PA-UT Presentation by All Nations

All Nations Co., Ltd

Address: Seo Chun B/D, 3rd Floor, #57, Chungdam-dong, Kangnam-gu, Seoul, 135-100, KoreaTEL: +82-2-514-0271, FAX: +82-2-514-0560, E-mail: [email protected]

ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the World

Replacement of Radiography with Phased Array Ultrasonic




PA-UTMotion Picture




Radiography vs. Ultrasonics



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldFlaw Detection-Radiography vs. Ultrasonics

Both techniques have practical applications and are complimentary in many cases

Each is known to have strengths and weaknesses when detecting flaws

Almost polar opposites in what type of flaws they detect best




Flaw Detection-Radiography vs. Ultrasonics

• UltrasoundMost sensitive to 2

dimensional discontinuities such as cracks, lack of fusion, etc

• RadiographyMost sensitive to 3

dimensional discontinuities such as slag, porosity, and lack of penetration



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldFlaw Detection-Radiography vs. Ultrasonics

Radiography– Classification of defect is

almost always required (i.e.

crack, porosity etc).

– Typically no way to size in depth/height plane.

– Acceptance criteria often varies by type of flaw detected and are often based on stringent good workmanship criteria

Ultrasonics– Classification of flaw may not

be required.

– Sizing of flaw in length and

height planes usually emphasized

– Allows fracture mechanics /ECA acceptance



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldDisadvantages of Radiography

Radiation safety hazardsLicensing and training costsDisruption of work area/extra movement of partsChemical wastes/Consumable costsFilm deteriorationSlow SpeedLower Probability of detectionLack of vertical plane sizing - usually can’t apply ECA criteria Repair can be hinderedSubjective interpretation/weakness in finding critical flaws




Comparison of Data Interpretation

• Ultrasonics (digital file/reports) to Radiography (film, digital, reports)

• Ultrasonics typically color based to emphasize inspection purpose– Amplitude response

– Thickness/depth/TOF

– Indications typically less subjective than radiography




What is AUT



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldWhat is AUT

• Automated Ultrasonics

• Can be one technique or combined

• Can be semi-automatic or fully automatic

• Can be unidirectional/ rastered/ multiple scans

• Can be computer based or run directly off flaw detector unit



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldWhat is AUT (continued)

Phased Array and TOFD combinations are heavily favored today versus multi-probe systems because of flaw detection and sizing capability as well as reduced hardware and mechanics

Systems more user friendly and less cumbersome then ever, reducing overall investment and training

Code accepted Quality training available

Most common Techniques Phased Array TOFD Conventional Shear/Longitudinal Wave Creeping waves Etc



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldWhat is AUT – Technique Examples

Phased Array Multi-zone TOFD

Phased Array and TOFDPulse Echo and TOFD



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldWhat is Phased Array

Utilizes multi-element arrays

Incorporates time delays for increased control of beams (steering, focusing etc)

Fixed Angle linear and multi-angle sectorial scans most often utilized



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldWhy Phased Array Technology

Faster Inspection– Performing the same or improved inspection as

other NDE techniques with greater speed, repeatability, and procedure compliance.

Better Inspection– Overcomes Access limitations – Better detection and sizing of flaws through the

use of focused multi angle inspections– Easier characterization of flaws and geometry– Reducing dependence on the skill of the

operator– Ability to record digital data and retain inspection

records– Typically allows one line scans and reduced

footprint/mechanics



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldPhased Array Advantages

Offers all the benefits of Ultrasonics with the following advantages

– Increased coverage and detection capabilities through multi-angle, electronic rastering and beam control

– Imaging and recordable data in manageable file sizes viewable by all parties as needed.

