December 2017

Volume 15 Issue 11

NDT IN
OIL & GAS INDUSTRY
 DECEMBER 2017 Volume 15 - Issue 11

Vadodara

FACE TO FACE
- Dr. Krishnadas Rao, Former Chairman-HAL

17
- Prediction of Mechanical Properties in Tempered Dual Phase
Steel through Non-Destructive Magnetic Hysteresis Loop
Technique
- Pulsed Eddy Currents: Improvements in Overcoming Adverse
Effects of Galvanized Steel Weather Jacket
- Robotic Inline Inspection and Leak Detection System for Oil
and Gas Pipelines
- Simplifying Phased Array UT Process with Digital Solutions
and Wireless Collaboration
- Study of Distortion of Low-Frequency Axisymmetric
Ultrasonic L (0, 2) Guided Waves in Pipe Bends and Elbows

41 ARTICLES
- Inspection of Off-shore Structures using Remotely Operated
Vehicles: Planys Experience

45 - Infrared Thermography and its Applications in Refinery

51 PRODUCT GALLERY
NDT IN
OIL & GAS INDUSTRY

54 - International Events Calendar, 2018

- 15th APCNDT 2017 - Brief Report
- 1st NDT Seminar, 1979 - Brief Report

59
- Meeting Schedule
- NGC/NCB Officers Team

61

62

December
2017
 LETTERS 3

PRESIDENT
"Oil & Gas Sector is one of the six important sectors in India and affects Indian economy to a great extent. As per survey carried out in
2013, India was the fourth largest consumer of Oil & Gas in the world and expected to take over Japan by 2025. There are 19
refineries in Public sector & 3 in private sectors and nearly 25000 KM pipe line for transportation of these products. Assets used as
pipelines, floating/fixed platforms, drilling rigs, tanks, vessels, heat exchangers or other equipments within the Oil and Gas industry
are complex and have a limited life cycle. Well done NDT is a highly valuable tool that can save both money and time. The
conventional and advance NDT technologies and inspection by well trained and qualified personnel can help to extend the life cycle
of these assets in a safe and compliant manner.

This issue of JNDE, specially devoted to Oil & Gas sector will certainly be interesting to the NDT professionals working in this field.
The other topics such as Basic NDT, information on NDT products, the latest news in the field of NDT and the advertisement by
prominent NDT equipment manufactures will also of be great attraction to NDT professionals and industry at large.

I appreciate the great efforts by every member of the editorial board and the supporting staff to try to bring this issue timely for the
NDT professionals. I am sure that all the NDT professionals will also appreciate this issue of the NDE Journal."

D.J.VARDE
president@isnt.org.in

/ CHIEF EDITOR
We kick off with an array of interesting technical papers from the desk of our guest editor, Mr. V.Manoharan, Senior Scientist
GE Global Research, Bangalore. My sincere thanks to him. Followed up by an article shared by Planys Technologies on Inspection of
Offshore Structures.

We will be looking back at some memorable events. Do read through major international events for 2018 listed, that you might
want to consider booking a trip to.

This is the last issue for 2017 and I would like to close the year with a bit of news that ISNT registered more than 1000 new
memberships in current year; including student, corporate & life members.

It is interesting how you feel when there is a year's worth of time ahead of you at one moment and when the same year is behind
you the very next moment. This is exactly how I felt as I was signing off on the last issue for the year, a year that comes fast to
completion.

As always, you may provide your feedback on any aspect of our magazine by contacting us at isnt.jnde@gmail.com. I would very
much like to hear your thoughts on any part of this editorial, how we can further publicize the magazine's distinctive features and
objectives, and ultimately how we can make it more appealing to you, our valued readers.

RAJUL PARIKH DR. KRISHNAN BALASUBRAMANIAM

Managing Editor Chief Editor
secretary@isnt.org.in balas@iitm.ac.in

December
2017
 LETTERS 5

I am very delighted to be part of this special edition of Journal of NDE focusing on Oil & Gas (O & G) Industries. Non-Destructive
Evaluation (NDE) plays a major role in ensuring safe operation of plants in O & G and petrochemical Industries. NDE at specific
intervals saves cost and time if testing reveals threats and equipment is repaired before shutting down the facility or experiencing a
catastrophic failure.

Historical NDE data of assets provide insights on how often a component should be inspected, repaired, or replaced. These insights
help in proactive maintenance of equipment’s and reducing unplanned shutdown. High temperature, large volume of
infrastructure to inspect, inaccessible areas, hazardous environment are some of specific challenges of O & G industries. Industries
and technology organizations are making considerable effort to overcome these challenges by investing in technologies such as
permanently installed sensors, robotics & automations, digital inspection, data analytics and wireless communication of data.

This issue contains technical papers which are good examples of recent technology trends and addressing issues specific to O & G
industries. My best wishes and thanks to all authors who have contributed technical papers to this issue of JNDE.

V.MANOHARAN
Senior Scientist
GE Global Research, Bangalore
Manoharan.V@ge.com

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December
2017
December
2017
 PUNE- AUGUST 2017 - DECEMBER 2017
Ÿ 14th and 15th September 2017- A workshop for last year
Engineering Students was arranged by ISNT Pune Chapter
at Sharad Institute of Technology, Yedrav, Ichalkaranji
which was coordinated by Mr. Sunil Gophan. Mr. Sunil
Gophan, Mr. Kalesh Nerurkar and Mr. Brahme were the
faculties for theory and practicals.
Ÿ 5th and 6th August 2017 - ISNT Pune Chapter supported
NCB for Examiners workshop for QMSD Implementation,
held at Hotel NooryaHometel, Chinchwad, Pune. 25 people
representing 9 of the ISNT Chapters attended the workshop.
The workshop was well received and appreciated by NCB.
Faculties for workshop were Mr. Paritosh Nanekar (UT), Mr.
C.M Khade (VT & LT), Mr. J R Hiremath (PT & MT), Mr. D D
Joshi (RT) & Mr. Arbind Kumar (ET)
Ÿ 22nd and 23rd August 2017 - A two days National
Workshop on "Radiation Safety" was conducted at
Quality NDT Services, Bhosari, Pune. Shri Bhausaheb
Pangare was the Convener for the workshop. About 20
participants attended the workshop.
Ÿ 27th September 2017 - AGM of the Chapter was held and
new EC was elected.
Ÿ 19th August 2017, 6th September 2017, 25th
September, 16th October 2017 and 5th November
2017 - EC meetings were held.

Students at MT Level II Course Examiners Workshop Radiation Safety Workshop At the AGM

MUMBAI - SEPTEMBER 2017 - DECEMBER 2017 Ÿ 30th October 2017 to 3rd November 2017 - NDT for
Ÿ 16th September 2017 - managers course started.
ISNT AGM was conducted at Shri L.M.Tolani was the
Capers Banquet, Andheri. course co-ordinator.
Ÿ 3rd October to 10th Ÿ 6th November to 10th
October 2017 - Ultrasonic November 2017 - RTFI-
Testing Level-II regular Level-II course was held.
Participants at UT Level II Course course conducted. Shri Examination date: 12th
L.M.Tolani was the course co-ordinator. ( Examination Date: November 2017 EC Meeting
11th OCT.2017) Ÿ 3rd Nov 2017 - EC Meeting held at ISNT, Mumbai office.

TRIVANDRUM - SEPTEMBER ‘17 - DECEMBER ‘17
Ÿ 2nd August 2017 - First EC meeting of the new committee
conducted at Trivandrum hotel.
Ÿ 10th August 2017 - Inauguration of first student chapter at
Govt. Engineering college Barton Hill, Trivandrum by
Chariman, ISNT.
Ÿ 17th August 2017 - Inauguration of second student chapter
at College of Engineering Trivandrum by Chairman, ISNT.
Ÿ 26th September 2017 - EC Meeting conducted at
Trivandrum hotel.
Ÿ 26th October 2017 - Young engineers forum: Technical
lecture on “Pyro Devices for Space: Applications & Ndt” by
D r. M . N a l l a p e r u m a l , D G M , N D T F, V S S C
NDT: Shri Sambamurthy E, NDTF, VSSC at Trivandrum Hotel.

Shri Levin .G, Chairman, ISNT
Trivandrum chapter handing over
the ISNT Corporate membership
of the institute to the Principal,
CET, Trivandrum.
Shri Arumugam.M, Vice
C h a i r m a n , Tr i v a n d r u m , a t
inaugural ceremony of first
students chapter at Govt.
Engineering College, Trivandrum.
S h r i . K . R . M o h a n
Ananthanarayanan, Vice
chairman, ISNT, Trivandrum
chapter delivering the lecture in
one day workshop on NDT.
Shri Sambamurthy
Engula,Scientist,
VSSC,Trivandrum delivering
talk on “Pyro devices - NDT”

December
2017
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 12

MANAGER & HEAD ACCOUNTS OFFICER ADMIN OFFICER OFFICE ASSISTANT JNDE EXECUTIVE
OFFICE IN-CHARGE In ISNT since 1-11 2010. In ISNT since 23-3-2011. In ISNT since 4-8-2014. In ISNT since 17-8-2015.
In ISNT since 02-01-2012. In-charge of work In-charge of work Coordinates with JNDE In-charge of corresponding
Has vast knowledge and connected with Accounts, connected with Training Executive, correspondence & coordinating with Editors
experience in Accounts, Preparation of MIS, and Certication conducted with subscribers and other / Authors / Chapters for
Taxation & Administration payment of statutory dues by NCB-ISNT as per the institution in connection write ups & managing
Matters. Managing day to maintenance of accounting instruction of NCB Ofce with JNDE journal. contents. Sourcing
day functioning of Head
records, preparation of Bearers. Takes care of Assisting accounts in- advertisers & handling
Ofce, matters connected
monthly income & general correspondences charge in matters advertisements. Invoicing,
with statutory compliance,
expenditure statement and and other administration connected with coordinating payments &
co-ordinates with ISNT
matters connected with matters of Head Ofce. preparation of vouchers, JNDE related matter with
chapters and ISNT Chapters
ISNT membership. Assisting accounts ofcer in receipts, tabulation of Head Ofce. Laying out,
and ISNT Ofce bearers,
regular matters. service tax, data entry in designing nal cover page,
arrangements for Meetings,
guiding HO Staff in their tally and other work editing, proof reading,
respective area of work. assigned from time to time. taking journal for nal
print.

December
2017
June 2017
14
Dr.C.G.Krishnadas
Dr.C.G.Krishnadas
Nair
B.Tech Metallurgical Engineering, M.Sc Engineering, Ph.D.
Metal Fatigue.
Dr.C.G.Krishnadas Nair, Former Chairman, Hindustan
Aeronautics Ltd, Former Vice Chancellor, Mahaveer Academy
of Technology and Science University, Raipur is also Founder
President of Society of Indian Aerospace Technologies and
Industries (SIATI) and Chancellor, Jain University. He is one of
the founder members of NDT Society of India, which got
merged with ISNDT later.
D r.C.G.Krishnadas Nair, Former Chairman, Hindustan
Aeronautics Ltd, Former Vice Chancellor, Mahaveer
Academy of Technology and Science University, Raipur is
also the Founder President of Society of Indian Aerospace
Technologies and Industries (SIATI) and Chancellor, Jain
University. Dr. Nair holds a Ph.D. in Metal Fatigue & M.Sc
(Engineering) from the University of Sask, Canada, and is a
distinguished Alumni of IIT Madras, with a B.Tech in
Metallurgical Engineering. He is one of the founder members of
NDT Society of India, which got merged with IINDIE later. He is a
technologist and Industry leader of eminence. During his
distinguished professional career spanning over 36 years, he has
made significant contributions in Engineering Education,
Research and Industry Management. He has authored 20 books,
edited and published proceedings of many National and
International seminars and authored over 200 technical papers
in national and international journals and conferences.
For his immense contributions, Dr. Nair has been
honored with several awards and recognitions; INAE Life Time
Achievement Award (2007), IIM Platinum Award (2004), Scope
Award for Best Chief Executive and Gold Plaque from Prime
Minister of India (2003), National Metallurgist Award (2003),
Padmashree from Government of India (2001), Dr. Ambedkar
Bharath Shree Award (2001), Rashtriya Ratna Award (2001),
Swadeshi Science Puraskara (2000), Indira Gandhi Priyadarshini
Award (1997), Omprakash Bhasin Award for Aerospace (1996),
Vasvik Research Award (1992), National Award for R&D (1991),
FIE Foundation Award (1991), National Aeronautical Prize
(1990), National Award for Best Employer of Physically
Handicapped and several others. Recently Ministry of Steel and
Mines, Government of India, and Indian Institute of Metals, has
honoured him with Lifetime Contribution Award in Metallurgy
and Material Science (2017). His areas of Interest include
Metallurgy and Materials Science, Aerospace Industry, Small
Scale Industries, R&D Management, Post Graduate Research &
Education, Teaching and Skill Development/Entrepreneurial
Development, Industry, Project and Research Management,
Materials Testing and Evaluation including NDT.
He has been a member of various scientific advisory
councils and committees like the Scientific Advisory Committee
to the Cabinet, Govt. of India; Research Council, Regional
December
2017
Research Laboratory, National Aerospace Laboratories;
Governing Council Member, Jawaharlal Nehru Research and
Development Center for Aluminium, and Standing Scientific
Advisory Committee, Department of Steel and Mines. He has
served as president for two leading Professional Associations,
viz., President, Aeronautical Society of India, and President,
Indian Institute of Metals. He has been a director / member board
of several public and private sector corporates.
Sir, you have a very enriching career of nearly 5 decades
with so many accomplishments. Your longest stint has been
at HAL where you joined as an Engineer and rose to the
position of the Chairman. Can you give us a brief highlight of
that journey and the challenges you encountered as you
made it to the top?
It is a very long story but let me share some highlights. I joined in
the Helicopter Design and Development division initially as a
material scientist to help with the definition of the helicopter
from a materials perspective - especially various types of
aluminum alloys and composites. With that background, we
started working on indigenous development of various types of
alloys and composite materials which were then being mostly
imported into the country. I moved to the Central laboratory
which was a Testing Lab and we converted into a Research Lab,
got recognition by DST as a Materials and Process Laboratory
and incubated a lot of development activities. They were not
inventions but were developed elsewhere in the world but you
had to pay a lot to get the knowhow or sometimes it was
impossible to get it. Thus, we started our indigenization journey.
We developed the alloys and got it manufactured from Indian
industries like Indian Aluminum, Alloy Steel Plants, Tata Steel,
and others. Then we came to Composites and at that time only
NAL was doing some research in this field but they were using
chopped glass mat and was not aerospace grade. We wanted to
substitute the imported glass fibre composites for our
Helicopters. We started from the beginning to set up R&D. We
went to Pilkington who was making the glass fibre and then it
had to be treated and woven into cloth for which we got
expertise from textile engineers. Next, we did chemical treatment
followed with resin impregnation & certification after creating
the entire process and product. We set up our first fibre glass

plant in HAL enhancing self-reliance and created lot of job
opportunities which gave me and my team a lot of satisfaction. It
was a good example at that time of converting research into
production.
When I was in the Lab, we developed the NDT
capabilities into a Centre for R&D and Training. Mr. Jayamangal
Prasad was in-charge of that under my guidance and we trained
and certified nearly 1000+ technicians and engineers in the HAL
NDT Centre and developed a lot of NDT techniques for complex
aircraft welded structures, sophisticated castings, forgings and
composites.
Then I joined the corporate office and under the
guidance of the Chairman and Chief of Planning and
Development set up a Corporate R&D which would cut across the
country where we had many different divisions of HAL. That gave
me very good exposure and helped me to reach out to all HAL
divisions and many R&D labs across the country. That changed
my career. From corporate planning I moved to the Management
Cadre and rose to be General Manger of HAL Foundry & Forge
and HAL Engine division. However, I actively pursued R&D in
metallurgy, materials, testing and analysis including NDT in
addition to being a professional manager. I progressed to the
position of Executive Director, combining aircraft division,
engine division, helicopter division and foundry and forge
division. That was the time I took initiative in setting up a
dedicated space division with support from ISRO to fabricate
satellites and launch vehicle structures. The co-operative team
work and the achievements were appreciated by HAL’s top
management.
Considering my interest in metallurgy and materials,
HAL allowed me to serve on the Board of prestigious
metallurgical industries and research laboratories, Bharat
Aluminium Company, National Aluminium Company, Mishra
Dhatu Nigam Ltd, Jawaharlal Nehru Centre for Aluminium
Research, Defense Metallurgical Lab, National Aerospace Lab to
mention a few. When I was in the Foundry division, I suggested
to develop titanium alloy compressor blades and super alloy
turbine blades for Jet engines, but the management hesitated
thinking it was not possible to develop such sophisticated and
advanced technological items in India. However, my friends and
mentors in DRDO and metallurgical community encouraged and
motivated our team and we succeeded in developing these and
getting them type certified. Our cost was only about one sixth of
what it costed to import.
Dhruv, HAL’s Advanced Light Helicopter (ALH) is a great
success story in recent history. It was totally designed and built
by HAL. It holds the world record for high altitude flying (7 kms
above sea level). It can fly over the sea, over deserts and over the
high snow-clad mountains in the Himalayan ranges. Several
versions of Dhruv have been developed to meet specific needs of
Army, Navy, Coast Guard and for passenger service / search and
rescue/disaster relief. Advanced technology & lightweight
materials have contributed significantly for the successful design
of the Advanced Light Helicopter and for Light Combat Aircraft.
HAL was the primary partner with DRDO in developing the
worlds lightest advanced combat aircraft, Tejas. One major
challenge encountered during the development of ALH and LCA
was the embargo on materials, equipments and technology
imposed after our peaceful but highly misunderstood nuclear
experiment ‘Pokhran’. However, HAL along with national
15
laboratories through their dedicated R & D mitigated the issues
and successfully completed the ALH and LCA projects.
The stringent demand for Quality and Reliability in the
aerospace sector has always been one of the prime
motivators for the growth of NDT and Inspection. What are
the current unmet needs which the NDT professional should
focus on?
The ever-increasing demands of structural integrity, safety and
multi role capabilities have given rise to new lighter weight
materials, engineered materials, such as composites,
honeycomb bonded sandwich structures, co-cure co-bonded
structures and many advanced processes such as adhesive
bonding, isothermal forging, hot iso-static pressing, additive
manufacturing (3D printing) and the like. Automation and
robotics in manufacturing are becoming extensively used
techniques for improving productivity and quality. There has
been a continuous pressure on developing NDT technology and
techniques for the new materials and processes. I am happy to
record that our scientists and engineers in the field of non-
destructive testing have met these challenges by developing
appropriate technologies and equipments and capabilities
within the country. Many examples can be given. One case is the
testing of the large LCA carbon fibre composite wings for which
manufacturing technology was established along with
inspection technology and equipments.
HAL jointly with CAIR and NDT experts designed and
developed the C-Scan equipment for the full-scale wing testing
and X-ray and ultrasonic testing for honeycomb bonded
sandwich structures. Lot of people were skeptical about the
development of such NDT equipments in India but we
succeeded. Our cost was about 20% of cost for import. Similarly,
the large auto-clave with all its online monitoring of temperature
pressure and other parameters was developed by NAL and its
industry partner. Developments were also taken place in the field
of X-Ray radiography of castings, cluster welds. Today, we can
monitor the X-ray images on a screen and make immediate
decisions unlike in the earlier times where we used to take
images on films to be developed and examined after several
hours and then analysis to take decision. We also have scanning
methods as in health care industry, which gives 3D images and
facilitate more quantitative analysis.
Our R&D labs and industry partners should make much
more efforts for marketing and commercializing these
developments worldwide. We also do not upgrade the
technologies and equipments continuously and sometimes loose
out even in the Indian market. We should make adequate efforts
in developing skills among NDT technicians and engineers.
Several of the training institutes for training and certification in
NDT are ill equipped both in infrastructure and experienced
faculty.
Who or what has been the biggest inspiration and
motivation behind your successes which is continuing even
now?
During my early professional life, the motivation came mostly
from professional bodies and societies like IIM, ISNT (ISNDT that
time), Institution of Engineers, Aeronautical Society of India.
Senior members of these associations and several R&D
institutions who were top leaders and visionaries were my role
December
2017
14
models. These associations and the visionary leaders
C.G.Krishnadas
encouraged, motivated, helped us network, do team building
and helped keep a positive mind set continuously. Many times,
the thought of leaving HAL crossed my mind, it was my friends
and colleagues from these societies and my mentors in HAL who
advised me against it. When my work was appreciated by
colleagues and it also created employment, I felt a sense of pride
and this inspired me and my team to do more. Founding of
Society of Indian Aerospace Technologies & Industries (SIATI) for
enhanced private industry participation particularly small and
medium scale industry in aerospace and support from all
stakeholders has been very motivating. This year is SIATI’s silver
jubilee and we are celebrating it throughout the year all over the
country. Many industries are given awards of excellence for their
achievements in indigenous development of aerospace
materials, processes and equipments. So far, SIATI has honoured
156 industries and 16 individual entrepreneurs. SIATI member
industries have become not only cost effective and reliable
quality conscious, supply chain partners but also R&D and
Innovation partners for India’s space and aircraft and defense
projects. Some of them have also emerged as exporters of their
products and services and this is very inspiring.
In an article in one of the journals, you were described as an
Engineer, Scientist, Manager and Academician. Which one
of these do you associate yourself the most?
I always believed that a good manager must be a good teacher,
and sustain and grow in his field of specialization either as
Engineer or Scientist. What one knows, one should be able to
teach one’s colleagues and the team will become stronger and
do great things together. There must be a good combination of
all the above elements to be successful and to help others to be
successful.
With the new initiatives like “Make in India“, “Skill
Development” etc. we are seeing an increase in young
engineers wanting to be entrepreneurs and create new
startups . What do you see the role of professional bodies in
fostering this culture?
We all have a big role. First of all this is a very good sign that
many youngsters are getting charged with this mission and
motivation of “Make in India”. Professional societies should
actively continue to encourage them to work together for these
national initiatives and help learn from each other. In
engineering, inventions and innovations will take place only
when we have multi disciplinary teams working together with
passion and dedication. All professional bodies should
encourage knowledge and skill development by organizing
seminars and workshops for these youngsters using the
expertise available within the societies and elsewhere. They are
our future and we have a duty towards them. The issue of finance
will always be there but there are several agencies today, who
are coming forward to assist. What professional bodies may do is
to create awareness workshops for the young entrepreneurs /
start-ups to enable them for wise evaluation and choosing of
such financial offers particularly from venture capitalists. Skill
development in entrepreneurship will be welcome. Celebrating
success by encouraging through awards for achievements and
taking up common issues and challenges with appropriate
forums in the government for policy changes / policy formulation
September
2017
to create suitable eco-system for the growth of start-ups will be
helpful. Association may also join with the governments and
industries for establishing skill councils and quality training
institutions in concerned fields to provide skill training and
certification to provide adequate number of qualified human
resources.
What would be your dream for the aerospace industry in
India ?
My dream for aerospace industry in India is maximizing
indigenous manufacture of aerospace needs of our country for
both military and civil. We should collaborate wherever
necessary with international OEMs and make the ‘Make in India’
mission a success and beat the import lobbies. Our biggest
problem in India inspite of efforts at the top, is the presence of a
strong import lobby with vested interests who decry indigenous
development. LCA and ALH are two great examples of
indigenous technologies which are far superior to anything a
foreign supplier can offer in that category. Our products are on-
par or better in most cases, so we should become independent.
Like the other countries, China, Russia, USA, France, who
encourage their own industries, we should do the same in India.
My dream is to work in harmony with the government and the
import lobby should not be allowed to flourish. Also, our retired
people working as agents for foreign companies should not be
encouraged and instead should work for Indian companies and
bring in international collaboration. We should encourage
indigenization and indigenous products wherever possible. Let
thoughts and ideas come from everywhere and let us digest it
and collaborate internationally by becoming a global player.
SIATI and IIAEM are good examples of these philosophies. We
have managed to get a lot of joint ventures, strategic
collaborations and influencing the government and other
external agencies.
Would you like to share something about activities other
than your professional ones and your other passions?
I like peaceful & soothing activities like music, meditation,
gardening, nature walk & tree planting. Photography, reading &
writing books is also something that I enjoy.
I am also involved with a few charitable institutions to
support poor school children and for education and support of
physically and mentally challenged children and the like.
Let me end by saying that I am delighted to note the
growth of ISNT and its activities and the publication of the JNDE,
which is of a high standard. I will be happy to associate with ISNT
and support its activities to take ISNT to higher national and
international levels. I feel it’s time, we hold a World Conference
on NDT in India, similar to the one held two decades back to
demonstrate the new positive environment prevailing in the
country and to showcase the world our capabilities and
achievements in the various sectors.
We thank Dr. Nair for taking time to share his vast decades of
experience for the benefit of the readers of this journal and
will act as an inspiration and motivation to do more.
As interviewed by Dr.Shyamsunder Mandayam,
Chairman, National Certification Board, ISNT
Prediction of Mechanical Properties in Tempered
Dual Phase Steel through Non-Destructive
Magnetic Hysteresis Loop Technique
*J. N. Mohapatra, Arbind Kumar Akela, Satendra Kumar and Prakash Rao S.
JSW Steel Limited, Toranagallu, Bellary 583275 Karnataka, India.
*E-mail: jitendra.mohapatra@jsw.in

