MODULE 5.

DRAFT PROTOCOL FOR GAMMA SCANNING OF INDUSTRIAL

PROCESS COLUMNS
5.1. DESIGN AND PLANNING
5.1.1. Work-scope planning
Prior to carrying out any work, the Team Leader should agree with the clients objectives of the work.
Details of the column diameter and wall thickness and trays or packed beds and other required
information should be available. A site visit and discussion may be carried out before carrying out the
scanning job. He/she will require a suitable general arrangement drawing showing the location of
features within the column. He/she will need to ensure that there is suitable safe access to the parts of
the column where the scanning team needs to position themselves He/she will ensure that there are
sufficient resources to carry out the work and that a suitable radioactive source is available.
5.1.2. Mechanical design Column characteristics
Normally columns are meant to perform the intended operations in the plant. Hence each column
differs in its characteristics and mechanical design. For getting complete insight of the column, team
leader should request plant authorities to provide a complete set of mechanical drawings. It is also
desirable to record all the process parameters during the period of scanning the column.
Mechanical designs serve to:

Select a proper reference (zero) point (manhole, external pipes, temperature probes, etc.).

Include the mechanical design data into an industrial design software (Autocad, Autosketch,
Labview, Excell etc.); all positions of internal and external structures are referred to the point zero.
For example, some of the characteristics of a column are listed as follows

Type of the column

Identification of the column

Internal diameter

Wall thickness

Trays (type)

Packing (type and density)

Orientations and position of internal and external structures

Process parameters such as

Throughput / Feed rate

Temperature profile

Pressure differences in various zones (Dp)

Refluxes

5.1.3. Selection of gamma source

Selection of the gamma source (60Co or 137Cs) and its activity shall be done based on the column
diameter, type of column to be investigated, etc. The activity required for the gamma scanning can be
estimated using the following formula already well described before on section 1.2.2.1:
2 2
=

Note: Approximately 200 mm needs to be added to the column diameter to take into account the
distance of source and detector positions from the column.
The value of D, mentioned in the above equation corresponds to the transmitted radiation intensity
which will give 5000 - 7000 cps (counts per second) in vapour space of the column (vapour base line);
and will decrease to around 1000 - 2000 cps in the tray level (liquid base line). This will give a good
compromise between the contrast (between liquid & vapour phases) and the accuracy of counting.
5.1.4. Example of source activity calculation
A gamma source is needed to scan a distillation column, which has the following parameters:
Internal diameter = 2.9 m, Wall thickness = 15 mm.
Normally the sensitivity of 2x 2 NaI(Tl) detector for 60Co is 7500 cps/(mR/h). The NaI(Tl) detector
sensitivity is determined by placing a sealed source of 60Co or of 137Cs at a distance where the dose
rate is 1 mR/h. The Na(Tl) detector sensitivity for 60Co is lower than for the 137Cs, because the
detector Na(Tl) is more sensitive to low energies of 137Cs than to high energies of 60Co.Calculation
of the 60Co activity for scanning a column of 2.9 m internal diameter gives:
=

2 2

1 2.9 + 2 2 2
1.332

30 22

18.6

Table 5.1 gives the 60Co activity (estimated, rounded off) in function of the column diameter (wall
thickness of 15 mm and the dose rate of 1 mR/h):
TABLE 5.1. COLUMN DIAMETER AND ESTIMATED GAMMA SOURCE ACTIVITY

Column Diameter (m)

1.0
1.5
2.0
2.5
3.0

60Co Source Activity

(mCi)
3
6
9
14
20

Column Diameter (m)

4.0
4.5
5.0
5.5
6.0

60Co Source Activity

(mCi)
34
43
52
63
74

Note: A similar table can be produced using different sources.

