AN OVERVIEW ON PHASED ARRAY TECHNOLOGY
HAROON CAJEE
PRESENTATION OVERVIEWPRESENTATION OVERVIEW
Company Introduction Brief Overview PA Method/Technology. Why should you embrace this innovation?
Oceaneerings number one ethic is the safety, health and well being of its employees, contractors, customers and the public.Safety will never be compromised.
POLICIES & STATEMENTSPOLICIES & STATEMENTS
United Kingdom
Middle East
Asia Batam, SingaporeKuala Lumpur, Perth
Africa
Americas
Dubai
OCEANEERING - GLOBALOCEANEERING - GLOBAL
UNBROKEN CONTINUOUS STERLING SERVICE TO PTMI SINCE 1993
SERVICE RANGESERVICE RANGE
ADVANCED AND CONVENTIONAL NDT - Phased Array TOFD - AUT
INDEPENDENT TRAINING SCHOOL
VENDOR & PROCUREMENT INSPECTION
MATERIALS ENGINEERING & TESTING
ROPE ACCESS
OFFSHORE & ONSHORE PIPELINES
INTEGRITY & INDEPENDENT INSPECTION AUTHORITY
Automated Phased Array Ultrasonic Systems Experienced in offshore and onshore, Sub-sea and difficult terrain Aberdeen, Indonesia and Abu Dhabi support facilities Large pool of permanent inspection personnel
PHASED ARRAY AUT - PIPELINESPHASED ARRAY AUT - PIPELINES
PORTABLE and or SEMI AUTOMATED ULTRASONIC & TOFD INSPECTION USING HAND HELD SCANNERS & PHASED ARRAY PROBES
WHY IS IT DIFFERENT FOM CONVENTIONAL UT Encoding & recording capability.
Another way to do UT No magic, only physics!
ADVANTAGES - PA facilitates speedier inspections, interpretation aids and smaller scanning devices thus increasing the application.
PORTABLE PHASED ARRAYPORTABLE PHASED ARRAY
CODE PERMITS IN LIEU OF RADIOGRAPHY
35 40 45 55 65
Delays
WELD INSPECTIONWELD INSPECTION
SOUND PROPAGATIONSOUND PROPAGATION
Multiple Crystals
Allows for larger inspection area and increased probability of detection
Beam Steering
Allows for optimal detection / sizing for traditional and complex geometries.
Full Coverage / Focusing
Allows optimal sizing of defects
Phased Array Image
X-Ray Image
TYPICAL IMAGE RT /PA
PorosityRadiography Phased Array technique
SCAN AND DEFECT SAMPLESSCAN AND DEFECT SAMPLES
InclusionRadiography Phased Array technique
SCAN AND DEFECT SAMPLESSCAN AND DEFECT SAMPLES
Incomplete Root Penetration
TOFD technique
Radiography Phased Array technique
SCAN AND DEFECT SAMPLESSCAN AND DEFECT SAMPLES
KEY OBJECTIVE The integration of RT activities with the production needs would require careful planning and
the use of new technologies to ensure minimal disruption at an affordable price. The NDT Scope especially RT needs to be completed in a manner that minimizes downtime of other trades and completed in a timely manner to ensure that crucial production and welder control information are relevant and that the production process in respect of hydro-test, painting, site erection and commissioning are not impeded. In this instance we have the added concerns of the proximity of existing plants and the potential impact on the nucleonic alarms
CHOICE OF TECHNIQUERT Conventional
RT SCARPA/TOFD
PRODUCTIVITY-COST EFFICIENCYINTEGRATION-SAFETY
METHODOLOGY PREMISE/DRIVERSMETHODOLOGY PREMISE/DRIVERS
INSPECTION TECHNIQUE COMPARISONINSPECTION TECHNIQUE COMPARISONMethod Pipe Crew Size
Scan / shot time
Set-up time
PRODUCTIVITY Welds per hour
Production Interruption
Safety Hazards
Record of Inspection
Auditable Results
RT2 Sch 40 2 man 5 min. 5 minutes per/weld 6 to 10 100% 100%
YES YES
12 Sch 80 2 man 30 min 5 minutes per/weld 2100% 100% YES YES
24 Standard 2 man 60 min
5 minutes per/weld 1.5
100% 100% YES YES
Manual UT
2 Sch 40 1 man 10 min. 5 minute per/weld NA 0% 0%NO NO
12 Sch 80 1 man 30 min 5 minute per/weld 20% 0% NO NO
24 Standard 1 man 60 min
5 minute per/weld 1.5
0% 0% NO NO
PAAUT
2 Sch 40 2 man 30 sec 3 minute per/weld 10 to 20 0% 0%YES YES
12 Sch 80 2 man 1 min3 minute per/weld 10 to 12 0% 0% YES YES
24 Standard 2 man 3 min
3 minute per/weld 10 to 12 0% 0% YES YES
Amounts are based on averages, results will vary.
