Weld Inspection using AUT (PE, TOFD, Phased Arrays)

Presentación del tema: "Weld Inspection using AUT (PE, TOFD, Phased Arrays)"— Transcripción de la presentación:

1 Weld Inspection using AUT (PE, TOFD, Phased Arrays)

2 2 INTRODUCTION u Phased arrays have been used in industry for over 10 years (not new technology) u Complexity and high price prevented wide access u A new generation of instruments, user friendly and affordable, allows access to its benefits u Code compliant with Performance Demonstrations Initiative u New codes editions will pre-qualify it hopefully this year (2006)

3 3 Facts u MUT is 70% of UT work u AUT usage grows rapidly –AUT means encoded and recorded scans u AUT techniques –Conventional multi-probes –TOFD –Phased Arrays u Why AUT –Speed and reliability – less operator dependant –RT alternative (safety & security issues) –Cost Savings (increase POD, accurate sizing, speed of inspection, ease of analysis, real time data, reporting)

4 4 Agenda  AUT  Example  TOFD  PA  Principle  Manual Inspection  Manual encoded (automated)  Automated and motorized inspection  Examples  Code status  Advantages and disadvantages  RT vs UT vs AUT  Conclusions & challenges for the industry

5 5 Wind Mill Tower Objective: Reduction of manpower From 10 to 2 operators From 8 hours to 40 min AWS, app K GEPS Qualified Increased POD Data recording

6 6 TOFD PE 45  SW PE 60  SW Inspection Technique

7 7 TOFD 60-SW 60 SW 45-SW Probe Movement Data Visualisation

8 8 60m per Day with 2 ops.

9 9 Defect Diffracted Wave Diffracted Wave Incidente Wave Reflected Wave All Directions Independant of angle Diffraction (TOFD)

10 10 The diffraction Phenomena

11 11 The A-scan Signal Emission Reception Lateral Wave LW Upper Tip Lower Tip Reflected Wave BW

12 12 Visualization White + Black - Amplitude Time OneA-Scan is replaced by one grey line A-scan

13 13 Visualization Laterale Wave Reflected Wave A-scan Indication

14 14 TOFD Image

15 15 Advantages of combining TOFD & PE u TOFD is sensitive to all defects including volumetric defects easily detected by RT u TOFD has dead zones near surfaces u PE complements TOFD u The combination covers 100% of the weld volume u Alternative to RT (ASME CC2235, AWS)

16 16 Phased Array Ultrasonics u Another way to do UT –No magic, only physics! u Benefits –Speed –Facilitate analysis (imaging) –Data recording –Reliability – less moving parts

17 17 Principle of operation

18 18 Electronique Scan

19 19 Angular Scan Direction of energyDirection de l’énergie

20 20 Focalization Focussed to cross at this point Point focal

21 21 Complexe Geometry Inspection

22 22 Types of Probes 1D 2D Linear Circular

23 23 Manual Inspection of Welds with Phased Arrays 40 degree beam 70 degree beam

24 24 Index axis Scan axis VC-END(D) VIEW Usound axis Index axis Side and End Views Usound axis VC-SIDE(B) VIEW Scan axis

25 25 Index axis Scan axis VC-TOP(C) VIEW Index axis Scan axis Top View

26 26 Root Crack TOFD technique RadiographyPhased Array technique

27 27 Porosity TOFD technique RadiographyPhased Array technique

28 28 Inclusion TOFD technique RadiographyPhased Array technique

29 29 Lack of Root Fusion TOFD technique RadiographyPhased Array technique

30 30 Concave Root TOFD technique RadiographyPhased Array technique

31 31 Incomplete Root Penetration TOFD technique RadiographyPhased Array technique

32 32 Manual Encoded Inspection

33 33 Encoded Sector Scan

34 34 Encoded Linear Scan

35 35 T Weld

36 36 Inspection Technique 1/2

37 37 Inspection Technique 2/2 BW reference

38 38 Overlay on Weld Bevels

39 39 Overlay on Weld Bevels

40 40 Omniscan References for Fabrication Users (# of Omniscan) ApplicationCountry Saipem (5)Pipeline Rosa Lirio Project Total GS PLR 420 REV 01 Nigeria – repair job for ExxonMobil (500 welds, less than 5 min / weld) Italy AMAGManual al ingot inspectionGermany KHI (2)FSW & Turbine - JISJapan NDTdoBrazil (2)PetroBrass Piping – ASMEBrasil AIT (4)Bechtel Piping SS - ASMEUSA Union Tk Car(4)Rail Car – Special PV CodeUSA Caterpillar (3)Heavy Machinery – AWSUSA GEA RaineyHeat Exchangers - ASMEUSA BAE SystemsSubmarines - DoDUK

41 41 Automated and Motorized Inspection 40 production days saved At BAE Systems, UK for submarine fabrication

42 42 Results

43 43 PipeWIZARD

44 44 Zone Discrimination Technique

45 45 Conventionel vs Phased Arrays Normes DNV F101, ASTN 1961-E et API 1104

46 46 Data Presentation

47 47 Codes

48 48 ASME Executed by Independant Level III

49 49 ASME Certification by EPRI

50 50 ASME CC 2235 ASME CC 2235 (CIT) allows to use UT instead of RT for wall thickness > 12.7mm TOFD et TOFD/PE techniques allowed Demonstration required ASME CC for phased arrays under approval by Comittee now

51 51 AWS & API u API & AWS also allow qualification by demonstration u API - UT1 & UT2 –C. Magruder (Olympus NDT employee) passed exam in Jan 06. Results to be published u AWS - Annex K –New version in 2006 allowing new inspection techniques and technologies

52 52 Approach for J Ray McDermott Pipe Mill in Dubai u Performance demonstration following API RP2X and AWS u Multi-Technology Inspection Technique using –Phased Array for Longitudinal Indications –TOFD for Volume Indications (all orientations) –PE for Transverse Indications (45 Deg) as well as Lamination (0 Deg)

53 53 Pipe Mill Long. & Circ. Seams Welding Multi-Probe Scanner Head to be Mounted on Welding Boom

54 54 Pipe Mill Automated UT Technique Example (72-inch dia; 80mm WT; Long. Indications) TOFD for Circ Weld PA for Circ Weld PA for Long Weld

55 55 Advantages of AUT vs RT Speed Reliability No work delays ($) No radiation Real time results – feedback to welders Defect sizing – reduce false calls

56 56 Advantages of Phased Arrays u Inspection Speed u Flexibility u POD ( many angles and imaging) u Access to remote areas u Analysis Tools u Reporting

57 57 Conclusions Many different PA & AUT systems can be used to fulfill weld inspection codes: portable phased arrays (OmniScan), TOFD-based (PV-100) more powerful phased arrays (PV-200 and FOCUS LT). Many possibilities for delivery systems: handscanners, welding bands, magnetic wheel scanners, rotate the vessel, robotics. Choice is controlled by codes, component requirements, budget and knowledge.

58 58 Industry Challenges for NDT Equipment Suppliers u Resistance to change – new technologies u Reduction of qualified operators u Training Facilitate use of instruments & data analysis u Cost u Inform & increase NDT value added