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ABSTRACT
Recent developments in the fields of electronics, computer systems and communication
technology have enabled the use of many new concepts within inspection and
monitoring. ULTRAMONIT is one such example where we try to extend the use of
ultrasonic measurements in terms of accuracy and what we can measure. In this
concept, an array of ultrasonic sensors is placed permanently onto the pipe. The location
of these sensors will typically be in a field joint directly at, or close to a weld, and the
objective will be to monitor for corrosion attacks and cracks. Permanently installed
sensors are advantageous as exact position, orientation and acoustic coupling are
maintained between surveys. Compared to conventional ultrasonic inspection, this
means significantly improved possibilities for high-resolution trend analysis of the data.
Under good conditions, UT wall-thickness can be measured with a resolution in the order
of 0.01 mm. Using fixed sensors; such very high resolution could be made available for
monitoring purposes.
Two versions of this system are developed, one for use on subsea pipelines, and one for
use topside or on land facilities. ULTRAMONIT Subsea is implemented as an
instrumented pipeline clamp, where the required electronics and sensors are placed and
protected in a rugged steel structure. Reliability has been a key objective for this
concept, and has been addressed by keeping the permanently installed electronics as
simple as possible, while making the more complicated parts of the instrumentation
accessible in an ROV carried unit. This ROV is used for interrogation with the sensors by
use of a specially developed inductive coupler, which provides power, analog signal for
the ultrasonic transducers, and digital communication for the signal multiplexer. This
unit is controlled digitally and the number of channels is only limited by signal
degradation due to total spanned length of analog cable, as the channel count gets very
high. Two 48-channel prototype clamps have been lab tested so far, one for 10" and one
for 32" pipe diameter. However, both HW and SW is ready for any practical number of
channels.
Topside/land facilities version of this same system is installed on a 12" pipe at the
Krst gas processing plant. This unit has been running since December 2003.
INTRODUCTION
Pipeline systems in service are commonly exposed to corrosive and erosive
environmental conditions. As such conditions may change over time, some form of
corrosion/erosion monitoring program will be crucial for the maintenance of a safe level
of operation.
Ultrasonic measurement of wall thickness is widely accepted as the most accurate
method for assessment of corrosion. Likewise, ultrasonic methods are very well suited
for detection and monitoring of cracks. However, when very high levels of accuracy or
defect sensitivity is desired, one will find that ultrasonic methods suffer from practical
limitations in repetitiveness of measurements, e.g. regarding sensor re-location and
acoustic coupling from one survey to another. The performance of these methods may
be increased by the use of permanently mounted ultrasound probes, and this is the
main idea with ULTRAMONIT.
ULTRAMONIT SYSTEM
INDUCTIVE COUPLER
1. Connection between the permanently installed subsea clamp, and the ultrasonic
instrumentation carried by the ROV takes place through a specially designed inductive
coupler which combines supply of electrical power to the signal multiplexer and sensors
in the clamp, and two-way IrDA communication. The inductive coupler is designed for
supply of 3 W of power at approx. 12 V.
The coupler is constructed as a splittable two-part transformer.
The ROV part of the coupler will only be submersed for limited
time, and is therefore made of a plastic material, with wires and
core covered by epoxy mould. The subsea section is designed
with pressure compensation, and with electrical wires and
transformer core covered by SilGel. Proper function of this
coupler requires that the gap between the two transformerhalves should be filled with non-magnetic, non-conductive
material, which at the same time keeps seawater out. In the
prototype, a 2 mm plate of glass was used for this purpose. The
orientation required for the IrDA devices to meet properly is
achieved mechanically by keyed cuts in the mechanical guide
structure for the coupler.
ULTRAMONIT subsea
coupler mounted into 32"
test clamp
1 W continuous
ULTRASONIC INSTRUMENT
The ultrasonic instrument is based on an
industry standard single board computer,
and is placed in a conventionally designed
atmospheric housing. This unit contains
the more complex parts of the
instrumentation. It is therefore considered
advantageous that the unit is accessible
for upgrade, maintenance and repair also
after ULTRAMONIT has been permanently
installed.
Connection between ROV and the
ultrasonic instrumentation is by one cable
to provide power and communication.
Required power is only 10W, either AC
(110-260V, 50 or 60 Hz) or 12v DC, which
would normally be available from the ROV
control panel. Most ROVs have one or
more extra twisted pairs in the umbilical,
and since high bandwidth is not important
for ULTRAMONIT, it was decided to use a
standard analog telephone modem for
communication to the surface. This
solution gives a bitrate of up to 56k, and
access to all the communication
technology which has been developed for
dial-up modem connections.
The computer is a single board pentium
class PC, with FreeBSD or Linux operating
system. In addition to telephone modem,
this computer has 10/100Mbit ethernet
Power requirement:
Ultrasonic frequency:
0.5-10 MHz
Sample rate:
40 MHz
Resolution:
12 bit
Gain:
-10 to +30 dB
Signal exitation:
Storage:
Full waveform
Ultrasonic frequency:
0.5-10 MHz
LAB EXPERIMENTS
ULTRASONIC MEASUREMENT ACCURACY Ultrasonic thickness measurements can be
very accurate if the acoustic conditions are favourable (planar surfaces, homogeneous
material and large dimensions compared to acoustic wavelength). An experiment was
carried out with a test specimen to study the potential accuracy of ULTRAMONIT for
thickness monitoring. The test piece was a block of ST52 grade steel, with four milled
slots with space for three ULTRAMONIT type of transducers in each.
