Ultrasonic non-destructive testing

Yesterday, Today and Tomorrow

AUT Seminar - Bangkok
Dirk Schindler
Commercial Manager Asia
Content
Yesterday: 1900 - 1990
Ultrasonic testing explored
Automated ultrasonic testing
Today: 1990 - 2000
Time of Flight Detection technique (ToFD)
Phased array technology (sectorial scan) Phased array technology (sectorial scan)
Tomorrow: 2000
2D imaging of defects with linear phased arrays
Matrix phased arrays and 3D imaging
Conclusions
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Ultrasonic testing: the pulse-echo technique
1928: Transition technique by
Sergei Y. Sokolov. Applied in
Germany and USA
Data display by A-scan
Only defect detection
1940: First pulse-echo system by Floyd
Firestone, USA and Donald Sproule,
England
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England
Manual scanning
Defect sizing based on amplitude
Automated ultrasonic testing (AUT)
1959: First mechanized ultrasonic system
Rotoscan-Prototype for weld inspection
Zonal discrimination
Strip chart display
1978: Second generation
Rotoscan
Canada and offshore in
Italy
Bulky equipment
1989: Standards and codes allow AUT in
Canada
Todays industrial standard
Scanner on small carriage
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Time of Flight Diffraction (ToFD)
1980: Development of ToFD
Based on diffraction
Defect sizing based on travel time
Less dependent on defect orientation
Data interpretation requires training
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Phased array technology
1990: Application of linear phased array
technology for industrial non-destructive testing
Earlier used in medical field
Consist of small elements
Computer controlled beam steering
2000: First generation Phased Array Rotoscan
Flexible in use less probes
Inspection philosophy unchanged strip charts
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2D Imaging techniques
2000: Array technology used for 2D imaging
Based on sectorial scanning (like medical
field)
Inspection of complex geometries (nozzles,
turbine blades)
Detection and sizing still based on defect
orientation
2005: Array technology used for 2D imaging
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2005: Array technology used for 2D imaging
Earlier applied in seismic exploration
Detection independent on defect orientation
Defect size, position and orientation are
imaged correctly
Straight forward interpretation
3D imaging techniques
2007: Array technology used for 3D imaging
of defects
Full 3D interpretation possible
Requires computer power
2008 ?: Matrix phased array technology
Optimal beam control
Advanced equipment necessary
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Advanced equipment necessary
Conlusions
Ultrasonic testing has been done for ca. 80 years
Detection has become reliable
Accurate sizing and straight forward interpretation
To solve new complex challenges in NDT, we can benefit
from our experience
Development goes on
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Latest ROTOSCAN system development
Phased Array
Phased Array Scanner system
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Probe frame
Ultrasonic Hardware
P.A. Probes
Encoder
RTD Phased Array
Long cable between PC and scanner, due to electronics on top of
scanner
Very short cable (0,5m) between PA probes and ultrasonic pulsers
Has conventional PE channels for additional TOFD
Has 128 elements (divided over 2 probes)
Can activate up to 32 elements simultaneously to create focus and
beam steering beam steering
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Principle of Phased Array
electronically delayed pulses
elements
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angle variation focussing
Principle of Phased Array
Weld scanning
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64 element transducer
Conventional vs Phased Array
Conventional
<16 transducers (per frame)
Long calibration procedure
Calibration by hand
Bulky scanner frame
Phased Array
Two transducers
Short calibration procedure
Calibration with software
Compact scanner frame
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Phased Array Operational advantages
Small diameter pipelines with heavy wall can be inspected with
sufficient number of inspection (depth) zones
System can be programmed to cope with different pipe suppliers
(different sound velocity)
Set-up preparation time of system can be significant reduced (e.g. no
waiting time for probe fabrication)
Smaller scanner frame and umbilical, easier to handle Smaller scanner frame and umbilical, easier to handle
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NDT Inspection of Pipe lines under
construction
Comparison of RT vs AUT
Defect
XRAY AUT
Detection Characterization Detection Characterization
LOSF
(Lack of Sidewall Fusion)
Limited
Good
(if detected)
Yes Good
LOIF
(Lack of Interrun fusion)
No Not applicable Yes Good
Porosity
(Single pore & cluster)
Yes Excellent Reasonable Poor
(Single pore & cluster)
Yes Excellent Reasonable Poor
Crack Limited
Excellent
(if detected)
Yes Reasonable
LOP
(Lack of Penetration)
Limited Good Yes Excellent
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Based upon the inspection of a manual welded weld having a bevel
configuration of 60 degree
Comparison of costs
RT vs AUT
c
o
s
t
s
RT - large OD
RT - med. OD
RT - small OD
calibration
plate
probe
concept
inspection
concept
fixed and variable costs
0 50 100 150 200 welds per day
RT - small OD
AUT
initial costs
AUT RT
concept
procedure
preparation,
mob, demob
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break even
RT incl film costs
AUT incl probe
costs
Thank you for your interest
Applus RTD Project Services
Rotterdam, The Netherlands
Houston, USA
Perth, Australia
Singapore
Dirk Schindler Dirk Schindler
Commercial Manager Asia
23 Tuas View Close
Singapore 637 481
P: +65 6898 4046
M: +65 90257381
F: +65 6898 9704
E: dirk.schindler@applusrtd.com
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