in tracking down the cause of a fault. I am proud to be a part of this committed IXT team.”

in general. “There’s a solution to everything” is the mantra of any service technician. Our team members are jacks of all trades, responsible for a great deal on site. Whether greasing cables, changing oil and filters, installing new software or training customers, they have to perform a broad, diverse and practical range of tasks. Pride in your work is also needed.

We give honest answers, put our heads together with the client and deliver far more than the bare minimum. In this way we maintain good relationships with customers and deliver solutions they can benefit from. In many cases, long-term, trusted business partnerships stem from this intensive after-sales service.

You mentioned training. Is this also part of the service package?

Roland Vonlanthen: Yes, service technicians from the customer visit us for three or four days to receive product training.

We run these training courses twice a year, and they have proved very successful. We also offer tailored and individual on-site training for our customers.

us, this is a matter of course. Although we had budgeted for a whole week, we were able to put the system into operation within three days thanks to excellent preparation and execution. I must emphasize that the practical basic training of our staff is hugely important. Our staff have learned how to tackle problems. Of course, our success brings with it a good reputation – something we have to live up to every single day. Nobody rests on their laurels here.

Where do you see potential for improvement in your team?

Roland Vonlanthen: We want to expand our knowledge and enhance quality across all service processes. This may be

“We give honest answers, put our heads together with the client and deliver far more than the bare minimum.”

Roland Vonlanthen

How important is Swiss quality to customers?

Roland Vonlanthen: ‘Swissness’ is a byword for precision, reliability and quality for our customers. I recently visited a tire manufacturer in France. The customer was astounded that our service technicians had everything they needed – right down to the smallest screwdriver. For

achieved by taking the time to find out more about new products while they are being developed and manufactured, or by training new service staff. COMET is growing, just like our pool of customers.

We are challenged every day but our aim is to offer our customers even better support.

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COMET INSIDE The family-run company Bosello HT is managed in the second generation by Fabio Bosello (Managing Director) and his sister Antonella.

Non-destructive testing

“Think different is our motto” Bosello High Technology has made a name for itself with innovative x-ray and CT systems primarily for the automotive industry. Customers around the world rely on the x-ray systems developed and produced in northern Italy by this flexible, motivated and highly qualified team. In order to give its customers tailored solutions, Bosello’s motto is “think different”.

The headquarters of Bosello High Technology (HT) in Cassano Magnago in the northern Italian province of Varese is a brightly modern vision in glass. The new building was inaugurated just a few months ago with a party for customers and employees that also marked the 50th anniversary of the company. The

“Passion plays a part in everything we do.”

Fabio Bosello, Managing Director, Bosello HT

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name of the event was “look beyond” which is one of the most important concepts of the business. Now visitors can’t help but stop and gaze at the montage of photos from the party – with happy faces in every shot, the positive atmosphere is clear for all to see. “I think it’s important that everyone feels comfortable here, that our employees enjoy their work and that our customers visit us often,” explains Fabio Bosello, Managing Director of Bosello HT. “After all, only a highly motivated and flexible team is capable of delivering excellent results. Of course, it is also important for me to inspire confi-

COMET INSIDE

dence in them. I realize I have to play my part if I want to have motivated staff,” continues Bosello. Founded in 1962 by his father Aldo, Bosello HT remains a typically owner-managed family business. In recent years, Fabio and Antonella Bosello have led the company into a whole new era thanks to a far-sighted business strategy.

Moving into new markets – the right way The Italian company has made a global name for itself, with Bosello HT involved in non-destructive material testing since

the 1980s. The majority of customers come from the automotive industry, with others based in the aviation and food industries. “We are a world-leading company when it comes to testing car components,” explains Bosello. The exuberant owner is still not satisfied, however. “We want to move into new markets and make a name for ourselves there too. We want to grow, but know we need the time and security to go about this in the right way.”

