:

Applying AUT & other Advanced NDT techniques;

Reducing costs, Increasing efficiency

Presented By:
Hamed Malekmohammadi

Rotoscan System
3rd Iran Pipetech Conference,
24 May 2011

Contents

Foreword
Advanced UT techniques
TOFD
Mapping
Phased Array
AUT (Automated Ultrasonic Testing)
AUT in Iran
Codes and standards
Conclusion

Foreword

Now a days there is a high demand of using

technology and new developments on different
industries specifically NDT field.
NDT is one of the most critical fields which can
affect directly on the quality of
equipments/structures/etc., life time and indirectly
on costs and environment
This presentation will introduce some advanced
techniques of NDT, their capabilities and
advantages, and will show you their impact on
quality, costs and timeline of projects.

Techniques

Time Of Flight Diffraction

(TOFD)

Principle of TOFD
Time-Of-Flight Diffraction (TOFD) relies on
the diffraction of ultrasonic energies from
'corners' and 'ends' of internal structures
(primarily defects) in a component being
tested using a set of two probes.

TOFD Principle

Rx

Tx

TOFD Principle

Rx

Tx

Lateral wave

+ Pos

Amplitud
dB

Tiemper s

- Neg

TOFD Principle

Rx

Tx

Signal
Diffracted

+ Pos

Amplitud
dB

Tiemper s

- Neg

TOFD Principle

Rx

Tx

Reflection
From Back
wall

+ Pos

Amplitud
dB

Tiemper s

- Neg

TOFD Principle

6
5
4
3
2
1
Rx

Tx

TOFD Principle

+ Pos

Amplitud
dB

Tiem = s

- Neg

TOFD Principle
B Scan

Depth

Lenght

Typical TOFD Display

Gray scale
for RF
phase info
Lateral and
Backwall
visible
Defects
detectable
in middle

Defect Analysis with Cursors

Use of cursors on top and bottom of defect

to size the defect

Techniques

Phased Array

Phased Array Concept

An Array of transducers (Piezo) elements
in which the timing of elements excitation
can be individually controlled to produce
certain desired effects, such as steering
the beam axis or focusing the beam
Each element has its own connector, time
delay circuit and A/D converter
Elements are acoustically insulated from
each other
Elements are pulsed in groups with precalculated time delays for each element;
Phasing

Phased Array
Electronic Scanning

The beam is electronically translated by alternatively firing a given

number of elements of a linear or circular array transducer.

The advantages

- Faster inspection
- No mechanical movement or reduction of scan lines required
- Possibility of combining with electronic focusing and beam steering

Phased Array
Beam Focusing

The beam is electronically focused by applying symmetrical delay laws

to the different elements of a linear or annular phased array
transducer.

The advantages

- Only one probe can focus at each depth

- Faster inspection of complete volume of thick pieces with dynamic
focusing
- Electronic focusing can compensate focusing aberrations due to
cylindrical interfaces

Phased Array

Beam Steering

The beam is electronically deflected by applying delay laws to different

elements of a linear, circular or matrix array. Linear and circular arrays
allow for 2D beam steering

The advantages

- Only one transducer required for inspection at variable angle

- Faster inspection of complex geometry pieces
- The advantage of this technique can be combined with the
advantages of electronic focusing

Phased Array

Normal
Focusing

Angled
Focusing

Phased Array

Multi-angle inspection of a calibration block with

stacked side-drilled holes.
Left: inspection setup;
Right: ultrasound display-sectorial scan.

Example of UT range selection and sweep range for

a crack detection and sizing with skip angles.
Top: principle and UT range setting;
Bottom: results for a fatigue crack of 8 mm height.

Techniques

Ultrasonic Mapping

Principle of Mapping
Based upon amplitude and transit distance
measurements
Amplitude response related to defect size and
orientation
Digitization of time gate

Principle of Mapping
The mapping feature enables the system to
visualise the presence of the geometrical
welding features such as the position of the
weld cap and root penetration, which
minimises the possibility of the system
generating false calls. Furthermore this
feature enables the system to cope with
most existing UT procedures and acceptance
criteria, because of its capability to detect
and, to a certain extent, quantify volumetric
defects.

Mapping image- Porosity

Root Mapping image

Example Mapping image

Principle of Mapping

Advantages of mapping:

Increase of inspection integrity

Reducing of false calls
Characterization of defects
Can be combined with pulse-echo technique

Techniques

Automated Ultrasonic Test

(AUT)

What is AUT?
The AUT system is used for weld
inspection as a combination of
two or three different techniques.
It provides detailed information
on the position, size, and
orientation of defects. Using
either a conventional multi-probe,
or phased array setup, the
system scans a weld in a single
pass. The operator is then able to
view the results in a graphical
presentation.

