Post on 05-Feb-2018
transcript
NON-DESTRUCTIVE EXAMINATION OF PUMPS
PRESENTED BY
JOSEPH HEALEY, P.ENG, CFEI
ACUREN GROUP INC.
WWW.ACUREN.COM
NDE Overview
• Non-Destructive Examination or Evaluation (NDE)
• Also referred to as Non-Destructive Testing (NDT)
– The act of evaluating a material or component with out – The act of evaluating a material or component with out
degrading the integrity or serviceability of the material or
component.
Purpose for Application of NDE on Pumps
• To verify integrity and specifications of new pumps
and systems.
• To evaluate in-service condition.
• To monitor in-service degradation.• To monitor in-service degradation.
• To prevent failure and loss.
Typical Pump Issues Evaluated by NDE
• Corrosion, Erosion, and Cavitation material loss.
• Cracking.
• Thermal degradation.
• Vibration wear and fatigue.• Vibration wear and fatigue.
• Coating deterioration.
• Connected piping systems
Cavitation Erosion
Cavitation Erosion
Traditional Challenges for NDE on Pumps
• Access
• Complex Geometries
• Coatings
• Difficult Materials• Difficult Materials
Approach to NDE of Pumps
• Evaluate as a system
– Pumps can often cause failure elsewhere in a system
• Identify governing codes, standards, and practices
• Gather operational history and Failure history of • Gather operational history and Failure history of
similar systems
• Have drawings and material lists available
Typical NDE Technologies and Techniques used on Pumps
• Classic/Code Techniques
– Visual examination
– Ultrasonic (UT)
– Radiography (RT)
• Advanced/Supplemental
Techniques
– Eddy Current Testing (ET)
– Acoustic Emission (AE)
– Magnetic Particle
Inspection (MT/MPI)
– Liquid Penetrant (PT/LPI)
– Vibration Analysis
– Strain gauging
– Thermography
– In-situ Metallography
– Hardness testing
– PMI
Applicable Codes and Standards
• API 610 / ISO 13709
– Centrifugal Pumps
• API 674
– Positive Displacement
• ASME Boiler and Pressure
Vessel Code
– Section V – Non-destructive
Examination
– Section VIII - Rules for – Positive Displacement
Pumps - Reciprocating
• API 681
– Liquid Ring Vacuum Pumps
and Compressors
• API 685
– Sealless Centrifugal Pumps
– Section VIII - Rules for
Construction of Pressure
Vessels
• ASME B31.1, B31.3
• CSA Z662, CSA B51
API 610 Inspection Standards
Standards and Codes Development Cycle
Industry NDT
Components in Service
Industry NDT
Failure Analysis
Failures
Detected
Causes
Addressed
Visual Examination
Visual Examination
• Abbreviation VT – Visual testing.
• The backbone and oldest non-destructive method.
• Relies on human visual acuity and interpretation.
• Can be aided by microscopes, boroscopes, video • Can be aided by microscopes, boroscopes, video
crawlers.
• Often easily documented with high quality
photography.
• Initial inspection method before all other methods.
• Can examine fit of components such as seals.
Visual Examination Limitations
• Restricted access.
• Internal flaws.
• Interpretation and experience.
• Critical defect size often not visible to the naked • Critical defect size often not visible to the naked
eye.
• Defects are often in the wrong profile to be visually
detected.
Ultrasonic Testing (UT)
Ultrasonic Testing (UT)
IP: INITIAL PULSE
DE: DEFECT ECHO
BWE: BACK WALL ECHO
DEFECT
TRANSDUCER
TEST PIECE
Ultrasonic Testing (UT)
• Utilizes the emission and detection of high
frequency, low amplitude, mechanical stress waves
through a material.
• Equipment primarily consists of piezoelectric • Equipment primarily consists of piezoelectric
transducer crystals and an oscilloscope.
• Detects discontinuities in materials based upon
interpretation of reflected wave characteristics
UT Techniques
• Pulse Echo 0° or Straight Beam
• Shearwave
• Phased Array (PA)
• Time-of-Flight-Defraction (TOFD)• Time-of-Flight-Defraction (TOFD)
UT Limations
• Geometric Traps.
• Material quality.
• Casting grain size.
• Material acoustic transmission properties.• Material acoustic transmission properties.
• Surface condition.
Radiography (RT)
Radiography (RT)
• Utilizes radiation to image surface and internal
features of a material or component.
• Relies upon a radiation source, either tube
generated or radioactive isotope, and a radiation generated or radioactive isotope, and a radiation
sensitive media or film.
