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WELCOME TO THE
UT THICKNESS
COURSE
24 Hour Course.
Class Hours: 8:00am to 4:30pm.
Breaks: At the discretion of the instructor.
Lunch: 1 hour - 11:30 - 12:30
Restrooms:
Safety:
HELLIER
COURSE OBJECTIVES
Purpose: Present the body of knowledge of
Ultrasonic Thickness Testing
Objective: Impart an understanding of the
following topics of UT Thickness Inspection
STUDENT OBJECTIVES
Objectives: To achieve an
understanding of UT thickness
inspection and a proficiency in using
portable ultrasonic thickness gages for
taking thickness measurements.
HELLIER
Name:
Company:
Job Title:
Background:
HELLIER
CLASS FORMAT
Instructor led presentation of information
Informal open discussion
Ask pertinent questions
Be respectful of others
HELLIER
PERSONNEL CERTIFICATION
SNT-TC-1A
NAS 410
CP 189
ISO 9712
ACCP
CSWIP
CGSB
AWS-NDE
Employer Certification
Central Certification
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NDT PERSONNEL
QUALIFICATION AND
CERTIFICATION
Recommended Practice SNT-TC-1A:
Guidelines for NDT PQ&C to assist the
employer
Published by ASNT
Uniform procedures for the qualification and
certification
Satisfy the employer's specific requirements.
HELLIER
QUALIFICATION AND
CERTIFICATION
HELLIER
NDT NAMES
NDT Nondestructive Testing
NDI Nondestructive Inspection
NDE Nondestructive Examination or
Evaluation
Common Names Zyglo test, Magnaflux
test, Sonic test, etc.
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ELEMENTS OF A
NONDESTRUCTIVE TEST
DEFINITIONS
Indication - Response from an NDT Test
False - Caused by improper technique;
usually not repeatable
Non-relevant - Condition in the part;
intentional or unintentional
Relevant - Unintentional discontinuity in
the part
Discontinuity - An interruption in the
physical structure of the test piece that
may be intentional or unintentional
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DEFINITIONS
Flaw An unintentional discontinuity, an
imperfection; which may, or may not be,
rejectable
Rejectable Discontinuity - A flaw related to
a relevant indication that exceeds the
acceptance criteria; a rejectable, relevant
indication.
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DEFINITIONS
Defect a discontinuity that will cause the
part not to be used for its original purpose.
A condition that will render the part not
useable or that could cause part failure or
malfunction
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No
NonRelevant?
Yes
Interfere
with
Inspection?
Yes
No
No
Relevant
Indication
Interpretation
Ignore
No
Violate
Acceptance
Criteria?
Use?
Yes
Re-Process
Yes
Accept
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Reject
AE
NRT
TIR
AE
VA
Laser Methods
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ADVANTAGES OF NDT
All of these methods of NDT share some
common advantages:
Increased product reliability
Increased product safety
Increased productivity
Increased profitability
Increased product serviceability
Minimized product liability
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ADVANTAGES OF NDT
However, they also share a common
limitation:
The NDT method applied, regardless of
the equipment and materials used, will
only be as effective as the inspector skill
allows. It is not a panacea!
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ULTRASONIC INSPECTION
Inspection method using sound
Introduces high frequency sound
waves into test object.
Measures two quantities:
time for sound to travel.
amplitude of received signal.
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HISTORY
1880 Curie brothers discovered piezoelectric
principle.
Certain crystals develop a voltage when
pressure is applied.
1881 Lippman discovered the piezoelectric
principle operates in reverse.
Piezoelectric crystals will change shape
when a voltage is applied.
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HISTORY (CONTINUED)
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HISTORY (CONTINUED)
1941 Floyd Firestone (US) and James
Sproule (England) developed pulse - echo test
instruments.
Echoes reflected from material boundaries
and discontinuities provide test signals.
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UT THICKNESS APPLICATIONS
Discontinuity detection.
Thickness measurements.
Corrosion/Erosion.
Pipe Wall Thickness.
Vessel Wall Thickness.
Plastics
Precision Measurements
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UT - ADVANTAGES
HELLIER
UT - LIMITATIONS
WHAT IS SOUND
Mechanical energy
propagating through a
material in the form
of pressure waves.
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GENERATION OF SOUND
UT instrument produces an electrical pulse
Transducer:
Converts electrical pulse to sound energy.
which travels through the material
Returning echoes are converted back into
an electrical signal
UT instrument processes the returning
signals for display
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ULTRASONIC TESTING
Ultrasonic Transducer
Like a speaker when transmitting;
Like a microphone when receiving
Piezoelectric Effect:
Apply electrical energy, mechanical
energy is produced
Apply mechanical energy, electrical
energy is produced
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PIEZOELECTRIC EFFECT
When exposed to an alternating current an element expands and contracts
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WAVE MOTION
The pressure in the sound waves displace
the molecules in the material.