5.1.5. Selection of source-detector collimators
Collimators for source and detector shall be selected based on column configuration and diameter to
obtain maximum signal to noise ratio on the detector and to minimise the effect of scattered radiation
on the detector and to prevent radiation interference from nearby source of radiation such as installed
nuclear gauges, radiography activity, etc. If the finer details are expected then slit opening could be

smaller and for gross scanning of a whole column larger slit opening shall be selected. For example
one shall select 5 mm slit opening for source collimator coupled with 10 mm slit opening of detector
collimator to scan a column up to 2 meter diameter.
Since higher activities sources are required for the examination of large diameter and thick-walled
columns, it is necessary to design source collimators which could be transported in the source housing
itself. Such source housing-cum-collimator devices shall be designed using heavy alloy or depleted
Uranium to reduce the weight of such housing and to minimize the radiation hazard to the scanning
team and the general public. For example, 100 mm diameter source collimator made of tungsten of
less than 10 kg weight is recommended.
Figure 5.1 shows a set of source (right) and detector (left) collimators in use during a normal column
scanning.

FIG. 5.1. Example of detector holder (left) and source holder (right)
5.1.6. Selection of traversing mechanism
Source and detector traversing mechanism shall be selected so that source and detector collimators
openings always remain aligned in the same horizontal plane. Great care shall be taken to minimise
the swing of source and detector particularly while examining the columns with small diameters (less
than 1.5 m).
Depending upon availability of the equipment with a particular scanning group the traversing
mechanism shall be selected. Preference should be given to the ease of handling and comfort of the
scanning team being familiar with the type of traversing mechanism. The complexity of external
hardware and the working conditions in the plant mostly have an impact on the selection of the
mechanism.
Manual Traversing Mechanism

Normally manual scanning (as shown in Fig. 5.2) shall be selected for scanning a smaller section of a
column as well as where there is complex external obstructions, thus limiting the movement of source
and detector collimators.

FIG. 5.2. Two examples of manual traversing systems

Automatic Traversing Mechanism
For columns with larger height, and lesser external obstructions and, if the repetition of the scanning is
required for several different operating conditions automatic traversing mechanism shall be used.
Example of automatic traversing mechanism is presented in Fig. 5.3.

FIG. 5.3. Two examples of automatic traversing systems

5.1.7. Selection of source-detector orientations for scanning

Scanning of tray columns:
The source - detector orientations for scanning of trayed column shall be selected depending upon the
orientation of tray downcomers. In order to distinguish between normal liquid vapour separation
between adjacent trays and abnormalities such as foaming, flooding, weeping, etc, the scanline shall
avoid cutting through downcomers as shown in Fig. 5.4.

FIG. 5.4. Typical orientations of source and detector for tray-typed columns
However, scanline may cut through the downcomers when the information about downcomer flooding
is required.
Scanning of packed-bed columns:
To inspect packed beds, the grid scanning shall be applied. This technique can also be used for the
inspection of the correct installation of distributors as well as the correct distribution of incoming
liquid feed of the sieve-tray column. The schematic of grid scanning is shown in Fig. 5.5.
In general, four grids are recommended for the inspection of packed columns. However, the number
shall be increased when more information required.

FIG. 5.5. Typical orientations of source and detector for packed-bed columns.

5.1.8. Preparation of the scanning equipement

Preparation of following check-list is recommended:
Equipment and tools (units):
Detector (3)
Detector holder (2)
Portable scaler-ratemeter (3)
Computer (laptop or palmtop) (2)
Source-holder/source container with proper collimator (e.g. panoramic beam) (2)
Measuring tapes (2)
Cable connectors (4)
Coaxial cables (3)
Computer cables (2)
A/C lines and adaptors (2)
Guide steel wires or cables (2)
Rope / nylon / steel ropes (2)
Gamma source:
60Co or 137Cs
Radiological safety measures:
License of the source and certificate of the operators
Radiation sign and danger strip
Survey meters
Personnel monitors (film badge, TLD etc)
Lead bricks
Others:
Mechanical drawing of the column
Notebooks
Marker pens
Masking tape
Walkie-talkies / communication system
Set of extra battery for computer and scaler-ratemeter
Personnel protective equipment including safety shoes, overall, goggles, helmet, earplugs, etc.
Example of the gamma scanning equipment and traversing mechanism, both for manual and
automatic modes can be seen in Figs 5.6 and 5.7.