• Typical in-situ field radiography is performed with
gamma radiation from Cobalt 60 or Iridium 192
isotope sources.
Common RT Techniques
• Film radiography
• Digital radiography
• Computed Radiography
RT Application
RT Application
Radiography Safety
• Appropriate access, space, and time (shooting
window).
• Highly regulated and monitored activity.
• Exposure levels are generally lower than other • Exposure levels are generally lower than other
occupations.
• Respect for barriers is critical.
Radiography Limitations
• Material type and thickness.
• Material geometry.
• Source intensity and film quality and speed.
• Safe access. • Safe access.
• Plane of discontinuity relative to plane of film and
source.
• Relies upon the visual interpretation of the captured
image.
Magnetic Particle Inspection (MPI/MT)
Magnetic Particle Inspection (MPI/MT)
• Surface defect evaluation
technique.
• Relies upon the visual
interpretation of patterns of interpretation of patterns of
magnetic particles applied
to the surface and
influenced by a directional
magnetic field induced in
the material.
Common Types of MPI/MT
• Wet Colour Contrast – commonly referred to as
black and white.
• Dry particle – common for weld root and elevated
temperature inspection.temperature inspection.
• Wet Fluorescence – highest degree of detection.
MPI/MT Limitations
• Material must be ferro-magnetic.
• Material surface must be satisfactorily clean.
• Limit of detection is often dependant on surface
polish condition. polish condition.
• Can be affected by residual magnetization and EMF
fields.
MPI
Stress corrosion cracking found on pipe
Liquid Penetrant Inspection (LPI/PT)
Liquid Penetrant Inspection (LPI/PT)
• Surface defect evaluation technique.
• Relies upon the visual interpretation of patterns of
die penetrants applied to the surface and
developed. developed.
• Can be colour contrast or florescent.
LPI/PT Requirements and Limitations
• Material surface must normally be non-absorbant .
• Material surface must be satisfactorily clean.
• Limit of detection is often dependant on surface
polish condition. polish condition.
• Can be affected by surface features and
contaminants in surface breaking discontinuities.
LPI on Progressive Cavity Pump Rotor
Eddy Current Testing (ET)
• Uses measurement of variation in induced eddy
current field flow to detect discontinuities in non-
magnetic metallic materials.
• Relies upon the visual interpretation of the field • Relies upon the visual interpretation of the field
return patterns.
Thermography
• Visual imaging of infrared
radiation.
• Can be used to analyze
heat loss and heat flaring. 200
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280
300
°C
heat loss and heat flaring.
• Excess heat is often
associated with excessive
wear, bearing and
lubrication issues.
• Excellent tool for predictive
maintenance.
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°C
Thermography
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Acoustic Emission (AE)
• Acoustic Emission is essentially ultrasonics without
remote wave generation.
• Ultrasonic transducers are used to measure and
monitor sonic waves generated in material by a monitor sonic waves generated in material by a
change in stress.
• Generally used for longer term or near failure
monitoring
Vibration Analysis
• The measurement of induced or resonant vibration
using accelerometers.
• Useful as a monitoring and preventative
maintenance system.maintenance system.
• Can help prevent or indentify causes of fatigue and
bearing failures
Hardness Testing
In-situ Hardness Testing
• Used to measure the
surface hardness of a
metal component.
• Hardness can be related to • Hardness can be related to
strength.
• Required for sour service
• Can be used to monitor in
service hardening or
softening due to wear or
thermal issues.
In-situ Replication
• Non-destructive method of
evaluating microstructure
of metal components.
• Evaluates surface layer • Evaluates surface layer
with minor surface
prepartation.
Positive Material Identification
• Provides the ability to identify or verify the material
of a component.
• Two primary in-situ non-destructive methods are x-
ray fluorescences (XRF) and spark spectroscopy.ray fluorescences (XRF) and spark spectroscopy.
• Some light element and accuracy limitations.
Nondestructive Testing & Quality
• NDE methods exhibit limitations– Probability of detection (POD)
– Reflectivity, absorption, attenuation
– Accuracy of sizing in three dimensions
– Access, environment, service
• Operator dependence
• Many tradeoffs exist• Many tradeoffs exist– Sensitivity vs. penetration
– Speed of inspection (screening) vs. accuracy (quantitative measurement)
Ways to Improve NDT Reliability
• Use multiple methods
– confirm indication
– separate detection and sizing
• Employ advanced technologies
• Process sign off (PSO)• Process sign off (PSO)
• Performance demonstration
• Training (beyond ASTN & CGSB)
• Test procedures & techniques
• Report review and auditing
• Automation
• Clarity around limitations
Advanced Test Methods