ABSTRACT
Dual phase steel with different content of martensite were prepared by quenching a C-Mn steel after
soaking at various temperatures in the range of 700-850oC. With the increase in martensite content
the strength was found to be increased with decrease in ductility. The steels were tempered at 300oC
for 1 hour to improve the ductility as the steels are used in the oil and gas industry in tempered
condition for better hydrogen embrittlement resistance. Optical and scanning electron microscope
conrms the formation of dual phase and tempered martensite microstructure. Magnetic hysteresis
loop (MHL) measurements were carried out to evaluate mechanical properties through a
nondestructive magnetic device. The measured coercivities were used to predict micro-Vicker’s
hardness and compared with the measured values found to be well within the acceptable range. The
results inferred that monitoring coercivity of the MHL could estimate the extent of hydrogen
embrittlement induced change in mechanical properties.
1.0 INTRODUCTION service conditions of the components. With proper preventive
actions could helpful for the prevention of catastrophic failure

D ual phase steels possess unique feature of low yield
strength, high tensile strength, high work hardening
rate at early stage of plastic deformation, continuous
yielding, good ductility, and formability owing to their use in
the automotive sector for obtaining high strength/weight ratio
to reduce the fuel consumption and consequently reduction in
CO2 emission [1-4]. The properties of DP steels are achieved by
its microstructure consisting of optimum combination of
martensite and ferrite. The martensite gives the superior
strength whereas the ferrite provides the adequate ductility.
Generation of martensite phase through water quenching is a
prominent method of achieving mechanical properties,
however tempering is usually conducted to improve the
ductility of the steels [5, 6]. Through tempering the yield
strength and tensile strength decreases with the improvement
in the elongation of the steels.
In oil and gas industry various components in contact with the
hydrogenous materials resulted in diffusion of hydrogen to the
materials causing hydrogen embrittlement lead to catastrophic
failures. Appropriate tempering to the steel resulted in an
excellent resistance to hydrogen embrittlement which makes
the material a potential candidate for oil and gas industries
where hydrogen embrittlement is of the major problem [7]. The
hydrogen induced embrittlement resulted in decrease in
ductility and increase in strength of the materials with a brittle
mode of fracture. Hence by periodic monitoring the change in
ductility or strength of the components in use through
noninvasive means could helpful for the assessment of the
of the components.
As the yield strength and tensile strength is related to hardness
of steels, measuring the hardness could also represent the
relative change in mechanical properties. Numerous works
could be found for the evaluation of microstructure and
mechanical properties of the steels [8-11], however a limited
number of literatures available for the study of physical
properties such as electrical, magnetic, ultrasonic etc. of the
steels [12-15]. For the precise control of microstructure and
mechanical properties of the steels and their evaluation is a
need to develop suitable advanced non-destructive evaluation
methodologies [16]. Since magnetic properties of the steels are
strongly dependent on the microstructure, magnetic based
techniques such as magnetic hysteresis loop and magnetic
Barkhausen emissions are in growing demand. Evaluation of
change in structures in terms of ageing, creep, fatigue,
carburization, decarburization, embrittlement and residual
stresses effects etc. through magnetic based techniques are a
great interest by the researchers for the high sensitivity of the
techniques [17-21]. Although magnetic based techniques are
not well established for the evaluation of materials degradation
in oil and gas industries more research is required for the
establishment of the techniques in such eld.
In our earlier study [22], a very good correlation was
established between the volume fraction of martensite,
hardness and tensile strength with the coercivity of the steels.
In the present investigation, specimens with varying
martensite volume fractions were tempered to improve the
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ductility. Coercivity was monitored on the samples whereas
hardness was predicted from the regression equations of our
earlier study [22].
Hv = 36.38 Hc-120.7 ……………………… (1)
Where Hc = Coercivity and Hv = Micro Vicker’s Hardness
present in the sample due to cold rolling. Microstructure of dual
phase steel soaked at 700-850oC with 50oC step for 15 min
followed by water quenching is shown in Fig. 2 (a)-(d) and their
corresponding tempered microstructres are shown in Fig.2 (e)-
(h). The corresponding SEM micrographs are shown in Fig. 3.

Micro Vicker’s hardness tester was used to measure the

hardness of the steels. The measured hardness was compared
with the predicted values. The results were found to be well
within the acceptable range. As the hardness is related to the
yield strength and tensile strength of steels, by monitoring the
coercivity the mechanical properties of dual phase steels could
be evaluated very precisely in a non-invasive way.
Fig.1: (a) Microstructure and (b) SEM micrograph of as-received
2. EXPERIMENTAL DP steel.
In the present study, C-Mn dual phase steel of thickness 1.3mm
in full hard condition is used for further treatment. The chemical
composition of the steel sample is given in Table-1.

C Si Mn P S Al N Cr Mo Ni

0.08 0.02 1.95 0.013 0.002 0.036 0.0039 0.02 0.15 0.01

Ta b l e - 1 : C h e m i c a l c o m p o s i t i o n o f t h e s t e e l

Specimens of dimensions 120 mm×50 mm soaked at different

temperatures in the range of 700-850oC with a step of 25oC and
a soaking time of 15 minutes (mins) followed by water
quenching (WQ). The heat treatment produced martensitic
phase in the range of 21-58% [22], were tempered at 300oC for
1hour (hr) followed by air cooling (AC) to improve the ductility
of the steels. Mechanical properties were evaluated with same
heat treatments on standard tensile specimens. Magnetic
hysteresis loop (MHL) measurements were carried out on the
specimens from both the sides (top and bottom) at a
magnetizing eld of 80 kA/m and magnetizing frequency of
0.05 mHz using a magnetic nondestructive evaluation (NDE)
device (MagStar) before subjecting the specimens to further
heat treatment. MHL measurements were carried out on the
samples to monitor the coercivity. Microstructure variation
study was conducted using optical and scanning electron
microscopy (SEM) by polishing the sample to mirror nish and
etching the samples using Nital. Volume fractions of
martensites were measured using image analysis software by
area fraction method. Mechanical properties were evaluated in
Zwick made tensile testing machine at a strain rate of
0.008/sec. Micro Vicker’s hardness tests were conducted at a
load of 0.5kg with minimum ve indentations on each sample.
Fig. 2: Microstructure of dual phase steel (a)- (d) soaked at
temperature between 700-850oC with 50oC step for 15 min
3. RESULTS AND DISCUSSION followed by water quenching, (e)-(h) are their microstructure
after tempering at 300oC for 1hr.
3.1. Microstructure and mechanical properties
The optical image and SEM micrograph of as-received (As-R) DP The measured volume fraction of martensite and mechanical
steel is shown in Fig.1 (a) & (b) respectively. The martensitic properties of the samples is shown in Table-2. The as-received
phases are in elongated form along the rolling direction. A high sample contains a volume fraction of martensite 34%. The
densityof dislocations and residual stress are expected to be samples soaked at 700oC/WQ showed a low volume fraction of

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martensite 21% and the % of martensite increased with
increase in soaking temperature and a maximum of 58% is
obtained at the soaking temperature of 850oC [22]. The sample
soaked at 700oC/WQ showed low tensile strength and the
tensile strength increased with increase in soaking temperature
due to the increase in volume fraction of martensite. A decrease
in % of elongation was also found with increase in volume
fraction of martensite. The Proof Stress (PS) at 0.2% strain was
low at 725oC and increased with further increase in soaking
temperature.
The Ac1 and Ac3 temperatures for the said composition are 704
and 858oC, as calculated using the Andrew’s relation given
below [23].
Ac1 = 723 - 16.9Ni + 29.1Si-10.7Mn + 16.9Cr + 290As
…………..(2)
Ac3 = 910 - 203√(C) + 44.7Si-15.2Ni + 31.5Mo + 104V
………….(3)
Where: Mn, Ni, Cr, Mo – mass contents of the elements in the
investigated steel, Cγ – carbon concentration in the austenite.
As 700oC is below the Ac1 temperature there is no possibility of
increase in volume fraction of martensite and at 725oC & 750oC
temperatures there is a possibility of increase in small volume
fraction of martensite however tempering and dissolution of
existing martensites resulted in a total low volume fraction of
martensite compared to the as-received sample. The increase in
volume fraction of martensite with the increase in soaking
temperature are due to the transformation of ferrite fractions of
steel in to austenite phase in the inter critical temperature range
which further transformed to martensite during water
quenching. The martensite transformation being diffusion less
resulted in increase in hardness of the steel due to the lattice
distortion. It is attributed that the increased volume of material
during austenite to martensite transformation induces high
density of dislocations at the ferrite-martensite grain boundary
[24, 25]. Rashid et. al., has reported 2-4% increase in volume
during the martensitic transformation process [26]. After
tempering the tempered martnsitic microstructure can be seen
such structure with presence of dislocations in the ferrites due
to volume change from austenite to martensite is reported
earlier [6].

The change in micro-Vicker’s hardness of the steels in as-

Fig.3: SEM Micrograph of dual phase (a)- (d) soaked at
temperature between 700-850oC with 50oC step for 15 min
followed by water quenching, (e)-(h) are their SEM micrograph
after tempering at 300oC for 1hr.
quenched condition and after tempering is shown in Fig.4. The
hardness is increased with increase in soaking temperature due
to the increase in volume fraction of martensite phase. The
martensite phase obstructs the dislocation movement to
increase the hardness of materials at small volume fractions
and at higher volume fractions the hardness is more due to the
hard martensite phase itself. After tempering the hardness is
expected to decrease with decrease in tensile strength and

Sample
As-R 7000C 7250C 7500C 7750C 8000C 8250C 8500C
ID

Martens
34 21 26 33 40 43 52 58
ite

YS -
622 414 322 365 415 403 522 680
PS(MPa)
UTS
905 523 597 677 869 801 857 1181
(MPa)

% EL 4.3 31.2 34 24.6 17.7 18.5 16.9 8.6 Fig.4: Micro Vicker’s hardness of the DP steels soaked at different
temperatures in as-quenched condition and tempered at
Table-2: Volume fraction of martensites (%), YS, UTS and % EL. 300oC/1h/air cooled.

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increase in ductility (% of elongation). Such hardness decrease
is found to be more on tempered samples having higher
volume fraction of martensites. The lattice distortions caused
by transformation of martensites would be more for higher
volume fractions of martensites and hence by tempering the
lattice distortions gets minimized more due to highly unstable
microstructures tens to stabilize.
3.2. Magnetic properties
The magnetic hysteresis loop of the samples at selected soaking
temperatures before and after tempereing is shown in Fig. 5.
Fig.5: Magnetic hysteresis loop of samples in as quenched
conditions soaked at (a) 700oC, (b) 750oC, (c) 800oC and (d) 850oC
with their corresponding tempered conditions, (a′)-(d′) are their
corresponding high magnication loops at the coercive regions.
The change in coercivity before and after tempering is shown in
Fig.6. The coercivity decreased with tempering indicating
magnetic softness of the samples. The degree of softness
increased through tempering on the samples with higher
volume fraction of martensite phase. Coercivity is related to the
pinning force of magnetic domain wall and dened the
maximum pinning force against domain wall movement in
ferromagnetic materials [27].
Fig.6: Change in
coercivity of the DP
steels soaked at
d i f f e r e n t
temperatures in as-
quenched condition
and tempered at
300oC/1h/AC.
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2017
The magnetic domains are restricted by several metallurgical
factors such as grain boundary, precipitates, dislocations and
secondary phases present in ferromagnetic materials resulting
in a high value of coercivity. In addition presence of
compressive residual stress resulted in increase in coercivity of
the materials. With the decrease of any of the above factors
resulted in decrease in coercivity. In the present case with the
increase in volume fraction of martensite as the seconday phase
resulted in increase in coercivity of the steels. With the
tempering treatment the compressive residual stress generated
through water quenching gets relaxed resulted in decrease in
coercivity of the steels. The mechanical properties of materials
and hardness gets inuenced by grain boundary, precipitates,
dislocation density, secondary phase and the type of stress
present in materials. As the coercivity and mechanical
properties are inuenced by the metallurgical parameters in a
similar trend, both the coercivity and hardness were found to be
changed in a similar trend that is increased with volume
fraction of martensite phases and decreased through
tempering. Hence by monitoring coercivity could provide the
information about change in metallurgical parameters or
mechanical properties.
The hardness was predicted by using coercivity in the
equation(1) and also measured using micro Vicker’s hardness
tester. A plot of predicted and measured hardness for different
soaking temperatures is shown in Fig.7.
Fig.7: Predicted and
measured hardness
of tempered DP steels
after soaking at
d i f f e r e n t
temperatures.
It is observed from the gure that the measured hardness
values and hardness values calculated based on magnetic
coercivity are in very good agreement. Hence it is possible to
predict the mechanical properties of DP steel by measuring the
coercivity through magnetic hysteresis loop measurement.
3. CONCLUSIONS
Magnetic hysteresis loop measurements were carried out to
monitor the coercivity on tempered DP steels with varying
martensite contents. The micro Vicker’s hardness was predicted
from coercivity values. The hardness was also measured
through micro Vicker’s hardness tester and compared to the
predicted values revealing very good accuracy. As hydrogen
embrittlement of DP steel in oil and gas industries is resulting in
decrease in ductility with increase in strength, the results clearly
show that magnetic hysteresis loop would be a very potential
tool for the non-destructive evaluation of change in strength in
dual phase steels for the evaluation of hydrogen induced
embrittlement. A detailed study is required for the laboratory
scale hydrogen embrittlement and its evaluation through
magnetic hysteresis loop technique for the application of the
technique in the oil and gas industries.
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Yang Dezhi and Yang En, Magnetic evaluation of fatigue
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2017
Pulsed Eddy Currents: Improvements in
Overcoming Adverse Effects of Galvanized Steel
Weather Jacket
V. Demers-Carpentier, M. Rochette, F. Hardy, M. Grenier, C. Tremblay, M. M. Sisto and A.Potvin†
Eddy, 2800, rue Louis-Lumière, Québec, Canada.
†E-mail: apotvin@eddy.com@company.com

ABSTRACT
Pulsed Eddy Current (PEC) has been successfully deployed over the last decades for a variety of
corrosion-related applications, most notably for Corrosion Under Insulation (CUI) inspections,
Corrosion Under Fireproong (CUF) and Flow Accelerated Corrosion (FAC). This technology has
proven to be an efcient screening tool, allowing for detection of corrosion without having to
remove coating or insulating material over typical pipes, tanks and vessels. However, the use of this
technique has been severely limited for components wrapped in galvanized steel weather jacket,
which abound in some geographic markets. This paper discusses the challenges of working with
galvanized steel as well as some of the solutions that allow quality PEC inspection of such
components. We present the most recent improvements in PEC technology, including a novel PEC
probe specically designed for inspections through ferromagnetic weather jackets. This new probe
design, combined with an optimized analysis algorithm, greatly enhances signal quality and defect
sizing accuracy when measuring through ferromagnetic jacket materials. Laboratory and eld
results will be presented and analyzed.

