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July 20, 2009

Attention: Nicolas Bublitz


Re: High Temperature Phased Array Inspection Solution Packages (HTPA200 applies)

Proposal for a High Temperature Phased Array


Inspection Solution Package
High temperature phased array inspection
targeting various temperatures
Range 30oC to 100oC (86oF to 212oF) Product package HT-PA100
Range 100oC to 200oC (212oF to 400oF) Product package HT-PA200
Range 200oC to 300oC (400oF to 575oF) Product package HT-P300
Project Dialog

Prepared By:
Eclipse Scientific Products Inc.
Waterloo Ontario, Canada
N0H 2V0

Head Office Software Engineering & Distribution Center Accounting & Application Laboratory
th
60 Baffin Place, Unit 4 2045 20 Avenue East, Suites 20 & 21 255352 Concession 1, RR#1
Waterloo, Ontario Canada N2V 1Z7 Owen Sound, Ontario, Canada N4K 5N3 Williamsford, Ontario, Canada N0H 2V0
Phone (800) 490-1072 Phone (519) 372-1831 Phone (519) 794-0110
Fax (519) 886-1102 Fax (519) 372-2039 Fax (519) 794-4437
ESP_ONDT HT-PA Inspection Solution 09G1.doc www.eclipsescientific.com
High Temperature Inspection Solution Packages Page 2
ESP_ONDT HT-PA Inspection Solution 09G1.doc

Introduction
The following proposal has been prepared to address the need for high temperature phased array
inspection of components up to temperatures of 300C. Three temperature ranges have been
established to enable package solutions to be offered. Defined duty cycle practices will enable each
cited temperature range solution to be applied to the highest stated temperature for the specific range
selected.

High temperature inspection offers considerable benefits for monitoring defects and corrosion during
operation, which potentially can save outage costs and permit better scheduling of repairs, as well as
offering improved safety due to routine monitoring. There are significant potential cost savings since
inspection costs and time allocation would no longer be based on the critical path inspection shutdown
periods.

Conventional ultrasonic inspection has significant problems at high temperature:


Couplant can be an issue, depending on temperature. This applies to phased array inspection
also but by proper delivery and chambering of couplant this negative impact can be reduced
and managed.
Probes are easily damaged. This applies to phased array inspection also but by monitoring and
shielding, the negative impact can be reduced and managed.
Temperature compensation is necessary since beams are skewed due to unknown temperature
and velocity variations.

Phased arrays provide a convenient solution to the third and most significant problem that occurs with
conventional UT beam, that being the skew resulting from varied velocities as influenced by
temperature. A wide variety of angles can be generated using S-scans, which can cover the whole
component/volume of interest. Though the actual angles may not be accurately known, S-scan
imaging of geometric structures can be used to evaluate the component. Monitoring of wedge and
material temperatures can provide additional information enabling compensation for the resulting
angles which will allow for improved detection and sizing awareness. The other benefits of the phased
array approach include speed of inspection, permanent records and encoding the position for ease of
interpretation, and detailed reporting for monitoring or repair.

For crack sizing, similar geometric imaging can be used to monitor growth. Cracks would be typically
measured relative to some known geometric feature, e.g. a corner or weld root. This minimizes any
temperature compensation requirements and the problems with beam skewing.

HT (high temperature) inspections are not routinely performed yet, partly due to the lack of approved
techniques, as well as difficulties with the equipment and lack of procedures. The package solution
overcomes all of these factors by providing an out of the box phased array solution for elevated
temperature inspection. Along with procedures and the techniques the package includes all the
required background knowledge and the hardware probes and wedges needed to perform the
inspection. Instrumentation is not included but can be quoted if required.

Eclipse Scientific
High Temperature Inspection Solution Packages Page 3
ESP_ONDT HT-PA Inspection Solution 09G1.doc

Technical Issues
There are technical issues associated with every aspect of HT inspections:

1. Couplant: Suitable couplants are available commercially, and can be applied during inspection
for the high temperature applications. Due to the piping utilization, couplant must not induce
any chloride cracking. Eclipse will provide recommendations for couplant options.

