Processor Quality Control Problem Solving Midterm Topic 2
Processor Quality Control Process of Processor Quality Control Process of Processor Quality Control Check the temperature of the developer by use of a thermometer.Check the temperature of the developer by use of a thermometer. Check water temperature.Check water temperature. Check fixer temperature.Check fixer temperature. If developer temperature is within ± 0.5° of specifications produce and process the sensitometric strip.If developer temperature is within ± 0.5° of specifications produce and process the sensitometric strip.
Check Developer Temperature Proper development of the latent image is dependent upon: Proper development of the latent image is dependent upon: Developer temperatureDeveloper temperature Concentration of developer solutionConcentration of developer solution Time film spends in the developerTime film spends in the developer Temperature must be to specificationsTemperature must be to specifications
Check of Water Temperature If the water is too cold, it will be more costly to heat the developer to operating temperature. If water is too warm, the developer will over heat. If the water is too cold, it will be more costly to heat the developer to operating temperature. If water is too warm, the developer will over heat.
Check of Fixer Temperature The fixing of the image is dependent upon the fixer being within factory specification but is not as critical as developer temperature. The fixing of the image is dependent upon the fixer being within factory specification but is not as critical as developer temperature.
Expose Sensitometric Strip The Sensitometer produces highly reproducible step wedge images used to monitor the performance of the developer. The Sensitometer produces highly reproducible step wedge images used to monitor the performance of the developer. Using film set aside for processor quality control, expose both sides of the film with the Sensitometer. Using film set aside for processor quality control, expose both sides of the film with the Sensitometer.
Process the Sensitometric Strip Always feed the film into the processor the same way and on the same side of the feed tray. Always feed the film into the processor the same way and on the same side of the feed tray. Bromide drag and affect the image. Bromide drag and affect the image.
Read the Sensitometric Strip A Densitometer is used to read the optical density of the strip. A Densitometer is used to read the optical density of the strip. Read an area of unexposed film to check the base plus fog (B+F) of the image. Read an area of unexposed film to check the base plus fog (B+F) of the image. Then read the Speed and Contrast Steps. Then read the Speed and Contrast Steps.
Read the Sensitometric Strip The amount of light passing through the image is the optical density of the image. The amount of light passing through the image is the optical density of the image. Speed or Mid Density is the step closest a reading of Base+ Fog or 1.20 OD Speed or Mid Density is the step closest a reading of Base+ Fog or 1.20 OD Contrast or Density Deference is the deference between the steps closest to Base + Fog or 0.45 and the step closest to Base + Fog or 2.20 OD. Contrast or Density Deference is the deference between the steps closest to Base + Fog or 0.45 and the step closest to Base + Fog or 2.20 OD.
Graph the Results on the Processor QC Chart The processor should be checked before x-rays are taken on the first patient. The processor should be checked before x-rays are taken on the first patient. If a problem exists, it must be corrected before processing patient films. If a problem exists, it must be corrected before processing patient films.
21.3 Processor QC Problem Solving Processor QC monitors the development of the film. These factors impact development: Processor QC monitors the development of the film. These factors impact development: Developer TemperatureDeveloper Temperature Time of DevelopmentTime of Development Activity of the DeveloperActivity of the Developer Also the darkroom and film storage conditions will impact Processor QC.Also the darkroom and film storage conditions will impact Processor QC.
Base Plus Fog Any unexposed area of the film can be tested to determine the Base Plus Fog exposure level. Any unexposed area of the film can be tested to determine the Base Plus Fog exposure level. Base Plus Fog is the level of pre- existing exposure exposure above the blue tint of the base of the film. Base Plus Fog is the level of pre- existing exposure exposure above the blue tint of the base of the film.
Base Plus Fog Items that will impact the Base Plus Fog includes: Items that will impact the Base Plus Fog includes: Condition of film storage after manufacture.Condition of film storage after manufacture. Light integrity of the dark roomLight integrity of the dark room The light spectrum from the safelightThe light spectrum from the safelight Temperature of the developerTemperature of the developer Contamination of the developerContamination of the developer
Speed Index or Mid Density This is the step closest to 1.00 plus B+F or 1.20 Optical Density. It corresponds to the middle of the useful exposure level on x-ray film. This is the step closest to 1.00 plus B+F or 1.20 Optical Density. It corresponds to the middle of the useful exposure level on x-ray film. Factors that will impact the Speed Index include: Factors that will impact the Speed Index include: Developer Temperature: Low Temperature will produce lower speed.Developer Temperature: Low Temperature will produce lower speed.