1.0 INTRODUCTION 1.1 Principle of operation of Pulsed Eddy Currents

The principle of operation of PEC is described as following. A

P ulsed Eddy Currents (PEC) is a versatile non-destructive
evaluation technique that can measure wall thickness of
conductive components at high lift-offs [1]–[3]. PEC is
well suited for non-destructive analysis of Corrosion Under
Insulation (CUI), Corrosion Under Fireproong (CUF) and Flow
Accelerated Corrosion (FAC) in carbon steel structures like
pipes, tubes [4], [5], vessels, sphere legs, etc. PEC is best used
as a screening tool owing to its ability to inspect in-service
components through insulation and cladding. As no insulation
stripping is required, PEC allows the asset owners to expand
the scope and frequency of screening inspections without
increasing the facilities downtime. This broader screening
allows to identify potential corrosion areas outside the
shutdown period, and enables a more focused application of
complimentary methods such as radiography and ultrasounds
during shutdowns.
The PEC technology is routinely used to inspect through
thermal insulation up to 300mm thick and can tolerate up to
about 1mm thickness of aluminum or stainless-steel weather
jackets covering the insulation. However, conventional PEC
systems detection and sizing performance is impaired by
galvanized steel (GS) jackets due to the ferromagnetic
properties of this material. In this paper, we discuss how GS
affects PEC signals and we present a novel (patent pending)
PEC probe design that mitigates these effects.
magnetic pulse is generated by a coil placed at some elevation
(or lift-off) from the surface of a component under inspection,
which must be ferromagnetic and conductive. During a rst
excitation phase, the pulse remains active long enough for the
magnetic eld to penetrate the full thickness of the component.
Following the abrupt extinction of the pulse, eddy currents are
generated in the metal mass to oppose the rapid change in
magnetic eld. These currents induce a secondary magnetic
eld which can be sensed by a magnetic sensor and decays over
time. In this phase, referred to as the reception phase, the
sensor generates a voltage signal that is recorded and
analyzed. The voltage signal as function of time is referred to as
an A-scan. The shape and decay rate of the A-scan are directly
related to the thickness of the component being inspected. By
controlling the length and the intensity of the magnetic pulse,
the PEC technique can be used to inspect carbon steel plates
with thickness ranging from a 3 mm to 100 mm.
2 0 IMPACTS OF GALVANIZED STEEL WEATHER
JACKETS ON PEC SIGNALS
Galvanized steel interacts with PEC pulses in many ways [6].
First, as the material is ferromagnetic, it screens part of the
magnetic eld generated by PEC during the excitation phase.
Hence, only a fraction of the magnetic eld emitted by a PEC
probe reaches the surface under test. Correspondingly, during

September
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the reception phase the intensity of the secondary magnetic
eld from the plate that reaches the magnetic sensor is also
reduced.
Figure 1: Normalized magnitude of the magnetic ux in a carbon
steel plate covered with 50 mm (2 in) insulation (non-conductive,
non-magnetic) and (A) 0 mm, (B) 0.5 mm (0.020 in), and (C) 1 mm
(0.039 in) of galvanized steel.
To evaluate the importance of this effect, we calculated the
magnitude of the magnetic ux density (B) in a 12.7 mm (0.5 in)
thick carbon steel plate, 50 mm (2 in) liftoff and up to 1 mm
(0.039 in) GS jacket. The results, computed in COMSOL®
Multiphysics®, appear in Figure 1. With only 0.5 mm (0.02 in)
of GS, the maximum magnitude of the magnetic ux in the plate
drops under 40 % of the value without a jacket.
A second detrimental effect of GS on PEC signals is that it
enlarges the magnetic footprint of PEC probes. The magnetic
footprint is dened by the spatial distribution of the intensity of
the B eld (Magnetic ux density). More precisely, we dene the
area of the magnetic footprint as the region (on the inspected
plate) encompassed by the isoline at 50% of the maximum
intensity of B.
PEC offers the best sizing accuracy over defects larger than the
probe’s footprint. Over defects smaller than the footprint, PEC
signals are inuenced by the defect and the surrounding
nominal plate thickness. In this situation, the thinnest region
(the defect) is averaged out by the thicker surrounding wall,
leading to underestimating the defect’s wall loss. This is called
defect undersizing. GS amplies defect undersizing by
enlarging the probe’s footprint. This happens because the
jacket captures and spreads out the magnetic eld from the
probe (in the excitation phase) and from the inspected plate (in
the reception phase).
Another detrimental effect of GS jackets is revealed during the
PEC reception phase. As GS is conductive, eddy currents in the
jacket generate a magnetic eld recorded by the probe’s sensor.
The rst few milliseconds of the received A-scan are therefore
typically dominated by the GS signal. Fortunately, the decay of
the GS contribution is relatively sharp compared to the signal
from the much thicker surface under test. Figure 2 shows a
typical A-scan from a 12.7 mm (0.5 in) thick
Figure 2 Typical A-
scans measured with
and without GS
jacket. The gain is
a d j u s t e d t o
superimpose A-scans
beyond 20 ms
component, at 50 mm (2 in) liftoff, with and without a GS
jacket. The GS contribution may partially mask the signature of
some types of defect, especially defects smaller than the
probe’s footprint.
Finally, GS jackets vibrate during the PEC excitation and
reception phases. Each time a PEC probe res a pulse, the GS
jacket is attracted to the probe’s magnetic eld, causing a
transient mechanical vibration. At a pulsation rate of 1–100 Hz,
vibrations disrupt PEC signals. Typically, the shape of vibrations
and the spectral content vary according to several uncontrolled
factors: the GS jacket thickness, the mechanical dampening
from the insulation, the quality and tightness of jacket xations,
etc. In addition, vibrations are synchronized to PEC pulses and
cannot be eliminated by averaging over multiple pulses.
All the effects outlined above offer a sense of challenges facing
PEC on components wrapped in galvanized steel, which usually
result in reduced detection and sizing capabilities of
conventional PEC systems. However, mitigation measures are
possible.
3.0 A NOVEL PROBE DESIGN FOR INSPECTION
THROUGH GALVANIZED STEEL WEATHER
JACKET
Improvement of analysis agorithms and GS jacket vibration
damping are among the techniques that can mitigate the
adverse effects of GS jackets [6]. However, in search for a more
fundamental solution, we developed a PEC probe specially
designed for inspection through GS weather jacket. The novel
feature of this patent pending design is that permanent
magnets are positioned close to the probe’s magnetic sensor.
These magnets are employed to magnetically saturate the GS
under the probe. The magnetic permeability of the jacket is
therefore signicantly reduced over a region covering the
magnetic footprint of the probe on the jacket. The multiple
advantages of this concept are presented in the following
sections.
3.1 Improved A-scan signal-to-noise ratio
The screening effect described in Section 2 is greately reduced,
owing to the lower magnetic permeability of the saturated GS
jacket. Hence, during the excitation phase a lower portion of
the magnetic pulse emitted by the PEC probe is captured by the
jacket. Similarly, during the reception phase, a larger portion of
the PEC secondary magnetic signal from the inspected
component can reach the magnetic sensor. In addition, the
permanent magnets act as a sort of anchor, magnetically
attracting the jacket to the probe and effectively preventing
mechanical vibrations. All these effects contribute to improve
the A-scans signal-to-noise ratio compared to a conventional
probe design.
3.2 Attenuated contribution of the GS jacket on the A-scan
During the detection phase, the saturated GS jacket still
generates eddy currents. However, the contribution of the GS
jacket on the A-scan is reduced compared to the unsaturated
case, although not completely eliminated. Figure 3 illustrates
an example of A-scan captured on a 0.5 inch plate with 2 inch
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insulation and 1mm GS jacket. The red dashed curve is captured
with a conventional probe, while the black curve is captured
with the GS probe. The contribution from the GS jacket is
attenuated and effectively shortening the portion of the Ascan
where it dominates over the component signal. Indeed, the GS
signal is still well visible in the rst 5ms of the A-scan, compared
to a signal captured without jacket (thin line), but the difference
is sufcient to improve the sizing of small defects whose
signature may otherwise be partially masked by the GS
contribution.
3.3 Reduction of the probe footprint
The probe’s footprint shrinks to dimensions approaching those
found without jacket, which also diminishes the undersizing of
small defects. To illustrate this phenomenon, Figure 4 (left)
shows simulations of the footprint for a conventional probe
with and without GS jacket (0.5mm thick) as well as the
footprint for the GS-specialized probe design, assuming a 12.7
mm (0.5 in) plate and 50 mm (2 in) of insulation. In this
example, on GS jacket the specialized probe footprint area is
66% of the footprint found for the conventional probe and it is
approximately equal to the footprint found without jacket.
Figure 4 (right) shows how the footprint dimension along the A-
B axis varies with the lift-off (LO or insulation thickness): on
both 0.5mm and 1mm of GS jacket, the GS-specialized design
can bring the footprint back to the no-jacket case. The reduction
in footprint is related to the level of saturation of the jacket: for a
thick jacket, the saturation of the simulated design is not
complete and the footprint is slightly larger than the one found
with thin jacket.
Figure 4: (Left) Comparison of footprint simulated on 0.5 inch
plate with 2 inch insulation. (Right) Evolution of footprint with
insulation thickness (lift-off, LO) for conventional and GS-
specialized probes on 0.5 inch plate.
4.0 EXPERIMENTAL RESULTS
The GS-specialized probe was tested in laboratory environment
on a set of 30 reference defects machined on carbon steel plates
with thickness ranging from 0.25 inch to 1 inch. Insulation
thickness values comprised between 0.5 inch and 2 inch and GS
jacket thickness of 0.5 mm and 1 mm were considered. The
defects were machined with at bottom cylindrical shape,
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diameter ranging from 2 to 6 inches and wall loss ranging from
33% to 66% of the nominal. Table 1 shows aggregated
statistics over all the tested defects for the sizing error, dened
as the difference in measured wall thickness between data
points captured with and without GS jacket for the same plate,
defect and insulation thickness.
Table 1: Sizing error compared to sizing obtained without GS
jacket.
With the GS-specialized probe, the average sizing error induced
by the presence of the GS jacket is no more than 5.1%, while the
error is as large as 12.3% with a conventional probe. This
improved sizing performance was conrmed by tests on real
samples. For example, Figure 5 shows 2D sizing maps of a pipe
with 203.2 mm (8 inch) outer diameter, schedule 40, 50.8 mm
(2 inch) thick insulation, 0.7 mm (0.03 inch) thick galvanized
steel jacket, and a ange. Figure 5A shows a map from a
conventional PEC probe, affected by enlarged footprint and
noise from the galvanized steel vibration, which all contribute
to make some defects hard to detect. Figure 5B shows the same
sample scanned with the GS-specialized PEC probe. Defects are
better detected and sized thanks to the smaller footprint of the
probe and the improved A-scans signal-to-noise ratio. The
probe is even able to detect a defect near the ange, which was
otherwise undetected with a conventional probe.
Figure 5 : 2D sizing maps of (A) conventional PEC probe (B)
galvanized steel-specialized probe
One minor disadvantage of the proposed design is that the
probe sticks onto the jacket due to the attraction of the
magnets.
Hence, the probe is more difcult to move than a conventional
design, particularly on thick jackets. Still, this may turn into an
advantage in some situations, like long inspections on vertical
pipes or vessels, as the probe stays in place with no need for the
inspector to support its weight.
5.0 CONCLUSIONS
The inspection of components covered with ferromagnetic
jackets like galvanized steel is a challenge for conventional PEC
systems, as the galvanized steel adversely inuences the PEC
signal in several ways. As a consequence, the defect detection
and sizing capabilities of conventional PEC systems are
typically reduced on GS jackets. In this paper, we presented a
novel GS-specialized probe that mitigates these problems. This
novel, patent-pending probe design is based on magnets
placed near the PEC magnetic sensors. The magnets saturate
the GS jacket, reducing its effective magnetic permeability. The
sizing of defects covered by insulation and GS jacket is
signicantly improved compared to conventional probe
designs.
6.0 REFERENCES
[1] J. C. Moulder, M. W. Kubovich, E. Uzal, and J. H. Rose,
“Pulsed Eddy-Current Measurements of Corrosion-Induced
Metal Loss: Theory and Experiment,” in Review of Progress in
Quantitative Nondestructive Evaluation, Springer, Boston, MA,
1995, pp. 2065–2072.
[2] R. A. Smith and G. R. Hugo, “Transient Eddy-current NDE for
Aging Aircraft – Capabilities and Limitations,” Insight: Non-
Destructive Testing and Condition Monitoring, vol. 43, no. 1,
pp. 14–25, 2001.
[3] V. Demers-Carpentier et al., “Pulsed Eddy Current as an
Inspection Tool for Nuclear Power Plants,” in NDT in Canada
2016 & 6th International CANDU In-Service Inspection
Workshop, Burlington, ON, 2016.
[4] W. Cheng, “Pulsed eddy current testing of carbon steel
pipes’ wall-thinning through insulation and cladding,” Journal
of Nondestructive evaluation, vol. 31, no. 3, pp. 215–224,
2012.
[5] M. S. Sazadeh and M. Hasanian, “Gas pipeline corrosion
mapping using pulsed eddy current technique,” International
Journal of Advanced Design and Manufacturing Technology,
vol. 5, no. 1, p. 11, 2011.
[6] C. Dalpé et al., “Pulsed Eddy Currents: Overcoming Adverse
Effects of Galvanized Steel Weather Jacket,” presented at the
Cofrend 2017, Strasbourg, 2017.
Robotic Inline Inspection and Leak Detection
System for Oil and Gas Pipelines
Ramineni Ajayraj*, Avinash Kumar, Dr. Krishnan Balasubramaniam, Dr. Prabhu Rajagopal
*Email: ajayraj.ramineni@gmail.com

ABSTRACT
Accurate leak detection and location methods are vital for safe operation of pipeline assets. This
paper discusses the development of a spherical robot congured with acoustic sensors, camera,
illuminating system and encoders for pipeline inspection. The sensors on the robot monitor the
pipeline to detect leaks, corrosion and sediments. A method based on acoustics is proposed for leak
detection in gas pipelines. An experimental setup was developed to simulate real life conditions in
the pipeline. The robot collects acoustic signals inside the pipeline as it moves along the pipe. The
camera is used for visual inspection to detect corrosion and sediments along the pipeline. The visual
data together with encoder data is used for localization of the robot to nd the location of the
defects. The data recorded was analyzed and leak detection was demonstrated successfully.

1.0 INTRODUCTION photograph of the spherical robot prototype developed by the

authors. Once the robot is placed inside a pipeline under

L eak detection and location methods play a vital role in the
integrity management of the pipelines. Even small
leakage can grow and cause signicant damage to the
environment apart from injuries and fatalities. Various methods
are currently used for monitoring pipelines for leak detection.
Hydrocarbon sensors [1], ber optics [2], Pipeline Inspection
Gauges [3] are some of the widely used approaches.
This paper presents the development of a spherical
passively propelled robot for leak detection and location in
pipelines by using acoustic sensing and visual inspection. To
test the working of the robot an experimental setup was built to
simulate the real life conditions. Properties of the acoustic
emissions were analyzed for various leakage sizes and
pressures inside the pipe.
This paper is organized as follows: Firstly the need for pipe leak
detection and provides a brief introduction to the current
technologies available for inspection of the pipelines. Next, the
design of the spherical robot for pipeline inspection is described
followed by development of experimental setup. Then a brief
introduction to the acoustic emission technique and visual
inspection is given. The method of experimentation is then
explained after which the results are presented and discussed.
The paper concludes with directions for further work.
2.0 DESIGN OF THE ROBOT
Most of the pipelines used for transporting oil and gas are
buried under the ground to avoid trespassing. Also the lengths
of these pipelines are in hundreds of kilometers. The robot has
to travel hundreds of kilometers inspecting the pipe for leaks
and other defects. The major constraint for this operation is the
electric charge of the batteries. The batteries could be only used
for powering the sensors and not for propulsion of the robot. In
view of this, a spherical shape was considered for the robot, as
this allows for passive propulsion. Figure 1 shows a
operation, it will be rolled along the pipeline due to the drag
force generated on it by the ow of the pipeline product.
Figure 1. Photograph of the
spherical robot
The robot consists of a spherical casing while the payload
consists of acoustic, visual, power and odometric systems. The
casing protects the payload from harsh conditions inside the
pipe. Since the robot has acoustic and visual sensors, it is
necessary for the robot to have a controlled motion. To make
accurate recordings the camera and acoustic sensors must
translate inside the pipe uniformly even when the spherical
shell is rolling. So, the robot is designed in such a way that the
spherical shell rolls inside the pipe while all the sensors inside
the spherical shell translate forward. It is ensured that the
rolling motion of the spherical shell does not transfer to the
payload. This makes sure that the sensors does not roll along
with the spherical shell. This patent pending design of the robot
consists of a self stabilizing mechanism that induces controlled,
smooth and stable motion of the sensors mounted inside the
robot along the pipeline.
3.0 EXPERIMENTAL SETUP
An experimental setup was built to simulate real life conditions
in gas pipelines. The experimental setup was designed
towithstand a pressure of up to 10 bar. The setup consists of
pipelines connected at the ends through anges.

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To prevent the air leakage at the anges, rubber gaskets are
used. Different sizes of leaks were simulated along the pipeline.
Two threaded couplers were welded on the pipeline as shown
in the gure 2. Bolts with through holes can be fastened into
them to simulate the leaks of different apertures. The
experimental setup is shown in the gure 2.
Figure 2. Photograph of the experimental setup
There are two parameters that are varied manually while
performing the experiments, namely pressure in the pipe and
size of the holes on the pipe wall. During the experiments,
acoustic signals are recorded using a combination of these
parameters and compared. The pressure inside the pipe can be
adjusted by a regulating valve which is connected at the outlet
hose of the compressor. A provision was made on the pipe to
change the size of the leak. Two holes each of 20 mm diameter
are drilled on the center pipe with 1 m distance between them.
Two M20 nuts are welded at these holes. Holes of different sizes
are drilled on ve different bolts as shown in gure 3. The size of
the leak on the pipeline can be varied by inserting different
bolts in the welded nuts. The leak sizes are varied from 3 mm to
9 mm.
Figure3. a) Female coupler welded for connecting air compressor,
b) Nut welded on the pipe wall, a provision for varying hole sizes,
c) and d) Bolts drilled with holes of different sizes
4.0 ACOUSTIC EMISSION TECHNIQUE
Acoustic Emission (AE) refers to the generation of transient
elastic waves produced by a sudden redistribution of stress in a
material. When a structure is subjected to change in pressure,
load, or temperature localized sources trigger the release of
energy, in the form of stress waves. These waves which
propagate to the surface can be recorded by sensors. But there
is problem of attenuation of signals in case of using xed AE
sensors. As the distance from the source increases, the sensor
nds it more difcult to pick up the signal due to wave
attenuation. AE can be related to an irreversible release of
energy. It can also be generated from sources not involving
material failure including friction, cavitation and impact. When
a leak occurs, the escaping gas generates turbulence, friction
and impact which results in acoustic emission as it passes
through the leak hole of a pipeline[4].
AE is different from other non-destructive testing (NDT)
techniques in two regards. Firstly the energy is not supplied to
the object under examination, instead AE technique listens the
energy released by the object. AE tests can be performed on
structures while in operation, as this provides adequate loading
for propagating defects and triggering acoustic emissions.
Secondly the AE technique deals with dynamic processes. The
ability to differentiate between developing and stagnant
defects is a signicant attraction for using the AE approach.
However, it is possible that aws go undetected if the loading is
not high enough to cause an acoustic event. AE systems can use
multiple sensors during testing in order to record a hit from a
single AE event. These AE systems can be used to determine the
location of an event source. As hits are recorded by each sensor,
the source can be located by knowing the velocity of the wave
in the material and the difference in hit arrival times among the
sensors. In the present project the arrival time technique is
avoided since we are not using xed sensors but using moving
sensor. The sensor moves past the defects recording the level of
sound and acoustic emission.
AE is widely used for detection of leakages in many cases as
mentioned below. The properties of the acoustic signals
emitted by a leakage on a pressurized pipeline depend on the
dimensions, shape of the hole and pressure difference across
the leak[5]. This study includes the characterization of the
frequency spectrum of the leak signal as the function of crack
parameters such as geometry and dimensions, as well as the
uid properties such as pressure, density, viscosity etc.
Figure 5. Picture of conguration of circular hole
According to this theory, the frequency of the acoustic waves is
given as follows [5]:
(1)
where ΔP is the pressure difference in pascals across the pipe
wall and D is the diameter of the circular hole and is in mm. It is
proven experimentally that the frequency content of the signal
due to air leakage depends on the size, shape and morphology
of the leak [6]. The analysis of leak signals in this application
also shows that the maximum signal change rate of the
transient leak signal is related to not only the gas leakage rate,
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but also the leak positions. It increases with the leakage rate
increasing or the leak distance decreasing. It is reported that
dynamic pressure sensors are used in AE leak detection for gas
pipelines [7], they need to be inserted into gas pipelines for
picking up leak noise. It is also showed that detecting and
positioning of defects in pressure pipe during normal operation
of the pipeline is possible by using AE sensors with attached on
the outside of the pipeline [8].
At constant pressure the frequency of the acoustic emission
having maximum amplitude depends on the diameter of the
hole. The frequency decreases with increase in the hole
diameter. This is proved experimentally. The experiments were
conducted for 3mm, 5 mm and 7 mm holes at 2 bar and 1.2 bar.