– Reduced mechanics and difficulties over multi-probe techniques

– Application of traditional ultrasonic acceptance criteria




VC-Side(B) and VC-End(D) viewsIndex axis

Scan axis

VC-END(D) VIEW

Usound axis

Index axis

Usound axis

VC-SIDE(B) VIEW

Scan axis




나 우 기 연 주 식 회 사

VC-Tpo(C) views

Index axis

Scan axis

VC-TOP(C) VIEW

Index axis

Scan axis




VC-Tpo(C) views

VC-END(D) VIEW

Usound axis

Index axisScan axis

Usound axis




Weld Application(S-scan)

Phased Array Practical Application




Thick Weld Application




나 우 기 연 주 식 회 사

Bolt Application




Bolt Application-2




Tube to Tube Sheet Weld Application




Tube Weld Application

Phased array image

Radiographic image




Application O.D 4 ~ 8 in., THK 4 ~ 12 mm Piping

Result

No. of JOINTTest Result

RemarkRT PAUT

130 ACCEPT ACCEPT BOTH ACCEPT

7 REJECT REJECT BOTH REJECT

3 ACCEPT REJECT DEVIATION

Conclusion PA has too enough capability to replace RT

Comparison Table Between RT and PA in a Site Test




Refinery & Chemical Plant Project Career

CLIENTPROJECT

NameProject Type RT or PA Country Remark

FOMOSA Refinery No.5RefineryPiping

PA TaiwanHad been

completed

GS CALTEX HOU No. 2 & 3RefineryPiping

RT & PA Korea Still going on

HYUNDAI OIL BANK HOU No.2RefineryPiping

RT & PA Korea Still going on

SK Chemical MaintenanceChemical

PipingRT & PA Korea Still going on

QAFCO Q1 ProjectFertilizer

PipingRT & PA Qatar Still going on

ADNOC GDPRefineryPiping

RT & PA UAE Still going on



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldOffshore & Shipbuilding Application Career

TYPEPROJECT/OWNER

Class

PAUT Length (M) Thickness(mm)

RT Sheets ( Per

250mm) Remark

Structure

(Defect Length)

Pipe(Defect Length

)

Structure

Pipe(O.D)

HULL TEEKAY LR269(0)

Blank 10~ 30 Blank 1,076DNV Approval

Complete Test within 3 days

FPSO NEXUS DNV80(0)

Blank 30 Blank 320

DNV and Owner ApprovalFPSO Bp DNV1,064(1.83)

Blank5.6 ~

60Blank 4,256

Semi-Rig

Seadrill DNV264(0)

Blank7.0 ~

20Blank 1,056

Semi-Rig

VYBORG RS4,151(5.79)

120(0.59)

6 ~ 506 ~ 17.5(4 ~ 20)

17,084 Owner Approval

JACKET ONGC BV5,070

(0)170

(4.53)6 ~ 19

6.35 ~ 30

(4 ~ 20)20,960 Owner Approval

Drillship

Mosvold ABS150(0)

Blank 8 Blank 600 ABS and Owner Approval

TOTAL - - 10,893 290 44,720 -



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldDNV Approval Letter for PA Application



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldShip Owner Approval Letter for PA Application



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldCombined Technique- Phased Array and TOFD

By utilizing both techniques we offer the most flexibility and power for:

– Coverage and code compliance

– Detection and sizing

– Correlation and assessment




AUT Codes



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldOutline on AUT CodesOutline on AUT Codes

ASME – AUT codes and Code Cases today

ASME Code requirements

ASME Codes - where we are going

TOFD Codes – esp. ASME

Other code activities – API, ASTM, AWS, EN, ISO etc.

Summary




Current ASME Codes

and Code Cases



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldASME AUT Codes TodayASME AUT Codes Today

AUT dominated for years by ASME Code Case

2235 (from Sections I, VIII and XII) Twelve year old code case for using AUT instead

of RT Now in 9th Edition, but closing soon Very widely used - globally Wide variety of options: technique, equipment,

mechanics, data displays etc.




ASME Code Case 2235ASME Code Case 2235

Based on Performance DemonstrationRequires detecting three defects (ID, OD, sub-surface)Requires full data collection and encoderCan fulfill with single linear passOften interpreted as TOFD, but can be pulse-echo or

combination, or PA, or….Similar code in API 620 App U, B31.3 etc.