Various wave modes can be generated.
VELOCITY OF SOUND
The speed that sound goes through a
medium.
Depends on two material properties:
Density: How tightly packed
are the
molecules.
Elasticity: Restoring force of the electrical
bonds.
And the Type of
the Sound Wave
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VELOCITY
Measured in distance travelled per unit of time.
Inches/second (in/sec)
Inches/microsecond (in/sec)
Kilometers/second (km/sec)
meters/second (m/sec)
centimeters/microsecond (cm/sec)
LONGITUDINAL WAVES
Also known as Compressional Waves
Particle Vibrations parallel to the direction
of wave propagation.
Propagation
Particle vibrations
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LONGITUDINAL WAVES
Alternating zones of compression (high
pressure) and rarefaction (low pressure)
Propagation
Particle vibration
Travel in solids, liquids and gases.
SHEAR WAVES
Vibrations at right angles to the direction of propagation.
Finds flaws not parallel to the surface
Propagation
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SURFACE WAVES
Elliptical vibrations
Special wave at the surface of the part
Finds cracks and scratches
Not used with thickness gages
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FREQUENCY
Frequency Ranges:
Audible range: 20 to 20,000 Hz.
Ultrasound: above 20,000 Hz.
Commercial testing: 100 kHz to 25 MHz.
Frequency units:
Hertz (Hz): cycle per second.
Kilohertz (KHz): thousand cycles per second.
Megahertz (MHz): million cycles per second.
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WAVELENGTH
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WAVELENGTH / FREQUENCY
V = f
V = velocity
f = frequency
= wavelength
Far
Zone
Yo
Beam Diverges
(Spreads)
Distance
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D ff
D
NN 4 V
4 V
22
Where:
f = Frequency (MHz)
V = Velocity (Km/sec)
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NEAR ZONE
2
D
Near Zone
4
D f
4V
Where:
1.22 V
arcsin
D f
f = Frequency (MHz)
V = Velocity (Km/sec)
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BEAM SPREAD
K
KV
Sine
or
2 D
Df
The larger the diameter the less the beam spread
The higher the frequency the less the beam spread
The lower the velocity the less the beam spread
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ATTENUATION
Material Loss Attenuation:
Scattering of sound by grain structure of
the material.
Conversion of sound energy into heat
Sound amplitude lost due to:
Attenuation
Beam Spread.
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SOUND AT AN INTERFACE
Interface: Boundary between two materials
Incident Wave
Reflected
Interface
Interface
Transmitted
ACOUSTIC INTERFACE
Boundary between two materials with
different acoustic impedance values.
Reflected
Acoustic
Interface
Transmitted
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Z=Vx
V = Velocity
= Density
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REFLECTION PRINCIPLES
Formula for reflected energy (RE):
2
Z 2 Z1
100
% RE
Z 2 Z1
Z1 = impedance of the first material the sound is in
Z2 = impedance of the material the sound reaches
Note: Due to the Law of Conservation of Energy
Transmitted Energy = 100% - Reflected Energy
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HELLIER
CONTACT TRANSDUCER
DESIGN
SINGLE ELEMENT
TRANSDUCER
Electrical
Leads
Connector
Electrical
Network
Inner
Sleeve
External
Housing
Backing
Active
Element
Electrodes
Wear
Plate
Acoustic
Barrier
Receiver
Element
Connector
External
Housing
Delay
Material
Test Sample
Angular
Sound
Path
DUAL CRYSTAL
Sound beam is reflected and refracted into
the receiving element
Transmitter Receiver
DELAY TRANSDUCER
Introduces sound perpendicular (normal) to the test surface.