5.0 VISUAL INSPECTION

Due to the recent developments in digital image processing
and computer vision, automated visual inspection is being
(a)
extensively applied in many elds such as automatic inspection
[9], detection of welding defects [10], part measurements [11],
assessment of surface texture [12]. This spherical robot
described here, introduces a novel vision system with self
stabilizing mechanism for the detection and assessment of
internal defects of pipeline such as corrosion, sediments, cracks
etc.
(b) ( c)
6.0 METHODOLOGY OF EXPERIMENTS
Figure 5. Results of acoustic signals recorded by spherical robot
First, the robot is switched on and placed inside the pipeline at
with: (a) no leak, (b) 7mm leak and (c) 9 mm leak
one of its end. Then the pipeline end is closed with a circular
plate. To simulate a 3mm leak a bolt with 3mm hole is inserted
into the nut on the experimental setup and this hole is closed
temporarily till the pipeline is pressurized. The pipeline is then
lled with pressurized air using a compressor. To simulate a
3mm leak a bolt with 3mm hole is inserted into the nut on the
experimental setup and the this hole is closed temporarily till
the pipeline is pressurized. The pipeline is then lled with
pressurized air using a compressor. The ow of compressed air
into the pipeline is stopped after the pressure inside the pipe Table 1. Dependence of frequency spectrum on pressure and leak
reaches desired level. Then the leak is opened and the size
pressurized air is allowed to escape from it. The air escapes with
high velocity creating turbulence near the leakage. This in turn Results are also shown extracted in table 1. according to which
the frequency output is dependent on the leak size and pressure
generates noise at the leak. Once the desired pressure is
inside the pipe. Higher the pressure, higher the output
obtained, the robot starts recording acoustic signals and video
frequency and higher the leak size, lower the frequency output.
inside the pipe. While it is recording, the experimental setup is
The size of the leak could be estimated by using the data about
lifted up manually on one side. The gravity pulls the robot to the frequency of the AE having maximum amplitude. The
other side of the pipe and the robot starts to roll As the robot device has to be calibrated to accurately estimate the leak size
rolls, it crosses the leak and comes to rest at the other side. The solely based on the output signal.
recorded signals are then extracted and analyzed to detect the The camera onboard the robot records live video
leaks. There are two parameters that are modied in all the inside the pipe. The recorded videos are analysed to detect
experiments performed: (a) pressure inside the pipe and (b) internal defects. Machine learning algorithms are being
sizes of the simulated holes. Experiments are carried out with developed to process the video and nd the defects
different combination of pressures and sizes of the holes. autonomously. Figure 8 shows a surface anomaly which was
captured by the camera on board.
7.0 RESULTS AND DISCUSSIONS:
A graph of the amplitude of the recorded audio signal against
time is plotted for each experiment. Figures 6 and 7 shows the
increase in the amplitude of the acoustic signals near the Figure 8. A photograph
taken by the robot
location of the leaks. This can be compared with the output
showing a defect inside
signal when there is no leak as shown in gure 5(a). It can be the pipe
observed from gures 5(b) and 5(c) that there is an increase in
the amplitude of the output signal when the robot approaches
7.0 CONCLUSION
the leakage. The spike in the amplitude of the output signal
A passive self-propelled spherical robot has been designed and
corresponds to the acoustic emission generated by the high developed for leak detection and location. The experimental
velocity uid escaping from the leak aperture. results showed that the acoustic method implemented in
September
2017
spherical robot allows for detecting and characterizing the
leaks in pipelines. Internal defects such as corrosion, scaling
and blockages were detected by using visual sensors
incorporated in the spherical robot. The spherical robot
proposed here could offer a practical solution for the inspection
of existing pipeline networks. Thorough experiments are being
performed to increase the sensitivity of the robot towards
extremely small leaks. Machine learning algorithms are being
developed and tested to make the system completely
autonomous.
8.0 REFERENCES
[1] C. Sandberg, 1. Holmes, K. McCoy, and H. Koppitsch, "The
application of a continuous leak detection system to pipelines
and associated equipment,"IEEE Transactions on Industry
Application,voI.25, pp.906-909,1988.
[2] Y.Zhou,S.Jin,and Y.Zhang, and L.Sun,"Study on the
distributed optical ber sensing technology for pipeline leakage
detection," Journal of Optoelectronics Laser,voI.16,pp.935-
938,2005.
[3] L.Yang. G.Liu, G.zhang,S.Gao, "Sensor development and
application on the oil-gas pipeline magnetic ux leakage
detection," The Ninth International Conference on Electronic
Measurement & Instruments,pp. 2-876 - 2-878,2009.
[4] Shuaiyong Li, Yumei Wen*, Ping Li, Jin Yang, Lili Yang. “Leak
Detection and Location for Gas Pipelines U sing Acoustic
Emission Sensors”, IEEE International Ultrasonics Symposium
Proceedings, pp. 957-960, 2012
[5] W.A Wassef, M.N. Bassim, M. Houssny Emam and K. Tangri.
(1984). Acoustic emission spectra due to leaks from circular
holes and rectangular slits.
Journal of Fluid Mechanics, 213, 234-245.
[6] Andreas J. Brunner and Michel Barbezat. (2006). “Acoustic
emission leak testing of pipes for pressurized gas using active
ber composite elements as sensors”, Journal of Acoustic
emission, vol 25, pp.42-50, 2007
[7] L. Meng, Y. Li, W. Wang,and J.Fu, "Experimental study on
leak detection and location for gas pipeline based on acoustic
method," Journal of Loss Prevention in the Process Industries,
voI.25,pp.90-102, 2012.
[8] L.Sun,Y.Li, T.Liu, SJin,and W.Wang, "Leak detection and
position method for pressure piping using acoustic emission",
Proceedings of the 7th World Congress on Intelligent ContTol
and Automation,pp.8425-8429,2008.
[9] Daaland A. Real-time radiography for in-service inspection
of exible pipeline system. Trends in NDE science and
technology. Proceedings of the Fourteenth World Conference
on Non-Destructive Testing, New Delhi, vol. 3; 1996. pp.
1361–1364.
[10] Rihar G, Varilstvo ZA, Rant J, Stefan J. The rst application
of imaging plates to an examination of welded joints.
Proceedings of the Seventh European Conference on Non-
Destructive Testing, vol. 3(8); 1998.
[11] Gadelmawla ES, Elewa IM. On-line measurement of
product dimensions using computer vision. Proceedings of
nineth IMEKO Symposium Metrology for Quality Control in
Production Surface Metrology for Quality Assurance, Cairo,
Egypt, vol. 4; 2001. pp. 1–10
[12] Gadelmawla E, Elewa I, Soliman H. Assessment of surface
texture using a uniquely featured computer vision technique.
Society of Manufacturing Engineering, Fourth International
Machining & Grinding, Troy Michigan; 2001. pp. MRO1–23
September
2017
Simplifying Phased Array Ut Process with Digital
Solutions and Wireless Collaboration
Anandamurugan Subramanian, BHGE Inspection Technologies, JFWTC, Bangalore, India
Email : anandamurugan.s@bhge.com
1.0 INTRODUCTION
F or decades, the industry has improved productivity and
efciency, reducing costs to maintain their most critical
industrial assets using Non-Destructive Testing (NDT)
hardware and software. These traditional inspection
technologies are poised for disruption through new services for
connectivity and digital inspection, which will unlock
tremendous value for asset owners, OEM’s and service
providers. In an industry climate driven by today’s oil prices, an
aging workforce and increasingly complex industrial assets and
inspections, it is critical to improve operational efciency.
Today’s most advanced inspection technologies such as phased
array ultrasound and digital x-ray are rmly part of the digital
industrial age. Derived from healthcare and hardened to stand
up to the toughest eld conditions, these techniques help to
detect corrosion, erosion, weld failures and other indications
before they turn into costly downtime. Armed with these tools,
inspectors generate large volumes of digital inspection data
which can be viewed in real-time, centralized, analyzed and
archived, and shared.
Phased array ultrasound technology is now widely used across
industries for Non-Destructive Evaluation. According to
Markets And Markets research: The ultrasonic testing (UT)
market is expected to reach USD 3.93 Billion by 2022, at a CAGR
of 8.3% between 2016 and 2022. The factors which are driving
the growth of market include development of portable phased
array ultrasonic testing equipment, need for reliable non-
destructive testing technique for berglass and carbon ber
composites in manufacturing, growth in ultrasonic testing
services market, and government mandates.
Even though phased array ultrasonic testing technology is
wide-spread across the world, appropriate training is
extensively needed to understand the product operation and
clear instructions, checklists are needed as document to
perform inspection as per the inspection expectations from
experts to perform inspection with high degree of accuracy and
precision.
Today’s NDT and inspection managers face a complex and ever-
changing environment, including:
Ÿ Increasing complexity of inspections
Ÿ Loss of domain expertise from departing or retiring
inspection experts
Ÿ More demanding codes and standards
Ÿ Constant drive for improved detection and productivity
Ÿ Pressure to reduce asset downtime
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NDT industry has begun the journey toward more reliable,
connected and smart inspection hardware and software. One
way to address this issue is using advanced technology, giving
inspectors the tools and resources they need.
Designing the phased array ultrasound products, with the
features and functionalities they share, help organizations
embrace the industry shift toward digitization, improve
inspection productivity, contribute to long-term equipment
reliability. With the modernized digital transformation adding
inspection procedures, training, demonstration videos, help
documents and drawings can be built into inspection devices
and provide step-by-step procedures or embed a demo video.
l
Guided & Customized “apps” — Digitizing the Inspection
procedures, training, demonstration videos, help documents
and drawings and built into inspection devices will change the
way inspection is done or prepared for the inspection. This
improves consistency and reduces training costs. Instead of
asking the inspector to guess about how to conduct an
inspection, by providing the step-by-step procedures or embed
a demo video.
l
Intuitive User Experience (UX) — Just like your smartphone,
operating an ultrasound device just makes sense, and interface
features are common across devices. Rather than adjusting
manual dials or buttons, navigating ultrasound device like
smartphone will be fast, easy and intuitive for inspectors at all
levels. Selecting, dragging and scaling screen features is easy,
and reduces levels of awkward and confusing analog menus.
l
Wireless connectivity — With the modernized technology
connecting devices with internet will make lot of operations
easier for the user. Instruments with standard onboard Wi-Fi
will provide secure wireless connectivity streamlines reporting
and analysis, makes software upgrade service and enables
real-time remote collaboration with off-site experts. If the
technician needs a second opinion, instant service via remote
collaboration will improvise the inspection process and
reliability to greater extent.
2.0 GUIDED & CUSTOMIZED “APPS”
Digitizing the Inspection procedures, training, demonstration
videos, help documents and drawings by building into
inspection devices can improve consistency and reduces
training costs. Reecting author’s expectation for the
application solution in a UT “app” as how we prepare power
point slides for the presentation will improve the inspection
process for both the author (or Level III) of the application and
the inspector who performs the inspection. Examples of the
“App on Device” concept for different phased array UT
applications and its solution to overcome the challenges are
discussed ahead.
 2.1 Corrosion Inspection
Phased array ultrasonic inspection for corrosion on pipes, tank
bottom and on other complex surfaces increases productivity
and provide more data points compared with conventional
(a) (b)
thickness gauge data. For the accuracy of thickness, specially
designed phased array UT probe can be used to detect near
surface indication and hence able to measure the thickness
nearer to the scanning surface. Dual Element Array (DM) probe
is designed with the array of elements which is used for
transmission and another set of elements which is used for
receiving. The required effective area of virtual probe can be
congured by grouping the array of elements as it is inevitable
with Phased Array UT. DM array probe will give the
performance like conventional TR Dual probe.
To perform the required calibrations and the setup for corrosion
inspection using phased array technology is not straight
forward. Hence, creating the “app” with all the inputs needed
which will guide the user to verify the list of items needed for
the inspection, perform the required calibrations and perform
the inspection on actual job will enhance the inspection
preparation and reduce the day to day documentation like
worklist. Figure 1 shows how the digital checklist can be
prepared for the list of materials needs to be collected for the
eld inspection.
Fig 1: Digital List of Material - Checklist for corrosion inspection
Two “apps” that can be created at 2 different level as shown in
gure 2a and 2b to differentiate the guided and expert “app”
and highlight the “App on Device” concept. The guided or demo
“app” can be used by the starters which will guide the user on
every page to complete the inspection successfully with
reference to the images, guidelines and videos. The expert
“app” can be used by the experts who can use the “app” with
minimal inputs but focused on UT settings as per the part
geometry and material characteristics. The picture 2a and 2b
shows the difference between guided & expert “app” to
achieve the inspection of corrosion with expected accuracy and
precision.
Author of these “apps” has designed with proper guidelines
and hence the user can accomplish the raster scanning of
corrosion demo block with xed scanner can be done faster
with very minimal training. Corrosion demo block is designed
to demonstrate the capability of detecting the corrosion defects
like pitting. The “app” has been created with pictures of demo
block for calibration and scanning as shown in gure 2.
(a) (b)
Fig 2a: Step by step guidelines Fig 2b: Expert app for 2-Point
( l e f t ) t o p e r f o r m 2 - p o i n t calibration with no instructions
calibration
With this “app”, the users will realize the simplicity of “app on
device” concept and learn the application faster as how to do
the calibrations and scanning of demo block. Expert (Corrosion
DM app) “app” is created with no instruction as shown in gure
2b as its designed for the trained user to use this app to
congure the setup for the inspection. Every application
solution will have written procedure which will be used as
reference to design the day to day work list.
Fig 3b: Demo app created with
Fig 3a: Inspection setup for
cross-section of corrosion block
demo block scanning
and its C-scan
Cross-sectional image of corrosion demo block as shown in
gure 3a and 3 b gives the instant access to replicate the data in
C-scan which will increase the condence of the user. Inspector
or the experts will refer the inspection procedure is lot of
instances during inspection or for inspection planning. So,
adding the soft copy of inspection procedure as part of “app”
will be easy for the user to verify the procedure from instrument
“app” itself in case of any reference is needed for the inspector.
Figure 4: Digital
corrosion inspection
procedure embed in
the “app”
2.2 Composite Inspection
Composite inspection can be done effectively using the exible
interface to adapt the surface irregularities. Phased array UT
probe which is designed with exible interface and hence the
probe can be adapted on any surface and perform inspection.
The challenge with exible interface is the setting of interface
gate as shown in gure 5a and then to apply the proper
calibration.
Hence creating a “app” with the guidelines of how to easily
setup interface gate will avoid the confusion on interface gate
September
2017
setup and makes it easy. If user can be provided with the
document to refer as how interface gate functions as pdf
document as shown in gure 5b in the “app” then user doesn’t
need to worry too much about instrument operations and setup.
Fig 5a: Step by step guidelines Fig 5b: PDF le added in the
to setup the interface gate as “app” to explain the interface
per the author’s word gate working principle
So far, the instrument software had given the option of pre-
dened layouts for the user to select them as per the inspection
need. In some applications instrument provided layouts may not
exactly fulll the author’s (or Level III) expectation to organize
the data views. If the instrument software can provide the ability
to create the layouts or to align the data views (i.e., S-scan, C-
scan, B-scan, A-scan etc.,) as per author’s imagination it will
make the application solution better. In the gure 6 the layouts
are designed by the author to track the backwall (using Gate B)
and the material region (Gate A). The layout is customized with 4
C-scans as per the composite inspection need. Customized
parameter which is needed for the inspection process that can be
directly accessible on the screen as shown in gure 6 will help
the inspector by directly using them instead of searching for the
parameter hiding under the wizard or menu list.
Fig 6: C-scan of composite block using RotoArray probe
2.3 Low Prole Weld Inspection
Weld inspection on boiler tube is a challenge with radiography
due to accessibility and large volume of welds to be inspected in
limited time. Phased Array UT (PAUT) is another best option to
inspect the tube weld. It has an advantage of good Probability of
Detection (POD), image recording with 3-dimensional data on
Top, Side and End Views with overlay for easy decision making.
Though the technique is powerful and efcient to inspect welds,
there is a challenge on mechanics. The scanner and probe are
designed with low prole due to the limited space constraints.
Fig 7: Screenshot
of video playing
the PALM scanner
operation as
instruction for the
operator
September
2017
Even though the phased array ultrasonic testing of weld
inspection technique is same, how to use the complex
mechanics of probe and scanner assembly on the boiler tube is
a challenge. To overcome the complexity of this operation, a
video of how to operate this scanner and mechanics with “app”
as shown in the gure 7 will greatly help the user to refer
mechanics operation at any time which will minimize the
burden on longtime training to know the operability of scanner
and its mechanics.
Figure 8: Instruction to perform encoder calibration using PALM
Scanner on Boiler Tube
Another complexity is the encoder calibration on the eld due
to the scanner design and mechanics. The setup should be
attached on the reference block or on the actual tube for
encoder calibration. Hence the customized image as shown in
the gure 8 as how to perform encoder calibration will simplify
the inspector’s job of performing encoder calibration.
(a) (b)
Fig 9: Boiler tube
weld inspection
setup and data
( c)
Figure 9 shows the complete setup of boiler tube weld
application and its sector scan & C-scan image with weld
overlay using the “app” created for this inspection solution.
2.4 Glue line and seam inspection for automotive
body panels
Adhesives are being increasingly used as a joining technology
for automotive body panels including edge and non-edge
joints. Total accumulated length of glue lines can reach
hundreds of meters per automobile body. Like other
automotive joining processes, adhesive bonding may not
provide 100% process reliability. To identify areas with lack of
adhesive as well as misaligned bond lines, destructive or
nondestructive testing is necessary.
‘Bond Seam Scanner’ is easily clamped on body panels joined
by a seam or other adhesive bonding process. The design
enables the array to adopt to contoured parts commonly used
in automobile designs. Adhesive bond lines up to 32 mm width
can be inspected. A spring-loaded encoder wheel provides a
stable inspection platform and tracks the sensor position. A
protection foil minimizes the need for couplant and enables
manual scanning.
In this application, the challenge is to perform the inspection of
car doors in sequence for mass production in automotive
industry. So, the chances of inspecting the wrong side of door is
high due to the fatigue of inspector. Hence the “app” is
intuitively customized by adding the picture of door and
highlighted the side A, B and C on each panel to inspect the
doors. Always a visual feedback will help the inspector to
perform better and reliable. This app will reduce the chances of
error due to the customized guideline and UI designed for the
bond seam application as shown in the gure 10a and 10b.
Fig 10a: Inspection setup Fig 10b: Red box on door
instructs the area to be inspected
3.0 Intuitive User Experience (UX)
Another residual factor with the users of phased array
ultrasonic instrument is how to use the tools in instrument.
Ensuring the inspector’s expertise is focused on the work they
are doing, not on the product they are using will make the
inspector’s job easier and more productive.
Figure 11: User experience
of inspection device
Like how the smart phones have evolved with user experience,
designing the product with ease of touch operation without the
aid of mouse or buttons or any hard keys can enhance the
inspection instrument user experience. With the intuitive UX
user doesn’t need to worry about how to operate the tools
using buttons, menu and parameter. User can just operate the
tools in the same fashion as how a person operates the smart
phone. Automatic setup like range, gates and other UT settings
for calibration and inspection will help the operator to just input
the signicant parameter needed.
4.0 WIRELESS CONNECTIVITY
One of the most exciting technologies available today enables
real-time streaming and remote collaboration. This technology
will experts the ability to participate in live inspections
anywhere in the world via wireless connection. Imagine an
inspector who nds a severely corroded section of piping on an
offshore oil rig, and is unsure whether to take the unit out of
service. In an analog world that inspector might have been
forced to make a judgment call, or at best y in an expert via
helicopter for consultation, incurring costly delays. Today that
inspector can connect wirelessly to an onshore expert who can
view a live stream directly from the inspection device, providing
guidance and recommendations for additional further
inspections, helping to make the right call. Real-time streaming
makes it possible to reduce costs and improve workforce
training in many situations.
Fig 12: Connected solution for more condent decisions
For inspection service providers who manage large eets of
inspection equipment, digital inspection tools are boosting
productivity. Imagine being able to deploy digital procedure
updates and work plans to a large eet of inspection hardware
and technicians in multiple cities at the push of a button, or
centralizing inspection data management and reporting for
your company.
Imagine a situation wherein instant guidance is needed for the
inspector by supervisor and due to limited space constraint
(i.e., scaffolding, rope hanging, man hole accessibility etc.,)
only one person can see the instrument but the supervisor
guidance is mandatory. Instant desktop sharing via Wi-Fi as
how smartphone works (i.e., apps are designed to see the
screen of television in the phone) will help the inspection
process. The supervisor can use the tablet or smartphone who
can instantly see the screen hold by inspector and provide
guidance.
5.0 CONCLUSION
As the Phased Array Ultrasonic Testing is growing rapidly for
wide variety of applications, it’s also important to simplify the
process of operating the instrument. Since every application
needs a unique inspection solution (i.e., it can be ultrasonic
technique or probes or scanner or user experience etc.,), it’s
very difcult and complex for the inspectors to get updated
with every solution. Hence specialized “apps” design will help
the user to guide the operation and simplify the training for the
unique application solution. Pre-planning “app” design
software like “Mentor Create” from BHGE Inspection
Technologies can bridge the gap between the expert’s
innovation and inspector workow operations. With the new
phased array ultrasound instrument – “Mentor UT”, new
“apps” have been created for different application which
provides instruction and ease of operation with customized UI
tailored as per the application needs. Mentor devices are
designed by the team of experts and engineers who work to
September
2017
understand the challenges inspectors face and nd innovative
ways to build the “smarts” into the instrument to help make the
inspector’s job easier.
Besides all the advantages of app based concept and ease of
operation, if a technician does not understand a step or a data
signal, he or she can push a button on the device and wirelessly
stream their inspection to the PC, phone, or tablet of a remote
expert. The advancement of digital eld and adapting the digital
technology in inspection eld will help the industry to become
more reliable, efcient and more connected. The
Inspectionworks platform from BHGE Inspection Technologies
offers eet management and analysis tools that make data
search, storage, analysis and sharing easy in a secured
environment for inspection teams of all sizes. Mentor devices
can be connected to tablet or smartphone using Wi-Fi hotspot
even without internet and share the screen using desktop
sharing option with the supervisor tablet or smartphone who
can instantly see the screen and provide guidance.
These new technological developments are making it possible to
realize the benets of phased array ultrasonic inspection on a
global scale and taking the complex solutions into simplied
approach using the power of digital evolution.
September
2017
REFERENCES
[1] GE Inspection Technologies,
https://geinspectiontechnologies.wordpress.com/tag/mentor-
ut/
[ 2 ] M a r k e t s A n d M a r k e t s ,
h t t p : / / w w w. m a r k e t s a n d m a r k e t s . c o m / M a r k e t -
Reports/ultrasonic-testing-market-131229239.html
[ 3 ] B H G E I n s p e c t i o n Te c h n o l o g i e s ,
https://www.inspectionworks.com/#/supportDetails/mentoru
t
[ 4 ] B H G E I n s p e c t i o n Te c h n o l o g i e s ,
Mentor_UT_Users_Manual.pdf
[5] Anandamurugan S, Ultrasonic Phased Array Technology for
Enhanced POD & Inspection Speed in Corrosion Detection and
Wall Thickness Measurement, APCNDT 2013
[6] Anandamurugan S, Phased Array UT Application for Boiler
Tube Inspection in Manufacturing and In-Service, APCNDT
2013
Study of Distortion of Low-frequency Axisymmetric
Ultrasonic L(0,2) Guided Waves in Pipe Bends and
Elbows
M Venkata Sai Siva Ramakrishna*, Radhakrishna Korlam*, Harikrishnan A S**, Renjith P**, Tarun
Kumar Mishra**, Krishnan Balasubramanian*
*Centre for Non Destructive Evaluation, IIT Madras **Detect Technologies Private Limited