Bosello’s management style is measured: the company does not rush into areas and markets it is not (yet) ready for. Europe, the USA, China, Taiwan, Vietnam and Ko-

Given that quality comes first, Bosello HT has aworked with COMET for 25 years.

The new headquarters of Bosello High Technology in Cassano Magnano.

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COMET INSIDE

The majority of customers come from the auto­ motive industry, with others based in the aviation and food industries.

rea are among the most important sales regions for Bosello HT. Trust and quality are top priorities What is the secret of the company’s success? “Trust,” answers Bosello immediately. “And, of course, the highest levels of quality that justify trust. There can be no success without trust. After all, the customer doesn’t just buy a system and that’s that. In most cases, you enter into a relationship with the customer which should last years, or even decades. These are also highly sensitive products that have to comply with the strictest safety regulations. Customers want to be sure

“Only a highly motivated and flexible team is capable of delivering excellent results.”

Fabio Bosello, Managing Director, Bosello HT they are getting the best product possible.” The trust of customers is critical: not only at Bosello, but also in the Sales and

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Technical Service teams in various countries, such as Germany and the USA. “A sales team can only market our products properly if they are fully convinced about the products themselves. If this is not the case, customers will pick up on that straight away.” The company also has to be at the absolute forefront of technology at all times in order to offer the best possible solutions.

New materials such as carbon fiberreinforced plastics and new components require new testing procedures and systems, which means the company has to keep pace with the testing needs of the customer. How does Bosello HT manage to stay one step ahead of the field? “Our motto is ‘think different’ and ‘look beyond’. That means not being pigeon-holed into a certain method and not doing what everyone else is doing,” emphasizes the Managing Director. One specific example of this is the absence of robots at Bosello HT; instead, hands-on work of the highest quality is what counts. “Nothing creates more trust than a testing system that was planned, developed and produced entire-

COMET INSIDE

ly by hand. This means that we can meet the highest quality standards.” After all, as Bosello says: “We show our superiority on the market with quality, not with shortterm solutions.”

X-ray tubes at the heart of the system Given that quality comes first, Bosello HT has worked with COMET for 25 years.

“The x-ray tubes are at the heart of our testing systems. We build systems that allow our customers to test particularly bulky or sensitive parts. However, all the top-quality equipment in the world doesn’t help if the x-ray tube is not of the highest standard,” says Bosello.

Customers are won over by the combination of two high-performance products, as in the latest development from northern Italy: the Omnia Experience material testing system. This system offers maximum flexibility, something that is increasingly in demand. The parts being tested do not move during the process – instead, the xray system itself rotates. “The technology has no limits,” says Bosello with pride.

“We can therefore meet customer demands for testing bulky, round and very

large parts.” Testing time is also significantly reduced: a pipe curve can be tested in just a fifth of the time previously required. “This is our strength – a customer comes to us with a problem and we show them the options available. It’s also thinking different in line with our motto.”

Another development that Fabio Bosello can be proud of is unsurpassed on today’s market: WRE Thunder 3 is a high-speed inspection system for alloy wheels. No other device currently on the market analyzes the structure of a wheel faster. The record stands at 2.5 seconds dead time between wheels, with the full inspection throughput of more than two wheels per minute. “Time plays an important role in these tests, as several thousand wheels often need to be inspected in one day,” explains Bosello. His fascination with the system is palpable, as if it were discovered only yesterday. “Yes, passion plays a part in everything we do. If we can inspire customers with the same passion for our products, we will have achieved a lot.”

Bosello High Technology Bosello HT was founded in 1962 in Lombardy, northern Italy, by Aldo Bosello. The company has been involved in non-destructive material testing since the 1980s. In that time, management of the company has passed down to Aldo’s children, Fabio and Antonella.

About 50 employees currently work at the new company headquarters in Cassano Magnago (Varese province), with small sales teams active in various countries around the world. Bosello HT produces high-level x-ray systems for material testing across a variety of applications for the automotive, aviation and food industries. learn more: www.bosello.eu

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COMET INSIDE

Non-destructive material testing

X-ray technology plays an important role in the paper production process Maximum precision and accuracy in material tests, as quickly as possible: that’s what Danish firm Magnatek guarantees its customers thanks to innovative x-ray systems. Its clients include the Swedish firm Mantex, which inspects wood chips used in paper production.

