Diverse Uses of Advanced Ultrasonic Inspection

Technologies for Pipeline Manufacturing, Construction,

and Maintenance

October 21, 2014

Presented by: Nicholas Bublitz

Co-Authored by: Andre Lamarre

Basic Ultrasonics

One 0 degree or one angle depending on wedge

Ultrasonics work best when interaction with flaws is 90°

Typically single raw A-scan or some imaging

Manually rastered in most case for flaw detection

Limited reporting

Advanced Ultrasonics

In comparison with conventional ultrasound, advanced ultrasonics are:

Phased Array (PA)

Time of Flight Diffraction (TOFD)

Guided Wave (GW or LRUT)

Automated Ultrasonics

Used to assure the integrity of pipelines at different stages:

Fabrication of the pipes

Construction of the pipeline

Maintenance of the pipeline

What is Phased Array?

Utilizes multi-element arrays and software to create multiple angles, focus, or electronically raster ultrasound.

Improves coverage, characterization, detection and sizing capabilities.

Sector Scan and Electronic Scan

Different elements excited at different times to create multiple angles,

change focus, or electronically move through the probe

How Does It Work?

Physics +Software

Phased Array for Welded Pipe

Manual or encoded

Better characterization of damage mechanisms

Better detection and sizing

Encoded Weld Scanning

Use encoders to record position in relation to ultrasonic data

Allows for length to be linear in data similar to viewing a radiograph

Allows for post manipulation and reprocessing of digital data

Can be one technique or combined ultrasonic techniques

Can be semi-automatic or fully automatic

Phased Array Imaging

Particularly useful for complicated damage mechanisms:

Hydrogen induced cracking

Stress corrosion cracking

Etc.

Provides more information for the operator to make the right analysis

Phased Array vs. Radiography

Advantages of Phased Array:

Higher probability of detection

(POD) especially for lack of fusion

and cracks

Fracture Mechanics vs.

Workmanship Criteria

No radiation / extra licensing /

chemicals

No screened off areas, work can

go on around ultrasound

Instant evaluation and feedback to

welder

Phased Array for Corrosion

Increased Coverage and

speed

Semi-automated or fully

automated

Imaging

High resolution

Better characterization

Large Effective Beam

2.36”.187”

Conventional Pitch Catch Phased Array 64 element

~12 Times more coverage with phased array probe.

Diffractedwaves

Diffractedwaves

Incidentwave

Reflectedwave

FLAW

What is Time of Flight Diffraction?

Send and receive

technique

Diffracted energy

technique

Uses time information for

accurate measurement

TOFD Advantages

Accurate sizing capability based on

time

Rapid scanning with wide coverage

Detection and sizing not reliant on

flaw orientation or weld shape

Flaw Detection

Corrosion Assessment

Send Receive

Data Analysis

On the instrument or in offline analysis software

Amplitude, depth, height, & length are typical for flaws

Thickness, remaining wall or material loss for corrosion

Portable Equipment Considerations

Manual and encoded

Techniques

Multi-Group

Specific scanners

Probes, wedges and

accessories

Setup and analysis

software

Automated inspection solutions for: Seamless and welded pipe

Transverse, oblique, and longitudinal flaw detection

Wall thickness and lamination

Multiple units can be connected to meet speed and detection needs.

Eddy Current Array capability can be added

Able to meet and exceed code requirements (API 5L etc.)

Pipe Inspection for Fabrication

Inspection Concept

Phased Array for New Pipelines

Narrow BevelEmitter

Receiver

F1

F2

F3

F4

F5

Zones

Phased Array Zone Technique:

Zone Discrimination Technique

Weld is divided into small zones (1-3mm)

A single beam is generated to cover each zone

Pitch – Catch technique to hit narrow bevel correctly

Strip chart for each beam is used for rapid detection

and sizing

Cap

HPLCPRoot

F5F4F3F2F1

3mm 3mm3mm 3mm3mm

Major Features:

Speeds Up to 100mm/sec

IP66 and designed for harsh

environments

User friendly and fast setup, operation

and analysis to keep up with pipeline

welding

Strong field experience:

Hundreds of units in the field

Millions of welds inspected

Approved by most or all major oil

companies

PipeWIZARD

Advanced PipeWIZARD Software

Guided Waves Guided Wave Ultrasonics

Used to screen in-service pipes and pipeline over long distances

Inspect pipes with limited access from a single position

Pinpoint locations requiring further inspection

Can provide significant reduction in operating costs

Also known as LRUT, or long range ultrasonic testing

Applications of Guided Waves

Corrosion detection / in-

service pipes and pipelines

Inspection of above

ground and buried pipe

Coated or insulated pipe

Detection of corrosion at

supports and pipe racks

Inspection of through-

wall pipe, vertical pipe,

and buried pipe

Guided Waves Coverage

Inspection with Conventional

Ultrasonics Localized inspection

Underneath or in the vicinity

of the sensor location

Inspection with Guided Waves

(Long-Range Ultrasonic

Testing) Screen the entire pipe wall

Covers long distance (up to

600’, 300’ each direction)

from a single inspection

position

Guided Wave Detection

Guided Wave does not provide an accurate measurement of wall-

thickness variation but detects a general change in the total pipe

cross sectional area (CSC).

Equally sensitive to OD and ID corrosion.

Can estimate the circumferential extend (using focusing tools).

Other NDT methods are needed to validate and size indications.

10% CSC

(Total area) distributed

differently

UltraWave LRT

The system features the UltraWave LRT instrument

(which is secured in a backpack), a rugged touch-

screen laptop with advanced software, flexible

inspection collars, and all the necessary tools to

perform an inspection.

Guided Wave Imaging

Training Requirements for Advanced Ultrasonics

Dictated by code, contract

and other requirements

Typical – x formal training

and x OTJ training

Olympus partners with

training and consulting

companies who can

certify to applicable

standards, offer training

and services

Benefits of NDT Screening

Maximizing and shortening

shutdowns by preparing other

NDT work in advance for

targeted areas

Minimize manual labor to

access and prepare for 100%

volumetric inspection

Pinpoint areas for minimized

and calculated shutdown of

operations

Conclusions Advanced Ultrasonics include many different types of Ultrasound

inspections:

Phased Array

Time of Flight Diffraction

Guided Wave

Automatic Ultrasonics

Advanced Ultrasonics are used at all stages of pipeline life to:

Improve speed and quality of inspection

Increase detection, sizing and reporting capabilities

Improve characterization of certain damage mechanisms

Replace radiography and conventional ultrasonic methods

Reduce mechanics and increase coverage from traditional Ultrasonic

approach

Solve complex inspection problems with flexible techniques like zone

discrimination

Thank You!www.olympus-ims.com