Speed Index or Mid Density Developer Temperature: High Temperature will produce increased speed.Developer Temperature: High Temperature will produce increased speed. Fog level of the film: Increased Base + Fog will increase the Speed Index.Fog level of the film: Increased Base + Fog will increase the Speed Index. Time spent in the developer: Increased time at the correct temperature will increase speed.Time spent in the developer: Increased time at the correct temperature will increase speed. Activity of the developer: under replenishment will lower the Speed IndexActivity of the developer: under replenishment will lower the Speed Index
Speed Index or Mid Density Activity of the developer: under replenishment will lower the Speed IndexActivity of the developer: under replenishment will lower the Speed Index Over replenishment will result in increased Speed Index.Over replenishment will result in increased Speed Index. Contaminated Developer: If fixer gets into the developer, the developer will be contaminated.Contaminated Developer: If fixer gets into the developer, the developer will be contaminated.
Contrast or Density Difference Contrast Index is the difference between a step that produces a light shade of gray (0.25 O.D. + B+F) and the step that produces upper range of viewable light on an exposed film ( B+F)Contrast Index is the difference between a step that produces a light shade of gray (0.25 O.D. + B+F) and the step that produces upper range of viewable light on an exposed film ( B+F) Step closest to 2.20 minus Step closest to 0.45 equals the Contrast Index.Step closest to 2.20 minus Step closest to 0.45 equals the Contrast Index.
Contrast or Density Difference Factors that will affect the contrast level include:Factors that will affect the contrast level include: Fog level on the filmFog level on the film Developer TemperatureDeveloper Temperature Development TimeDevelopment Time Contamination of the developerContamination of the developer
Processor QC limits The action level or results that should result in corrective steps being taken vary between national limits and those recommended by California.The action level or results that should result in corrective steps being taken vary between national limits and those recommended by California. California recommends the tightest standards that will produce the most consistent image quality.California recommends the tightest standards that will produce the most consistent image quality.
Processor QC limits Developer Temperature: ± 0.5° F (Ca); ± 1 to 2° F.(US)Developer Temperature: ± 0.5° F (Ca); ± 1 to 2° F.(US) B+F: OD (California); OD (US)B+F: OD (California); OD (US) Speed Index: ± 0.10 OD (Ca.); ±0.15 OD (US)Speed Index: ± 0.10 OD (Ca.); ±0.15 OD (US) Contrast Index: ± 0.10 OD (Ca.); ±0.15 OD (US)Contrast Index: ± 0.10 OD (Ca.); ±0.15 OD (US) The California Standards are used in this course.The California Standards are used in this course.
Monitoring Frequency Daily when patients will be x- rayed: Daily when patients will be x- rayed: Check fresh chemical levelsCheck fresh chemical levels Check that water flowing into wash tank and tank is fullCheck that water flowing into wash tank and tank is full Check drive gears for wear.Check drive gears for wear. Check developer temperature when heater begins to cycle.Check developer temperature when heater begins to cycle. Clean work surface and feed tray of processor.Clean work surface and feed tray of processor.
Monitoring Frequency Daily when patients will be x- rayed: Daily when patients will be x- rayed: Clean cross over rollers or process two to three roller cleaning films.Clean cross over rollers or process two to three roller cleaning films. Perform Processor Sensitometry or QCPerform Processor Sensitometry or QC Determine B+F, Speed and Contrast IndexDetermine B+F, Speed and Contrast Index Chart resultsChart results Analyze results and take action as indicated.Analyze results and take action as indicated.
