Ultrasonic non-destructive testingYesterday, Today and Tomorrow

AUT Seminar - Bangkok

Dirk Schindler

Commercial Manager Asia

Content

Yesterday: ±1900 - ± 1990 Ultrasonic testing explored Automated ultrasonic testing

Today: ±1990 - ± 2000 Time of Flight Detection technique (ToFD)

Phased array technology (sectorial scan) Phased array technology (sectorial scan)

Tomorrow: ±2000 … 2D imaging of defects with linear phased arrays Matrix phased arrays and 3D imaging

Conclusions

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Ultrasonic testing: the pulse-echo technique

1928: Transition technique bySergei Y. Sokolov. Applied inGermany and USA

Data display by ‘A-scan’

Only defect detection

1940: First pulse-echo system by FloydFirestone, USA and Donald Sproule,England

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England

Manual scanning

Defect sizing based on amplitude

Automated ultrasonic testing (AUT)

1959: First mechanized ultrasonic systemRotoscan-Prototype for weld inspection Zonal discrimination Strip chart display

1978: Second generationRotoscan Canada and offshore in

Italy Bulky equipment

1989: Standards and codes allow AUT inCanada Today’s industrial standard Scanner on small carriage

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Time of Flight Diffraction (ToFD)

1980: Development of ToFD Based on diffraction Defect sizing based on travel time Less dependent on defect orientation Data interpretation requires training

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Phased array technology

1990: Application of linear phased arraytechnology for industrial non-destructive testing Earlier used in medical field Consist of small elements Computer controlled beam steering

2000: First generation Phased Array Rotoscan Flexible in use less probes Inspection philosophy unchanged strip charts

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2D Imaging techniques

2000: Array technology used for 2D imaging Based on sectorial scanning (like medical

field) Inspection of complex geometries (nozzles,

turbine blades) Detection and sizing still based on defect

orientation

2005: Array technology used for 2D imaging

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2005: Array technology used for 2D imaging Earlier applied in seismic exploration Detection independent on defect orientation Defect size, position and orientation are

imaged correctly Straight forward interpretation

3D imaging techniques

2007: Array technology used for 3D imagingof defects Full 3D interpretation possible Requires computer power

2008 ?: Matrix phased array technology Optimal beam control Advanced equipment necessary

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Advanced equipment necessary

Conlusions

Ultrasonic testing has been done for ca. 80 years

Detection has become reliable

Accurate sizing and straight forward interpretation

To solve new complex challenges in NDT, we can benefitfrom our experience

Development goes on

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Latest ROTOSCAN system development

Phased Array

Phased Array Scanner system

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Probe frame

Ultrasonic HardwareP.A. Probes

Encoder

RTD Phased Array

Long cable between PC and scanner, due to electronics on top ofscanner

Very short cable (0,5m) between PA probes and ultrasonic pulsers

Has conventional PE channels for additional TOFD

Has 128 elements (divided over 2 probes)

Can activate up to 32 elements simultaneously to create focus andbeam steeringbeam steering

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Principle of Phased Array

electronically delayed pulses

elements

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angle variation focussing

Principle of Phased Array

Weld scanning

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64 element transducer

Conventional vs Phased Array

Conventional

<16 transducers (per frame)

Long calibration procedure

Calibration by hand

Bulky scanner frame

Phased Array

Two transducers

Short calibration procedure

Calibration with software

Compact scanner frame

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Phased Array Operational advantages

Small diameter pipelines with heavy wall can be inspected withsufficient number of inspection (depth) zones

System can be programmed to cope with different pipe suppliers(different sound velocity)

Set-up preparation time of system can be significant reduced (e.g. nowaiting time for probe fabrication)

Smaller scanner frame and umbilical, easier to handleSmaller scanner frame and umbilical, easier to handle

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NDT Inspection of Pipe lines underconstruction

Comparison of RT vs AUT

DefectXRAY AUT

Detection Characterization Detection Characterization

LOSF(Lack of Sidewall Fusion)

LimitedGood(if detected)

Yes Good

LOIF(Lack of Interrun fusion)

No Not applicable Yes Good

Porosity(Single pore & cluster)

Yes Excellent Reasonable Poor(Single pore & cluster)

Yes Excellent Reasonable Poor

Crack LimitedExcellent(if detected)

Yes Reasonable

LOP(Lack of Penetration)

Limited Good Yes Excellent

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Based upon the inspection of a manual welded weld having a bevelconfiguration of 60 degree

Comparison of costsRT vs AUT

cost

s RT - large OD

RT - med. OD

RT - small OD

calibrationplate

probeconcept

inspectionconcept

fixed and variable costs

0 50 100 150 200 welds per day

RT - small OD

AUT

initial costs

AUT RT

concept

procedure

preparation,mob, demob

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break even

RT incl film costs

AUT incl probecosts

Thank you for your interest

Applus RTD Project Services

Rotterdam, The Netherlands

Houston, USA

Perth, Australia

Singapore

Dirk SchindlerDirk Schindler

Commercial Manager Asia

23 Tuas View Close

Singapore 637 481

P: +65 6898 4046

M: +65 90257381

F: +65 6898 9704

E: dirk.schindler@applusrtd.com

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