Magnatek works closely with COMET. We encounter paper every single day – in our morning newspaper, in the office or when out shopping, to name but a few possibilities. Daily life without paper is unimaginable, despite our computerized age and the paperless office. But does anyone give thought to how paper is actually made when they hold it in their hands? The magazine you are holding this very minute may already have come into contact with COMET at an earlier stage of its production – because x-ray technology plays an important role in the paper production process.

“We see ourselves as an R&D department for our customers, or a branch of their own R&D department.”

Henrik Ibsen, CEO, Magnatek

One company that works for the paper industry (among others) is Mantex. The Swedish firm’s Flow Scanner inspects 14

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the wood chips used in paper production according to various criteria, the most important of which include measurements of density, weight and moisture.

These parameters are essential to the subsequent paper production process: the wood chips are cooked for several hours and treated with chemicals, thus separating the required fibers from the remaining parts of the wood. The information from the wood chip measurement also determines the chemicals needed and the cooking energy. The more exact the measurement, the more precise the cooking process – which means using only as many chemicals and as much energy as necessary.

“Our Flow Scanner is a very important innovation in the field of wood chip measurement,” explains Gustav Wolrath, CTO at Mantex. “We used to have to weigh and measure the wood by longwinded, conventional means. Aside from being nowhere near as accurate as those produced by the Flow Scanner, the measurements were also very time-consuming. Thanks to dual x-ray technology, which has been successfully deployed

COMET INSIDE

An abundance of raw materials: When trees are machined into chippings for the paper industry, the wood has to be checked precisely.

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COMET INSIDE

Measurement of the wood chippings is both swift and precise thanks to the flow scanner. Henrik Ibsen (CEO of Magnatek) and Gustav Wolrath from Mantex are delighted with the results.

in the medical sector for a long time, the Flow Scanner measures extremely accurately in a matter of seconds.” Another advantage of x-ray technology is that foreign bodies such as stones or metal particles can be identified and removed before they block the filter or machines.

Magnatek Magnatek is an independent, innovative company specializing in research and development into high-precision x-ray systems for industry, medicine and science. Its numerous fields of application include non-destructive material testing, which covers the inspection of mechanical components, computed tomography scanning, food inspection, measurement of bone density, materials analysis and sorting, and much more.

Learn more: www.magnatek.dk

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“We looked for an extremely reliable and flexible partner when we set out to develop our Flow Scanner,” continues Gustav Wolrath. “We are very happy to have found that partner in Magnatek.”

Magnatek, a Danish company founded in 1984, has been active in the field of x-ray technology for 30 years and has corresponding experience in the sector. Henrik Ibsen, the owner and CEO of Magnatek, worked for many years in the research and development department of a large Danish defence company before taking over Magnatek. “We see ourselves as an R&D department for our customers, as it were, or a branch of their own R&D department,” explains Ibsen. “Most of our products are developed in close partnership with our customers. With many years of experience in the x-ray sector, we know how to use this technology. We develop our products so they can easily be tailored according to our customers’ wishes.” The accuracy and reliability of products are what matters most to Henrik Ibsen. “This is ultimately the way we gain our customers’ trust, which is the

most important element in a long-term, positive collaboration.”

To be able to supply Mantex with the centerpiece of the Flow Scanner, Magnatek itself needed a reliable and trustworthy partner – and COMET was at the top of the list. “I knew that COMET and Magnatek could develop a long-standing customer relationship,” says the CEO of Magnatek. “The relationship is important to us because Magnatek is a small company, which obviously means we don’t have the same possibilities as a larger company. That’s why COMET’s support is relevant to our own work. We know we can rely on x-ray tubes that come from Flamatt.”