Monitoring Frequency At close of business each day or shut down: At close of business each day or shut down: Raise cover of processor about two inchesRaise cover of processor about two inches Drain wash tankDrain wash tank Semi-annual and at startup tests: Semi-annual and at startup tests: Immersion time or Speed of Processor DriveImmersion time or Speed of Processor Drive Water Flow RateWater Flow Rate
Chart 1 Problem solving: Problem solving: Start with developer temperature Start with developer temperature Then look at Base + Fog Then look at Base + Fog Then look at Speed Index Then look at Speed Index
Processor within Limits Chart 1 With proper developer temperature, reasonable volume of films processed and proper rate of replenishment the processor should stay within limits. With proper developer temperature, reasonable volume of films processed and proper rate of replenishment the processor should stay within limits. After cleaning the speed will increase due to fresh developer. This is normal. After cleaning the speed will increase due to fresh developer. This is normal.
Processor within Limits Chart 1 Trends can be monitored when the processor is within limits. Trends can be monitored when the processor is within limits. Continued lower than normal speed index is a symptom of under replenishment. A slight increase in replenishment may be warranted Continued lower than normal speed index is a symptom of under replenishment. A slight increase in replenishment may be warranted
Processor within Limits Chart 1 If you are under replenishing the chemicals and the case volume drops, the developer may go bad. If you are under replenishing the chemicals and the case volume drops, the developer may go bad. Continued high reading means over replenishing of the developer. Continued high reading means over replenishing of the developer.
Chart 2 Problem solving: Problem solving: Start with developer temperature Start with developer temperature Then look at Base + Fog Then look at Base + Fog Then look at Speed Index Then look at Speed Index
Problem #1 Chart 2 Symptoms: Symptoms: B+F and Speed are upB+F and Speed are up Contrast is downContrast is down Developer Temp normalDeveloper Temp normal Diagnosis: Diagnosis: Problem with dark room with safelight or light leak in darkroom.Problem with dark room with safelight or light leak in darkroom.
Problem #1 Chart # 2 Solutions: Solutions: Check bulb wattage in safelightCheck bulb wattage in safelight Check for light leaksCheck for light leaks Check for damage to filter in safelight.Check for damage to filter in safelight. Check fluorescent fixture for after glow.Check fluorescent fixture for after glow. Move safelightMove safelight
Chart 3 Problem solving: Problem solving: Start with developer temperature Start with developer temperature Then look at Base + Fog Then look at Base + Fog Then look at Speed Index Then look at Speed Index
Problem #2 Chart #3 Symptoms: Symptoms: Gradual decrease in Speed IndexGradual decrease in Speed Index Temperature within limitsTemperature within limits B+F within limitsB+F within limits Diagnosis: Diagnosis: Low volume of films processedLow volume of films processed Under replenishmentUnder replenishment
Problem #2 Chart #3 Solutions: Solutions: Run two to three fresh 14”x17” films or roller cleaning films each day through processor. Do Not run rejected films as they will contaminate the developer with residual fixer.Run two to three fresh 14”x17” films or roller cleaning films each day through processor. Do Not run rejected films as they will contaminate the developer with residual fixer.
Problem #2 Chart #3 Solutions: Solutions: Slightly increase the developer replenishment rate until the volume of cases increase.Slightly increase the developer replenishment rate until the volume of cases increase. Check for low levels of chemical in processor tanks.Check for low levels of chemical in processor tanks.
Chart 4 Problem solving: Problem solving: Start with developer temperature Start with developer temperature Then look at Base + Fog Then look at Base + Fog Then look at Speed Index Then look at Speed Index
Problem #3 Chart 4 Symptoms: Symptoms: Gradual rise in speed and contrastGradual rise in speed and contrast Sudden drop in Speed, Contrast and Developer temperatureSudden drop in Speed, Contrast and Developer temperature These are two separate but common problems. These are two separate but common problems.
Problem #3 Chart 4 Symptoms: Gradual rise in speed and contrast. Symptoms: Gradual rise in speed and contrast. Problem: If the volume of x-ray films processed each day increases significantly, the developer will be over replenished. Problem: If the volume of x-ray films processed each day increases significantly, the developer will be over replenished. Solution: If film processing volume remains high, reduce replenishment. Solution: If film processing volume remains high, reduce replenishment.
