FRL_Digital_Radiography___Computed_Tomography_System_(Minimuum_Requirements).docx

FRL Digital Radiography/Computed Tomography System Minimum Technical Requirements

FRL Digital Radiography/Computed Tomography System Minimum Technical Requirements

Summary This procurement is for a turn-key, state-of-the-art, 7-axis, 225kV micro-focus, industrial grade digital radiography (DR)/computed tomography (CT) system. The system must be able to scan parts up to a 19.5” diameter and 24” in length, weighing up to 75 pounds. The system must be a fully shielded and interlocked cabinet-style unit. It must comply with all applicable industry, state and federal regulations. The system must include a flat panel detector, 225Kv Microfocus Tube, digital radiography image processing acquisition workstation and software, and a separate computed tomography reconstruction workstation including software and meet the Technical Requirements listed below.

Technical Requirements System Capabilities

· Advanced 2D X-Ray inspection

· 2D CT Slice reconstruction

· CT volume reconstruction for 3D inspection

· 3D internal and external surface scanning

· Measurement and Analysis tools System Specifics X-Ray tube:

· Tube Voltage: 25 - 225kV Microfocus

· mA Range: 0-3 mA

· Power: 320 W max

· Focal Spot Size: < 6 microns

· Detail Recognition: < 2 microns

· 10m High Tension Cable

· Closed Loop Water Cooler

X-Ray control unit:

· Workstation with Windows operating system

· Automatic tube warm-up (High voltage, filament current)

· Automatic focusing, electron beam alignment and target loading control

· Spare parts and service kit X-Ray detector:

· 8” x 10” (203mm x 254mm) image area

· Premium CT Grade (best quality)

· Cesium Scintillator (best contrast)

· 127 micron pixel pitch. 1536x1920 pixels (approx. 3 Megapixels)

· Tungsten shielded to 225kV (increased lifetime)

· Receptor Type: Amorphous Silicon

· Conversion Screen: Direct Deposit CsI, DRZ Plus

· Pixel Area Total: 19.5 x 24.4 cm (7.68 x 9.6 in.)

· Pixel Matrix Total: 1,536 x 1,920 (1 x 1), 768 x 960 (2 x 2)

· Pixel Pitch: 127 μm2

· Limiting Resolution: 3.94 lp/mm

· MTF, X-Ray: >48% @ 1 lp/mm (1 x 1), CsI screen

· Energy Range: 40 - 160 kVp

· Fill Factor: 57%

· Image Capture: Gigabit Ethernet

· Scan Method: Progressive

· A/D Conversion: 16-bit resolution

· Frame Rate: 12.5 fps (1 x 1 pixel binning), 30 fps (2 x 2 pixel binning)

· Data Output: Gigabit Ethernet

· Exposure Control: Opto-Coupled, External Sync, Expose OK

Manipulator:

The manipulator system shall allow for motorized control of the positioning device and associated X-Ray system.

Required Features:

· All drives shall be variable-speed joystick controlled. Each axis control shall be independent, allowing simultaneous movement of all axes.

· Tethered desktop control console.

· Focal Distance: Variable; up to 52" (132cm).

· Part travel:

Vertical - 24” (60cm) Horizontal - 15” (38cm) standard, 21” (53cm) for ergonomic loading Z-axis – 49” (124cm)

· Flat panel translation to adjust the focal distance Detector Lateral Shift of 32”

· Rotation - 360 Degrees. Micro CT precise nickel plated rotational stage

· 75lb (34kg) Stage capacity.

· The Motion Control Module shall include a ‘Teach and Learn’ interface to create complex motion control programs easily and quickly.

· The system shall utilize programmable computer-numeric-control (CNC) motion control.

Cabinet: The cabinet shall have the following characteristics:

· Shielding: Shielding must be adequate to prevent all radiation from escaping from cabinet when operating at X-Ray tube maximum output levels.

· Radiation safety features: The system shall meet all applicable federal and state requirements for X-Ray systems

· The system shall have primary and secondary fail-safe interlocks.