To guarantee maximum quality and precision, Magnatek not only cooperates bilaterally with Mantex and COMET; representatives of Magnatek and Mantex have also visited the COMET base in Flamatt together. “Trust is very important right down the line, which is why it makes eminent sense to get all partners together around a table,” says Ibsen. Wolrath from Mantex agrees: “For us, the visit to Flamatt was a way of improving our knowledge about an extremely important core component in our Flow Scanner. Moreover, we require extremely high stability in our x-ray sources and therefore in need of a close relationship not only with Magnatek, but also with Comet.”

COMET INSIDE

Pipeline inspection

Safety for the environment’s sake The huge global demand for oil and gas has triggered numerous new pipeline projects. Applus RTD is an international leader in the field of pipeline inspections, guaranteeing its clients safety, time savings and efficiency. To meet the high demands of its clients, the company relies on x-ray systems from COMET.

Safety is paramount, so industrial customers around the world trust in the 75-year experience of Applus RTD when it comes to product and system inspections. Even the smallest crack in a pipe or a faulty weld seam can produce devastating environmental damage over time. That’s why Applus RTD focuses strongly on research and development for new technologies in the field of non-destructive testing.

An important field of activity for Applus RTD is pipeline inspections. “The mar-

ket potential for new pipeline projects is huge. This is where our strength lies, and this is what we concentrate on,” says Steven Mims, Project Manager at Jan Xray services, Inc. (an Applus RTD USA Company). Given the steadily growing demand for energy, more and more new oil and gas pipelines are needed. Steven Mims is particularly proud of the RTD Rayscan system: “It enables us to offer x-ray inspections with a digital system.

More than 60 percent of new oil and gas pipelines are still inspected using convenX-RAY insight 1 | 2014

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COMET INSIDE

Given the steadily growing demand for energy, more and more new oil and gas pipelines are needed.

A Rayscan MKII small bore system.

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COMET INSIDE

“We provide x-ray inspections with a digital system, so we can offer better, more efficient testing than conventional methods.”

Steven Mims, Project Manager, Jan x-ray services, Inc. (an Applus RTD USA Company).

tional radiography methods. This means that there is a large portion of the market with the potential for clients to improve the efficiency of their inspection.” Applus RTD developed the Rayscan system, which allows digital x-ray inspections in real time and guarantees full inspection of a pipe in a single pass, providing high quality digital images.

The feedback from customers is suitably positive. “We offer a product that promises more safety, better quality and greater efficiency,” says Mims. The demand for x-ray inspections is growing steadily. Only 10 years ago, though, it was generally thought that ultrasonic testing would replace x-ray technology completely: obviously that is not the case.

Safety and accuracy take top priority in testing and pose the biggest challenge, as Steven Mims emphasizes: “Millions of dollars are invested in a pipeline project. Every interruption in production costs a lot of money, so on-site inspections should not hold up production.” As if this fact alone were not enough of a challenge, engineers at Applus RTD also have to contend with exceptional working conditions: work is carried out at temperatures between minus 50 and plus 60 degrees Celsius. “We have to be able to use our systems in extreme weather conditions,” says Steven Mims. The pipelines themselves have to work for up to 40 years with as few faults as possible; systems are normally

checked every five to 10 years. An offshore project can cost up to US$50,000 an hour. “You can work out for yourself what it costs if operations are interrupted for an unnecessarily long period of time.”

Applus RTD therefore places great demands on itself and on its partners. “When we launched Rayscan in 2010, we looked for the best supplier of reliable x-ray systems,” says Mims. Slowly but surely, a close relationship developed between Applus RTD and COMET. “We began by testing a few systems from COMET. In time, COMET became an important supplier of x-ray systems that work with the RTD Rayscan system.” In order to offer clients individual solutions, Applus RTD and COMET maintain close contact – and COMET brings its full R&D expertise to bear. As Steven Mims emphasizes, “What makes the cooperation between COMET and Applus RTD special is a highly personal relationship based on a great deal of trust. I sense COMET goes out of its way to make sure we get the tools we need from them to be successful. What’s more, we have something very important in common: we both want to be the leader in our field.”