2. RT: Assumes required exposures with 20 curie source.
3. Manual UT: Assumes minimum scanning requirements as per ASME.
4. Set up time is based on typical accessibility and work plan.
NOTE: Does not include time and or cost for film processing, reporting, re-shots, etc.
RADIOGRAPHY vs PHASED ARRAYRADIOGRAPHY vs PHASED ARRAY
RADIOGRAPHY
Radiation Source requires large area of clearance.
Results take time to filter through the system , films to be processed , interpretation and reports
One Dimensional view Productivity in the region of 20 welds
per RT crew per 10 hour shift in a fabrication shop environment
Productivity in the region of 10 welds per shift in situ i.e platform field welds
Re-location of spools for RT
PHASED ARRAY
Work does not require any personnel clearance
Three dimensional Images Hard Copy digital record Automated systems Immediate results in most cases Inspection can take place along side
welders , no need for re-location of spools
Immediate repairs can be carried out if needed
Productivity in the region of 75 welds per PA crew per 10 hour shift in a fabrication shop environment.
Productivity of 30 welds per PA crew per 10 hour shift in situ
YES , WITHOUT A DOUBT
RT PLACES A CEILNG ON YARD PRODUCTIVITY
INTEGRATING RT WITH EXISTING TRADES IS A MAJOR CHALLENGE
RT RESULTS IN DELAYS WHICH PARLAYS INTO FINANCIAL LOSSES
YOU CAN CREATE THE MOST EFFICIENT PROCESSESS HOWEVER YOUR OVERALL CAPABILITY AND OUTPUT WILL BE IMPEDED BY RT
THERE IS NO SAFE LEVEL OF RADIATION BUT DUE TO LITTLE ALTERNATIVES WE ACCEPT AS LOW AS REASONABLY POSSIBLE
ALARP
RT RESULTS IN BACKLOGS, MULTIPLE HANDLING OF ITEMS,CO-ORDINATION & DELAYS
RT RESULTS TAKE ON AVERAGE 24-36 hours TO CONFIRM
DOES THIS METHOD ADDRESS A NEED IN YOUR ENVIRONMENT?
DOES THIS METHOD ADDRESS A NEED IN YOUR ENVIRONMENT?
YES , IT UNDOUBTEDLY ADDRESSES A NEED IN THE MARKET
CODES AWS D1.1
ASME B31.3ASME VIII
ASME B31.1
MATERIALS RANGE Carbon Steels Stainless Steels
TitaniumInconel
THICKNESS RANGE >6MM
>3.5MM TO 6MM WITH ADDITIONAL VALIDATION AND CLIENT APPROVAL
CONFIGURATIONSAll welds with access to one side as a minimum can be inspected with PA , including nozzles , nodes , circumferential welds and Longitudinal welds
LIMITATIONS Pre-engineering required Planning is a requisite Will not cover complete
scope of welds
WHAT ARE THE PRIMARY APPLICATIONS FOR THIS METHOD?
WHAT ARE THE PRIMARY APPLICATIONS FOR THIS METHOD?
THE SIMPLE ANSWER IS NO
THE PARAMETRES AND TECHNOLOGY RELATED TO RT IS SIMILAR TO THE EDISONS BULB, NOTHING MUCH HAS CHANGED
ASIDE OF SEMI AUTO UT THERE IS NO OTHER TECHNOLOGY ON THE HORIZON
ITS EITHER RT OR PA UT
ARE THERE ANY COMPETING TECHNOLOGIES OR OTHER
OPTIONS
ARE THERE ANY COMPETING TECHNOLOGIES OR OTHER
OPTIONS
RESISTANCE TO CHANGEInternal & External factors
START UP COSTS All new and emerging technologies require high capital investment thus discouraging adoption
PRICE AS PERCEIVEDDirect price higher as generally we disregard the intangible costs. Radiography overall is a very expensive option.
WHAT ARE THE MAJOR IMPEDIMENTS THAT WE FACE IN
INTRODUCING THIS TECHNOLOGY
WHAT ARE THE MAJOR IMPEDIMENTS THAT WE FACE IN
INTRODUCING THIS TECHNOLOGY
RT HAS BEEN ADOPTED AS THE PRIMARY METHOD DUE TO COMPETENCY ASSURANCE ISSUES WITH MANUAL ULTRASONICS.
MANUAL UT Lack of hardcopy and
completely relies on the skill, competency, experience and integrity of the individual and highly influenced by the environment and location and other external issues
PHASED ARRAY UT
Validated Techniques for all operators to work to.
Recordable System which provides a digital hard copy , with encoded scans providing an accurate reference point.
All key processes are automated
Automated reporting system available
HOW DO WE ADDRESS THE COMPETENCY ASSURANCE ISSUES?
HOW DO WE ADDRESS THE COMPETENCY ASSURANCE ISSUES?