ABSTRACT
The use of ultrasonic guided waves in long range pipeline monitoring is restricted to straight
sections, especially in pipes of larger diameters. However, there have been recent studies on the
propagation of these waves through bends of different angles and bend radii. The transmission co-
efcient and velocity characteristics of the wave at pipe bends have been studied for pipes of lower
radii (typically 3-8 inches nominal pipe diameter). This paper studies the wave front changes
primarily in pipes of larger diameter (~24 inches nominal pipe diameter). 3D nite element
simulation has been done on commercial software to understand the L (0, 2) wave behaviour at the
bends, and the shift in the wave front is experimentally validated using GUMPS (Guided Ultrasonic
Monitoring of Pipe Systems), an MsS Technology for pipeline corrosion monitoring; developed and
owned by Detect Technologies. The study shows that the wave tries to move at a constant velocity
and hence gets distorted at the farther region of the bend from the Centre of curvature, thus
resulting in an angled, elliptical wave front from the original circular wave front.
1.0 INTRODUCTION : The third section describes the experiment designed to validate
the simulation results. And nally, the paper concludes with

T he interaction of low-frequency axisymmetric ultrasonic
guided waves in bends has already been studied [1] to
understand the transmission and reection of the incident
wave as it passes through the bend, for different bend angles
and bend radii. The propagation of guided waves in straight
pipelines is well understood and used widely for corrosion
inspection in pipelines in industries such as oil and gas [2-8].
Although there have been recent developments to use guided
wave sensors for monitoring across elbows, a reduction in POD
is observed and the signals appear to be erratic beyond the
elbow. [9-17] . The fundamental problem of using existing
sensors across bends is that bends can result in the dispersion
of guided waves and hence signals from any defect in the
region may get masked by the dispersed signals. [1] However,
this study reveals that in pipes of larger diameters, the
dispersion is not the major concern as much as the distortion of
the wave front. This study reveals distortion of the wave
happening in the outer region, with the possibility of a blind
spot in the inner region of the pipe bend. An understanding of
this is crucial in the development of guided wave LRUT
inspection tools.
This paper is organized as follows. The rst section of the paper
presents the dispersion plot of a 24-inch nominal size, standard
industrial pipe (on which the experiments and simulation was
conducted). This section describes the possible wave modes
that are generated and the group velocity of these waves. The
second section presents the results of the simulation.
inferences from this study and the scope of future work.
2. 0 BACKGROUND
This study is conducted on a pipeline of OD 609.60 mm and
pipe thickness of 5.537 mm (24 inches nominal pipe size SCH 5s
Mild Steel Industrial pipe). It is seen (from simulations) that the
pipe material does not affect or change the behaviour of these
waves and hence the phenomenon applies in general to pipes
of any alloy compositions, although the validation is performed
only on a mild steel pipeline for practical reasons. A standard
90º elbow of 24 inches is welded onto the straight section and
the study is done by placing GUMPS transducers on the elbow
region and the straight region. For L (0, 2) mode guided wave
analysis of the pipe, a frequency of 90 kHz was chosen for its
non-dispersive nature in that frequency region, as shown by
the dispersion plot below.
An in-plane 3-cycle Hanning window burst is applied at the
transmitter side, uniformly throughout the angular positions to
result in a circular wave front L (0, 2) wave mode. To understand
the distortion of the wave front that occurs at the bend,
GUMPS-array receiver probes are placed at different angular
positions of the pipe along the elbow. The simulations are
conducted keeping in mind the same boundary conditions , i.e.
uniform circumferential excitation to generate a circular wave
mode and probe points at different angular positions to
monitor the received signal. Wave visualization was also done
using simulations to get a better understanding of the
distortion occurring at the bend.

September
2017

Figure 1 : Dispersion curves for a 24 inch MS pipe.
Figure 2 : Schematic of the pipe setup used for experimental
validation
3.0 METHODS
3.1 3D Finite Element Simulations
The model is a straight-bend-straight pipe. A fully 3 dimensional
time transient simulation is conducted using Solid Mechanics
Module COMSOL. The meshing is quadrilateral in the straight
regions and tetragonal in the bend to capture accurately
simulate mode conversions. Maximum meshing size is set as 1
mm meaning 6 divisions of thickness allowing for study along
the thickness. Meshing size is chosen according to the frequency
and wave speed. The time step is chosen as 1E-8 s and the
simulation is conducted for an interval of 0 to 1 ms.
Axisymmetric L (0, 2) mode excitation was achieved by giving a
uniform longitudinal force along the axis at one end of the pipe.
A 3-cycle Hanning pulse window entered around 90 kHz was
used for excitation. Material of Steel Having the modulus of
elasticity E = 210 GPa, density ρ=7800 kg/m3 and Poisson ratio
ɳ = 0.303 were specied.
3.2 Experimental procedure
In order to validate the FE simulation results, laboratory
experiments were performed using Mild Steel pipes of 610 mm
OD and 598.926 mm ID and of geometry as shown in gure 2.
The experiments were conducted using GUMPS, a novel MsS
Transducer developed by Detect Technologies. The transducer
was excited in the axial (in-plane) direction through a 3 cycle
Hanning windowed tone burst with a centre-frequency of 90 kHz
generated by a RITEC 4000 pulser-receiver (Ritec Inc., USA). The
excitation was given symmetrically using strips of 10 cm length
made of iron-based magnetostrictive material, bonded axially at
symmetrical positions around the pipe. The receivers were made
using similar strips of 10 cm length, bonded circumferentially at
symmetrical positions around the pipe. The signals generated
were then received at 7 different angular monitoring points, the
rst along the longer part of the bend and at different clock
positions in sequence till the last one along on the shorter part of
the bend, as shown in Fig. 2 using an Agilent DSO 7012B digital
storage oscilloscope (Agilent Technologies, USA).
September
2017
4. RESULTS
4.1 Finite Element Simulation Results :
Figure 3 : Visualization of Von Mises Stress in the axial direction
over increasing time steps (initial timestamp is shown by
subgure 1 and the time steps increase all the way till subgure
5)
Figure 4 : Schematic of the setup used for simulation. The 3 Probe
point sets used are marked in the gure
Figure 5: A plot of the stress peaks at different clock positions vs
the time at which they are recorded by the probe point.
The wave front before it hits the pipe bend is
fairly straightforward to understand. The
peaks of stress are in line (as shown by the
red line in the plot) and form a circle (along
the cross section of the pipe). The peak
amplitudes are also more or less the same
(as shown by the blue line). Therefore, the
uniform source stress distribution is
maintained along the straight section of the
pipe.
The wave gets distorted at the elbow,
with the peak stress of the wave
getting concentrated at the 12 o’clock
position as it reaches the mid point 45
o
region of the elbow (where probe set
3 is marked in figure 4), as shown by
the blue line. Also the wave front of
(the now varying-amplitude) peaks is
tilted (and hence of ellipsoidal cross
section) with the peaks reaching earlier
along the shorter 6 o'clock position as
shown by the red line.
As the wave crosses the 45o part of the
elbow, the wavefront begins to rotate around
the circumference, with max amplitude stress
roughly reaching the 9 o’ clock position at
the end of the elbow. The stress approaches
near uniform distribution again as it traverses
along the the second straight section of the
pipeline after the elbow.
Figure 6: Plots showing how the stress concentrates at one point
of the elbow and starts rotating (in a helical fashion) after the 45º
point of the elbow.
4.2 Experimental Results
Figure 7: Experimental plot of the stress peaks at different clock
positions vs the time at which they are recorded by the receivers.
Due to the limited test bench setup, the end wall reection is used
to see the behaviour of the distorted wave.
Figure 8: Experimental plots of the amplitude variation with clock
position for different indications (at different receiving points.
5. 0 CONCLUSION
Comparing Figure 7 and Figure 5, it is evident that the time
delays of the peak stresses that were estimated in the
simulation did not match with the experimental cases. This
could be due to the fact that the creation of a perfect cylindrical
wave at source (transmitter) could not be achieved. However
the results of the stress concentration that occurs at the elbow
and the helical rotation of this stress as simulated by gure 6
closely resembles the experimental results obtained by the
array-GUMPS receivers R1 and R2 (shown in schematic in gure
2) as shown in gure 8.
These results provide insight on how a particular defect in an
elbow could be missed if it lies in the position of low stress
concentration and hence work on controlling this distortion of
the guided wave would be crucial in creating advanced LRUT
systems capable of inspection beyond elbows and in the elbow
itself.
6.0 ACKNOWLEDGEMENT:
The authors would like to thank inspection engineers at Detect
Technologies, Mr. Madan Raaj and Mr. Dhanapal Natarajan for
promptly helping with the collection of experimental data.
7.0 REFERENCES
Ÿ Bhupesh Verma, Tarun Kumar Mishra, Krishnan
Balasubramaniam, Prabhu Rajagopal, “Interaction of low-
frequency axisymmetric ultrasonic guided waves with
bends in pipes of arbitrary bend angle and general bend
radius”, B. Verma et al. / Ultrasonics 54 (2014) 801–808
Ÿ M.H. Park, I.S. Kim, Y.K. Yoon, Ultrasonic inspection of long
steel pipes using Lamb waves, NDT and E International 29
(1) (1996) 13–20.
Ÿ H. Kwun, K.A. Bartels, Magnetostrictive sensor technology
and its applications, Ultrasonics 36 (1) (1998) 171– 178.
Ÿ J.L. Rose, D. Jiao, J. Spanner Jr., Ultrasonic guided wave NDE
for piping, Materials Evaluation 54 (11) (1996) 1310–1313.
Ÿ H.J. Shin, J.L. Rose, Guided wave tuning principles for defect
detection in tubing, Journal of Nondestructive Evaluation
17 (1) (1998) 27–36.
Ÿ M.J.S. Lowe, D.N. Alleyne, P. Cawley, Defect detection in
pipes using guided waves, Ultrasonics 36 (1) (1998)
147–154. [11] H.J. Shin, J.L. Rose, Guided waves by
axisymmetric and non-axisymmetric surface loading on
hollow cylinders, Ultrasonics 37 (5) (1999) 355–363.
Ÿ M.J. Quarry, J.L. Rose, Multimode guided wave inspection
of piping using comb transducers, Materials Evaluation 57
(10) (1999) 1089–1090.
Ÿ D. Alleyne, B. Pavalkovic, M. Lowe, P. Cawley, Rapid long-
range inspection of chemical plant pipe work using guided
waves, Insight 43 (2001) 93–96.
Ÿ J.L. Rose, X. Zhao, Flexural mode tuning for pipe elbow
testing, Materials Evaluation 59 (2001) 621–624.
Ÿ J.L. Rose et al., A natural focusing low frequency guided
wave experiment for the detection of defects beyond
elbows, Transactions of the ASME – Journal of Pressure
Vessel Technology 127 (3) (2005) 310–316.
Ÿ H. Nishino, K. Yoshida, H. Cho, M. Takemoto, Propagation
phenomena of wideband guided waves in bended pipe,
Ultrasonics 44 (2006) 1139–1143.
Ÿ T. Hayashi, K. Kawashima, J.L. Rose, Calculation for guided
waves in pipes and rails, Key Engineering Materials
270–273 (2004) 410–415.
Ÿ T. Hayashi, K. Kawashima, Z. Sun, J.L. Rose, Guided Wave
Propagation Mechanics Across a Pipe Elbow, Transactions
of the ASME – Journal of Pressure Vessel Technology 127 (3)
(2005) 322–327.
Ÿ K.E. Rudd, K.R. Leonard, J.P. Bingham, M.K. Hinders,
Simulation of guided waves in complex piping geometries
using the elastodynamic nite integration technique, The
Journal of the Acoustical Society of America 121 (3) (2007)
1449–1458.
Ÿ H. Nishino et al., Experimental investigation of mode
conversions of the T (0, 1) mode guided wave propagating
in an elbow pipe, Japanese Journal of Applied Physics 50 (4)
(2011) 046601-1–046601-7.
Ÿ S. Furuhashi, K. Sorimachi, T. Sugiura, Change in Mode
Congurations and Propagation Velocity of Guided Waves
through an Elbow Section of a Pipe, in: IEEE International
Ultrasonics Symposium Proceedings, 2010 pp. 2211–2214.
Ÿ A. Demma, P. Cawley, M. Lowe, The effect of bends on the
propagation of guided waves in pipes, Transactions of the
ASME – Journal of Pressure Vessel Technology 127 (3)
(2005) 328–3
September
2017
 ARTICLE

ARTICLE
Inspection of Off-shore Structures using Remotely
Operated Vehicles: Planys Experience
*Vineet Upadhyay1, Manas Galipalli1 , Sanchit Gupta1, and Prabhu Rajagopal1,2
1
Planys Technologies Pvt. Ltd., IITM Research Park, Taramani, Chennai-600113, T.N., India
2
Center for Nondestructive Evaluation and Department of Mechanical Engineering, IIT Madras,
Chennai-600036, T.N., India
*Email : vineet@planystech.com

ABSTRACT
ABSTRACT
Underwater structures in coastal areas (for example, ports and terminals) and off-shore platforms
(for example, tanker terminals and buoy moorings) need to be inspected periodically for detecting
damage and initiating maintenance activities. The conventional method of using human divers
suffers from various limitations such as shallow depth reach, limited endurance and capability to
carry payloads and an inherent risk to human life during poor weather conditions or when
operating inside conned places. The Center for Non-Destructive Evaluation (CNDE) at IIT Madras
together with spin-out company Planys Technologies has been developing compact ROVs with
exible payload capacity addressing these challenges. This paper presents case studies from on-
eld inspections using Planys ROV Beluga, a double-hull vectored multi-thruster ROV custom-
developed for near offshore and in-land shallow-water applications. The results show the damage
detection and inspection capabilities using visual and LASER payloads. This work will be of interest
to offshore platform asset integrity and plant safety professionals.

1.0 INTRODUCTION This paper describes methodology for usage of

India is one of the largest crude oil importing countries in the
world. Oil and Gas in the country are mainly produced in the
Bombay High oil-eld development area in the Arabian Sea and
the Krishna-Godavari Basin in the Bay of Bengal. Large numbers
of offshore platforms situated in these regions perform
excavations on a daily basis. Periodic maintenance activities are
performed by trained professionals to ensure that these
platforms keep functioning without any down times. Regular
inspections are performed to identify any signs of weakness or
damage of the structure or its sub-systems. The most
challenging areas to inspect are the underwater portions of the
platforms due to their restricted accessibility and availability or
high costs of underwater equipment and trained divers,
limitations on diving depth, poor weather conditions, poor
underwater visibility and an inherent risk to human life during a
diver-assisted operation. Off-shore platforms, rigs, ship
propellers and internal ballast tanks also need regular
maintenance and inspection for corrosion and bio-fouling.
Currently, in India, inspection operations of immersed
structures and ships are mostly performed by divers and off-
shore technicians or by third-party inspection service providers
during dry docking sequences. Lives of operators are at risk in
such operations which are often performed in low-accessibility
or inaccessible areas where communication and endurance are
limited. In addition to such constraints and risks, due to
challenges in availability of service providers and operators of
required technical experience, manual operation is also prone
to unreliability.
Remotely Operated Underwater Vehicles (ROVs) in such
scenarios which not only mitigates these risks or limitations but
also provides advanced inspection capabilities. ROVs are
unmanned vehicles which are controlled remotely by pilots, to
perform structural inspections and hydrographic surveys of
inland and coastal water regions [1, 2]. They are capable of
reaching the desired location based on on-shore navigation,
performing inspection in conned spaces and providing more
efcient, reliable and safe inspection solutions. The paper is
based on the operational and technology development
experience of the authors, through an Indian Institute of
Technology Madras (IITM) incubated startup company, Planys
Technologies Private Limited (www.planystech.com).
The paper is organized as follows. Firstly, a brief
background on the traditional inspection methods and their
challenges are presented while describing ROV capabilities to
overcome them, followed by a concise description of features,
capabilities, and typical applications of ROV Beluga developed
by Planys Technologies. The further sections include a detailed
description of inspection and survey methodologies illustrated
through case studies from Planys experience. Finally, the paper
concludes with some directions for further development and
future work.
2.0 BACKGROUND
The traditional method for underwater exploration or
inspection dates back to ancient times where human diversould
recover shells, food, pearls and sponges from the sea [3]. Today
diving is a major commercial industry involving professionaL

September
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 31

ARTICLE
as well as recreational activities. Although underwater diving
is beneting from continuous development of technology, a
diver’s life is prone to risks such as entanglement, rough
weather conditions, equipment malfunction, umbilical
damage, excessive nitrogen or oxygen absorption in the body,
pulmonary embolism and dangers from marine life [4]. Divers
continue to face challenges in accessing conned spaces such
as those in tunnels, pipeline or dams. As the diving depth
increases, so do the complexity of engineering equipment,
expertise required and the associated costs. ROVs were
developed to perform such and more complicated tasks with
higher reliability and in marine areas entirely out of human
reach. ROV operation does not endanger human life as it is
controlled remotely from a safe location above water surface.
ROVs can perform greater numbers of activities simultaneously
and with more signicant repeatability as compared to the
conventional diver based inspection methodologies. Further,
ROVs can be operated round the clock, provide stable live
inspection data streams to the shore control station, reach
greater depths, carry heavy work equipment and operate in
bad to worse environmental conditions. ROVs have been
widely used in the offshore industry for various activities such
as drill support, seabed survey, structural integrity inspection,
pipe-lay jobs, debris removal, inspection, maintenance, repair
jobs and environmental surveys [5]. ROVs are further used for
near shore and inland water applications such as the inspection
of ships, jetties, dams and bridges. Small and portable ROVs
can be efciently used for accessing locations that may be
remote or have restricted accessibility such as inside long and
narrow pipelines or tunnels [6, 7].

3.0 ROV BELUGA

Developed entirely in India by Planys technologies, Beluga
illustrated in Fig. 1 (see Table 1 for technical specications), is a
compact, modular and portable ROV that can sustain 2-4
meters of wave height, moderately rough swell, up to 1 m/s of
sea currents and can dive up to 200 meters of depth. An
observation class ROV, Beluga’s design has a state-of-the-art
dual hull and heavy bottom hydrodynamic design, providing it
with static and dynamic stability in harsh underwater
environments. Beluga is equipped with eight thrusters
providing control in 5 degrees of freedom along with forward
thrust of 17.5 kg-f and an operating speed of 3-4 knots. The
heavy bottom feature of the vehicle inhibits roll motion. Beluga
also carries an Inertial Measurement Unit (IMU) for orientation Table 1: ROV Specications (www.planystech.com)
feedback, a pressure sensor for depth feedback and a Global
Positioning System (GPS) for position feedback on the water Beluga is suited for services in the offshore oil & gas sector,
surface. Its modular architecture allows Beluga to carry a shipping industry (hull, propeller, rudder and ballast tank),
variety of additional payloads such as high-denition cameras, ports & marine terminals, dams, power plants, thermal plants
high-intensity lights, LASERs as crack measurement unit, and nuclear plants, including visual and non-destructive
Altimeter, Side-Scan Sonar, Ultrasonic thickness measurement techniques (NDT) based inspection of immersed underwater
unit, Cathodic Potential measurement unit, bio-fouling structures. Capabilities to perform detection of ooding in
cleaning equipment, 2D & 3D Imaging/Scanning SONARs [8]. structural members of offshore platforms through acoustic
techniques, bathymetric surveys using SONARs to study seabed
topography and hydrographic surveys to characterize water
properties such as conductivity, temperature, pH, dissolved
oxygen (DO),turbidity and oxidation-reduction potential can be
as plug-and-play payloads as per the application. Further,
capabilities for cleaning of marine and bio-fouling growth from
piles, ship hull and underwater structures, measurement of
structural thickness and cathodic protection potentials on
Fig. 1: Photograph of ROV Beluga with highlights of its features offshore structures are under development.
September
2017
 ARTICLE
ARTICLE 4.0 INSPECTION CASE STUDIES
4.1 VISUAL INSPECTION
Planys performs underwater visual inspection using its ROVs to
analyze the supercial integrity of immersed structures. Live
inspection provides a real-time video feed to the operating pilot
and the surveyor. For this purpose, ROVs are mounted with
multiple cameras which provide standard or high denition
streams from various angles. Further, as sunlight does not
penetrate beyond 15 – 20 m in clear water or 10 – 12 m in
turbid waters from the surface, Planys ROVs are equipped with
high-intensity lights to illuminate the inspection targets [9].
Water turbidity is a signicant factor in setting the underwater
visibility which in turn affects the quality of video output.
Navigation in highly turbid waters is an extremely challenging
task, and thus SONAR units are deployed to navigate to the
submerged inspection site. Further, in turbid areas, the ROV
must be brought extremely close to the target in order to
examine it visually. Such proximity to the target increases the
risk of entanglement and collision especially in shallow water
zones where the effect of wind-generated swell is high. ROV
cameras are often augmented with features such as optical
zoom, auto-focus, auto-iris, low light visibility and image
stabilization. Often a laser scaling payload is attached to the
camera to help determine the dimensions of the objects seen in
the video.
4.1.1 Case Study 1: Visual inspection of piles of an
Offshore Tanker Terminal
Planys Technologies conducted an underwater visual
inspection of 52 supporting piles of an offshore marine tanker
terminal facility and expansion loops of a pipeline trestle
connected to the shore, shown in Fig. 2. The terminal is located
in an open area on the eastern Indian coast around 1.5 km
away from the shore at Karaikal, Puducherry Union Territory
with an average water depth of 12 m. Due to the shallow depth
and wave action, the visibility in the region was observed in the
range 1 – 1.5 m at the surface and 0 m beyond 8m depth.
(a) (b)
Fig. 2: A photograph of piles investigated in Case study 1 (a) at
the pipeline trestle and (b) at the terminal facility
The operations were carried out over three and a half days
during daytime averaging to 14 piles scanned per day from two
diagonally opposite angles each. The inspections were
conducted using Planys’ ROV Beluga with 120 m of tether
length, one high denition 720p 50 FPS frontal color camera
with two scaling LASERs, a standard denition 30 FPS bottom
looking color camera and an altimeter. The ROV control console
was set up at three different locations, sequentially, on the
terminal platform, to access all the piles from at least two
angles. The operations crew, as shown in Fig. 3, consisted of
one supervisor, one winch operator and two ROV pilots with
additional supporting staff provided by the terminal
authorities. Many difculties were faced by the ROV pilots due
to swell induced oscillations, near zero visibility closer to the
September
2017
seabed and challenges faced during launch and recovery
process. Since a crane facility was unavailable at the site, a sh
trawler was provided to assist the manual launch and recovery
of the 50 kg weight ROV.
(a) (b)
Fig. 3: Photograph of (a) ROV pilots at work on their portable
control console and (b) ROV Beluga being launched manually
from boat deck, for investigation described in case study 1
The inspection results showed signicant marine growth on the
piles. The section of piles above the water surface was also
found to be heavily corroded. In some piles, major cavities were
observed due to localized corrosion over prolonged periods.
Data Processing and Report Creation:-
Planys team processes the data in multiple stages [10] before
delivering it to the client through a rich and interactive software
interface also called as the Planys Assessment Dashboard
(PAD). At rst, the raw data is cropped to meaningful sections,
followed by ltering and tagging of the data points. Inspection
videos are rendered with overlaid metadata such as depth,
sensor measurements, altitude, date, dive number and
inspection index. Planys further processes the images and
videos to enhance their quality in case of recordings done in
low visibility conditions as shown in the Fig. 4 below.
(a) (b)
Fig. 4: Enhanced images showing a processed rectangular region
of interest with more clarity than the surrounding strip: (a) a
section of a pile & (b) a dam wall
Haze removal algorithms are used to enhance videos or images
recorded in turbid waters with low visibility. Similarly, color
correction is performed to remove the extra blue or green tinge
added to the videos by the surrounding water. Fig. 4(a) shows a
section of a pile enhanced with Haze removal method whereas
Fig. 4(b) shown a picture of dam wall normalized using color
correction.
A highly interactive and user-friendly software
platform (software report) is developed to access the processed
data, images and videos of inspection. Fig. 5(a) is a snapshot of
the software report which depicts the area covered in
inspection and locations of defects using a Computer-Aided
Design (CAD) diagram of the structure. Images and videos of
the inspection are made accessible to viewers in software
report as shown in Fig. 5(b). These results helped the client site
engineers gain vital information regarding marine growth and
structural integrity of the immersed portions of the piles.
4.1.2. Case Study 2: Visual inspection of Single Buoy
Mooring (SBM)
A Single Buoy Mooring (SBM) is a oating buoy anchored at an