· The system shall have a warning light to indicate when X-Rays are being produced.

· Interior LED lighting.

· X-Ray on warning light.

· Viewing windows shall be lead glass.

· The main system cabinet shall be < 80” in height and weigh less than 10,000 pounds.

Computer hardware and Software:

The system shall include a computer workstation(s) and necessary software to operate the system. The included software shall be produced by the hardware/system manufacturer (not third-party).

The workstations shall include:

Hardware (Minimum Requirements)

· Windows® 10 Operating System

· Eight-Core Intel® Xeon® Processor

· 8 GB RAM

· 1 TB SSD Operating System (OS) Drive

· 3TB of Data Storage in RAID 0 Configuration

· DVD+/-RW Drive

· 10/100/1000 Network Interface

· NVidia High Performance Display Adaptor

· 30” (762mm) 4 Mega Pixel Color Display

· Keyboard and Mouse

DR software

High performance image analysis system with a comprehensive set of image analysis tools.

· Windows® based

· Non-proprietary image storage format.

· Multiple Windows interface

· High performance image processing and measurement functions utilizing graphics processing unit (GPU) technology

· Automatic parallelization for systems with multiple central processing units (CPUs) and GPUs

· Live Imaging up to 30 frames per second

· Live Averaging

· Live Histogram

· Live line Profile

· Live Rotation between portrait and landscape modes

· Live Measurements with 1 pixel resolution

· Live image gain/offset calibration and defective pixel correction

· Automatic creation of Technique sheet for operator record

· Capture video into AVI files.

· Supports digital flat panel detectors, LDA’s and digital/analog cameras at 8, 10, 12 and 16 bits.

· Read and store images in TIFF 32 bit / 16 bit / 8 bit, BMP, JPEG, RAW

DR CT Acquisition Module

The CT acquisition module shall provide automated CT acquisition capabilities.

· Capable of CT acquisition up to 10,000 angle steps.

· Technique sheet creator for operator record.

· Monitors X-Ray performance and will pause the CT scan if X-Ray interruption is detected.

· Capable of acquiring projections in a continuous mode for faster CT

Fast CT Acquisition Module

The CT acquisition module shall allow continuous fast CT acquisition of projections for fast CT scans from 5 seconds to minutes for thousands of projections.

Reconstruction Workstation (Minimum Requirements)

System shall meet or exceed the following:

· Windows® 10 Operating System

· Eight-Core Intel® Xeon® Processor

· 16 GB RAM

· 512 GB SSD Operating System (OS) Drive

· 3TB storage in RAID5 Configuration

· DVD+/-RW Drive

· 10/100/1000 Network Interface

· NVidia High Performance Display Adaptor

· 11GB GPU Memory

· 3584 Processing Cores

· 31.5” 4K Color Display

· Wireless Keyboard and Mouse

CT Computed Tomography Software

CT software shall include:

· CT calibration, Cone-Beam reconstruction, 3D real time visualization and analysis tools in the same interface.

· The software shall not limit the size of the reconstruction

· The software shall be capable of the following:

· Combining 2 or more datasets taken at different current settings

· Significantly improving CT quality of widely varying densities.

· Increasing the dynamic range of the CT dataset.

· Reducing noise and photon starvation in the CT reconstruction

· The software shall be able to perform local CT reconstructions of a small area of interest inside a larger object.

Simplified processing - The software shall include a simplified, user-friendly mode that lets the user quickly navigate through the full CT scanning process, from the creation of the project to the final results. The simplified interface shall include features to guide the user through the calibration and reconstruction process.

Automatic Calibration - The software shall include a tool to optimize cone-beam CT reconstruction process and to simplify CT and μCT equipment.

· Cone Beam Reconstruction – Reconstruction performed on GPU hardware.

· 3D Volume Rendering capabilities shall include:

· Real time volume rendering

· Export slices at any angle

· Create movie animations

· Perform localized reconstruction.