Problem #3 Chart 4 This is not typically recommended because a drop in film volume will quickly result in under replenishment. This is not typically recommended because a drop in film volume will quickly result in under replenishment. Other factors that can cause this increase: Other factors that can cause this increase: a new box of control film that is a little faster. Change aim if speed changes with the new box of control film.a new box of control film that is a little faster. Change aim if speed changes with the new box of control film.
Problem #3 Chart 4 Other factors that can cause this increase: Other factors that can cause this increase: a drop in the drive speed will cause the film to remain in the developer longer. This can be the result of a bad bearing, or roller or problem with the drive motor.a drop in the drive speed will cause the film to remain in the developer longer. This can be the result of a bad bearing, or roller or problem with the drive motor. Always check the developer temperature first. Always check the developer temperature first.
Problem #4 Chart 4 Problem 2 Symptoms: Problem 2 Symptoms: Drop in developer temperature, speed and contrast.Drop in developer temperature, speed and contrast. Diagnosis: Developer Temperature Control Problem or the test was done before the developer reached operating temperature. Diagnosis: Developer Temperature Control Problem or the test was done before the developer reached operating temperature.
Problem #4 Chart 4 Solutions: Solutions: If the developer temperature was checked before the strip was run, the problem would have been addressed without the need for the film. If the developer temperature was checked before the strip was run, the problem would have been addressed without the need for the film. It is very important to know how long it takes the processor to warm up in the morning. Time varies from 20 to 45 minutes.It is very important to know how long it takes the processor to warm up in the morning. Time varies from 20 to 45 minutes.
Problem #4 Chart 4 If some time has passed between the check of the developer temperature and processing the control strip, the following must be considered:If some time has passed between the check of the developer temperature and processing the control strip, the following must be considered: The developer thermostat, developer heater or fuse for the heater has failed. The developer thermostat, developer heater or fuse for the heater has failed. Most processor will have a light that blinks when the heater is on. If the light remains out, the heater is not working. Most processor will have a light that blinks when the heater is on. If the light remains out, the heater is not working.
Problem #4 Chart 4 If the water coming into the processor is too cold, the developer heat controls will:If the water coming into the processor is too cold, the developer heat controls will: Fail prematurely because of excessive needs for heat. Fail prematurely because of excessive needs for heat. You will use more power to maintain the developer temperature. You will use more power to maintain the developer temperature.
Chart 5 Problem solving: Problem solving: Start with developer temperature Start with developer temperature Then look at Base + Fog Then look at Base + Fog Then look at Speed Index Then look at Speed Index
Problem #5 Chart 5 Problem: Repeated increases in developer temperature, Speed Index and Contrast Index Problem: Repeated increases in developer temperature, Speed Index and Contrast Index Solutions: The developer temperature is controlled by the heater, thermostat and water temperature on most processors. The problem will generally be within these systems. Solutions: The developer temperature is controlled by the heater, thermostat and water temperature on most processors. The problem will generally be within these systems.
Problem #5 Chart 5 If the water was not turned on, the developer will over heat.If the water was not turned on, the developer will over heat. If the water was turned on but the water flow control valve is defective or clogged, the developer will over heat.If the water was turned on but the water flow control valve is defective or clogged, the developer will over heat. Test control valve every six months Test control valve every six months Use a water filter to control mineral content of water. Use a water filter to control mineral content of water.
Problem #5 Chart 5 The thermostat may have failed closed resulting in the over temperature condition.The thermostat may have failed closed resulting in the over temperature condition. The film may have been run with the processor set at the wrong speed and developer temperature. The film may have been run with the processor set at the wrong speed and developer temperature. Medical facilities use extended processing for mammography to reduce radiation by increasing speed and improve contrast.Medical facilities use extended processing for mammography to reduce radiation by increasing speed and improve contrast.
Problem #5 Chart 5 IF the Speed Index, Contrast Index and Base + Fog increased with normal developer temperature, the drive system is faulty.IF the Speed Index, Contrast Index and Base + Fog increased with normal developer temperature, the drive system is faulty.