(a)
Fig. 5: (a) and (b), Snapshots(b)of Planys’ interactive software
report user interface
offshore location to allow Oil & Gas tankers ofoad their cargo
thorough interconnects running from the SBM to an onshore
storage or processing unit. Planys conducted a visual
inspection of an SBM off the coast of Kochi, Kerala India, in April
2017, photographs of which are shown in Fig. 6.
(a) (b)
Fig. 6: Photographs of (a) ROV Beluga approaching the SBM and
(b) ROV Pilot along with the support crew positioned on the deck,
for investigation in case study 2
The operations were carried out from a Diving Support Vessel
(DSV) using a 4-membered crew from Planys and additional
support from the onboard diving team. The operations were
carried out during daytime over two days, recording two dives
of 4 hours each. The objective of the inspection was a visual
examination of the Buoy Underside, six Catenary Mooring
Chains holding the buoy, the Bend Restrictor, Hose Connector
and the Anchor Chain Connectors. Snapshots taken from the
visual inspection are shown in the gure 7.
(a) (b)
( c)
Fig. 7: A photograph of (a) various catenary chains and the
connecting hoses from buoy underside, (b) anchor chain
connector and (c) the underside of buoy, obtained in inspection
performed by Planys as described in case study 2
31
ARTICLE
The inspection results as shown in Fig. 7, showed the presence
of signicant marine growth on the structures. However, no
alarming structural anomalies were found. The visibility
underwater at the site was greater than 5 meters which
allowed the ROV to take clear and distinct images & videos of
the SBM. The presence of large swell and strong surface
currents made it extremely challenging for the pilots to control
the ROV as desired.
4.2 ULTRASONIC THICKNESS MEASUREMENT
Determining the structure’s thickness is crucial for analyzing
structural deterioration which helps in determining further
usable lifespan and ultrasonic NDT is widely used for this
purpose [11].
4.2.1 Case Study 3: Support Beam Inspection
Planys conducted an underwater ultrasonic inspection of
submerged supporting beams of the operating platform in an
indoor wave ume. The inspection was focused on obtaining
thickness measurements of the structural beams of the platform
at multiple locations using a compact ultrasonic thickness
measurement unit with a probe frequency of 2.25MHz,
mounted on ROV Beluga. The operation was carried over half a
day, inspecting ve supporting beams, taking measurements at
different locations varying over depth.
The ultrasonic thickness measurement unit was
initially calibrated with a construction material sample.
Subsequently, the unit and an electric spot-cleaning system
(brush-type) [12] were mounted on the ROV and deployed for
inspection in the wave ume. Before performing the thickness
measurement, it is essential that the surface is clean enough for
the ultrasonic probe to make an appropriate contact with the
metal surface. Incorrect contact of the probe with surface
results in inaccurate or no measurement. The targeted areas
were cleaned with the spot-cleaning system controlled
remotely by the ROV pilot. Then, the thickness measurements
were taken using the ultrasonic unit by making an appropriate
contact, as shown in Fig. 8. To perform the inspection the pilot
uses live visual feeds from the cameras which are mounted on
the ROV in such a way that the payloads (ultrasonic thickness
measurement unit and cleaning system) are visible in the eld
of view, and real-time readings of the thickness measurements
are made visible to pilot in a graphical user interface. The water
depth at which the thickness measurements were taken was
obtained using a depth sensor onboard the ROV.
(a) (b)
Fig. 8: A photograph of ROV Beluga (a) cleaning the structure using
spot cleaning equipment and (b) performing ultrasonic thickness
measurement, for investigation described in case study 3
There are several essential prerequisites to the inspection such
as selection of suitable probe based on the inspection
requirements, pre-inspection calibration of the probe, cleaning
of immersed metal structures before taking the measurement,
ne control of the ROV to make gentle contact of the ultrasonic
September
2017
 ARTICLE

ARTICLE probe with the metal surface to avoid any damages to the 7.0 REFERENCES
probe, and provisions for real-time measurements, data [1] J. Yuh, Design and Control of Autonomous Underwater Robots: A
S u r v e y, K l u w e r A c a d . Pu b l . 8 ( 2 0 0 0 ) 7 – 2 4 .
acquisition and data visualization to the pilot or surveyor
doi:10.1023/A:1008984701078.
[2] L. Whitcomb, Underwater robotics: out of the research laboratory and
5. CONCLUSIONS AND FUTURE WORK into the eld, Proc. 2000 ICRA. Millenn. Conf. IEEE Int. Conf. Robot.
The paper described various inspection methodologies offered Autom. Symp. Proc. (Cat. No.00CH37065). 1 (2000) 709–716.
by Planys Technologies Private Limited, an Indian Institute of doi:10.1109/ROBOT.2000.844135.
Technology Madras (IITM) incubated startup, using their [3] Research Repositor y. Rubicon. 2011. Available online
h t t p : / / a r c h i v e . r u b i c o n -
product ROV Beluga. Advantages of ROV inspection over foundation.org/xmlui/bitstream/handle/123456789/5894/SPUMS_V5N2
traditional methods were discussed. Technical details of the _2.pdf?sequence=1 (last accessed: 24 Oct 2017)
ROV are also presented. Further, case studies elaborating [4] R.. Murphy, E. Steimle, M. Hall, M. Lindemuth, D. Trejo, S. Hurlebaus, Z.
various capabilities including visual and ultrasonic inspection, Medina-Cetina, D. Slocum, Robot-assisted bridge inspection, J. Intell.
video enhancement and surface preparation are discussed. Robot. Syst. Theory Appl. 64 (2011) 77–95. doi:10.1007/s10846-010-
9514-8.
Limitations and challenges with different inspection
[5] A. Shukla, H. Karki, Application of robotics in offshore oil and gas
methodologies and in different operational environments have industry— A review Part II, Rob. Auton. Syst. 75 (2016) 508–524.
been highlighted. doi:10.1016/j.robot.2015.09.013.
Planys is consistently working to increase the [6] R. Montero, J.G. Victores, S. Martínez, A. Jardón, C. Balaguer, Past,
capabilities of its ROVs. Advanced power supply and present and future of robotic tunnel inspection, Autom. Constr. 59 (2015)
propulsion system with improved hydrodynamics and control 99–112. doi:10.1016/j.autcon.2015.02.003.
[7] A. Jasper, Oil/Gas Pipeline Leak Inspection and Repair in Underwater
system are being developed to operate ROVs in challenging Poor Visibility Conditions: Challenges and Perspectives, J. Environ. Prot. 3
offshore environment. Underwater inspection capabilities are (2012) 394–399. doi:10.4236/jep.2012.35049.
being developed to perform underwater proximity based [8] V. Upadhyay, S. Gupta and P. Agarwal, Multi-functional Remotely
ultrasonic thickness measurement, ooded member detection, Operated Submersible Vehicle (ROV) System, Patent Filed with Indian
concrete integrity inspection, cathodic potential measurement Patent Ofce (2016), No. 201741022485.
[9] R. Sirikonda and P. Agarwal, Underwater Lighting for a submersible
and multi-beam SONAR surveys. Further, development of
ROV. Patent Filed with Indian Patent Ofce (2016), No. 201741000411.
marine growth removal technology using ROVs is also in the [10] V. Upadhyay and S. Gupta, A ROV System for Underwater Data
pipeline. A new ROV segment is being developed for inside Processing and Method Thereof. Patent Filed with Indian Patent Ofce
pipeline inspections up to 2 km length. (2016), No. 201741022484.
[11] X. Gros, P. Strachan, D. Lowden, Fusion of Multi Probe NDT data for
6.0 ACKNOWLEDGEMENT ROV inspection, Glob. Environ. Conf. Proceedings. Ocean. ’95 MTS/IEEE. 3
(1995) 2046–2050. doi:10.1109/OCEANS.1995.528892.
The lead authors would like to thank Mr. Antony Jacob Ashish,
[12] A. Chandra and R. Sirikonda, Underwater Cleaning Equipment for
NDE Lead at Planys Technologies Pvt. Ltd., for help with Observational Class ROVs. Patent Filed with Indian Patent Ofce (2016),
technical discussions and language used in the paper. No. 201641040231.

Radiation Detection &

Measuring Equipments

Dose & Dose Rate

Survey Meter

Contamination Dose & Dose Rate

Monitor Survey Meter

Area Zone
Monitor

Analogue Survey Personal Radiation

Meter Monitor

Pocket
Dosimeter

8, 2nd Floor, Jyoti Wire House, Near Kolsite, Off Veera Desai Road, Andheri (W), Mumbai 400 053. India
Tel No.: +91-22-6150 3800 / 26 / 40 ♦ Fax:- +91-22-6691 9792
Email: ndtsales@eecindia.com ♦ Web: www.eecindia.com
Regional Offices: CHENNAI, BANGALORE, KOLKATA, HYDERABAD, PUNE, PATNA, NAGPUR, NEW DELHI, VADODARA

INFRARED THERMOGRAPHY AND ITS APPLICATIONS IN
REFINERY
*M.Menaka and B.Venkatraman
Health, Safety and Environment Group, Indira Gandhi Centre for Atomic Research, Kalpakkam-603102.
*Email: menaka@igcar.gov.in
1.0 INTRODUCTION
I nfrared Thermography is an indispensable condition
management tool for oil and gas industry being widely used
for both predictive condition management as well as
preventive maintenance. The method being non contact and
non invasive, makes it an ideal NDE solution especially in
hazardous, harsh and challenging environmental conditions
that are likely in such plants. Recognizing the potential
problems at an early stage will save millions of dollars and
reduce non-productive down time. Thermography has proved
its niche in these industries as a predictive maintenance and
management tool that can recognize potential problems at a
very early stage thus providing enormous monetary savings
and also preventing untimely outages. The advanced infrared
thermography systems with high spatial and temperature
resolution, advanced focus systems, exible viewing options
has created revolutionary change in the inspection by
delivering ultra-high resolution images with better sensitivity
as demanded by the industry from safe distances and faster
inspection. Today, all the major reneries, petrochemicals and
process industries use thermal imaging to ensure the safety,
reliability and integrity of the components and plants in a cost
effective manner. Literature survey reveals that a number of
reviews have been published in the areas of condition
management using thermal imaging. However, a focused
article with a blend of basics, specic case studies and general
factors that an investigator needs to be aware of when making
such thermal surveys was found to be a gap area. This paper
focuses on the application of thermal imaging especially in
reneries. After a brief overview of the physical principles and
factors that affect quantitative measurements, case studies
pertaining to oil and gas industry including corrosion detection
and thermal imaging of typical mechanical components that
are invariably present in such industries are presented.
2.0 THEORY OF INFRARED THERMOGRAPHY
In 1800 Sir William Herschel discovered infrared radiations. Sir
William Herschel was carrying out an experiment where he was
trying to measure the temperature of individual color in the
light spectrum by passing the sun light through glass prism. He
kept thermometers with blackened bulb on each color and
measured temperature and he observed that the temperature
increased from violet to red. He placed thermometer in the
darkness, just beyond the red color and for his surprise the
thermometer recorded temperature which was higher than red.
Then he repeated the experiment and deduced the existence of
radiation beyond the visible range.
Though it was discovered in 1800, IR as a tool for non-
destructive testing had to wait till 1950s. It was only after
World War II that signicant advances in the eld of infrared
45
imaging and detection took place. By the late 1960s while still
most of the applications were oriented towards military
purposes, IR imaging started nding its niche in the eld of
condition monitoring, detection of hold over res, medical
diagnosis, etc. Thus, infrared imaging moved out of the
laboratory into the real-life situation. In the current years, IR
imaging has evolved into a mature technique [3]. The non-
contact nature and exibility of the technique blended with the
ingenuity of the practicing thermographer has led to extremely
diverse applications such as scanning wide areas of earth from
outer space, missile guidance, condition monitoring of
equipment and plant components in electrical [4-6], steel [7]
and process [8] industries, materials characterization,
intelligent processing of materials and determination of
temperature of microwave oven cooking.
2.1 PRINCIPLE OF THERMAL IMAGING
Thermal imaging or Infrared imaging or thermography is the
mapping of temperature proles on the surface of the object or
component. It makes use of the infrared band of the
electromagnetic spectrum. Infrared refers to a region of the
electromagnetic spectrum between the visible and microwave.
The IR spectrum extends from 0.75 mm to 1000 mm. The
properties of infrared radiations are similar to other
electromagnetic radiation such as light. They travel in straight
lines; propagate in vacuum as well as in liquids, solids and
gases. They can be optically focused and directed by mirrors
and lenses. The laws of geometrical optics are valid for these
also. The energy and intensity of infrared radiation emitted by
an object primarily depends on its temperature and can be
calculated using the analytical tools such as Wein’s law,
Planck’s law and Stefan Boltzmann law.
The Planck’s law describes the spectral distribution of radiation
intensity from a black body and is mathematically expressed as:
[Watts m-2 sr-1mm-1] -------- (1)
where, Wl is the blackbody spectral radiant emittance at
wavelength l (mm) c is the velocity of light (3 x 108 m/sec), h
is the Planck’s constant (6.6 x 10-34 Joule-sec), k is the
Boltzmann’s constant (1.4 x 10-23 Joule/K), T is the absolute
temperature (K) of the blackbody. Figure 1 is the spectral radiant
emittance for a black body plotted as a function of temperature.
Fig. 1 Spectral Radiant
Emittance of a black body as a
function of temperatures
December
2017
46
Differentiating Planck’s law with respect to l and setting the
derivative equal to zero, we obtain the wavelength at which
Wl is a maximum. The result is Wien’s displacement law,
which is:
mm --------- (2)
where, lmax is the maximum wavelength of the radiation
curve for the temperature T (K). It can be seen from eqn. 2 that
as the temperature increases, the radiation peak shifts towards
shorter wavelength end of the IR spectrum.
Integrating Planck’s law with respect to l between the limits l
= 0-¥ for constant absolute temperature T, we get the total
radiant power emitted into a hemisphere from a body. This is
the Stephan-Boltzmann law and is mathematically represented
as:
Total emmittance= (W/cm2) --------- (3)
where, s = Stephan-Boltzmann constant 5.6686 x 10-12 Wcm-2
K-4. The law states that the total radiant power is proportional to
the fourth power of the source temperature. Using this
formula, it is possible to calculate the power radiated by the
human body. For example, a body with a temperature of 300 K
and an external surface area of (say) 2 m2 will radiate power of
about 1 kilowatt.
3.0 INFRARED IMAGING SYSTEM
A typical IR imaging system essentially consists of the infrared
camera, control unit, image acquisition and analysis unit as
shown in Figure 2. The heart of the system is the IR scanner. The
IR scanner unit converts the electromagnetic thermal energy
radiated from an object into electronic video signals. These
signals are amplied and transmitted to a display monitor via
an inter-connecting cable. IR imaging systems can be classied
as qualitative or quantitative systems. A qualitative system
displays only an isothermal map. This isothermal map needs to
be corrected for emissivity variations, system non-linearity or
atmospheric effects (in case of large distances). Thermal
measurements are not possible from the image, as it does not
indicate the temperature. In a quantitative system, the IR signal
is temperature calibrated using an internal black body
reference. Appropriate correction factors are also applied such
that the IR image displayed has a temperature distribution
approaching the true surface temperature distribution on the
object.
Fig. 2 IR Imaging System
The main advantages of thermal imaging are that it is a non-
contact method, on-line monitoring, and fast inspection rates
are possible and we have a wide variety of applications.
However, interpretation of thermal images requires skill and
adequate knowledge of infrared physics. The main
disadvantage of thermal imaging is that it is basically a surface
phenomenon. Thus thick objects or defects deep inside are
likely to be missed.
The basic factors affecting the thermal measurement
include (a) emissivity, (b) surroundings, and (c) atmosphere.
December
2017
Factors which affect outdoor thermography inspections are
winds peed, solar loading and weather conditions.
(a) Emissivity - Thermal measurements are inuenced by a
variety of factors; emissivity is one such parameter, which has a
major inuence on the temperature measurement. Emissivity is
dened as the ratio of the total energy radiated by a given
object surface at a particular temperature of object to the total
energy that would be radiated by the surface of a blackbody at
the same temperature.
Total emittance from the material surface
eo = --------------------------------------------------------------------
Total emittance from the surface of a black body at
the same temperature ..................(5)
Black bodies have an emissivity of 1.0 while for all other bodies,
the emissivity varies from 0-1. Emissivity is a function of the
surface condition of the object, wavelength of radiation,
viewing angle and object temperature. For opaque objects,
Kirchoffs law relates the emissivity eo of the object surface to
the reectivity ro. For an incident isotropic radiation,
ro= 1 - eo .................(6)
Thus objects with low emissivity, such as highly polished metal
surfaces, will have high reectivity and vice versa. To give an
example, the emissivity of human skin is 0.94 or 0.95 but the
emissivity of a polished metal band of a wristwatch on a
person’s arm is very low. When viewed using an infrared
camera, the wrist watch band will appear to be at a very much
different temperature (in fact higher than hand) even though it
is obvious that the metal band would be at approximately the
same temperature as the surface of the skin. This is clearly
shown in g.3.
Fig. 3. Thermal image of
hand with wrist watch
band. Note that the wrist
watch band has a
different temperature
compared to hand due to
emissivity variations.
For accurate temperature measurements emissivity is thus very
crucial parameters. Emissivity of materials can vary from 0.01
to 0.99. Typical emissivity values of commonly used materials
are given in Table 1.
Table – 1 Emissivity values for typical materials
(b) Surroundings - It is important to have the object
surroundings free from thermal radiation sources; otherwise
the radiation from these sources would also be reected by the
object under examination leading to erroneous values. 1