2. Wedges: The wedge material must be able to withstand high temperatures, and/or will need
cooling; these are both standard approaches. Commercial high temperature wedge materials
will be selected based on the temperature range. Standard wedge material should be exposed to
a maximum temperature of 40C to 50C (100F to 125F). Some alternative materials will be
used as sub-assembly components to aid shielding and the resultant probe assembly geometry
will need to be factored when limited access conditions apply.

3. Cabling: These need to either operate at high temperature, or be cooled. There are two
possible approaches and consideration for the shielding which will be critical to the
implementation of the techniques. Protective casing jacket with insulation will be fundamental
but additional chamber cooling via some circulating cooling may be required to ensure cable
integrity. Consideration of these as recognized consumables will be an important factor when
costing projects.

4. Arrays: Standard off-the-shelf arrays will be used; a water jacket has been developed for high
temperature inspections (up to 300oC). By improved shielding the standard transducer can be
used but the duty cycle for inspection time will need to be closely monitored. If required for
more extreme environments the development of an alternative array design will need to be
considered and commissioned.

5. Temperature Compensation: Two approaches will be applied for this aspect of the project.
Compensation for angle changes due to the temperature variations should not be necessary if
the phased arrays are using multi-angle S-scans covering the range of interest. This should
permit inspection by using the component geometry for reference in these cases. The
installation of thermocouples, temperature control of calibration samples, and wedge velocity
change compensation can be implemented for those applications requiring accurate sizing.

6. Scanner: A standard basic encoding device is included with package solutions. If pipe or
vessel inspection requires more capable scanner ability these will need to be modified to work
at the required temperature. The common solution is to add an insulation ring on the piping to
keep a distance between the scanner and the hot tubing. This approach also applies to vessel
applications but attachment of the insulating layer can be more difficult.

Scope
This proposal provides cost awareness for a functional solution for high temperature inspection of
components in operating plants up to ~300oC using phased array technology. Defined duty cycle
practices will enable these package solutions to be applied to the noted temperature range. The probe
will use a water-cooled jacket (air cooling for some temperature ranges can also be applied) for a
standard array with a thermally-insulated wedge. The use of a standard encoding device with an offset
wheel arrangement will provide position correlation capability.

Eclipse Scientific
High Temperature Inspection Solution Packages Page 4
ESP_ONDT HT-PA Inspection Solution 09G1.doc

Current Technology Status of HT Arrays


At this time, there are a number of companies which manufacture conventional ultrasonic transducers
for HT, either for intermittent or for continuous use. Some transducers meet the HT monitoring
requirements with additional cooling. Other companies manufacture couplant and wedge materials for
HTs.

Eclipse Scientific has been involved in working with phased array zero degree and shear angle beam
inspection at elevated temperatures. The three temperature ranges are:

1. Range 30oC to 100oC (86oF to 212oF) Product package HT-PA100

a. Product package HT-PA100L for zero normal beam delay line arrangement

b. Product package HT-PA100S for shear angle beam wedge arrangement

2. Range 100oC to 200oC (212oF to 400oF) Product package HT-PA200

a. Product package HT-PA200L for zero normal beam delay line arrangement

b. Product package HT-PA200S for shear angle beam wedge arrangement

3. Range 200oC to 300oC (400oF to 575oF) Product package HT-P300

a. Product package HT-PA300L for zero normal beam delay line arrangement

b. Product package HT-PA300S for shear angle beam wedge arrangement

HT inspection is normally targeted to be performed on limited regions previously screened and


identified.

