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PIH Services MEP O Box 62574, Dubai, UAE. Tel +971 4 267 9989 Fax +971 4 267 9585Email [email protected] www.pihme.com

PIH SERVICES ME LTDAutomatic Ultrasonic Testing

A.U.T

Regional Offices : Abu Dhabi, Oman, Qatar, Bahrain.

PIH Services ME Ltd have recently purchased two new AUT Pipeline systems from Olympus Canada, bringing the group total to 8 at present, with corporate approval for the purchase of an additional 6 systems.

In October 2006 CRC-Evans (PIHME Parent Company) acquired a Scottish based company UNISPEC, who specialize in AUT, for both on-shore and off-shore pipelines. UNISPEC have been successfully performing Phased Array inspections since the year 2002. UNISPEC also maintain a register of experts in this field that can be resourced from, if and when needed.

A sample list of the AUT projects completed is as follows.

BP WEST NILE PROJECT. WILLIAMS BANJO SEAHAWK PROJECT. DONG NINI CECILLE PROJECT. BURRULUS SIMIAN SAPHIRE PROJECT. ENI K2 PROJECT K2 PIPELINES IN THE GULF OF MEXICO. KERR MCGEE TICONDEROGA PROJECT. MARATHON ALVHEIM PROJECT. NORSK HYDRO VILJE PROJECT. BP GREATER PLUTONIO PROJECT. Although Phased Array maybe a new technology for PIH Services ME Ltd, it has been successfully used on numerous projects since the 1990s. PIH Services ME entry into this market has necessitated the conception of a bespoke AUT division within the company. To facilitate this division PIH Services ME have appointed Ewen Nagy as AUT manager, he brings to this division 15+ years AUT experience, predominately in the last 5 years with the Olympus Pipewizard system in worldwide locations both on and off shore. Along with the purchasing of the most advanced inspection system on the market, PIH Services ME have also and most importantly, recruited some of the most qualified and experienced technicians in the world, to provide a solid core foundation for this division. PIH Services ME will continue to provide professional and dedicated services in this new avenue of inspection.

PIH Services ME is fully cognizant that in order to maintain the highest level of service to our client base, expansion of this division is mandatory. To achieve this expansion PIH Services ME have opened a fully functional training facility in our Dubai premises, and currently some of our experienced conventional NDE ultrasonic technicians are under going an extensive training program with the Phased Array systems. Within the next 6 months, PIH Services ME intends to submit the trainee candidates to TWI for certification to internationally recoginised CSWIP level II in Phased Array. Additional technicians will subsequently be recruited to undergo AUT training and certification to continually expand the database of technicians available to undertake projects, in line with our quality plan.

For further Information please contact any of the management below

Alan Everett Managing Director at [email protected] Fisher Group General Manager at [email protected] Nagy AUT Manager at [email protected]

For further enquiries please contact



A.U.T


What Are Phased Arrays?Phased arrays use electronic beam forming to generate and receive ultrasound. Each element in the array is individually pulsed and delayed to create a wide range of beam angles and focal distances. A series of focal laws is developed, which enables weld scanning in a manner similar to conventional ultrasonic, but with only two arrays and with much greater flexibility. Setups are performed by loading a file, not by adjusting transducer positions. Electronic scanning permits customized weld inspections, including multiangle time-of-flight diffraction, advanced imaging, and detailed inspections.

Advantages of Phased Arrays for Girth Weld Inspections

Smaller and lighter probe pans with potentially reduced cutback (down to 2 in.).

One PipeWIZARD can scan pipes ranging in diameter from 2 in. to 56 in. while only changing the band, setup file, and wedge.

The standard PipeWIZARD can scan pipe walls from 6 mm to 50 mm (0.25 in. to 2 in.).

Increased number of zones for better detection and vertical sizing.

Scan time is reduced by several seconds due to the narrower probe pan.

Any weld profile, pipe diameter, or wall thickness can be accommodated by recalling the appropriate setup files.

Arrays can be programmed to perform real coupling checks using the back wall.

Setup wizard enables automatic setups.

Automated ultrasonic inspection of pipeline girth welds using phased arrays.Meets or exceeds ASTM E-1961, DNV2000 OS-F101, and API 1104 codes:

Fast scanning speed: 100 mm/s Weld-to-weld inspection time of less than four minutes for 36-inch pipe Very flexible for different pipe diameters, wall thicknesses, and weld profiles Low operating costs High reliability "One size fits all" Great for special scans

Output display from weld with defects.




A.U.T


PipeWIZARDPipe diameter 50 mm to 1424 mm (2 in. to 56 in.)Pipe wall thickness 6 mm to 50 mm (0.25 in. to 2 in.)