The depth of each slot was carefully machined to give remaining thickness of 10 mm for
slot 1 and 2, 11 mm for slot 3, and 12 mm for slot 4. For the actual experiment, the test
piece was mounted in a CNC milling machine upside-down compared to the picture
above, and milled down in controlled steps of 0.05 mm.
Between each pass of the mill, the measured waveform from all ultrasonic sensors was
recorded.
The experiment was completed after collection of 12 passes of the mill. The reason for
doing this experiment with more than just a couple of transducers was to gain some
experience and statistics on absolute and relative accuracy with this kind of simple
transducer design. Signal analysis was based on extraction of thickness from the
autocorrelation of the received waveforms and a P-wave velocity of 5950 m/s.
The signal analysis was carried out for all transducers and each step in the milling, and
the results were compared to the expected values. Due to the fabrication and mounting
procedure in the CNC machine, initial absolute accuracy in thickness was not better than
0.1mm, and the whole experiment is therefore mostly relevant for analysis of change in
thickness. The resolution in the measurement system for the CNC milling machine was
0.02 mm.
Based on careful analysis of all measurements, the following figures for thickness
measurement accuracy were stated for the ULTRAMONIT transducer design:
Absolute accuracy:
0.1 mm
Relative accuracy :
0.02 mm
For a thickness monitoring application, the relative accuracy is the significant measure.
A change in thickness of 0.02 mm should therefore be detectable. A remark is
appropriate at this point: These figures are obtained under ideal conditions with a
machined piece and plane surfaces.
the Statoil materials research department were instrumented and measured with the
ultrasonic instrumentation described above. In this work, the raw signals were recorded,
together with best possible reference data (thickness) about the test pieces. Analysis
was carried out later using numerical tools like MATLAB.
Based on a fairly large number of individual measurements on many different test pieces
and transducers, the student's results can be summarized as follows:
Sophisticated methods with high resolution (correlation methods) that work well
for ideal geometry (plane parallel surfaces) may give considerable errors or totally
fail when used on samples with real corrosion.
Simpler methods with reduced resolution are found to be more robust and better
suited on real specimens. The accuracy in this case was found to be within
0.5mm
It must be pointed out here that the main idea with ULTRAMONIT is to monitor
development of corrosion, and the interesting parameter is how accurately a change of
thickness due to real corrosion can be measured.
In these raw waveforms, the first ultrasonic event starting at around 0.0 mm wall
thickness corresponds to the outer surface reflection from the pipe. The smaller event
which is displaying a clear trend from around 8.1 to around 7.6 mm corresponds to the
reflection from the inner surface which has been naturally corroded during the 21 first
weeks of the test period.
The trend line which gives the corrosion rate can be determined from this plot by placing
a ruler through the first break of the first arriving acoustic event as indicated above.
There is a complication to this straightforward approach. If measurement geometry had
been ideal (plane parallel surfaces) this would be simple. Thinning would manifest itself
as a clean small time-shift of the reflection from trace to trace. However, when the
acoustic target is small compared to wavelength and beam width, wave propagation
effects come in to play. The result is that we get changes in phase and amplitude of the
reflected echo, in addition to the pure time shift caused by the corrosion. More
sophisticated signal processing will thus be necessary to obtain corrosion rates over
time.
performance. We can here mention that the accuracy with conventional manual UT
measurement for corrosion at the Krst plant is judged to be around 1 mm based on
many years of experience.
The Time-of-Flight-Diffraction-technique (TOFD) [4], is by many considered the most
advanced ultrasonic scanning method. It consists of scanning a pair of angle-beam
transducers along a line (for example a weld), while the ultrasonic waveform is
recorded. Data are presented as a gray scale raster scan image, with ultrasonic
propagation time on the first axis, and position along the weld on the second. The
ultrasonic amplitude is represented as pixel intensity or colour. The method was
pioneered by AEA in the 1970's, and this kind of imaging technology has benefited
vastly from the introduction of the PC and all that came with it. Today, TOFD and similar
technology can be purchased from many suppliers.
Although TOFD is considered the most sophisticated ultrasonic scanning method, it is
primarily intended for detection and sizing of defects, like cracks in a weld. For corrosion
assessment in or near a weld it has the advantage that it is possible to measure without
placing the probe immediately onto the weld which is often not possible or desired. But
apart from this, a conventional straight P-wave probe should measure the thickness
more accurately in the general case compared to using a pair of angle-beam probes.
This is very likely the reason why suppliers of TOFD do not specify better accuracy than
0.5mm when the method is used for corrosion assessment [5].
It is our ambition that permanently installed equipment like ULTRAMONIT can be used to
improve the performance of ultrasonic monitoring measurements an order of
magnitude, for example to bring the usable accuracy from figures like 1mm to 0.1mm.
ACKNOWLEDGMENTS
This material is based on work carried out by Sensorlink AS in cooperation with Statoil
ASA. Funding for the work comes from the Statoil Research programme "New Ideas".
REFERENCES
1. ELECTROMATIC Equipment CO. inc., www.checkline.com
2. Kenneth A. Fowler et al., "THEORY AND APPLICATION OF PRECISION ULTRASONIC
THICKNESS GAGING", NDTnet - October 1997, Vol.2 No.10, www.ndt.net
3. www.sondex.co.uk/specs/ultrasonic_thickness_tool.pdf
4. N. Trimborn, "The Time-of-Flight-Diffraction-Technique", NDTnet - September
1997, Vol.2 No.09, www.ndt.net
5. DnV: www.dnv.com
NDT.net
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