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
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