FIG. 5.6. Equipment used for manual system

FIG. 5.7. Traversing mechanism and data acquisition system for automatic scanning system
Scanning detection system shall be checked in laboratory with a check source. Details on this
procedure may be referred to Protocol on Maintenance and Calibration of Data Acquisition System
for Radiotracers and Sealed source Application, RAS/8/111-P4. However, a brief guideline is given
in the following paragraphs.
Verification of the operational condition of detection system.
Calibration for NaI(Tl) scintillation detector:

Fix the THR on 10 mV.

Fix the WIN IN-OUT in OUT.
Place a small gamma source (~1Ci) near the detector and record the counting intensity (with
and without source) increasing the voltage with 50 V. Construct the graph of intensity versus
high voltage.
Fix the voltage at the beginning of decreased slope of the graph.
The supplier has already fixed the high voltage. The routine control can be done every year or
when something is wrong.

Scaler-Ratemeter check:

Check the batteries charge through BAT option

Check the connections to detectors
Measure the background (or a small source intensity) in Ratemeter option - cps (analogue
record) for some seconds, then switch to Scaleroption. Measure the same in digital regime
(5 measures each 10 seconds). Compare the results in cps. It should be about the same value.
If not, see the high voltage set up again and batteries conditions. If the ratemeter and scaler
results are not comparable (within 10%) send the equipment to the workshop for specialist
check up.

Check that the scanning software is installed in the computer.

5.2. EXECUTION
Upon arrival at the work site, supervisor will ensure that a suitable permit to work is obtained.
He/she will inspect the work site and ensure that there is safe access. The scanning team will carry out
the scan in the agreed manner. Any deviation from the agreed scanning procedure must be approved
by the project manager after due consultation with the client.
Following steps need to be taken in carrying out gamma scanning:

Assess the mechanical design of the column.

Design the scan line directions avoiding internal down comer and external structures.
Draw or mark the scanning lines on column wall
Install the guide cable for guiding the source and detector along the scanning line.
Set-up the source and detector or set-up traversing mechanism for source and detector holders
Insert the gamma ray source into the collimator-source holder
Select the reference point (zero point)
Record the temperature at different points on the column (external wall, pipes etc.), if
necessary.
Perform scanning by recording the gamma intensity per unit time interval (e.g. every 6
seconds) each 2 to 5 cm interval along the column height.
Record additional information regarding the obstacles or external structures (This will help in
interpretation of the data).
Plot the gamma intensity vs. scanning distance.
Compare the scanning profiles with the engineer drawings for interpretation.

The form acts as a record and is useful for future repetitions of the scanning of the same
column.

5.3. DATA INTERPRETATION

Gamma scanning profile provides a clear picture of the column inside, giving the internal structure,
defects and column process state without interrupting the process (refer to Figs 5.8 and 5.9).
When the radiation beam crosses a tray which is normally filled up with liquid, most of the
intensity is absorbed and a narrow peak is recorded. Negative peak means lowest intensity
corresponding to the liquid base line.
When the radiation beam crosses a liquid zone the registered intensity is relatively weaker, but
higher than crossing the tray with liquid.
When the radiation beam crosses a clear vapour space , the intensity is the maximum (vapour
base line), but the shape is not peak but rather large due to the fact that the vapour zone is larger
than liquid zone or tray size.
When the radiation beam crosses a liquid distributor in a packed-bed column, the intensity is
relatively weaker than in the vapour phase.
When the radiation beam crosses a packed-bed, the registered intensity is relatively weaker
due to large absorption in the packing elements.
When the radiation beam crosses a support structure of a packed-bed, the intensity is relatively
weaker than the packed-bed due to high density structure of the support structure.
When the radiation beam crosses the liquid level at the bottom of either trayed or packed-bed
columns, the registered intensity is relatively weaker.