Neither company is content to rest on its laurels, though. “New materials with a higher density are a big challenge for us, so we need x-ray tubes with more energy.

COMET has already supplied us with 4500 watt tubes which we can use in place of the old 3000 watt tubes,” says Mims. The next step in the future of Rayscan has been taken.

Applus+ Applus+ is one of the world‘s biggest inspection and certification companies. Its main business fields involve development and engineering, motor vehicles, climate and environment and food and beverages. The company has 18,000 employees at 350 locations in more than 60 countries. Group headquarters are in Spain.

The Applus RTD division is active in numerous areas of non-destructive testing, from shipbuilding and the chemicals industry to power plant technology.

ApplusRTD employs engineers, technicians, welding experts, test engineers and material testers, who use their knowledge of various methods to identify defects, thereby preventing and reducing damage.

Learn more: www.applus.com

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EXPERTISE

Research and development

Putting the latest x-ray methods to the test Photon-counting flat-panel detectors constitute a large step forwards in x-ray detection for security applications and in non-destructive material testing. The direct conversion method using a photon counter (DC/PC) is currently in the development phase. The Federal Institute for Materials Research and Testing (BAM) in Berlin is responsible for putting the photon counters to the test.

At Frankfurt Airport, about 7,000 pieces of luggage have to be inspected by hand each day.

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X-RAY insight 1 | 2014

EXPERTISE

Federal Institute for Materials Research and Testing (BAM) The Federal Institute for Materials Research and Testing (BAM) in Berlin is one of the world’s oldest research institutes.

It was founded in 1871 as the first of the royal Prussian research institutes (MTV) and was tasked with performing strength tests. Today, BAM is an internationally renowned scientific and technological subordinate authority to the Federal Ministry for Economic Affairs and Energy, and primarily deals with R&D and the management and execution of processes, tests and certifications. It also supports the German Society for Non-Destructive Testing (DGZfP) in developing new training contents for state-of-the-art non-destructive testing methods. BAM is responsible for the following: • Improvement of safety in technology and chemistry • Execution and evaluation of physical and chemical tests on materials and systems

• Cooperation in the development of legal regulations and standards, such as the definition of safety standards and limit values Prof. Dr. Uwe Ewert and Dr. Uwe Zscherpel work in the Non-Destructive Testing department, one of nine specialist departments at BAM. Areas of application include research, testing and standardization in a wide range of applications, from nuclear power to automotive, aerospace, medicine, safety and security. In doing so, BAM works closely with companies and universities.

From film to digital imaging Although digital technology has long been an integral part of industrial x-ray applications, film is still used in many areas. “Film is still a popular choice when carrying out non-destructive testing of welding seams in the field. Digital flat-panel detectors are currently far too sensitive and expensive to be used in the wind and weather conditions found on site,” explains Uwe Ewert.

In contrast, digital radiology and digital flat-panel detectors are widely used during tests in the laboratory. In the automotive industry, “digital@line” tests are made on engine blocks; for example at VW.

“At present, the bag has to be opened and inspected by hand in the event of an alarm. At a rate of over one minute per bag, this takes up a lot of time.”

Uwe Ewert, Senior Scientist at the Non-Destructive Testing Department, BAM

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EXPERTISE

At work: Prof. Dr. Uwe Ewert making adjustments to the TomoCAR system (mobile tomography of pipelines) for demon­ stration and exhibition, and Dr. Uwe Zscherpel setting up a weld inspection for an image quality certificate (from left).

Uwe Ewert Prof. Dr. Uwe Ewert is Professor and Manager of the Non-Destructive Testing department at BAM.