Crystal
Damping
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ULTRASONIC INSTRUMENT
FUNCTIONS
Theinstrumentcontainssixbasicsections:
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INSTRUMENT FUNCTIONS
Connecting a probe and coupling it to the
test object completes the test system
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INSTRUMENT FUNCTIONS
The Power Supply provides voltage from the
AC or batteries to drive the other instrument
circuits
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INSTRUMENT FUNCTIONS
The clock initiates the chain of events that
results in one complete cycle of an
ultrasonic test
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INSTRUMENT FUNCTIONS
The clock emits s trigger signals, repeated
at the pulse repetition frequency (PRF)
Depending on instrument, the PRF may be:
Set by the operator
self-adjusting/ or both
INSTRUMENT FUNCTIONS
TheclocktriggerstheTimebaseandPulser
atregular,evenlyspacedintervals
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INSTRUMENT FUNCTIONS
The timebaseinitiatestime/distancedisplay
ontheinstrumentshorizontalscale
usedfordistancereadout
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INSTRUMENT FUNCTIONS
Thepulsersendsinitialpulsetotransducer,
causingsoundtoenterthetestobject
initialpulsegoesthroughtheReceiver/Amplifier
tothedisplay
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INSTRUMENT FUNCTIONS
The Initial Pulse is a fast rising, high
voltage pulse that activates the transducer
Duration of transducer ringing determines
the length of the dead zone
Dead zone is the depth range in the test
material where relevant indications are
hidden inside the Initial Pulses indication
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INSTRUMENT FUNCTIONS
Sound travels through the test object as
time elapses along the display
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INSTRUMENT FUNCTIONS
Soundreflectsfrommaterialboundaries
anddiscontinuities
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INSTRUMENT FUNCTIONS
Transducerechovoltageisprocessedbythe
receiveranddisplayed
INSTRUMENT FUNCTIONS
Time base Controls
Zero Offset Control
adjusts when the horizontal display starts
relative to the activation of the initial
pulse
Range Control
adjusts the amount of time displayed
along the horizontal scale to correspond
with sound travel time through a specific
thickness of material
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INSTRUMENT FUNCTIONS
Time base Controls
Velocity Control
adjusts the amount of time displayed
along the horizontal scale to
correspond with sound travel time
through material of a particular
velocity
HELLIER
INSTRUMENT FUNCTIONS
Pulser Controls
Pulser Energy Control
adjusts the size of the Initial Pulse
Damping Control
adjusts transducer performance for
resolution versus penetrating power
Note: Both Pulser Energy and Damping
affect duration of the dead zone
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INSTRUMENT FUNCTIONS
Receiver processes and amplifies signals
going to the Display
Processing is provided by detector and
filter sub-circuits
Detector sub-circuit can provide choice of
various types of signal passing through the
receiver RF or Selected video mode
HELLIER
INSTRUMENT FUNCTIONS
Comparison of RF and all Video modes
COUPLANTS
Liquid (usually) used to exclude air from
the path of the sound beam.
Considerations
Wetting Ability
Viscosity
Reactivity
Ease of removal
Expense
HELLIER
TYPICAL COUPLANTS
Water
Oil
Cellulose and water mixture
Grease/Petroleum Jelly
Commercially prepared
High temperature couplants
HELLIER
THICKNESS INSPECTION
Thickness inspection incorporates:
Pulse Echo Technique
Resonance Method
Measurements are made of:
Thickness of new parts
Erosion / Corrosion
HELLIER
THICKNESS CONSIDERATIONS
THICKNESS CONSIDERATIONS
Use two point calibration when possible
Calibration block
Known, documented NIST thickness
Same material as part being inspected
Similar temperature to the part
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DATA PRESENTATION
Display hardware
Electro-luminescent displays
Liquid crystal displays
Paper chart recorders
Digital readouts
Computer screens
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DATA PRESENTATION
A-scan
horizontal scale:
displays time to
indicate distance
vertical scale:
displays
transducer output
voltage to indicate
echo amplitude
HELLIER
DATA PRESENTATION
Digital Readouts
B-scan
Side view of test object:
profile of interfaces
reflecting sound beam
Immersion Testing
Digital Thickness Gages
Computer Applications
HELLIER
TIME/DISTANCE
RELATIONSHIP
Thickness =
(Velocity) (Time)
2
HELLIER
THICKNESS GAGING
Uses High Frequency Sound Waves
Typically 5.0 MHz thru 20.0 MHz
Longitudinal Sound Energy
Thickness Measurement From One Side
Nondestructive
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PRECISION THICKNESS
GAGING
CORROSION THICKNESS
GAGING
Uses Dual Element Transducers
Erosion/Corrosion
Typically on Metal
Irregular/Pitted Reflecting Surface
HELLIER
DUAL ELEMENT
TRANSDUCER ON CORRODED
MATERIAL
TX RX
SINGLE ELEMENT
TRANSDUCER ON
CORRODED MATERIAL
First
Backwall
Echo
Second
Backwall
Echo
2 nd Echo
1 st Echo
HELLIER
DUAL ELEMENT
ADVANTAGES
Roof Angle narrows the beam for pits
High Temp. capabilities ( 1,000 F)
Separate Elements
Use Higher Initial System Gain
Better near surface Resolution
Stable Readings on Rough Entry Surfaces
HELLIER
CHOOSING TRANSDUCERS
Material
Carbon steel
Cast material
Aluminum
Thickness Range
Min and Max thickness
Geometry
Min Diameter
Convex/Concave Surface
Surface Condition
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TRANSDUCER CRITERIA
Frequency
Higher Frequency -- Better Resolution
Higher Frequency -- Better Sensitivity
Roof Angle
Steeper Angle Will Have Shorter Focus
THICKNESS GAGING
PERFORMANCE VARIABLES
Penetration: Ability to pass through a
material interface.
Improves with longer wavelength.
