Advanced Inspection Techniques and Best Practices

10/7/2010
2.4 Advanced Inspection Techniques and Best Practices

Guided wave ultrasonic long range inspection Advanced Ad d phased h d arrays for f weld ld inspection i i
Advanced Inspection Techniques

Inspection Techniques with Unique Ch Characteristics: t i ti
May Use One or More NDT Technologies Typically Computerized Inspection Utilizes Electronic Detection and g Processing Requires Very Specialized Training May Locate and Size or Just Locate
N. Al-Khirdaji, AZTech Sr Consultant
10/7/2010
Advanced Inspection Techniques

Advance Inspection Techniques for RBI and FFS
Acoustic Emission Ultrasonic Corrosion Mapping Ultrasonic Weld Inspection EMATS Phased Array Digital Radiography Leak Detection
Limitations of Conventional Inspection Techniques

The impetus for the use of long range ultrasonics is that ultrasonic thickness checks for metal loss due to corrosion or erosion are highly localized, in that they only measure the thickness of the area under the transducer itself. To survey a large area requires many measurements and access to much of the surface of the component. Where access is difficult or costly a detailed survey becomes unattractive economically, consequently, limited sampling only is carried out. Similar restrictions apply to other methods of measuring wall thickness, such as radiography, eddy currents etc.. Partial inspection of this type is not effective for reliable overall assessment as the probability of detection of defects in uninspected areas is zero.
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Guided Wave Ultrasonic Inspection

Guided waves are a form of ultrasonic waves that
travel t l through th h a bounded b d d test t t specimen i (in (i this thi case, a pipe), parallel to the boundaries (inner and outer wall), while being guided by these same boundaries. Due to the nature of the waves and the testing frequencies used, the technique can be used to scan extensive lengths of pipe from a single transducer location, thereby negating the time-consuming type of grid scans required by conventional techniques such as UT and ET.
Guided Wave Ultrasonic Inspection

The performance of the inspection depends on the generation of a high fidelity axisymmetric signal of the chosen kind, either extensional or torsional. Imperfections could arise from non-uniform strength of excitation of the transducer elements, phase errors between the signals at the adjacent rings, ovality of the pipe, or circumferential variation of the wall thickness of the pipe. Any such imperfections could lead to the generation of some of the other, unwanted, modes of the pipe; such signals would appear as coherent noise, that is to say, they could not be removed by averaging multiple signals.
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Why use EMATs ?

Because In-Service Inspection is DIRTY
EMATs can tolerate adverse conditions
EMATs can be FAST

High Speed Screening Global Inspections Capable of covering Large areas
EMATs can inspect areas not normally accessible

Buried or Hidden Regions can be reached with Guided Waves
Why use EMATs ?

Pipeline Direct Assessments Insulated Pipe Inspections On On-Line Line (CUI) High Temperature Piping Vessel Inspection Weld Inspections Pipe Support Inspection Fi d H Fired Heater t T Tube b I Inspections ti Tank Inspections
Weld location Soil to Air inspections
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EMAT Inspection Technology
EMAT Guided Wave

Flaw Detection
General Wall Thinning I l t d Pitting Isolated Pitti General Corrosion Hydrogen Induced Cracking Stress Induced Cracking Acid Etching Chromium Depletion Corrosion Under Insulation
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Localized Guided Wave

Can be in PLATES Or PIPES
EMAT
EMAT
AXIAL Or
CIRCUMFERENTIAL
Measurement Principals
Time of Flight Transmitted Amplitude Reflected Amplitude Velocity Attenuation ReflectionCoefficient Minimum Flaw Size proportional to Wave front
Large Wave Front Sensitivity Small Wave Front Sensitivity Long Distance/Lower Shorter Distance/Higher
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Volumetric Inspection
example in inch (12mm) plate
Am plitude Change vs Pit V olum e
Round bot t om hole s 5 m m , 1 0 m m , 2 0 m m , 3 0 m m dia m et e r
80 R2 = 0.947 70 60 50 dAM P 40 30
100 300 350 R = 0.8478
2
Change in Tr ansit Tim e vs Pit Volum e
250
dT ( n se c)
200
150
20 10 0 0.00
50
3.00
6.00
9.00
12.00
15.00
0 0.00
3.00
6.00
9.00
12.00
15.00
Pit V olu m e ( cc)
Pit V olu m e ( cc)
Guided Wave Propagation depends on the shape of the wave guide boundaries. Fundamentally these are volumetric inspections. Good Linear Correlation to VOLUME of round bottom holes
EMATs Efficiently Generate Guided Waves in Pipes