(c) Atmosphere - The effects of atmosphere are of importance
when the object is far away. The atmosphere not only
attenuates the -radiation from the target but also alters the
spectral characteristics. However, these effects are negligible in
cases where the object under investigation is located quite
close and the atmosphere is uncontaminated with vapours,
smoke, fog, hot gases etc. Occasionally, one may need to make
some critical measurements on an object in presence of hot
air/gases as in the case of furnaces. In such cases, suitable lters
such as high temperature gas lter are used along with the
appropriate correction factors to take into account the ambient
temperature and attenuation by these lters. In case where the
objects are situated at a large distance as in the case of airborne
thermography, atmospheric absorption plays a very important
role. The atmospheric absorption is quite a complex process
and in these cases, mathematical modelling is resorted to for
estimating the temperatures.
(d) Solar Reections - Solar Reections are one of the major
problem when thermal imaging is done outdoors during day
time. The reections of sun’s rays on the electrical components
results in spurious hotspots. The effect or false indications,
which can sometimes mask the true hot spots. To avoid the
solar reections, thermal imaging is carried out in the night or
late evening or early morning (two hours after the sunset or
sunrise). Another way of reducing the effect of solar reections
is through the use of appropriate lters. Figure 10 shows the
spurious hot spots on one the interruptor in a nuclear power
station switch yard due to solar reections encountered by the
authors during a campaign. Varying the angle of observation
did not eliminate the problem, which was ultimately overcome
by the application of a lter. Another interesting case
encountered was during the examination of 230kV transformer
bushing top. Figure 11 shows the thermal images of bushing
top and connector region of all the three phases of a 230kV
transformer. Hot spots can be observed on all the 3 bushing
tops and connectors. However repeat thermal scans from
different angles revealed that these hot spots were spurious
and primarily due to solar reections.
Figure 4 : Showing the
spurious hot spots
(indicated using arrow
heads) on the interrupter
due to solar reections.
(e) Wind Speed - Wind is another important parameter which
can inuence our thermal measurements and cause errors in
assessing the severity of the electrical fault. Wind causes
convection which can mask the true temperature values of the
components. Inspection of outdoor electrical installation
components should be avoided when wind speed is greater
than 16 km/hr (10 miles/hr). (f) Weather Conditions Humidity is
one of the main factors that can result in erroneous temperature
values. Figure 5 shows the infrared spectral transmittance of .
47
atmosphere. It can be observed that CO2 & H2O vapours are
the major elements that attenuate infrared radiations to large
extent. Appropriate corrections are needed for relative
humidity, especially when it has to be done over long distance.
Fig. 5. Atmospheric transmittance of infrared radiations for a
6000 ft horizontal path at sea level containing 17 mm of
precipitable water .
4.0 TECHNIQUES IN IR IMAGING [9]
IR imaging basically exploits the non – equilibrium thermal
state within a material for the detection of defects. This non
equilibrium state can be achieved through the use of sources
which can heat or cool the body. Such sources can be located
within the material itself or can be external to it. Thus, two
approaches or techniques are generally recognised in thermal
NDE – (a) active and (b) passive.
4.1 Passive Approach: Passive technique involves
applications where the material already contains its own
internal source of heat. In many industrial processes,
temperature is an essential parameter to assess proper
operation and passive thermography aims at such a
measurement. Important applications of the passive approach
are in production, predictive maintenance, medicine, forest re
detection, building thermal efciency survey programs, road
trafc monitoring, agriculture and medicine. In all of these
applications, abnormal temperature proles indicate a
potential problem that must be addressed. For some
applications, knowledge of the work-piece fabrication and
operation combined with proper thermal modelling opens the
door to quantitative extraction of information such as for
instance the remaining thickness of refractories, etc. The typical
case studies of condition monitoring application based on the
passive approach undertaken by the authors are detailed
below.
4.2 Active Approach: Contrary to the passive approach, the
active approach, involves the application of a external thermal
perturbation (heating or cooling) to the object as a whole or of a
small area of interest within the object. While both heating and
cooling can be applied, it is heating which is generally
preferred. This can be attributed to the fact that it is easier to
heat a body and a wide variety of heating sources are also
available. The choice of the heating method is quite critical as
this would decide the thermal contrast and hence the defect
detectability. Further the application of the heat by the source
itself should be non-destructive. That is it should not cause any
physical or chemical damage to the object being inspected.
Depending on the external stimulus, different approaches of
active thermography have been developed, such as pulse
thermography (PT), step heating (SH), lock in thermography
(LT), vibrothermography (VT).
December
2017
48
The authors have used step heating using a combination of
halogen lamps, as well as pulsed heating using hot air guns
with provisions to vary the temperature. Both reection and
transmission methods have been used for observations. The
choice of the observation method adopted was based on the
nature of the thermal source, its strength, object conguration,
material of the object, location of the defect and its size.
This article highlights the passive thermography application in
oil and gas industry.
5.0 APPLICATIONS IN OIL AND GAS INDUSTRY
5.1 OFF SHORE INSPECTION
Infrared thermography is a widely accepted predictive
maintenance technology within land-based facilities. However,
very little is published about its applications to marine systems
specically offshore wherein also we have electrical and
mechanical systems. In addition to cost effectiveness and
increasing uptime, thermography can also ensures the safety
and reliability of marine facilities wherein system failure could
lead to losses and sometimes disastrous environmental effects.
The primary purpose of offshore structures is to retrieve the oil
and gas from deep below the ground. In the offshore
environment this usually means drilling wells and maintaining
and managing them via an offshore platform. An offshore
platform or colloquially referred to as oil rig can be of xed or
oating type. In either case, its main function is to retrieve the
gas and oil from the wells. This is done through a combination
of mechanical and electrical systems.
Materials coming up from the wells are a complex
mixture of solid, liquid and gas. Sand is one of the main and
important constituent which comes along with the retrieved oil
and gas from wells. These sands are cause of concern as erosion
problems evolve in pipes and vessels. An effective means of
monitoring sand being carried up from the wells is by
conducting a thermographic survey of the separator vessels.
The main function of an offshore separator is to quickly
separate sand, water, oil, and gas. It is well known that these
four materials have different densities, thermal capacitances
and thermal conductivities. Thus based on thermal
capacitances and conductivities and coupled with rm
understanding of uid dynamics, thermodynamics, and erosion
mechanisms, thermal imaging has been successfully employed
to locate and highlight the relative levels of solids and uids
(gure 6) and also the quantitative erosions that occur in the
vessels due to the sand and other solids. Thermal imaging also
helps in visualizing the sand’s ow pattern through the outlet
nozzles, which can help to determine which valves will be more
affected by the erosive power of sand [10].
Once the oil and gas are separated, these are
transported. The crude oil is generally piped via undersea
pipelines to large holding tanks for further rening. Thermal
imaging is widely used for liquid level inspection of these tanks.
The rigs in offshore are energized through a variety of
electrical including distribution equipments such as SCR’s,
transformers, engine generators, MP/DW motor’s etc.
Identifying the extreme thermal stresses and also the various
electrical issues before any of these can become major causes
for outage is primarily accomplished by thermography.
December
2017
Normally all these electrical equipments are energized to about
40 % electrical load and subjected to thermal surveys.
Figure 6: Thermal image
of separator vessel clearly
revealing the oil, water
and sand deposit in the
vessel [10]
5.2 GAS LEAK DETECTION
Gas leak detection in pipes, vessels and various facilities of oil
and gas industry is an essential and challenging task as leak
detection of volatile organic compounds (VOCs), sulfur
hexauoride, and lately carbon monoxide need to be detected
as they are dangerous emissions. Recent developments in
Infrared camera make qualitative application of gas detection
possible. This detection is based on the basic principles of
absorption, emission and scattering properties of infrared
radiation by gas molecules due to their rotational and
vibrational excitations [11] in the infrared spectral range which
in turn change infrared radiation detected from the object of
interest passing through gases. In recent years oil and gas
industry have started to use thermal imaging extensively as
preventative maintenance solutions for spotting gas leaks in
tanks, pipelines and facilities to improve safety, productivity
and prot. The biggest advantage of rapidly scanning large
areas and miles of piping with considerable reduction in
inspection time using highly specialized infrared camera nds
its application in oil and gas industry.
Figure 7. LPG
compressor ange dark
line reveals the leak
[14]
For gas leak detection, stirling cooled photonic detector based
IR cameras coupled with spectral wavelength ltering to
visualize the infrared absorption of gases such as methane
(CH4) , hydrocarbons & VOCs, sulfur hexauoride (SF6), carbon
dioxide (CO2), and refrigerants. Wavelength range preferred for
detection of different gas leaks are tabulated in the table 2. The
success of detection of gas leak depends on environmental
conditions. If the contrast of gas leak is greater with the
background then it is easier for the camera to visualize the gas
leak and pinpoint its source. A Laser based backscattering
technique is suggested for active optical gas imaging which
works on principle of reective surface in the background. Rain
and strong winds will affect eh measurement. Rain can make
detection very difcult, but wind helps in visualizing the gas
because it makes the gas move. Gas leak detection by these
infrared cameras is qualitative and not quantitative but some
cameras claim to measure mass leak rates (g/h) or volumetric
leak rates (cc/ min or L/min) for most hydrocarbons. Biggest
advantage of using infrared camera for detection of gas leak in
oil and gas industries is operating from a safe distance.
Gases Wavelength Range boiler has to be carried out with appropriate heat shield to
protect the infrared camera from extremely high operating
Refrigerants 8.0 – 8.6 µm temperatures.

Sulfur hexauoride (SF6) and 10.3 – 10.7 µm

ammonia (NH3)

Methane (CH4), other 3.2 – 3.4 µm

hydrocarbons and VOCs
Figure 8. Typical Thermal Image Figure 9. Typical thermal
Carbon dioxide (CO2) 4.0 – 4.4 µm of tubes inside the furnace image of blockage in a tube

Carbon monoxide (CO) 4.52 – 4.67 µm

Table 2 reveals the spectral wavelength range for various gases

The ames in the furnace also have to be maintained in

optimum range. Operation of the tubes at temperatures higher Figure 10. Typical hot spot Figure 11. Thermal image of
than the limiting temperature for a sustained period of time observed due to improper wall of the furnace revealing
results in loss of ductility, cracking and creep damage leading to repair of refractory lining of a
refractory loss
furnace in a petrochemical
premature and catastrophic failure. In case the tubes are plant [17]
operated at lower than their optimum temperatures, it would
result in lower yield. Thus, periodic monitoring of the Thermal measurements of tubes inside a furnace or boiler are
temperature distribution of the tubes at regular intervals is inuenced by a variety of factors. In the present case, as can be
observed from g. 2, the radiation reaching the scanner is the
necessary to ensure optimum yield of the product, smooth and
sum total of the IR radiations emitted by the tubes, the hot
safe functioning of the plant and longer life for the tubes.
gases surrounding the tubes and the radiation reected from
Blockage in the ow of uid inside the tube due to deposition of
other surrounding sources on to the scanner. Mathematically,
foreign materials leads to serious problems such as burst of the
this can be written as
tube and unscheduled shutdown. This blockage overheats the
Scam =to . eo. Sobj + to (1 - eo ) Satm + (1 - eo ) Sobj ...... (6)
tube and heat starts to concentrate on a particular area. Early (From the Due to hot gases (IR reected
detection of the hotspots can be done with the help of tubes) surrounding the tubes by object)
Thermography. Process Heaters are very similar to boilers
where, Scam is the IR radiation received from all sources by the
except that tubes contain a petroleum product, which is highly
infrared imager, to is the transmission coefcient of the
ammable. If the tube gets overheated the result can be atmosphere between the scanner and object in the spectral
catastrophic damage. Thus on-line monitoring of tubes has to
window of interest, eo is the object emissivity, Sobj is the
be done using Thermography [8]. The temperature variation radiation received from the object and Satm is the radiation due to
would provide the presence of liquid levels in storage tanks. atmospheric self emission.
Storage tank sludge can be identied before tank cleaning. The
temperature of material inside the storage tank can be studied.
Local heating and hotspots can be noted with accuracy to
pinpoint the location. In the petrochemical industry, this
technique nds application in determination of state of Fig. 12. IR radiation
insulation lining in boilers and furnaces (g. 1.4), detection of received from various
boiler casing leaks, identication of location and extent of sources by the thermal
blockages in renery process components such as in feed imager
drums, furnace tubes (for cake deposits) and boiler tubes
(insufcient cleaning and desalting) [12, 13]. It has also been This equation gives us the basic idea of parameters which
used for the inspection of catalytic cracking vessels, monitoring inuence the temperature measurement of the tubes inside the
of stack temperatures, maintenance of plant equipment such as furnace or boilers.
reaction towers, detection of corrosion in oil tank shell and Apart from furnaces, some of the petrochemical
measurement of oil levels [14, 15].Insulation of the furnace plants may also have cryogenic processes such as CO2,
needs to be regularly monitored to minimize heat loss through ammonia, and liqueed natural gas. Thermal imaging has been
the wall. widely used for inspection of cold pie lines and equipment for
For industrial high temperature furnace applications, insulation-related problems and also monitor energy and
thermal camera with high temperature range of -40 deg C to efciency losses.
2000 deg C is required with very good thermal resolution of
few mK. The thermal resolution of few mK is possible is 5.4 CORROSION UNDER INSULATION
achieved with semiconductor detector and stirling cooling In general corrosion continues to be a major issue for all
system. Temperature mapping of the tubes inside the furnace or chemical, renery and petrochemical industries throughout the
boiler has to be carried out with appropriate heat shield to world.

December
2017
48
Over many years, all these industries have experienced
extensive damage due to corrosion. Statistics indicate that over
the past 20 years corrosion [17] related failures have cost all
these industries millions of dollars in plant downtime repair and
replacement costs. As a result, several of these industries have
been investing on corrosion monitoring and inspection
program. In this article monitoring of corrosion under insulation
has been discussed as it is more challenging than external
corrosion monitoring. As the pipe surface is not normally
accessible, detecting CUI may require the removal of the
insulation and cladding. Corrosion under inspection [18] is a
form of localized corrosion that may occur between the
insulation and the external surface of a thermally insulated
pipeline or vessel. Insulation materials such as thermal
insulation, foam rubber, polyurethane, calcium silicate, and
berglass used for insulation have higher adsorption properties
of water, oxygen and leachable chlorides which initiates and
accelerate the corrosion process. Corrosion under insulation is
caused by the moisture ingress and trapping of moisture in the
insulation system. Corrosion under insulation can cause
considerable damage to the integrity of an insulated pipeline or
vessel and if goes undetected the damage can be causing leaks
to possible catastrophic events. Various methods adopted for
inspection of corrosion under the insulation include visual
inspection, radiography, thermal imaging, moisture detectors,
and moisture removal methods (eg. drain plug).
Thermographic inspections using infrared cameras helps in
detection of localization of corrosion under insulation and
determining the condition of thermal and cold insulation
systems without taking the plant out of operation. This avoids
unplanned shutdown time and unnecessary investments in
maintenance. Pipelines can be scanned from a distance, which
avoids time-consuming construction of scaffolding works.
Fundamental principle behind the thermographic inspection is
wet insulation retain heat longer than dry insulation. Regions
where insulation is wet will be hotter than locations with dry
insulation.
Figure 13 Thermal
image of the pipeline
clearly revealing the
corrosion under
insulation (Courtesy-
Thermovision
http://thermalvision.ie/
cui-classication-with-
thermography)
Figure 13 Thermal image of the pipeline clearly revealing the
corrosion under insulation[18]
The important point to be remembered when corrosion under
insulation inspection is carried out using an infrared camera is
the time at which thermography survey is carried out in a day.
Usually thermography to be inspected for corrosion under
insulation would have seen considerable amount of solar
loading. Solar heating would enhance the contrast and in turn
help in detection of wet survey is carried out 2 to 3 hours after
the sunset so that all the structures or all pipelines which need
insulations. Hence it is obvious that thermography survey need
to be carried out on a sunny day with no or minimum strong
winds to avoid convection factor. Thermal camera with thermal
detector (un-cooled micro bolometer detector)
December
2017
and spectral wavelength ranging from 7 microns to 14 microns
is highly recommended. Temperature range of camera may be -
40deg C to 500 deg C with thermal resolution of 0.04 deg C.
5.5 ELECTRICAL AND MECHANICAL SYSTEMS [19]
All the industries have electrical and mechanical systems to
operate the plant for various purposes. Monitoring of the
electrical and mechanical systems in all these industries is vital
for smooth operation of the plants. Thermographic inspection is
recommended for condition monitoring of electrical and
mechanical systems as they quickly pinpoint problems, reduce
downtime and equipment damage prevents catastrophic
failures and avoids costly shutdowns.
In electrical and mechanical systems, excessive heat
generation by the system is an excellent indicator of upcoming
trouble. Electrical systems typically suffer from problems such
as loose connections; dirty contact surfaces, broken strands of
wire, cracked insulators, load imbalances and corrosion. These
problems increase the resistance to the current ow, which in
turn results in excessive resistive heating. The rate of
generation of heat (H) in the component or circuit is
proportional to the square of the current (I) passing through it.
Mathematically,
H a I2 R t ----------(7)
Where, R is the resistance and t is the time. If left undetected,
this heat buildup can result in meltdown of connection breaking
the circuit and causing sudden blackouts. In some cases, this
can also be a potential re hazard. Infrared inspection of
electrical power distributions systems can be performed right
from the point where electricity is produced i.e. in generating
stations till it reaches the consumer.
Figure 14. Thermal image of Figure 15. Oil storage tank
electrical installation with high above the transformer clearly
temperatures mapped at the L indicating the level of oil
pad circuit breaker
Mechanical Systems: IR imaging is an indispensable part of
periodic condition monitoring programs in the industries
mentioned above. Apart from these, IR is also applied for the
inspection of mechanical systems and condition monitoring of
rotating equipments in these industries. Electrical motors,
pumps etc frequently fail due to excessive vibrations, poor
lubrication, misalignment of bearings and shaft, deteriorating
insulations, poor windings, etc. All these cause an increase in
temperature which can be easily detected by IR imaging.
Figure 16 shows the typical thermal image of motor and pulley
6.0 CONCLUSION
Thermography is a versatile tool for condition monitoring with
wide application range. The non-contact and on line
monitoring of the defects adds great potential to the technique
for condition monitoring in a wide range of industries and for
wide variety of components. Many of the thermographic
applications carried out within the oil and gas industry are
highly challenging. Accurate evaluation and reliable
interpretation requires a good appreciation of the processes,
equipments and analytical understanding of the fundamentals
of heat transfer physics in order to properly identify and
diagnose problems and conditions. The recent advances in IR
sensor technologies with possibilities of remote transmission /
wireless capabilities and coupled with analysis using Articial
Neural Networks and data fusion offers many distinct
possibilities especially as an "IOT" based technology for
predictive condition as well as structural health management
tool in these industries.
REFERENCES:
[1] G.A. Raine and N. Smith, Back to Basics: NDT of On and Offshore Oil
and Gas Installations Using the Alternating Current Field
Measurement (ACFM) Technique, Materials Evaluation., Vol. 54, No. 4,
April 1996, pp. 461–462, 464–465
[2] B Mc Queen Smith, "Condition Monitoring by Thermography",NDT
International,June 1978, pp. 121 – 122
[3] Maldague. X.V.P.,Non Destructive Evaluation of materials by
Infrared Thermography", Springer Verlag Publications, 1993.
[4] B. Venkataraman, S. Kanmani, C. Babu Rao ,Baldev Raj and T. Prem
Kumar "Thermographic Investigation of 230 kV Main Transformer of
MAPS – I " IGCAR Report No. IGC/DPEND/R&D/92/03. (1992)
[5] B. Venkataraman and Baldev Raj, Inservice Inspection at Tarapur
Atomic Power Station, - Thermographic Campaign, 1992, IGCAR
Report : IGC/DPEND/R&D/92/04, Part "B".
[6] B. Venkatraman, S. Kanmani, C, Babu Rao, D.K. Bhattacharya and
Baldev Raj, Inservice Inspection of Electrical Components at Nuclear
Power Stations by Infrared Thermographic Imaging, Proceedings of
Non-Destructive Evaluation and Quality Assurance (NDE-92), Ed. By
C.R.L. Murthy, Baldev Raj, O. Prabhakar and A. Srinivasulu, Published
by Interline Publishers, Bangalore, 1992, pp. 102-109.
[7] L M Rogers, "Applications of Thermography in the Steel Industry",
Steel Times Annual Review, 1978, pp. 661 – 673
[8] Paul Grover, "Infrared inspection of Boilers and Process Heaters",
MaterialEvaluation, October 1991, pp1272-1274.
[9] Xavier P V Maldague and Patrick Moore, "Infrared and Thermal
Testing", ASNT Non Destructive Testing Hand Book, Vol. 3, 2001
[10] Sonny James,Common Thermography Uses and Applications
within the Petrochemical, Offshore Oil and Gas, Chemical, and Power
Generation Industries www.irinfo.org,2009
[11] J. F. Tegstam and R. Danjoux, Gas leak detection in the oil and gas
industry using infrared optical imaging , Thermography Colloquium
2007, DGZFP, Germany http://www.ndt.net/article/dgzfp-irt-
2007/Inhalt/v03.pdf
[12] Michael Vollmer and Klaus-Peter M¨ollmann, Infrared Thermal
Imaging, WILEY- Publisher, ISBN: 978-3-527-40717-0, 2010.
[13] Hui, S. U. N. "Application of Infrared Thermal Imagery Technology
in Catalyzed Lining Failure Diagnosis [J]." Industrial Furnace 6 (2011):
011.
[14] Sims, D. Using infrared imaging on production tanks and vessels.
Inframation 2001, Proceedings vol. 2, pp. 119–125
[15] Sims, D. Monitoring the processconditions in oil eld production
vessels with infrared technology. Inframation 2004, Proceedings vol.
5, pp.273–280
[16] B.Venkataraman, S. Kanmani, C. Babu Rao, D.K. Bhattacharya &
Baldev Raj,"Thermographic Investigation At Tamil Nadu Petro Product,
Manali Madras", IGCAR Report No.: IGC/DPEND/R & D/92/11.
[17] Qiang, Shi, Zhu Wensheng, and Ge Yongtao Hu Yang. "Application
of Infrared Thermo Imagery in Petroleum Reneries."Corrosion &
Protection in Petrochemical Industry 1 (2013): 020.
[18] Henderson, Steven. Inspection technology addresses corrosion
under insulation. Hart„s E & P. 2010; 83(8):41-2.
[19] B.Venkatraman, M.Menaka, P.Kalyanasundram and Baldev Raj,
Infrared Imaging-an Overview on its Multifarious Possibilities and
applications in IGCAR, Journal of Non- Destructive Testing & Evaluation
Vol.5, Issue 2 September 2006. pp 54-67
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 54

INTERNALTIONAL EVENTS CALENDAR 2018

APRIL 2018
10-12: Aerospace Event.
Organised by the British Institute of Non-Destructive Testing.
Venue: BAWA Conference Centre, Bristol, UK.
Contact: Conference Services, BINDT, Midsummer House,
Riverside Way, Bedford Road, Northampton NN1 5NX, UK.
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MAY 2018
7-9: Annual Conference of the German Society for NDT
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15-17: MFPT 2018: Intelligent Technologies for Equipment
and Human Performance Monitoring.
Venue: Sheraton Virginia Beach Oceanfront Hotel, Virginia Beach,
USA.
Contact: MFPT, 715 Twining Road, Suite 135, Dresher PA 19025,
USA.
Email: amy@mfpt.org; Web: www.mfpt.org
26-28: Digital Imaging and Ultrasonics for NDT 2018.
Venue: Foxwoods Resort, Mashantucket, Connecticut, USA.
Contact: ASNT, 1711 Arlingate Lane, PO Box 28518, Columbus,
OH 43228-0518, USA.
Tel: +1 614 274 6003; Fax: +1 614 274 6899;
Email: conferences@asnt.org; Web: www.asnt.org
JULY 2018
10-13: 9th European Workshop on Structural Health
Monitoring (EWSHM 2018).
Venue: Manchester, UK.
Contact: Conference Services, BINDT, Midsummer House,
Riverside Way, Bedford Road, Northampton NN1 5NX, UK.
Tel: +44 (0)1604 438300; Fax: +44 (0)1604 438301
Email: ewshm2018@bindt.org; Web: www.ewshm2018.com
OCTOBER 2018
28-31: ASNT Annual Conference 2018.
Venue: George R Brown Convention Center, Houston, Texas, USA.
Contact: ASNT, 1711 Arlingate Lane, PO Box 28518, Columbus,
OH 43228-0518, USA.
Tel: +1 614 274 6003; Fax: +1 614 274 6899;
Email: conferences@asnt.org; Web: www.asnt.org

27-1 Jun: 12th International Fatigue Congress.