(Additional transducers may be required.)Array Two linear 7.5-MHz, 60-elementScan speed 100 mm/s (4 in./s)Scanner size 250 mm (L), 120 mm (W), 75 mm (H)Scanner weight 2 kg (4.4 lb)Additional probe pan slots Extra slots for four conventional transducer pairs for transverse defects or

additional scansWeld profile All common welds: CRC-Evans, J-bevel, manual, V, double V, X, etc.

(any profile in principle)Probe pan weight 18 kg (39.7 lb) (typical)

UltrasonicsMethod Multichannel zone discrimination or custom scans as specifiedZone size Less than 1 mm is possible using increased number of zones. (Maximum

number of zones is 32 per view, and four views are available for a total of 128 zones.)ASTM E-1961 zone size is typically 1 mm to 3 mm.

Setup Automatic with file loadingAutomated setup From CAD file of weld profile or from predefined weld profile and appropriate

parametersDisplay 1. Conventional twin-gate strip chart display; or

2. Increased number of zones for improved defect sizing; or3. Multiple B-scans for improved defect characterization; or4. Customized combination of displays. Coupling and circumferential position

channels included, TOFD recommended. Calibration and codes ASTM E-1961, API 1104, DNV2000-OS-F101, or custom specificationsAdditional modules For transverse defects, thick walls, and customized scans

UmbilicalUmbilical length Typically 25 m (80 ft)Manufacture Armored cable 5 cm (2 in.) in diameterContents 128 ultrasonic cables, one motor drive cable, one encoder cable, and

waterline for couplingPhased ArraysInstrumentation Standard Tomoscan FOCUS 32:128 unit (32 simultaneous pulsers, 128channels)Bandwidth 1 MHz to 20 MHzMaximum pulsing rate 20 kHz PRFPulser delay Adjustable from 0 s to 25 s in 2-ns incrementsPulse output Amplitude from 50 V to 200 V, width from 20 ns to 500 nsReceiver delay Adjustable from 0 s to 25 s in 2-ns incrementsReceiver DAC Up to 30 dB/s on each element slope before summingInput filters Four user-selectable ranges:

None500 kHz to 5 Mhz2 Mhz to 10 Mhz5 Mhz to 15 MHz

Input impedance 50 WInspection mode Pulse-echo, pitch-and-catch (programmable), ToFD




A.U.T


PipeWIZARD Delivers

Real-time display and data analysis

Automatic data recording

TOFD scans for improved detection and sizing

Accurate defect sizing to the depth of one zone(1 mm to 3 mm) or better using TOFD

Precise measurement of defect length

Defect location in weld fusion line or centerline

Correct defect characterization

Special scans for specific defects: B-scans for porosity and tandem probes for centerline cracking

Optional top, side, and end views, or alternativedisplays

Defect Analysis

Amplitude data is color-coded to alert the operator when a signal crosses the rejection threshold.

Defects can be rapidly sized by counting thenumber of zones where the signal is detected.

Defect length can be measured directly from screen.

Defect location in the weld can be determined from the time-of-flight information (colored bar).

Characterization is performed using amplitude, zones, and TOF data from the appropriate zone(s) and TOFD.Complete zone discrimination can be performed with two 60-element arrays, one on each side of the weld. Time-of-flight diffraction (TOFD) and other scans can be performed using the same arrays, or dedicated probes. The probe pan has been designed to accommodate the additional probes required to perform transverse inspections. Additional sizing techniques can be used, such as TOFD or amplitude weighted techniques.




A.U.T


Ultrasonic phased arrays are a relatively new method of generating and receiving ultrasound. Phased array testing is a specialized type of ultrasonic testing that uses sophisticated multielement array probes and powerful software to steer high frequency sound beams through the test piece and map returning echoes, producing detailed images of internal structures similar to medical ultrasound images

Advantages

As such, phased arrays offer significant technical advantages over conventional single-probe ultrasonics; such as:

Electronic scanning (E-scans) which permits very rapid coverage of the components, typically an order of magnitude faster than a single-probe mechanical system.

Beam forming which permits the selected beam angles to be optimized ultrasonically by orienting them perpendicularly to the predicted defects; for example, lack of fusion in welds.

Beam steering (usually referred to as S-scans for sectorial scanning) which permits the mapping of components at appropriate angles to optimize probability of detection. S-scans are also useful for inspections where only a minimal footprint is possible.

Electronic focusing which permits optimizing the beam shape and size at the expected defect location, as well as optimizing probability of detection. Focusing significantly improves signal-to-noise ratio, which, in turn, permits operating at lower pulser voltages.

How does it work?

Ultrasonic phased arrays are similar in principle to phased array radar, sonar, and other wave physics applications. However, ultrasonic development is behind the other applications due to a smaller market, shorter wavelengths, mode conversions, and more complex components.

