Diverse Uses of Advanced Ultrasonic Inspection

Technologies for Pipeline Manufacturing, Construction,

and Maintenance

October 21, 2014

Presented by: Nicholas Bublitz
Co-Authored by: Andre Lamarre
Basic Ultrasonics
 One 0 degree or one angle
depending on wedge

 Ultrasonics work best when

interaction with flaws is 90°

 Typically single raw A-scan

or some imaging

 Manually rastered in most

case for flaw detection

 Limited reporting
Advanced Ultrasonics
 In comparison with
conventional ultrasound,
advanced ultrasonics are:
 Phased Array (PA)
 Time of Flight Diffraction (TOFD)
 Guided Wave (GW or LRUT)
 Automated Ultrasonics

 Used to assure the integrity of

pipelines at different stages:
 Fabrication of the pipes
 Construction of the pipeline
 Maintenance of the pipeline
What is Phased Array?

 Utilizes multi-element
arrays and software to
create multiple angles,
focus, or electronically
raster ultrasound.

 Improves coverage,
characterization,
detection and sizing
capabilities.
Sector Scan and Electronic Scan
How Does It Work?

Physics +Software

Different elements excited at different times to create multiple angles,

change focus, or electronically move through the probe
Phased Array for Welded Pipe

 Manual or encoded

 Better characterization
of damage mechanisms

 Better detection and

sizing
Encoded Weld Scanning
 Use encoders to record position
in relation to ultrasonic data

 Allows for length to be linear in

data similar to viewing a
radiograph

 Allows for post manipulation and

reprocessing of digital data

 Can be one technique or

combined ultrasonic techniques

 Can be semi-automatic or fully

automatic
Phased Array Imaging
 Particularly useful for
complicated damage
mechanisms:
 Hydrogen induced
cracking
 Stress corrosion
cracking
 Etc.
 Provides more
information for the
operator to make the
right analysis
Phased Array vs. Radiography
Advantages of Phased Array:

 Higher probability of detection

(POD) especially for lack of fusion
and cracks
 Fracture Mechanics vs.
Workmanship Criteria
 No radiation / extra licensing /
chemicals
 No screened off areas, work can
go on around ultrasound
 Instant evaluation and feedback to
welder
Phased Array for Corrosion
 Increased Coverage and
speed

 Semi-automated or fully
automated

 Imaging

 High resolution

 Better characterization
Large Effective Beam
Conventional Pitch Catch Phased Array 64 element

.187” 2.36”
~12 Times more coverage with phased array probe.
What is Time of Flight Diffraction?
Diffracted
Incident waves
 Send and receive wave
technique

 Diffracted energy
technique Reflected FLAW
wave

 Uses time information for

accurate measurement
Diffracted
waves
TOFD Advantages
Send Receive

 Accurate sizing capability based on

time

 Rapid scanning with wide coverage Flaw Detection

 Detection and sizing not reliant on

flaw orientation or weld shape
Corrosion Assessment
Data Analysis
 On the instrument or
in offline analysis
software

 Amplitude, depth,
height, & length are
typical for flaws

 Thickness, remaining
wall or material loss
for corrosion
Portable Equipment Considerations

 Manual and encoded

 Techniques
 Multi-Group
 Specific scanners
 Probes, wedges and
accessories
 Setup and analysis
software
Pipe Inspection for Fabrication
 Automated inspection solutions
for:
 Seamless and welded pipe
 Transverse, oblique, and
longitudinal flaw detection
 Wall thickness and lamination
 Multiple units can be connected
to meet speed and detection
needs.
 Eddy Current Array capability
can be added
 Able to meet and exceed code
requirements (API 5L etc.)
Inspection Concept
Phased Array for New Pipelines
Zone Discrimination Technique
Receiver
Narrow Bevel
Emitter

Zones

Cap
F5
F4
F3
F2
F1
HP
LCP
Root

Phased Array Zone Technique:

 Weld is divided into small zones (1-3mm)
F1 F2 F3 F4 F5

3mm 3mm 3mm 3mm 3mm

 A single beam is generated to cover each zone
 Pitch – Catch technique to hit narrow bevel correctly
 Strip chart for each beam is used for rapid detection
and sizing
PipeWIZARD
 Major Features:
 Speeds Up to 100mm/sec
 IP66 and designed for harsh
environments
 User friendly and fast setup, operation
and analysis to keep up with pipeline
welding

 Strong field experience:

 Hundreds of units in the field
 Millions of welds inspected
 Approved by most or all major oil
companies
Advanced PipeWIZARD Software
Guided Waves
 Guided Wave Ultrasonics
 Used to screen in-service pipes and pipeline over long distances
 Inspect pipes with limited access from a single position
 Pinpoint locations requiring further inspection
 Can provide significant reduction in operating costs
 Also known as LRUT, or long range ultrasonic testing
Applications of Guided Waves
 Corrosion detection / in-
service pipes and pipelines
 Inspection of above
ground and buried pipe
 Coated or insulated pipe
 Detection of corrosion at
supports and pipe racks
 Inspection of through-
wall pipe, vertical pipe,
and buried pipe
Guided Waves Coverage
 Inspection with Conventional
Ultrasonics
 Localized inspection
 Underneath or in the vicinity
of the sensor location

 Inspection with Guided Waves

(Long-Range Ultrasonic
Testing)
 Screen the entire pipe wall
 Covers long distance (up to
600’, 300’ each direction)
from a single inspection
position
Guided Wave Detection
 Guided Wave does not provide an accurate measurement of wall-
thickness variation but detects a general change in the total pipe
cross sectional area (CSC).

10% CSC
(Total area)
distributed
differently

 Equally sensitive to OD and ID corrosion.

 Can estimate the circumferential extend (using focusing tools).
 Other NDT methods are needed to validate and size indications.
UltraWave LRT
 The system features the UltraWave LRT instrument
(which is secured in a backpack), a rugged touch-
screen laptop with advanced software, flexible
inspection collars, and all the necessary tools to
perform an inspection.
Guided Wave Imaging
Training Requirements for Advanced Ultrasonics

 Dictated by code, contract

and other requirements
 Typical – x formal training
and x OTJ training
 Olympus partners with
training and consulting
companies who can
certify to applicable
standards, offer training
and services
Benefits of NDT Screening
 Maximizing and shortening
shutdowns by preparing other
NDT work in advance for
targeted areas

 Minimize manual labor to

access and prepare for 100%
volumetric inspection

 Pinpoint areas for minimized

and calculated shutdown of
operations
Conclusions
 Advanced Ultrasonics include many different types of Ultrasound
inspections:
 Phased Array
 Time of Flight Diffraction
 Guided Wave
 Automatic Ultrasonics

 Advanced Ultrasonics are used at all stages of pipeline life to:

 Improve speed and quality of inspection
 Increase detection, sizing and reporting capabilities
 Improve characterization of certain damage mechanisms
 Replace radiography and conventional ultrasonic methods
 Reduce mechanics and increase coverage from traditional Ultrasonic
approach
 Solve complex inspection problems with flexible techniques like zone
discrimination
 Thank You!
www.olympus-ims.com