fox-iq on-line xrf tube & rod analysis system webinar

Fox-IQ On-line XRF Fox-IQ On-line XRF Tube & Rod Analysis SystemTube & Rod Analysis System

• Ken Smith, Global Business Development

• May 8, 2014

Today’s Discussion Topics

• “I thought Olympus made cameras…”

• Field & Industrial Instrumentation Overview

• X-Ray Fluorescence (XRF) for Alloy Analysis

• Automated XRF QC & Sorting Technologies

Olympus Scientific Solutions Americas

Cameras & Audio

Medical & Surgical

Olympus offers solutions for:

•Gastroenterology

•Gynecology

•ENT

•Pulmonology

•Surgery

•Urology

Industry SolutionsOlympus provides solutions for a variety of industries

Weld Inspection Solutions Corrosion Inspection Solutions Composite Inspection Solutions Tube Inspection Solutions Industrial Scanners

Advanced NDT Solutions

Tube Inspection Systems

In-Line/Off-Line ERW Tube Inspection System

FOX-IQ Process & On-line XRF System

Rotating Tube & Bar Inspection Systems

Integrated Inspection Systems

Handheld XRF Analyzers

Mobile XRF Analyzers

Specialized XRF Workstations

Mobile & Benchtop XRD

Process & On-Line XRF FOX-IQ Process & On-Line XRF System

Automated XRF for Sorting and Recycling

Analytical Instruments

Meatballs: Removal of copper from ferrous streamsGlass: Removal of Titanium, Zirconium, and Lead from Glass cullet streamsZorba: Removal of copper and copper alloys from “heavies” stream & Purification of Aluminum and Stainless Steels from “lights” stream

Automated XRF for Sorting and Recycling

X-STREAM Applications:

Process & On-Line XRF

Analyze Liquids & Fluids in Real Time

Quickly Analyze & CompareAlloy Tubes & Rods to Grade Specs

On-line XRF Systems

HH XRF for Point & Shoot Alloy Analysis

1. X-ray tube emits x-rays

XRF Theory

2. X-rays “light up” sample, exciting atoms that return x-rays

Ni

FeCr

Mo

Test Sample

XRF Theory

3. Detector captures (counts) returning X-rays as an energy spectrum

XRF Theory

4. Optimized Algorithm turns spectrum into concentration (percent by mass)

XRF Theory

Peak Area - Background Corrections = Net Area

Net Area x Calibration Factors = Elemental % or PPM

How are XRF Results Calculated?

XRF is a statistical method

Ni

Fe

Cr

Mo

Test Sample

Up to 100,000 photons/secondUp to 100,000

photons/second

Surface Space is Critical

≈ 10 μm

Penetration in Iron Alloy Matrix

Detect P to Pu With On-Line XRF

What’s on your surface?

Coatings & Platings

Sand-blasting(Residual Si)

Shot-blasting (residual fromiron pellets)

Metallic dust

Sample PresentationSample Presentation

Precise sample movement to and from the

FOX IQ analysis window is key for:

–Successful material analysis–Cost effective integration into a manufacturing process

FOX-IQ Customer Applications

Fox IQ Tube & Rod Analyzer

PLC•Start / Stop•Interlocks

PC&

Peripherals

Analytical SW

RS-232RS-485

Up to 30 m Up to 30 m

Up to 30 mWhat am I pointing to?

Tube & Rod VideoTube & Rod Video

Small Samples - Wire Samples < 1 mm

Control Communication• Level 1 Analog

• Between the PLC&Fox IQ Controller– Dry contacts – able to accept any voltage from you PLC;– Signals Controlled:

• Input # 1: Start Test

• Input # 2: Safety Interlock

• Output # 1: Pass/Fail

• Output # 2: Status/Busy• Output # 3: Tube Active (radiation present)

Control Communication

• Level 2: Digital

• Between the PLC APIFox IQ PC SW– What is an API (Application Program Interface)?

• Software Utility that allows an external system to control the Fox IQ through PC Software• Host Software (supplied by OIX) will control Fox IQ hardware• Client Software (customer developed) links the PLC or another onsite computer to the Host

Software using a defined set of commands provided by OIX

Application StatementAnalytical & Installation Details

• Analytical Goal(s)– Pass/Fail– Alloy Grade ID– Detailed Material Chemistry– Key elements, concentrations or tolerances

• Output Requirements?– Voltage– Digital– Printer– Display

• Site Details?– Location Floor Plan – Process Schematics

• Anything else you want us to know (temp, RFI, vibration? Other?)

Calculatorof Net GainPer Month

Meatballs

Shredder Output (TPH): 100

Operational Hours (per mo): 240

Monthly Output (tons): 24,000

Ferrous Shred (tons): 16,320

Value added per ton: $7.00

Net increase/mo from Shred: 114,240.00$

Savings on Manual Labor/mo: 10,000.00$

Increase in Cu Extraction (%): 0.08

Extra Cu pulled (tons per mo): 13

Value of Cu Extract (per ton): $760.00

Value of incremental Cu Extract/mo: 9,922.56$

Grand Total Net: 134,162.56$

Economic Test

Win

Win

Win

Alloy Grade LibraryTwo Methods for Identifying Alloys

1.Fingerprint Method: Simple comparison to a reference material• Works best when:

• The total number of grades handled is low (less than 10 is best)

• The grades are not similar

1.Grade Specification

How Does a Grade Library Work?

• What does the Match # Accomplish?

• How is it calculated?

• How does the Tramp Element Library Help?• What are nominal values?

Chemistry is measured first • What is this material?

Grade Matching is a secondary function. • Convenient for the user

Grade Matching is always, ALWAYS RELATIVE• Grade Matching identifies the best match in the active library.

• The value of the grade match is extended by:

» Directly comparing/displaying the measurement relative to the library specification

» Showing the 2 nearest matches

Grade Matching

Required vs Tolerated vs Unspecified• Required Elements

– What the manufacturer and the user zero in on– These elements and concentrations define the material properties, function and value– Typically 95+% of the alloy

• Tolerated Elements– Not required in any way– They are expected and tolerated as long as they are less than the max allowed– Typically < 5% of the alloy

• Unspecified or “Tramp” Elements – Typically, the 0.05 to 0.5% that shows up as an “unnamed” or “non-specified”– Commonly referred to as “tramp material” – This small percentage of unspecified or “tramp” material is tolerated for most applications

Batch Test Screen

Measure Screen

Ready for testing after successful standardization

Thank you for reviewing this info!

• Please contact us:• Ken.Smith@OlympusNDT.com • www.olympus-ims.com

Thank you for joining us!

Questions?