Chart 6 Problem solving: Problem solving: Start with developer temperature Start with developer temperature Then look at Base + Fog Then look at Base + Fog Then look at Speed Index Then look at Speed Index
Problem #6 Chart 6 Symptoms: Speed Index and Contrast Index continue to fail with normal developer temperature and processing speed. The processor is fine right after service. Symptoms: Speed Index and Contrast Index continue to fail with normal developer temperature and processing speed. The processor is fine right after service. Solution: The processor is under used due to very low exam volume. Solution: The processor is under used due to very low exam volume.
Problem #6 Chart 6 The developer in the processor tanks will oxidize if fresh solutions are not added to the tank. As developer ages, it turns brown. The developer in the processor tanks will oxidize if fresh solutions are not added to the tank. As developer ages, it turns brown. The replenishing tanks should be air tight. The replenishing tanks should be air tight. To avoid this problem the following may be done: To avoid this problem the following may be done:
Problem #6 Chart 6 Every other day or daily turn on the processor and run two or three 14” x 17 films to pump fresh chemicals into the tanks. Every other day or daily turn on the processor and run two or three 14” x 17 films to pump fresh chemicals into the tanks. When you turn on the processor check chemical levels in the tanks. Evaporation is also a problem when film volume is low. When you turn on the processor check chemical levels in the tanks. Evaporation is also a problem when film volume is low.
Problem #6 Chart 6 Use flood replenishment to pump fresh chemicals into the tanks. Every few hours, fresh chemicals are pumped into the processor. Use flood replenishment to pump fresh chemicals into the tanks. Every few hours, fresh chemicals are pumped into the processor. This will maintain the proper chemical levels in the tanks and avoid chemical deposits on the rollers. This will maintain the proper chemical levels in the tanks and avoid chemical deposits on the rollers.
Water, Fixer and Q C Fixer Problems: Fixer Problems: Contamination: A very small amount of fixer getting into the developer will ruin or contaminate the developer.Contamination: A very small amount of fixer getting into the developer will ruin or contaminate the developer. Improperly clearing of a film jam can cause this. Improperly clearing of a film jam can cause this. Running rejected films to clean the rollers will contaminate the developer. Running rejected films to clean the rollers will contaminate the developer. Use new film or roller cleaning film. Use new film or roller cleaning film.
Water, Fixer and Q C Fixer Problems: Under replenishment Fixer Problems: Under replenishment If the replenishment of the fixer is too low, the film will jam in the wash tanks or dryer because of a lack of hardening of the emulsion. If the replenishment of the fixer is too low, the film will jam in the wash tanks or dryer because of a lack of hardening of the emulsion. The films will not dry properly.The films will not dry properly. The film will be easily scratched and will not last as long in the files.The film will be easily scratched and will not last as long in the files.
Other Processor QC Tests Water Flow Meter Accuracy: Measure water flow into processor. Criteria: ± 5% Done quarterly Water Flow Meter Accuracy: Measure water flow into processor. Criteria: ± 5% Done quarterly Processor Transport Time: Measure time from when the leading edge of the film enters the processor until leading edge exits the dryer. Criteria: ± 3% Done annually Processor Transport Time: Measure time from when the leading edge of the film enters the processor until leading edge exits the dryer. Criteria: ± 3% Done annually
Conclusions Processor Q C monitors the developer. Processor Q C monitors the developer. Developer replenishment, temperature and time the films spend in the developer are critical to consistent image quality. Developer replenishment, temperature and time the films spend in the developer are critical to consistent image quality.
Processor Troubleshooting Problem B+F up B+F Same MD up MD dow n DD dow n Darkroom Fog XXX Developer Temp Up XXX Developer Concentration Too High XXX
Processor Troubleshooting Problem B+F up B+F Same MD up MD dow n DD dow n Water Temperature Too High XXX Developer Over- replenishment XXX Developer Time Too Long XXX
Processor Troubleshooting Problem B+F up B+F Same MD up MD dow n DD dow n No Starter after processor service XXX Developer Contaminated XXX Expired Film XXX
Processor Troubleshooting Problem B+F up B+F Same MD up MD dow n DD dow n Developer Temperature too low XXX Developer Concentration Too Low XXX Under- replenishment XXX
Processor Troubleshooting Problem B+F up B+F Same MD up MD dow n DD dow n Oxidized or exhausted Developer XXX Inadequate Starter XXX Exhausted Fixer XXX