Transmitter Receiver
The Guided Wave travels around the circumference of a pipe. 100% Coverage is achieved from one location
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Circumferential Guided Wave

High Speed; Volumetric Inspection Performed in Pitch Catch, High Resolution Detection
through transmission mode
Attenuation Measures obstruction of beam

i.e.. Pitting
Velocity Measures thinning

i.e.. general corrosion
Geometry Affects Guided Wave Travel

Pits Scatter Sound Wave Attenuatio n
Wave Propagation
Thinning Speeds Up the W Wave Transit Time Change
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EMAT Guided Wave

Sample Amplitude A-Scan Presentation
EMAT Guided Wave

Sample E-Scan Presentation 10% 20% 30% 40% 50%
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EMAT Screening Tools

Can Be Designed for Client Specific Applications
High Speed Multi Size Encoded Crawler
Big Bore Circumferential Encoded Guided Wave Crawler
EMAT Guided Wave Inspection Systems

Multiple Unit Designs for field specific applications Lightweight and portable
Battery powered versions
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Guided Waves Can Provide Global Inspections

Piping, Tanks, Vessels, and Heater Tubes High Temperature Applications Repeatability Can be used In-service or During outages No Couplant needed High Speed Scanning Rough Surfaces Thick Coatings Numerous Scan Presentations Portable Systems for easy access
EMAT Guided Wave Inspections

Anything Inspectable from Large Structures to Small Tubing High Speed Screening Tool Remote Detection Capabilities
Great for Detection Relative Sizing Capable Absolute Sizing Capabilities in Limited and Special Cases
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These Claims are Possible because of Guided Waves

EMATs have superior control of Guided Waves
The EMAT specifies both WAVE LENGTH and FREQUENCY to precisely define the wave mode.
Inspection Methods - Surface

Direct: Intrusive:
Intelligent pigging, MFL, UT, RFT, Remote Visual Inspection. Guided Wave Ultrasonic Testing.
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Guided Wave Ultrasonic

What is Guided Wave Ultrasonic Testing?
A sonic technique using torsional and longitudinal waves. Sensitive to ID and OD wall losses. Up to 48 diameter.
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Guided Wave Signals
(a) A typical weld is completely symmetric and shows up as only a black curve. (b) A typical corrosion patch is non-symmetric and is identified by the presence of a red curve.
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Guided Wave Ultrasonics

Advantages:
Full circumferential data, data Non-intrusive, on-line and off-line, Up to 4,000 feet per day, Use on lined, coated, insulated or buried pipe, Portable, Repeatable results.
Guided Wave Ultrasonics

Disadvantages:
Buried pipe dampens signal (30 meters) meters).
Concrete lining, Coatings, Wrapping.
Placement on pipe critical. Pi configuration Pipe fi ti critical. iti l Not quantitative data; sorting tool only. Follow-up with direct inspection required.
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Guided Wave UT Inspection

The benefits of this inspection include:
100% of f large l sections ti of f piping i i can be b inspected i t d rapidly idl Minimal insulation removal Localized damage can be identified Previously inaccessible areas can be inspected especially where consequences and likelihood of failure are high p y inspected p Point of contact corrosion areas can be rapidly for piping systems resting on supports, eliminating the need to lift pipes. The environmental impact and potential for further damaging suspect pipes during live lifting is eliminated
Guided Wave Transducer System

Guided Ultrasonics solid transducer system is used for pipes up to NPS 8
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Guided Wave Transducer System