The “New” ApproachThe “New” Approach

One person operation• OmniScan• twin phased arrays,• TOFD • handscanner• couplant and pump• linear scanning.




Phased Array Code CasesPhased Array Code CasesCurrently have five ASME Code Cases:

– 2541: Manual PA with single beam

– 2557: Manual PA with S-scans

– 2558: Manual PA with E-scans

– 2599: Encoded (AUT) PA with E-scans

– 2600: Encoded (AUT) PA with S-scans

Essentially have full suite of Code Cases for PA




ASME Phased Array Code Case

Requirements




Phased Array Code Case RequirementsPhased Array Code Case Requirements

Calibrate all beams (OK for OmniScan)

Use same Focal Law for cal as for scanning

Develop Scan Plan to show coverage and appropriate angles

Use two (or more) S-scans if required

Scan parallel to weld with encoder/full data collection at fixed distance from centerline

50% beam overlap and >5% data drop-out

1 mm axial step for thinner materials




Scan Plans (1)Scan Plans (1)

Ray tracing using ESBeamTool with sample Bevel Incidence Angles (arrowed) calculated on 25 mm wall double-V weld.Can check if angles “not appropriate”




Scan Plans (2)Scan Plans (2)

9mm Wall using standard 45-70o refracted shear wave S-scanNote poor coverage of Heat Affected Zone -> move array for optimization.

9.00mm

-10.00mm

Generated with Eclipse Scientific ESBeamTool2

HAZ poorly addressed




Other Code Activities –

API, AWS, ASTM, EN/ISO etc.




Code activities - APICode activities - API

API similar in approach to ASME; two organizations work together

Approval using PA for API UT 1 and UT 2 procedures with no changes

Essentially scan known samples using new technology/techniques

Phased arrays now widely used for API, e.g. API RP2X and API 1104.




Code activities – ASTMCode activities – ASTM ASTM E-2491-06 Recommended Practice for phased

array set-up

Requires full “angle corrected gain” (ACG) over SDH

calibration range

Also requires TCG

Limits to angular range based on recommendations

and calibration

New E-2700 RP for PA of welds.



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldCode activities – ASTMCode activities – ASTM

From Insight

Under ASTM RP, this angular range is unlikely to be calibrate-able

Also generates both L- and S-waves.




Code Summary




Code activities – ASME summaryCode activities – ASME summary

Phased arrays, TOFD and AUT inherently accepted by ASME (and other codes)

May need to get techniques and procedures approved e.g. by Performance Demonstration approaches

PA Code Cases now available Ultimately, being codified in new Mandatory Appendix for

AUT and PA.




Code activities – other summaryCode activities – other summary ASTM RP for PA set-up published

ASTM RP for PA of welds published

API generally accepts PA

AWS D1.1 still requires Engineer’s approval

Europeans “behind” on PA and AUT codes

Overall objective: single pass, code-compliant inspections using E- or S-scans, encoded linear scanning for all codes.




Example - Cost/Time/Safety Analysis

Customer job Comparing Manual UT to

Radiography as well as to PAUT

2 inch butt-weld ASME requirements must

be met 360° access to weld



ALL NATIONSAltitude Producing the Profit CustomerManagement Toward All Over the WorldExample - Cost/Time/Safety Analysis




Special Considerations




High Variance – “Stick” and “Manual” Welds

Not impossible but more difficult

Typically require high level analysis of geometry reflectors by experienced Technician

Difficult to Automate




Thin Wall and Small diameter Inspections

Creates geometry problems for analysis

Resolution and sizing an issue, often go-no-go with Conventional Ultrasound

Weld caps disproportionate to wall thickness may require inspection in multiple legs

Mechanics also an issue with larger footprint of phased array probes

Often clearance is also an issue between process piping etc

Proposed Solution Small dedicated scanner (.084-4.5”)

with .5” clearance Dedicated internally curved probes

for better focusing and resolution of Small defects

PA-UT Presentation by All Nations

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