Included in the Package Solution


Eclipse can quote supporting instrumentation as an option. The solution package includes all that is
required to perform the inspection excluding the phased array ultrasonic instrument:

1. A high temperature cooled phased array probe and wedge arrangement for zero degree
inspection or/and shear wave inspection.
2. Basic encoding scanner for zero degree inspection and shear wave inspection
3. A procedure for HT monitoring
4. A general technique set for four typical applications
5. A specific technique for client specific requirements
6. Recommended HT couplant
7. Recommended couplant delivery system
8. Thermocouple for monitoring environment
9. Thermal awareness labels for monitoring (secondary safety consideration for array)
10. Documented users guide

Eclipse Scientific
High Temperature Inspection Solution Packages Page 5
ESP_ONDT HT-PA Inspection Solution 09G1.doc

Order Selection
Packages have been established and include noted content with specific items selected for inclusion in
each kit as required to target the noted temperature ranges.

Solution
Temperature Range Package Code and Description
Package Cost
Range 30C to 100C Product package HT-PA100L for zero $18,950.00
(86F to 212F) normal beam delay line arrangement
Product package HT-PA100S for shear $19,250.00
angle beam wedge arrangement
Product package HT-PA100L-S for zero $21,050.00
normal beam delay line and shear angle
beam wedge arrangement
Range 100C to 200C Product package HT-PA200L for zero $20,950.00
(212F to 400F) normal beam delay line arrangement
Product package HT-PA200S for shear $21,350.00
angle beam delay line arrangement
Product package HT-PA200L-S for zero $24,150.00
normal beam delay line and shear angle
beam wedge arrangement
Range 200C to 300C Product package HT-PA300L for zero $23,200.00
(400F to 575F) normal beam delay line arrangement
Product package HT-PA300S for shear $23,700.00
angle beam delay line arrangement
Product package HT-PA300L-S for zero $27,100.00
normal beam delay line and shear angle
beam wedge arrangement

Delivery Time Requirements


Eclipse Scientific requires 6 to 8 weeks from receipt of the initial payment to delivery. The proposed
phased array transducer is a standard commercial transducer version but some modifications are made
to accommodate the requirements of high temperature inspections.

Costs
Each package includes the basic minimum of components to help reduce costs as much as possible.
Replacement components, referenced in the users guide, can be purchased but limited alternative
combinations are offered.

Eclipse Scientific
High Temperature Inspection Solution Packages Page 6
ESP_ONDT HT-PA Inspection Solution 09G1.doc

Client Must Anticipate Some Additional Costs (estimates provided)


1. Couplant: Client must purchase appropriate couplant for temperature range and will require a
delivery system and suitable quantity for application. Couplant delivery system can range up to
$2000.00. Allowance for couplant: $500.00 to $1200.00
2. Coolant: Client will need to provide circulation/filtration of clean cool water or alternatively
air pressure system for the cooling jacket. Allowance: $250.00
3. Safety Equipment: Client will need to provide protective safety wear and shielding for
technicians, instrumentation and support equipment. Allowance: $500.00 to $1000.00

Authors notes:
Eclipse Scientific would like to take this opportunity to thank you for providing us with the
opportunity to prepare this proposal and looks forward to the opportunity to work together. Please
contact us if you have any questions or comments. Due to the environmental conditions and limited
control of exposure to elevated temperatures, no warranty applies. Workmanship warranty will apply
to items fabricated by Eclipse. Third party components can be scheduled but Eclipse is not able to
guarantee timely delivery package solution. Purchaser will be notified of any unforeseen delays
causing changes to stated delivery date. Eclipse will not be held responsible for any impact caused by
unanticipated delays.

Other Cost Consideration:


The total shown does not include shipping of components nor does it reflect any on-site assessments or
support if required to evaluate the application, or detail application prior to generation of any
commissioned aspect of this project, such as mock-up samples.
This quote does not include any allowance for application evaluation or for any required follow-up
presentation to end clients. For the application review or the noted follow-up travel allow $12,000 US
per trip.
The quote does not allow for any on-site support. Please allow $15,000.00 to $25,000.00 US extra for
the potential field support activity. Field consulting rate sheet supplied upon request.

Eclipse Scientific