Flexible, pneumatically clamped transducer system for larger diameter pipe ( > NPS 8)
Guided Wave UT Inspection
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Typical Ranges Obtained in Different Conditions with Standard Transducers

Application Ideal conditions Typical 30 year old pipe with little internal or external corrosion Typical yp ca 30 year yea old o d pipe p pe with w t some so e general ge e a corrosion co os o Typical pipe wrapped in factory applied foam Heavily generally corroded pipe Bitumen coated pipe Typical Range in each direction (m) 80+ 40 20 0 15 5 5*
* The range in bitumen coated pipe is strongly dependent on the bitumen condition (source: Guided Ultrasonics Ltd training manual)
Applicability Guided Wave Inspection Method

The method is essentially a screening tool since it gives only a qualitative measure of the wall loss of any defect. Its value is that it gives 100% coverage of the pipe, and so enables detailed inspection to be deployed only at areas identified as problematic. Therefore inspectors do not waste time doing detailed scanning of areas that the screening test have shown to be defect free. defect-free. The main application area of the technology is the rapid screening of long lengths of pipe.
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The application of the technique to the detection of corrosion under insulation (CUI) and similar cases where the feature density on the pipe system is low (i.e. infrequent welds, tees, bends etc) and the attenuation is low (no heavy general corrosion, no highly attenuating coating), is relatively straightforward, g , and the signals g obtained can be interpreted by experienced NDT

It is particularly cost effective in difficult to access locations such as: Sleeved road crossings Insulated pipes Wall penetrations Pipe racks Under supports Cases where rope access or scaffolding would be needed for conventional inspection
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Time-of-Flight Diffraction (TOFD)

Is basically another (mechanized) ultrasonic inspection technique. The TOFD technique is a fully computerized system able to scan, store, and evaluate indications in terms of height, length, and position with a grade of accuracy superior to other ultrasonic techniques. techniques It is based on diffraction of ultrasonic waves on tips of discontinuities, instead of geometrical reflection on the interface of the discontinuities.
TOFD Principles
The basic configuration for TOFD (Time Of Fli ht Diffraction) Flight Diff ti ) technique t h i consists i t of f a separate t ultrasonic transmitter and receiver. After emission of a compressional wave from a transmitter, the first signal to arrive at the receiver is lateral wave through upper surface. In the absence of defects the second signal to arrive at the receiver is the backwall echo. The diffracted signal generated at the upper tip of a defect will arrive before the signal generated at the lower tip of a defect.
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TOFD Principle
On both sides of the weld an ultrasonic probe is positioned. One acts as an emitter of ultrasound, the other as a receiver. The longitudinal g sound beam can encounter obstacles on its path, p which cause reflected and diffracted signals.
When the probes are moved parallel along the weld, the resultant waveforms are digitized, stored on hard disk and displayed on the video-screen as a grey scale image The image build up is in effect a through sectional view of the weld examined and can be used for accurate sizing and monitoring of indications.
Features of TOFD
High Probability of Flaw Detection Hi h Accuracy High A of f Fl Flaw L Location i Measurement M High Accuracy of Flaw Sizing in Length Weld Integrity to be observed on CRT in Real Time as probes scan All inspection Data to be Digitised and Stored so that the Data can be Recalled and Processed for InService Inspection
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Time of Flight Diffraction (TOFD)
TOFD Principle
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A-Scan to Grey Level Plot
TOFD System
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Cost of TOFD vs. Radiography
What is a Phased Array?

An array transducer is simply one that contains a number of separate elements in a single housing, housing and phasing refers to how those elements are sequentially pulsed. A phased array system is normally based around a specialized ultrasonic transducer that contains many individual elements (typically from 16 to 256) that can be pulsed separately in a programmed pattern. These transducers may be used with various types of wedges, in a contact mode, or in immersion testing. Their shape may be square, rectangular, or round, and test frequencies are typically in the range from 1 to 10 MHz
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What is a Phased Array?

