Breakthrough in Elbow and Pipe Scanning · 2019. 4. 8. · Semi-automated Corrosion Scanner for...
Transcript of Breakthrough in Elbow and Pipe Scanning · 2019. 4. 8. · Semi-automated Corrosion Scanner for...
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Semi-automated Corrosion Scanner for Pipe Elbow Inspection
Breakthrough in Elbow and Pipe Scanning
Presented by:
Richard Nowak
Product Manager – NDT
Olympus Australia
AOG March 2019
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Corrosion Mapping in Pipes (ID)
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What about This?
Greatest corrosion potential – Least ability to map and analyse
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1. Current technologies for pipe bends
2. Phased Array Ultrasonics – how it works
3. Phased Array for Corrosion
4. Developing a solution for Elbows
5. Elbow scanning in action
6. Spin off solutions
7. Conclusion
Today we cover
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Ultrasonic Spot Measurement
Curved Phased Array
Radiography
Eddy Current
Long Range UT
Common Techniques for Elbow Corrosion
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PHASED ARRAY ULTRASONICS - INTRODUCTION
Array of Elements
Array is most commonly linear
Element grouping provides aperture, power, direction
Programmed electronics sequence send and receive for each element
− Each selection produces an A scan
Distinct modes of operation:
− Linear or electronic scanning
− Sector or angle beam scanning
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Representing the A Scan Each beam has an A scan
Each A scan is digitized, stored and is the base data of each image
Color-encoded
A-scan (beam)
83% = Red
50% = Green
20% = Blue
Ultrasonic path /
TOF
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Linear Scan
Beams
1 2 3 4 5 6 7 8 9 10111213Beams
1 2 3 4 5 6 7 8 9 10111213
d
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Sectoral Scanning
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Linear Scan
Beams
1 2 3 4 5 6 7 8 9 10111213Beams
1 2 3 4 5 6 7 8 9 10111213
d
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Encoded Scans
Capture linear probe scan at regular intervals (often 1 mm)
Colour code thickness (most common) on plan view
C scan dimensionally correct imaging, length and width sizing
Allows off line analysis
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Thickness Data Views
C-scan
B-scan
D-scan
A-scan
Corrosion :
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Thickness Data Views
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Probe Considerations
Probe typical 7.5MHz, 1 mm spacing, 64 elements (=up to 64 mm scan width)
Protection of probe face: “wedge” – usually rexolite, water box or roller
Coupling to surface: water box adapts best to surface conditions (eg HydroFORM)
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The Problem with Elbows
Flat probe, curved surface
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Solution Key #1:Flexible Phased Array Probes !
Development of Array of Elements on flexible circuit
7.5MHz, 64 element , 1mm spacing - typical for corrosion probe
Ability to create a variable radius
How to deploy?
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Solution Key #2:3D Printed Probe Holder
Guide for flexible probe
Guide is same radius as pipe OD
Water path (like HydroFORM)
Connection to scan management
equipment
Easy low cost adaption for each
pipe diameter
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Solution Key #3Elbow Scanner
Convenient holder for probe and 3D Wedge
Encoding of position
Manage cables and irrigation
Cambered magnetic wheels
− Help tracking and pressure on water seal
Scanning scheme
Smart indexing system
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Scanner Components
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Water wedge
Flexible phased array
probe
Adaptative scanner
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Fast, easy and complete coverage
Covers 100% of the elbow surface
High quality data
− Increased POD
− High-resolution data
− Easy data interpretation
− Phased array imaging with full C-Scan capability
Versatile cost effective solution
− Wide range of diameters
− Compatible with elbow and pipes
FlexoFORM Solution
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Wide range of diameters
Fast, Easy and Complete Coverage
4.5in OD and up with the same probe and scanner
Cost effective
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Covers 100% of the elbow surface
Can fit intrados (concave) as well as extrados (convex)
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Reduced prep and inspection time
Fast, Easy and Complete Coverage
No need for drawing grids
Large beam width beam width ensure fast inspection
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Increased probability of detection (POD)
High Quality Data
Up to 1 × 1 mm scan resolution data points
Acquired and saved within the same file
Smart indexer clicker button pauses the
acquisition while the scanner is moved to
the next scan line, preventing overwriting
data
Example: Flow-Accelerated Corrosion
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Internal CRA Cladding
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Easy data interpretation
High Quality Data
Phased array imaging with full C-Scan
capability
Help understand damage mechanism
Essential tool for plant asset operation life
evaluation
Example: Corrosion in Ni clad piping
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Symmetrical Scan
Pattern
Standard
Scan Pattern
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Slide along pipe vs circumferentially
Corrosion detection at top or bottom
Large area coverage - fast
Bonus: Longitudinal Pipe Scanning
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Pipes too small for scanner solution
Manually scan
− Same flexible probe
− water wedge
− Miniwheel encoder
Diameter Range: 1.3” (33mm )’ to 4.5” (110 mm)
Extrados only
Small Diameter Pipes
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Boiler tube thickness scanning
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Wedges designed for map scanners (MapROVER, SteerROVER)
Same probe
Diameter 8.625” (220mm ) to flat
Alternative to HydroFORM
(long scan vs circ scan)
Automated Scanning
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Through Paint Coatings: Yes, can also use echo-echo for thicker paint
Pipes with contents: Yes
Flat: Yes
High temp: Up to 100 deg C
Welds: Not recommended – can deal with very low or flat caps ok
Non ferromagnetic materials: Yes but more difficult to manage
Sizing Accuracy: May require correction factors for precision – particularly small
diameters, thick walls. Generally not that critical.
FAQ
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An economical solution for elbow scanning is now available
The scan results are displayed and managed just like normal corrosion scans
Flexible probes and 3D printing form a powerful union
Longitudinal pipe scanning is a useful by-product of this development
Possibilities are only just starting to be explored
CONCLUSION
THANK YOU
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