Covering all aspects of fatigue.
Venue: Poitiers, France.
Contact: SF2M, 28 rue Saint Dominique, 75007 Paris, France.
Tel: +33 (0)1 46 33 08 00
Email: fatigue2018@sf2m.fr; Web: www.fatigue2018.com

JUNE 2018
11-15: 12th European Conference on Non-Destructive Testing
(12th ECNDT).
Venue: Swedish Exhibition and Congress Centre, Gothenburg
Contact: Sweden MEETX AB, 412 94 Gothenburg, Sweden.
Tel: +46 31 708 86 90; Fax: +46 31 20 91 03
Email: ecndt2018@meetx.se; Web: www.ecndt2018.com

24-29: 14th Quantitative Infrared Thermography Conference

(QIRT 2018).
Venue: Berlin.
Contact: Steffi Dehlau, German Society for Nondestructive Testing
(DGZfP), Max-Planck-Straße 6, 12489 Berlin, Germany.
Tel: +49 30 67807 120; Fax: +49 30 67807 129;
Email: tagungen@dgzfp.de; Web: www.qirt2018.de

December
2017
 55

15TH APCNDT - A REPORT

13th To 17th November, 2017

T he Asia Pacific Conference for Non-Destructive Testing & Prof Tsuyoshi Mihara - Department Head of Material Science
(APCNDT) considered a major regional event for the Asia and Engineering Tohoku University.
Pacific Federation for Non-Destructive Testing (APFNDT)
and its member societies, was held from 13th to 17th November
2017 at Marina Bay Sands, Singapore.
An MOU was signed between Mr. D. & Prof Tsuyoshi Mihara -
Department Head of Material Science and Engineering Tohoku
University.J.Varde-President, ISNT & Mr. , SINDT.
The conference included technical and scientific program and
workshops, which presented the latest developments in the field
of research and development as well as the applications of NDT
in all major industrial areas. 250 technical contributions were
accepted from practicing NDT professionals, engineers,
scientists and developers in academia and industr y
(manufacturers and end-users) covering all aspects of non-
destructive testing including novel applications, research and
technology development across all industrial areas.

The exhibition organised in conjunction with the conference

emphasized the close link between research and development
and the equipment and instruments used in the industry.

Key Note speakers for the event were Dr Mike Farley Chairman of
the ICNDT (2008-2016), Dr B. Venkatraman - Director of IGCAR
Health, Safety and Environment Group, Prof Krishnan
Balasubramaniam -Dean of Indian Institute of Technology
Madras, Dr Younho Cho - Professor of School of Mechanical
Engineering Pusan National University, Dr Gong Tian Shen -
President of The Chinese Society for Non Destructive Testing
(ChsNDT), Dr B. Stephen Wong - Professor of School of
Mechanical and Aerospace Engineering Nanyang Technological
University, Prof Len Gelman - Professor of Vibro-Acoustic
Monitoring, School of Aerospace, Transport and Manufacturing

ISNT President & SINDT signing the MOU

Dignitories at APCNDT event

ISNT President & SINDT signing the MOU

December
2017
 57

FIRST NDT SEMINAR - A REPORT

28th & 29th January, 1979
Organised by : Hindustan Aeronautics Ltd, Bangalore.
Compiled by Shri. P. Vijayaraghavan, HAL Bangalore

T
he First Seminar on Non Destructive Testing was Ÿ Proceedings of the seminar containing 24 full length papers
organized by NDT Centre, Central laboratory, Hindustan was bought out.
Aeronautics Limited, Bangalore, on 28th and 29th Ÿ The delegate fees was Rs 50/- only !!!
January 1979. Convenors of the seminar were Dr. Krishnadas
Nair & B. Chatterji.

Ÿ Key note address were given by Dr. S. Ramaseshan, Deputy

Director National Aeronautical Laboratory; Jawaharlal Nehru
Fellow, Raman Research Institute Bangalore .
Ÿ A souvenir was released containing 24 abstracts and there
were 24 advertisers
Ÿ 32 papers were presented in 7 sessions
Ÿ Exhibition of NDT equipments, products and technical
Mr. P.D. Chopra MD, HAL, Bangalore, addressing the gathering.
literature was organized on both the days
Sitting from L to R : Mr. B.Chatterji, Dr. S. Ramaseshan, Dr.
Ÿ 50 registered delegates participated, including exhibitors Krishnadas Nair

December
2017

NATIONAL GOVERNING
COUNCIL MEMBER'S LIST
(NGC)
1. Shri D.J. Varde
President, ISNT
M: 9821131522
president@isnt.org.in
2. Shri Rajul R. Parikh
Hon Secretary
M: 9820192953
secretary@isnt.org.in
3. Shri R.J. Pardikar
President Elect, ISNT
M: 9442613146
r.j.pardikar@gmail.com
4. Dr. B. Venkatraman
Vice President – ISNT
M: 9443638974
qadbvr@gmail.com
5. Diwakar Joshi
Vice President, ISNT
M: 9689928561
diwakarj@gmail.com
6. Shri Samir K. Choksi
Hon. Jt. Secretary - ISNT
M: 9821011113
choksiindia@yaqhoo.co.in
7. Shri P. Mohan
Hon. Jt. Secretary - ISNT
M: 94901 67000
metsonic@sify.com /
mohanp45@rediffmail.com
8. Shri S. Subramanian
Hon. Treasurer
M: 9444008685
nricsubramanian@gmail.com
9. Shri P.V. Sai Suryanarayana
Hon. Jt. Treasurer
M: 9490142539
sai895956@gmail.com
10. Shri. V. Pari
Immediate Past
President ISNT
M: 9840104928
pari@scaanray.com
MEMBERS
11.Shri. S. Adalarasu
12.Shri. Anil V. Jain
13.Shri. D.K.Goutham
14.Shri. Ambresh Bahl
15.Shri. Mandar Vinze
16.Shri. S.N.Moorthy
17.Shri. Mukesh Arora
18.Shri. Bhausaheb K.
19.Shri. Pangare
20.Shri. B.Prahlad
21.Shri. Sadasivan N.
22.Shri. R.Sampath
23.Dr. Sarmishtha Palit
24.Shri. B.K.Shah
25.Shri. Shashidar Pallaki
26.Shri. A.K.Sing
27.Shri. A.K.Singhi
28.Shri. R.Sundar
29.Shri. Sunil Gophan
30.Shri. Vivek Rajamani
31.Shri. N.V.Wagle
32.Shri. R.B.Bharadwaj
33.Shri. M.N.V. Viswanath
34.Shri. Bikash Ghose
35.Shri. Anilkumar Das
36.Shri. Jaiteerth Joshi
37.Shri. T.Kamaraj
38.Shri. R.G. Ganesan
39.Shri. Sreemoy Saha
PERMANENT INVITEES
40. Prof. S. Rajagopal
41. Shri G. Ramachandran
PAST PRESIDENTS
42. Shri V.R. Deenadayalu
43. Shri K. Balaramamoorthy
44. Shri Ramesh B. Parikh
45. Shri A. Srinivasulu
46. Shri Dr. Baldev Raj
47. Shri S. I. Sanklecha
48. Shri Shri D.M.Mehta
49. Shri K. Viswanathan
50. Shri Dilip P. Takbhate
51. Shri K. Thambithurai
52. Dr. P. Kalyanasundaram
59
CHAPTER CHAIRMEN / SECRETARIES
53. Shri D.S Kushwah 75. Shri Jeevan Ghime
54. Shri Rajeev Vaghmare 76. Shri Parag W. Pathak
55. Shri Vijayaraghavan 77. Shri M. S. Shendkar
56. Shri Shashidhar P. Pallaki 78. Shri Bikash Ghose
79. Shri V Ranganathan
57. Dr. Krishnan Balasubramaniam 80. Shri B Karthikeyan
58. Shri R. Vivek
81. Shri Elangovan Mudliyar
59. Shri Dayaram Gupta 82. Shri D B Sathe
60. Shri T. Kamaraj 83. Shri Mathivanan
61. Shri P. Mohan 84. Shri V. Deepesh
62. Shri M. Venkata Reddy 85. Shri G. Levin
63. Dr. Amitava Mitra 86. Shri Shanmughavel
64. Shri Tarun Kumar Das 87. Shri R.Venkatasubramanian
65. Shri B. Anandapadmanaban 88. Shri Kashyap N. Bhatt
66. Shri G. Kempulraj
67. Shri C.K. Soman EX-OFFICIO MEMBERS
89. Dr. M.T. Shyamsunder
68. Shri V. Sathyan
90. Shri P.P. Nanekar
69. Shri Dipankar Gautam 91. Shri S. Viswanathan
70. Shri Sreebash Chandra Saha 92. Shri T. Loganathan
71. Shri Ambresh Bahl 93. Dr. Baldev Raj
72. Shri A. Varshney 94. Shri V. Pari
73. Shri Hemant Madhukar 95. Dr. P. Kalyanasundaram
74. Shri Samir K. Choksi
NATIONAL CERTIFICATION BOARD MEMBER'S LIST (NCB)
1. Dr. M.T. Shyamsunder 17. Shri Bikash Ghose
18. Shri Chintamani Khade
2. Shri P.P. Nanekar
3. Shri T. Loganathan 19. Shri G.V.S. Hemantha Rao
4. Shri S. Viswanathan
EX-OFFICIO MEMBERS
5. Shri B. K. Shah
20. Shri D.J. Varde
REGIONAL CONTROLLER OF EXAMS 21. Shri. Rajul R. Parikh
6. Shri S.K. Bandyopadhyay 22. Shri S. Subramanian
7. Shri S.R. Ravindran
23. Dr. B. Venkatraman
8. Shri Jayaprakash Hiremath 24. Shri Diwakar D. Joshi
9. Shri K. Balaramamoorthy 25. Dr. Baldev Raj
10. Shri R.B. Bhardwaj
CHAPTER REPRESENTATION
11. Shri V. Manoharan
12. Shri Avinash U. Sonuwane
27. Shri Hemant Madhukar
13. Shri R. Sundar
28. Dr. Krishnan
14. Shri Phani Babu
Balasubramaniam
15. Shri Dilip Gatti 29. Shri M. S. Shendkar
16. Shri ME. K.A Nerurkar 30. Shri P. Mohan
December
2017
 61

ISNT LEVEL III COURSES

Exam Fees Practical Exam Fees
Course fees
Including 18% (If applicable)
SN Method Course Duration Exam Date Including 18% GST
GST Including 18% GST
(INR)
(INR) (INR)
02/04/2018 to 18,880 2950
1 Ultrasonic Testing 08/04/2018 4720 (4000+720)
06/04/2018 (16,000+2,880) (2500+450)
Specic – Weld Do 2950 (2500+450)
Specic– Cast/ Wrought Do 2950 (2500+450)
09/04/2018 to 18,880
2 Basic 15/04/2018 4720 (4000+720)
13/04/2018 (16,000+2,880)
16/04/2018 to 18,880 2950
3 Radiographic Testing 22/04/2018 4720 (4000+720)
20/04/2018 (16,000+2,880) (2500+450)
Specic – Weld Do 2950 (2500+450)
Specic– Cast/ Wrought Do 2950 (2500+450)
23/04/2018 to 11,800 2950
4 Magnetic Particle Testing 27/04/2018 4720 (4000+720)
25/04/2018 (10,000+1,800) (2500+450)
Specic – Weld Do 2950 (2500+450)
Specic– Cast/ Wrought Do 2950 (2500+450)
28/04/2018 to 11,800 2950
5 Liquid Penetrant Testing 01/05/2018 4720 (4000+720)
30/04/2018 (10,000+1,800) (2500+450)
Specic – Weld Do 2950 (2500+450)
Specic– Cast/ Wrought Do 2950 (2500+450)
02/05/2018 to 18,880 2950
6 ** Visual Testing 06/05/2018 4720 (4000+720)
05/05/2018 (16,000+2,880) (2500+450)
Specic – Weld Do 2950 (2500+450)
Specic– Cast/ Wrought Do 2950 (2500+450)
07/05/2018 to 18,880 2950
7 ** Eddy Current Testing 13/05/2018 4720 (4000+720)
11/05/2018 (16,000+2,880) (2500+450)
Specic – Tubes Do 2950 (2500+450)
Specic – Rods / Wire Do 2950 (2500+450)
14/05/2018 to 21,240 2950
8 ** Leak Testing 19/05/2017 4720 (4000+720)
18/05/2018 (18,000+3,240) (2500+450)
Specic – Weld Do 2950 (2500+450)
Specic– Cast/ Wrought Do 2950 (2500+450)

ASNT LEVEL III COURSES

Course Course Fees Tax @ 18% Total
Method Duration Dates in INR
in INR in INR
Ultrasonic Testing - UT 5 days 2nd to 5th April 2018 16,000 2,880 18,880

Basic 5 days 9th to 13th April 2018 16,000 2,880 18,880

Radiographic Testing 5 days 16th to 20th April 2018 16,000 2,880 18,880

Magnetic Particle Testing - MT 3 days 23rd to 25th April 2018 10,000 1,800 11,800

Liquid Penetrant Testing - PT 3 days 28th to 30th April 2018 10,000 1,800 11,800

Visual Testing 4 days 2nd to 5th May 2018 16,000 2,880 18,880

Eddy Current 5 days 7th to 11th May 2018 16,000 2,880 18,880

Leak Testing - LT* 5 days 14th to 18th May 2018 18,000 3,240 21,240

December
2017
62
United States Patent 9,557,302
Ultrasound inspection system and ultrasonic quality control
method
Inventors: De Miguel Giraldo Carlos, Lambert Gildas, Martinez
Oscar, Elvira Luis, Romero David, Gomez Ullate Luis, Montero
Francisco
Assignee: Airbus Operations S.L. (Getafe, ES)
An ultrasound inspection roller provided with a wheel, a sensing
system and a support for holding the sensing system inside the wheel,
a wedge connected to the ultrasound sensing system at one end and
provided with a curved prole at its other end facing the wheel,
adapted to the curvilinear shape of the wheel, and a liquid of a density
higher than 9.9*10.sup.2 kg/m.sup.m3 placed inside the wheel such
that the sensory system, the wheel and the wedge are acoustically
coupled. The roller allows the early detection of problems during
manufacturing of composites and the performance of corrective
measures in real time, and assures a good coupling between the
transducers and the material to be inspected in dry conditions.
United States Patent 9,803,976
Methods and apparatus for measurement or monitoring of wall
thicknesses in the walls of pipes or similar structures
Inventors: Simonetti Francesco, Instanes Geir
Assignee: Clamp On AS (Bergen, NO)
A method and an apparatus for guided-wave tomographic
measurement or monitoring of wall thicknesses of the walls of pipes
and similar structures are disclosed. The method is characterized in
that use is made of transducers preferably positioned in at least two
groups of a plurality of transducers arranged in a spaced apart pattern
on the external surface of the structures, the transducers individually
transmit ultrasound signal into the pipe wall in that each ultrasound
signal propagates within the pipe wall from the transmitting
transducer and is received at one or several receiving transducers, and
the received ultrasound signal is converted to an electrical signal by
the receiving transducers and recorded by the transceiver.
Measurements are performed by using a further plurality of
transducers that are placed apart from the two groups of a plurality of
transducers. There is also disclosed a method for guided-wave
tomographic measurement or monitoring of wall thicknesses in the
walls of pipes and similar structures producing a set of measurement
data by using the apparatus.
United States Patent 9,804,128
Turbine blade testing device and testing method thereof
Inventors: Yamamoto Setsu, Miura Takahiro, Semboshi Jun,
Ochiai Makoto, Murakami Masato, Nomura Hiroshi , Fuchi Takuya
Assignee: Kabushiki Kaisha Toshiba (Minato-ku, JP)
According to one embodiment, a testing device of a turbine blade
includes: a non-compressive elastic medium brought into close
contact with a platform of the turbine blade in a state fastened to a
turbine rotor; a probe which has piezoelectric elements arranged in an
array and transmits ultrasound waves toward a fastening portion of
the turbine blade through the elastic medium and receives echo
waves; and a display portion for imaging an internal region of the
fastening portion on the basis of the echo waves and displaying the
same.
December
2017
We hope that this section on NDE Patents will be found
interesting and continue to trigger your curiosity on this very
important topic of Intellectual property. Please send your
feedback, comments and suggestions on this section to
mandayam.shyamsunder@gmail.com
United States Patent 9,759,690
Method and system for nondestructive ultrasound testing
Inventors: Hoctor Ralph Thomas, Zingelewicz Stephen Eric
Assignee: General Electric Company (Niskayuna, NY)
Methods, systems and computer program products for nondestructive
ultrasound imaging are provided. An example method denes a
plurality of subarrays, each comprising a plurality of ultrasound
transducer elements. The method transmits a plurality of ultrasound
beams from each of the plurality of subarrays, each ultrasound beam
being transmitted at a preset beamsteering angle. Subsequent to each
transmit, the method receives, at the array, a plurality of ultrasound
reections corresponding to the plurality of ultrasound beams. For each
point to be imaged, the method selects one set of received element data
for each of the plurality of subarrays. The selected set of element data
corresponds to an ultrasound beam having a focal point closest to the
point to be imaged. Finally, the method reconstructs a point to be
imaged based on the selected received element data, and constructs an
ultrasound image by repeating this process for each point to be imaged.
United States Patent 8,670,952
Non-destructive inspection instrument employing multiple sensor
technologies in an integral enclosure
Inventors: Drummy Michael
Assignee: Olympus NDT Inc. (Waltham, MA)
A non-destructive inspection (NDI) instrument includes a sensor
connection system congured to receive test signals from at least two
different types of NDI sensors which are congured to obtain test
signals from an object being tested. The sensor connection system has
sensor-specic connection circuits and at least one common sensor
connection circuit. A data acquisition circuitry is coupled to the sensor
connection and has sensor-specic data acquisition circuits and at least
one common data acquisition circuit. It is further coupled to a common
digital data processor which executes sensor-specic processing
modules and at least one common processing module. A common
display screen and user interface is coupled to the data processor and
enables programs including sensor-specic user interface modules and
at least one common user interface module. The sensor types preferably
include all of or any combination of an ultrasound sensor, an eddy
current sensor and acoustic sensor.
United States Patent 9,390,520
Method and system of signal representation for NDT/NDI devices
Inventors: Bourgelas Tommy
Assignee: OLYMPUS SCIENTIFIC SOLUTIONS AMERICAS INC.
(Waltham, MA)
Disclosed is a method and system to provide an improved signal
representation of non-destructive test/inspection instruments by proper
color display, in order to emulate as closely as possible, the visual
rendering effect of those seen in the traditional non-electronic testing,
including penetrant testing and magnetic particle testing. The
foregoing object of the invention is preferably realized by providing an
eddy current or phased array instrument with a color palette module
that allows the deployment of an array of color representation system
typically used in traditional non-electronic testing methods.
 63

Word Search Puzzle

MAGNETIC PARTICLE TESTING
Magnetic Particle
The “Word Search Puzzle”, contains more than thirty (30) eeciflux
words related to Magnetic Particle Testing. These include Testing Equipments
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September 2017 Acoustics & Ultrasonics

S
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H E
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A I S O T R O P Y
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P E T Z
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C R R
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T R A N S M I T T E R
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December
2017
RADICAL