Phased array systems pulse and receive from multiple elements of an array. These elements are pulsed in such a way as to cause multiple beam components to combine with each other and form a single wave front traveling in the desired direction. Similarly, the receiver function combines the input from multiple elements into a single presentation. Because phasing technology permits electronic beam shaping and steering, it is possible to generate a vast number of different ultrasonic beam profiles from a single probe assembly, and this beam steering can be dynamically programmed to create electronic scans.
Advantages of Phased Array Testing as Compared with Conventional UT

The benefits of phased array technology over conventional UT come from its ability to use multiple elements to steer, steer focus and scan beams with a single transducer assembly. Beam steering, commonly referred to sectorial scanning, can be used for mapping components at appropriate angles. This can greatly simplify the inspection of components with complex geometry.
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The small footprint of the transducer and the ability to sweep the beam without moving the probe also aids inspection of such components in situations where there is limited access for mechanical scanning. Sectorial scanning is also typically used for weld inspection. The ability to test welds with multiple angles g from a single g probe p greatly g y increases the probability of detection of anomalies. Electronic focusing permits optimizing the beam shape and size at the expected defect location, as well as further optimizing probability of detection.

The ability to focus at multiple depths also improves the ability for sizing critical defects for volumetric inspections. Focusing can significantly improve signal-to-noise ratio in challenging applications, and electronic scanning across many groups of elements allows for C-Scan C Scan images to be produced very rapidly. rapidly
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Phased Array Testing
Waves that combine in phase reinforce each other, while waves that combine out-of-phase will cancel each other.
Phased Array Inspection Technique
E-scans inspect a weld at two separate angles
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Phased Array AUT Technology

The upper left corner in this figure illustrates the coverage options of the technologies. The single element probe in the upper left corner shows h the h li limited i d region i in i the h single i l beam b available. il bl In I the h upper right, a TOFD pair is used in transmit-receive mode and the entire weld volume is covered in a single pass. The lower left illustrates the phased array S-scan created by sweeping from 45 degrees to 70 degrees from a single range of elements (only 16 of the 64 elements available are used for this configuration).
Pressure Vessel Inspection using Phased Arrays
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Encoded Arrays for Semi-Automatic Inspections
(Creeping Head-wave Inspection Method)

The new technique (AEA Technology) offers large g area, , single g p pass screening, g, which inspects p the full volume between the probes (may be separated by up to 1 m). It can be used on both pipes and plate, and is suitable for inaccessible geometries such as clamps, saddles and pipe supports. This eliminates the need for expensive shutdown yet provides full information to indicate areas of corrosion and aid the prediction of plant lifetime.
CHIME
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(Creeping Head-wave Inspection Method)

The system employs a combination of ultrasonic head-waves head waves and creeping waves, waves hence its name: Creeping Head-wave Inspection Method. Creeping and head waves are generated using a piezoelectric transducer mounted on an angled shoe. The unique way in which the waves propagate provides complete isonification of plate or pipe with li l attenuation, little i allowing ll i the h transmitting i i and d receiving probes to be well separated (up to 1 m). Defects due to corrosion or cracking affect the signal magnitude and arrival time of the signal peaks.
CHIME
2.5 On-Line Monitoring
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On-line Stress/strain Monitoring