Wavelength increased by decreasing
frequency.
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THICKNESS GAGING
PERFORMANCE VARIABLES
Resolution: Ability to individually
display reflectors located at slightly
different depths along the sound beam.
Resolution increases with an increase
in bandwidth and/or frequency.
HELLIER
Worn
Probe
on Zero
Incorrectblock
Zero
Zero
Block
ZERO
OFFSET
ZERO
OFFSET
Worn Probe
on Curved
Pipe
Offsets
With Worn Transducers
On Curved Surfaces
On Rough Surfaces
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Rough
Surface
RX
Sample
True
Thickness
Angular
Sound Path
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Rx
Delay
Temperatures
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Tx
Delay
ECHO-TO-ECHO
Sound
Entry
1st ECHO
2nd ECHO
2 METAL+2C
3rd ECHO
2 METAL
2 METAL
COATING
COATING
COATING
COATING
2 METAL
Coating
Metal
Standard
Measurment
Echo-to-Echo
Measurment
Total Thickness
Coating and Metal
[ -1 Coating
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Thickness of
Metal Only
AUTOMATIC ECHO-TO-ECHO
No Gates To Set
Gage Automatically Finds The Two Highest Back wall Signals
Marker Indicates Detected Echoes
Users Verifies Proper Detection
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MANUAL ECHO-TO-ECHO
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Cal Zero
THICKNESS GAGE
ADVANTAGES
THICKNESS ACCURACY
Thickness measurement accuracy using
A-Scan gages is dependent on:
Detection
Flanking Gate Detection
Peak Gate Detection
Screen Resolution
Number of Pixels
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SIGNAL
AMPLITUDE
AT 50dB
SIGNAL
AMPLITUDE
AT -6 dB
THRESHOLD
GATE
Detection 1
Detection 2
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PEAK DETECTION
Dual Signals Have Multiple
PEAK
SIGNAL
Peaks
PEAK
GATE
Transducer Alignment
Surface Condition
Coupling Pressure
Backwall Surface Condition
Grain Structure
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TIME TO
PEAK
PEAK
SIGNAL
PEAK
GATE
TIME TO
PEAK
THE WAVEFORM
ADVANTAGE
Disbond
Disbond Detected
Solution
Disbond Reflection
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Blanked Out
SURFACE NOISE
Rough Surface
Aluminum
Reading Surface
Reflections
Solution 1
Solution 2
Surface Noise
Blanked Out
Reduce Gain
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GRAIN REFLECTION
Large Internal Reflections
From Grain Boundaries
Can Cause False Readings
Problem
Reading Grain
Noise
Solution 1
Grain Noise
Blanked Out
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Solution 2
Reduce Gain
FEATURES FOR
HIGH TEMP APPLICATION
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HIGH TEMPERATURE
COUPLING TECHNIQUES
ENSURE
TRANSDUCER LONGEVITY
Limit Transducer Contact Time to Five Seconds
Never Let Transducer Get To Hot To Hold
If Transducer Gets Hot
Cool in Air
Dip Tip in Water
Re-Zero
Avoid Dragging Transducer Cable Across Pipe
HELLIER
DATALOGGER INPUT
PRE-LOAD
HELLIER
BARCODE WAND
Plugs Into RS-232 Port
Reads Standard 3 of 9
(39) Labels
ID:TML 1.00
THk: 0.286
Internal Barcode
BAR CODE WAND
Software Is Standard
0.267
BARCODE WAND
Scan Barcode Tags
TML: 4.00
0.236
From Drawings
Scan Barcode Tags
Located On The
TML: 6.00
0.285
TML: 9.00
0.210
TML: 1.00
0.200
TML: 2.00
0.225
TML: 3.00
0.205
Equipment
TML: 5.00
0.241
TML: 7.00
0.300
TML: 8.00
0.310
TML: 10.00
0.231
INTERFACE PROGRAMS
INTERFACE PROGRAMS
Print/Read Files and Waveforms
Edit Files
Produce Color Reports
Create/Load Different File Formats
Create Statistics Reports
HELLIER
INTERFACE PROGRAM
STATISTICS
Identifier
Thickness
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OTHER DATA
MANAGEMENT PROGRAMS
Name
Manufacturer
Country
Credo
Chartex Software
UK
Cortran
Rios Software
UK
DataMate
Krautkramer
USA
UltraPipe
Krautkramer
USA
EMPRV
USA
EPRI Check/Works
EPRI
USA
IDM
Exxon
USA
Meridium
(under development)
USA
PIPE Sys
Atomic Software
UK
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Keyboard Lock
Press
6
Simultaneously
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Change Hold/Blank
Press and Hold
Allows the operator
2
to switch between
the display HOLD and
Then Press the display BLANK
conditions when no
MEAS
measurement is
being made (LOS).
and release both
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