· Ring Reduction - Using a combination of hardware and software to minimize ring artifacts caused by non-uniform pixel responses.

· 3D Surface Rendering - Surface extraction to CAD compatible format:

· Export to STL (Stereolithography), cloud points, OBJ, DXF, WRL, PLY. Visualization in wireframe mode. Map textures with reflection.

· Export an executable viewer module with a dataset to allow others to view, slice, rotate, window and manipulate the dataset on a traditional laptop or desktop computer. The viewer module shall be fully capable and equivalent to the post-processing capabilities of the CT Workstation.

· Spiral/Helical Acquisition

· The system shall be capable of performing automated spiral acquisition with a digital flat-panel detector for the scanning of elongated objects that traditionally cannot fit into a single exposure. The scan shall not require volume stitching and the object length shall only be limited by the system scanning area. This shall reduce or eliminates the cone angle artifacts caused by flat, planar features common in non-spiral CT techniques.

· Image stitching

· Larger parts may require multiple scans to completely scan the part when it is larger than the detector panel. The software shall be able to stitch multiple images into one seamless image of the part or assembly.

· Sub-pixel resolution

· The designed motion of the manipulator and the software shall be capable of displaying and analyzing scan data utilizing sub-pixel analysis routines that are typically double what the detector alone is capable of achieving.

· Time and motion analysis

· The system shall be capable of creating and analyzing moving or changing parts as dynamic, time-based data sets. The system shall be able to acquire time-based data in either a continuous or stepped mode. Continuous scan mode refers to repeatedly scanning the part while motion or change is occurring at a speed that is slow relative to the time it takes to complete a full scan. Stepped scanning refers to re-scanning the part multiple times after the part is removed from the CT unit, subjected to some condition that will cause motion or change in the part. The system shall be able to generate time-sequenced images (videos) showing the motion or change in the part resulting from the continuous or stepped scans.

· Continuous CT scan mode shall be included for faster CT scans in seconds or minutes.

· Local CT reconstruction capabilities (reconstruct just a small area of interest inside a larger object).

· No limitation of reconstruction size – Reconstruction size shall be at least 10000x10000x10000 voxels

Installation and Training

System Installation:

System crating/shipping shall be included. Vendor shall perform installation with factory trained personnel. FRL is responsible for movement of equipment from the shipping area to the installation site, placement of machine at final installation site, and providing for refuse disposal. FRL is also responsible for power requirements specified by vendor.

DR / CT System Training:

4 Days On-Site DR/CT system operation training. The offeror shall provide 4 Days On-Site training for system operators covering: digital radiography, computed tomography, and operation/maintenance/safety of the delivered CT system operation. This training shall be provided as part of the system delivery and acceptance.

Digital Radiography & Intro to CT Training (40 hour course):

Digital Radiography & Intro to CT training shall be included for 2 people. This shall be a 40 hour ASTM/ASNT Certified DR/CT training course, held at vendor’s site. This course shall follow the recommended curriculum of FWG-IDR, MAI, ASTM and ASME in a format for compliance with NAS 410 Qualification/Certification program.

Advanced CT Training:

Advanced CT Training shall be included for 1 person. This shall be a 4 day class at vendors’ site that covers the advanced capabilities of the Industrial CT technology. The course shall include CT Technique Development training and CT Reconstruction, The class shall focus on the advanced capabilities of the delivered system and Industrial CT technology. The course shall include CT Technique Development training and CT Reconstruction

Maintenance:

At least 12 Month Hardware Warranty and one preventative maintenance visit shall be included Local time zone support by main manufacturing facility

Software and hardware system shall be made by the same company First Year DR & CT Software Maintenance/Updates shall be included Technical Manual:

The system shall include a user’s guide technical manual that covers system operation, routine maintenance and basic troubleshooting information. The standard commercial user/technical manual(s) for the hardware and software shall meet this requirement.

Delivery Schedule:

The equipment shall be delivered and installed within approximately 90-120 days of receipt of the contract.