Acoustic Emission Binary Localizer y for on-line A new Acoustic Emission system Structural integrity monitoring of critical plant components has been applied successfully for over one year. AEBIL (Acoustic Emission Binary Localizer) is designed to identify and locate concentrated AE sources in the presence of a high rate of spatially scattered AE events, a typical condition encountered in on-line monitoring of operating plant components.
Stress/strain Microprobe
A portable in-situ Stress-Strain Microprobe (SSM) system is used to measure true true-stress/true-plastic-strain stress/true plastic strain behavior of several metallic materials, welds, and their heat-affected-zones (HAZs) in various metallurgical and damage conditions. The microprobe system utilizes an electromechanically-driven y indenter, , high-resolution g penetration transducer and load cell, a personal computer (PC), a 16-bit data acquisition /control unit, and software.
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Stress/strain Microprobe
The automated ball indentation (ABI) t h i technique of f the th SSM system t is i based b d on strain-controlled multiple indentations (at a single penetration location). The technique permits measurement of yield strength, stress-strain stress strain curve, strength coefficient, and strain-hardening-exponent (uniform ductility).
ACFM Technique - 1
The Alternating Current Field Measurement (ACFM) technique q is a non contacting g electromagnetic g technique for the detection of surface breaking defects in conducting materials. The technique provides reliable detection and sizing of cracks in metallic components and can be used over paint, coatings and process related residue. The significant advantage over magnetic particle inspection is that surface preparation is eliminated or significantly reduced.
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ACFM Technique - 2
The ACFM probe induces a uniform electric current into the material to be inspected which then produces a magnetic field which will be disturbed and flow around the edges of a defect if present. Small detectors (sensors) are built into probes which are used to detect these magnetic field disturbances.
ACFM Technique - 3
Two components of the magnetic field are measured, the Bx (to estimate crack depth p ) and Bz (to estimate crack length). These measurements together with software algorithms are used to determine the accurate length and depth of the defect.
Typical Bx and Bz traces as the probe passes over a crack
Characteristic ACFM Butterfly plot
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Advanced Inspection Techniques and Best Practices

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10/7/2010

2.4 Advanced Inspection Techniques and Best Practices

Advanced Inspection Techniques

N. Al-Khirdaji, AZTech Sr Consultant

Advanced Inspection Techniques

Limitations of Conventional Inspection Techniques

N. Al-Khirdaji, AZTech Sr Consultant

Guided Wave Ultrasonic Inspection

Guided Wave Ultrasonic Inspection

N. Al-Khirdaji, AZTech Sr Consultant

Why use EMATs ?

EMATs can be FAST

EMATs can inspect areas not normally accessible

Why use EMATs ?

N. Al-Khirdaji, AZTech Sr Consultant

EMAT Inspection Technology

EMAT Guided Wave

N. Al-Khirdaji, AZTech Sr Consultant

Localized Guided Wave

N. Al-Khirdaji, AZTech Sr Consultant

Change in Tr ansit Tim e vs Pit Volum e

Pit V olu m e ( cc)

Pit V olu m e ( cc)

EMATs Efficiently Generate Guided Waves in Pipes

N. Al-Khirdaji, AZTech Sr Consultant

Circumferential Guided Wave

Attenuation Measures obstruction of beam

Velocity Measures thinning

Geometry Affects Guided Wave Travel

N. Al-Khirdaji, AZTech Sr Consultant

EMAT Guided Wave

EMAT Guided Wave

N. Al-Khirdaji, AZTech Sr Consultant

EMAT Screening Tools

Big Bore Circumferential Encoded Guided Wave Crawler

EMAT Guided Wave Inspection Systems

Battery powered versions

N. Al-Khirdaji, AZTech Sr Consultant

Guided Waves Can Provide Global Inspections

EMAT Guided Wave Inspections

N. Al-Khirdaji, AZTech Sr Consultant

These Claims are Possible because of Guided Waves

Inspection Methods - Surface

N. Al-Khirdaji, AZTech Sr Consultant

Guided Wave Ultrasonic

Guided Wave Ultrasonic

N. Al-Khirdaji, AZTech Sr Consultant

Guided Wave Ultrasonic

Guided Wave Signals

N. Al-Khirdaji, AZTech Sr Consultant

Guided Wave Ultrasonics

Guided Wave Ultrasonics

N. Al-Khirdaji, AZTech Sr Consultant

Guided Wave UT Inspection

Guided Wave Transducer System

N. Al-Khirdaji, AZTech Sr Consultant

Guided Wave Transducer System

Guided Wave UT Inspection

N. Al-Khirdaji, AZTech Sr Consultant

Typical Ranges Obtained in Different Conditions with Standard Transducers

Applicability Guided Wave Inspection Method

N. Al-Khirdaji, AZTech Sr Consultant

Applicability Guided Wave Inspection Method

Applicability Guided Wave Inspection Method