Uwe Zscherpel Dr. Uwe Zscherpel is a Senior Scientist in the Non-Destructive Testing department at BAM. Learn more: www.bam.de

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Photon-counting flat-panel detectors The technology associated with photon counters is in its infancy. “At present, flatpanel detectors using photon counters are still very expensive, are only available as small panels and can usually only be used in small energy ranges. In practice, they are suitable for testing electronic modules and in medical applications such as mammography systems,” explains project manager Uwe Zscherpel. BAM has recently started initial tests using 5 x 7.5 cm panels when testing welding seams (up to 300 kV).

Practical benefits • Swift exposure and testing • Very good resolution • No electronic noise • Covers a wide dynamic range • Good differentiation of materials using dualenergy technology via color coding: • Blue: Metal • Green: Inorganic materials, halogenated polymers • Orange/yellow: Organic materials, plastics and explosives

Which industrial applications could benefit from this technology?

Security inspections: Testing of improvised explosive devices (IEDs), luggage and large objects such as shipping containers for explosives and smuggled goods. Containers are currently inspected only in terms of customs-related aspects to see if the goods have been declared correctly. The USA is urging that containers are also be inspected for hazardous objects. “This means that the process for inspecting containers has to be rethought,” comments Uwe Zscherpel.

Luggage screening: At Frankfurt Airport, about 7,000 pieces of luggage have to be inspected manually each day as part of normal screening, most of which turn out to be false alarms. “At present, the bag has to be opened and inspected by hand in the event of an alarm. At a rate of over one minute per bag, this takes up a lot of time,” explains Uwe Ewert. Images generated using a photon counter would provide more information on the contents and enable a quicker inspection compared to current xray systems. During a security inspection, the organic material displayed on screen can be determined more exactly using the evaluation software – is it cheese or plastic explosives? However, this method is not yet ready for everyday use.

Initial test results from BAM Photon-counting flat-panel detectors allow for measurements at a high dynamic level with over 16 bits. In contrast to film imaging, this enables complex cast parts with significant variations in wall thickness to be inspected in a single image.

These detectors are particularly suited to the testing of welding seams, pipes and complex components made from plastic or fiber composites (for use in the chemical industry and aviation, for example). Fiberglass can be distinguished particularly well from plastics.

Nuclear technology: Testing of austenitic pipes in nuclear power plants for detecting incipient crack development and for the quantitative measurement of crack geometries and their extent. Used for evaluating intergranular stress corrosion.

Aviation: Initial testing for mobile applications, on-site testing in maintenance hangars, use of mobile digital laminography and computed tomography.

PRODUCTS & NEWS

X-RAY EVENTS 2014 25 – 27 March 28. Aerospace Testing Los Angeles/CA, USA

Show us your images!

8 – 10 April S.E.E. Scandinavian Electronics Event Kista, Sweden Espresso pot, taken at Bosello High Technology.

15 – 18 April Expo Electronica Moscow, Russia 6 – 9 May 28th Control – trade fair for quality assurance Stuttgart, Germany 26 – 28 May DGZfP annual meeting Potsdam, Germany 28 – 30 July Digital Imaging XVII, Warwick, RI, USA 6– 10 October ECNDT Prague, Czech Republic

X-ray images are an integral part of our everyday work and continue to fascinate us, so we are always pleased to receive your correspondence. Send us your best x-ray images, whether these are imaginative shots of everyday objects or items from your workplace. The best entries will be published in upcoming editions of ‘XRay insight’.

The espresso pot shown above originates from the Bosello archives (see also page 10).

Send your images (300 dpi/max. 5 MB) and your personal details (name and company), with a description of the subject and how the image was taken, to magazine@comet-xray.com.

New facility XET US in Shelton The US subsidiary of Industrial X-Ray and ebeam Technologies (XET) will open its new facility in Shelton, CT, in April 2014.

The move to a modern facility increases XET Americas capabilities to support its customers. COMET is planning an open house celebration in the spring with a ribbon-cutting ceremony that will be attended by customers, employees and senior managers from Switzerland. Further informations will follow.

X-RAY insight 1 | 2014

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