FIG. 5.8. Typical gamma-ray absorption scans of trayed type column

10

FIG. 5.9. Typical gamma-ray absorption scans of packed column

5.3.1. Model of reference profiles for tray column

Scanning profile of a normally operating distillation column.

11

Scanning lines are perfect, they do not cross

the jet channels. Between the trays, the
intensity is the same as of vapour line. No
anomaly is shown besides the tray 25 which is
not identical with the other trays. This
difference is not significant to identify an
anomaly which could stop the column. This
difference in intensity can be caused by
external obstacles. The liquid level is almost
the same in each tray.

Gamma scanning profile of a column part with foaming.

A slight foaming appears on the two identical

trays of the scan profile. The slope change
appears just above the tray. There are no
liquid entrainment or obstructions because
there is no deviation from the vapour base
line. More details can be obtained if an
additional gamma profile is performed with
lower energy sources.

Gamma profile of a column part with weeping (shower).

Weeping is difficult to identify. An additional

scan profile performed with week energy
source is necessary to observe these
phenomena better. The slope changes from
the upper tray to next bottom tray. Two slight
foaming areas are shown on two trays.
Weeping is more evident in the tray 26 and
may be caused due to the flooding of the tray.

12

Scanning profile through the downcomers:

The detected radiation intensity

of the vapour phase is lower
under even trays (22, 24 and
26) than under the odd trays.
The scan of even trays partially
crosses the downcomers and
the signals are absorbed more.
A bad separation liquid/vapour
is observed between the trays
27 and 28. This means that
slight liquid entrainment from
tray 28 to tray 27. The liquid
level on the tray 28 is higher.
Liquid weeping is visible at the
tray 28.

Scanning profile of flooding due to blockage at downcomer

The scan profile shows the presence of a

blockage of the downcomer of the tray
38. The blockage causes heavy liquid
accumulation up to tray 33. This
blockage also hinders the normal liquid
flow from tray 39 to tray 40. The tray 39
and 40 are normal, but the tray 40 holds
less liquid than the tray 39. There is
normal separation of liquid/vapour
between trays 39 and 40.

13

Scanning profile of weeping condition

There is a bad separation of liquid

and vapour between trays 11 and 12.
This condition is due to partial
blockage of downcomer of tray 12.
There is clear evidence of flooding on
tray 11 from the transmitted intensity
of gamma-ray.

Damaged tray

Damage is caused by excessive

flooding on trays 19, 20 and 21. Due
to this, the transmitted gamma-ray
intensity will never reach the vapour
base line. Trays 16, 17 and 18 are in
normal operating condition. The
separation of liquid/vapour is
adequate on trays 16 and 17. Trays
19, 20 and 21 are badly damaged.

14

Normal, displaced and missing and trays

Tray 15 is intact and holding liquid.

Tray 16 holds relatively small amount
of liquid and is partially damaged.
Tray 17 is intact but slight flooding is
observed.
Tray 18 is partially damaged.
Trays 19, 20 and 21 are totally
damaged and are displaced.

5.3.2. Model of reference profiles for Packed-Bed column

Displaced packed-beds

There are two packed beds in the

column, and two scans were
conducted. The figure shows the
bed 2 (first scan green line)
undergone serious damage. The
bed was totally collapsed or
displaced. Results for the second
scan (blue line) show the bed 2
was intact. Bed 1 was intact
from both of the scans.

15

5.4. REPORTING
The report shall contain a detailed description of the column as well as the description of the scanning
performances (scan number, source and detector direction scan lines in relation to the trays).
Scanning report should include as minimum the following information:

16

Executive summary

Introduction which includes a brief on problem statements or motivation.

Column characteristics

Work order from the plant to scan the column

Duration of scanning and daywise progress report

Process data of the column for duration of the scan

Radiological safety aspects

Detailed methodology of gamma scanning.

Detailed table of results (for each tray, if necessary)

Summary of the results and interpretation

Submission of digital data

Suggestions and recommendations

References

Annexure