Phased arrays use a collection of elements, all individually wired, pulsed and time-shifted. These elements can be a linear array, a 2-D matrix array, a circular array, or some more complex forms. Most applications use linear arrays, since they are the easiest to program, and are significantly less expensive than the more complex arrays. However, as costs decline and experience increases, greater use of the more complex arrays is predicted.




A.U.T


As with all ultrasonic testing, elements are used to collect data. Within the phased array application the elements are ultrasonically isolated from each other, and packaged in normal probe housings. The cabling usually consists of a bundle of well-shielded micro co-axial cables. Commercial multichannel connectors are used with the instrument cabling.

Elements are normally pulsed in groups from 4 to 32. The acquisition and analysis software calculates the time delays for a setup from operator input on inspection angle, focal distance, scan pattern, etc. The operator could also use pre-prepared files. The time delays are back-calculated using time-of-flight from the focal spot, and the scan assembled from individual "Focal Laws." Time-delay circuits should be near 2-nanosecond accuracy to provide the phasing accuracy required.

Each element generates a beam when pulsed. These beams constructively and destructively interfere to form a wavefront. The phased array instrumentation pulses the individual channels with time delays as specified to form a pre-calculated wavefront. For receiving, the instrumentation effectively performs the reverse. For example, the instrumentation receives signals with pre-calculated time delays, sums the time-shifted signal, and then displays it




A.U.T


The summed waveform is effectively identical to a single-channel flaw detector using a probe with the same angle, frequency, focusing aperture, etc.

Manual ultrasonic weld inspections are performed using a single probe, which the operator "rasters" back and forth to cover the weld area. Many automated weld inspection systems use a similar approach, with a single probe scanned back and forth over the weld area. This is time consuming because the system has dead zones at the start and finish of the raster

In contrast, phased arrays use a linear scanning approach. Here the probe is scanned linearly around or along the weld, while each probe sweeps out a specific area of the weld. Often it is possible to use many more beams (equivalent to individual conventional probes) with phased arrays. The simplest approach to linear scanning is found in pipe mills, where a limited number of probes inspect ERW pipe welds



PIH SERVICES ME LTD


ToFD is arguably the most versatile and certainly the most extensively proven ofall non-intrusive in-spection techniques.

Developed in the early 1970s in response to the nuclear industrys need to moreaccurately size and characterisation integrity affecting flaws in critical plant componentsduring service. The benefits of the technique have only started to be fully recognised andaccepted by the rest of industry over the last few years. This belated recognition is largelyattributable to the inevitable inertia of established practise and over emphasis on theunique sizing capabilities inherent with the technique. But the real virtue of ToFD is itsunprecedented ability to efficiently and reliably detect the presence of both fabricationand service induced defects particularly those affecting integrity due to their throughwall orientation whilst simultaneously providing the data necessary for accurateassessment of their size.

Time of Flight Diffraction (ToFD)How It Works

This applicational efficiency and inherentreliability means that ToFD is an idealreplacement for both radiography andmore subjective reflectivity basedultrasonic methods and, as such,constitutes a valuable source of IT for theeffective management of vital productionassets.

ToFD Limitations Lateral wave impedes near surface

resolution. Additional B-scans necessary for

transverse positioning Sees everything (down to grain

structure) so interpretation can bedifficult if material/weld quality is very poor.

Stress/chemically assisted micro crackingSCC, LTHA

Corrosion/erosion profiling incl. weldroot erosion

Thick wall components Clad/lining interface bond/cracking. Pressure systems, vessels, tanks,

spheres, pipelines etc.

How it works

With ToFD, a single line scan of a pair of angle compression wave probes held at a fixed separation can provide full volumetric coverage of both weld and HAZ and generate an immediate scale image of through wall condition with defects shown in true location and size. The wide beam used defines the test surface by generating a lateral wave andthe inner surface by reflections off the material backwall. Any anomalies lying between these two surfaces are highlighted by signals diffracted and reflected off their extremities. The lateral location and length of these discontinuities is reported as a function of encoded scanposition.

ToFD Benefits Non-destructive, non-intrusive &

efficient (>10m/hr) Sensitive to integrity critical defects

(e.g. cracks) Reports actual thro wall position/extent

& length Fast volumetric coverage irrespective

of thickness Accurate, reliable & repeatabledetection & sizing

Immediate results in graphical format. Not equivalent, subjective or

comparative On stream application @ elevated

temperature Not affected by defect orientation All data stored for off-line retrieval &

analysis Accepted by major client & regulatorybodies

ToFD Applications

Fabrication QC especially in-situconstruction

Service induce defects & structural damage.

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