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Improving Work Efficiency through Small Innovations in the Flange Inspection Process at Zhengyuan Group – Author/Source: Lu’an Zhengyuan Group; Date: 2022-03-30; Clicks: 31. The flange inspection team at Zhengyuan Group carries out small innovations and creative projects during downtime, relying on standardized tools to ensure smooth non-destructive testing of containers. The radiographic inspection of small-diameter tubes such as heating tubes is a challenging process with high quality requirements. Due to differences among operators and the specifications of the tubes, the opening width of the elliptical images produced by these tubes varies frequently; moreover, the density of the film images fluctuates, which directly affects the quality of the films. As a result, a high number of defective films are generated. http://img.yf116.cn/image/img/20220330/814122965295.jpg A small-diameter pipe refers to a pipe with an outer diameter of no more than 100 mm. According to NB/T47013-2015, when using double-wall double-shadow radiography to obtain an elliptical image of such pipes, it is necessary to control the width of the image opening (the maximum distance between the projections of the upper and lower welds) to be around 1 time the width of the welds. Elliptical imaging separates the weld images on the source side from those on the film side, facilitating image evaluation and the location of defects for repair. Moreover, it can reduce the number of inspections required in most cases, thereby lowering costs and improving inspection efficiency while ensuring production progress. This represents an optimization of inspection processes, quality, costs, timing, and the ease of repairs. In the case of vertical transmission overlapping imaging, once a defect is detected, it becomes difficult to determine whether it lies on the source side or the film side, which hinders the localization and repair of the defect. Irregularities on the weld surface can also affect the assessment of defects. To solve this problem, the flaw detection team spent an entire afternoon using discarded welding wire to piece things together and fix them; after repeated adjustments, a ray inspection angle indicator for small-diameter pipes was finally created. After brief training on the use of the angle indicator, the process of radiographic inspection using small-diameter tubes became simple and easy to handle. The operators were able to quickly master the necessary techniques; the weld images obtained were clear, and the opening width was uniform, meeting all regulatory requirements, which greatly improved both the efficiency and quality of the work.