INITIALLY MARGINALLY HIGHER DIRECT COSTS BUT OVERALL PA MUCH CHEAPER
EFFECTIVELY ONE OFF START UP COSTS
HUGE PRODUCTIVITY GAINS
WHAT ARE THE COMMERCIAL IMPLICATIONS?
WHAT ARE THE COMMERCIAL IMPLICATIONS?
Price dependant on volume and duration of project.
PA IS SUBSTANTIALLY CHEAPER THAN RT
TECHNICAL
Pre Planning Mandatory
Pre Engineering Required
Training and Certification of Personnel
Streamlining the process
Gaining Client Approval
OPERATIONAL Integration into the piping
workshop process Expediting NDE Requests
, PA will be carried out much earlier in the process than Radiography
Determining NDE method for all welds on each spool and control
Co-Operation of All personnel
WHAT ARE THE TECHNICAL & OPERATIONAL IMPLICATIONS ?
WHAT ARE THE TECHNICAL & OPERATIONAL IMPLICATIONS ?
PRE_PLANNING REQUIRED
Validation to date shows a slight decrease in repair rates due to the ability to size in more dimensions .
Where radiography utilizes length only for accept or rejection , PA-UT utilizes Length and height
Fully encoded scanning ensures accurate defect information is available including depth , length and circumferential location
DEFECT DETECTION AND REPAIR RATESDEFECT DETECTION AND REPAIR RATES
NO MAJOR DIFFERENCE
CODES CODES
ASME CC 2235 (CIT) allows use of UT instead of RT for wall thickness > 12.7mm
Code case 181 allows use of UT instead of RT for all thickness ranges
TOFD, PA and TOFD/PE techniques allowed
Performance Demonstration required
CODE PERMITS AND FACILITATES
27
KEY DELIVERY COMPONENTS
CAPABILITY SKILLS SETS - Critical
PA/TOFD FACILITIESPA/TOFD FACILITIES
60m perDay with 2 ops.
PA/TOFD CAPACITYPA/TOFD CAPACITY
SCANNERSSCANNERS
Oceaneering has developed its own range of scanning devices to allow rapid high quality scans on all diameter pipes and plate welds.
The results of phased array encoded inspections are very reliant on the scanners utilized and Oceaneering has invested heavily to ensure the very best of equipment is available.
Link scanners in Use
SCANNER IN USESCANNER IN USE
Special scanners designed and manufactured
PROJECT SPECIFIC SCANNERPROJECT SPECIFIC SCANNER
VALIDATIONVALIDATION
Validation is required by ASME and Oceaneering manufactures in house code case compliant validation welds
34
TRAINING FACILITY
ABSOLUTELY VITAL COMPONENT
35
TRAINING FACILITY
ABSOLUTELY VITAL COMPONENT
36
INTERNAL TRAINING
ABSOLUTELY VITAL COMPONENT
37
CLIENT TRAINING
ABSOLUTELY VITAL COMPONENT
YOU NEED TO ADOPT THE BEST PRACTICES AND METHODS AVAILABLE
LARGE ORGANIZATIONS INHERENTLY FACE INERTIA AND LACK OF AGILITY.
THIS TECHNOLOGY REDUCES AND MITIGATES THE INHERENT RISK OF RT AS THE PRIMARY METHOD
WHY SHOULD WE PROCEED WITH THIS TECHNOLOGY?
WHY SHOULD WE PROCEED WITH THIS TECHNOLOGY?
IMPROVES EFFICIENCY AND PRODUCTIVITY
ENHANCES SAFETY AND ELIMINATES RADIATION HAZARD
RADIOGRAPHY IS A VERY EXPENSIVE OPTION
THANK YOU VERY MUCH
OUR GLOBAL EXPERIENCE, LOCAL TRACK RECORD AND TECHNOLOGY WILL PROVIDE
YOU WITH A VALUABLE PARTNER TO ACHIEVE YOUR GOALS AND OBJECTIVES TO
OUR MUTUAL BENEFIT
Slide 1PRESENTATION OVERVIEWSlide 3Slide 4Slide 5Slide 6Slide 7Slide 8WELD INSPECTIONSOUND PROPAGATIONTYPICAL IMAGE RT /PASlide 12Slide 13Slide 14METHODOLOGY PREMISE/DRIVERSINSPECTION TECHNIQUE COMPARISONRADIOGRAPHY vs PHASED ARRAYSlide 18Slide 19Slide 20Slide 21Slide 22Slide 23Slide 24DEFECT DETECTION AND REPAIR RATESSlide 26KEY DELIVERY COMPONENTSPA/TOFD FACILITIESPA/TOFD CAPACITYSCANNERSSCANNER IN USEPROJECT SPECIFIC SCANNERVALIDATIONTRAINING FACILITYTRAINING FACILITYINTERNAL TRAININGCLIENT TRAININGSlide 38Slide 39
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