AUT Principle
The weld thickness is divided into a number of
depth zones
Inspection concept is related to the weld
bevel configuration
Full weld inspection coverage is achieved by
placing an ultrasonic probe set on both sides
of the weld, each probe within the set
examines a layer within the weld.

Example Bevel configuration

Example Zone-discrimination
Concept

Example Transducer Layout

Multi-probe

Example Transducer Layout

Conventional Multi-probe

Calibration Block
A calibration plate, made of an original piece
of the pipeline material to be inspected, is
prepared with artificial defects such as flat
bottom holes and or notches, which
represent actual flaws.
Artificial defects are
present in each
depth-zone.

Example Calibration Reflectors

AUT Advantages

Can be used On and Offshore

No radiation hazard
No chemicals and films
No equipment inside pipe
Hot and cold operating temperatures

Application:
Offshore

Application:
Onshore

AUT Advantages
AUT allows clear detection and identification
of defects

Advantages

>100 welds/day onshore and>150

welds/day offshore
Digital and real-time results, final report on
a DVD
Inspection speed >80mm/sec
Instantaneous recording and evaluation of
results
Provides immediate feedback to the
welders

AUT Equipment setup- Offshore

AUT Equipment setup- Onshore

Example Software

Advantages

Capable of inspecting welds at elevated

temperatures
Acceptance criteria can be related to
ECA criteria, less repairs (fitness for
purpose)
All ambient temperatures, and conditions

(Onshore Canada) -35 c

(Onshore Saudi Arabia) +55 c

Capabilities

Diameter range 14 up to 56 (Onshore)

Diameter range 2 up to 48 (Offshore)
Single weld inspection Habitat
environments
Computerised data storage and display with
dedicated software, offering colour
enhanced user-friendly and coherent
presentation enabling quick and
unambiguous interpretation of inspection
results.

Scanner in operation:
Offshore- Main line station

Phased Array vs. Conventional

AUT
Conventional:
16> transducers
Long calibration procedure
Calibration by hand
Bulky scanner frame
Phased Array:
Two transducers
Short calibration
Calibration with software
Compact scanner frame

Example Transducer Layout

Phased Array

Phased Array Advantages

Small diameter pipelines with heavy wall can
be inspected with sufficient number of inspection
(depth) zones
System can be programmed to cope with
different pipe suppliers (different sound velocity)

Set-up preparation time of system can be

significantly reduced (e.g. no waiting time for
probe fabrication)

Smaller scanner frame and umbilical, easier to

handle

Distance between scanner and system not limited

due to cable

Example Inspection Result:

LOP

Example Inspection Result:

Porosity

Example Inspection Result:

LOF

Example Inspection Report:

Print-Out and site report

AUT in Iran
2004

Siri offshore pipeline by Saipem, 83 Km

SP 4&5 offshore pipeline by Saipem, 190 Km

2006

Salman (EPC 3) offshore pipeline by IOEC, ~30 Km

SP 8 offshore pipeline by Sadra/DOT, 100 km

2007

SP 9&10 offshore pipeline by IOEC, ~190 Km

2008

Siri-Asaluyeh offshore pipeline by IOEC, 282 Km

2009

SP 15 offshore pipeline by IOEC, ~80 Km

2010-2011

SP 12 offshore pipeline by IOEC, ~440 Km

AUT in Iran- brief summary

Total installation of pipelines using AUT in lieu of RT:

~1300 Km

Range of diameters:
32, 30, 14 and 4
Range or Thickness:
6mm to 29mm
Working hours/shift:
Shifts/day: 2

12

Record per shift: 107 welds

(32 main line and 4 piggy back)

Codes and standards

In 1998, the ASTM published the E-1961-98 code
(reapproved in 2003), which covers key elements of AUT of
girth welds zone discrimination, rapid data interpretation,
specialized calibration blocks, and configuration procedures.
The E-1961 code is designed for ECA. Similarly, in 1999, the
American Petroleum Institute (API) published the 19th
edition of Standard 1104, which covers mechanized
ultrasonic testing and radiography of girth welds.

Other codes:

DNV OS-F101, BS 4515-1 2009

TOFD Acceptance codes:

European norms: BS7706 and EN583_6
ASTM E-2373-04
ASME CC 2235-1
TOFD, AUT and PA are acceptable to be used in lieu of
RT

Conclusion
Advanced Techniques:
Can reduce time in operation
Increase the quality of weld because of higher POD
with respect to conventional techniques e.g. RT
Can help contractor to save time and money on overall
project execution
Can increase the safety of operation by preventing use
of Radio-active on site
Shorten time schedule in pipeline installation and
maintenance projects

Conclusion

Conclusion
Advanced Techniques:
More reliability in maintenance inspection
Much less restriction on thickness issues specifically in
maintenance inspection
No safety impact on personnel and timing, no
environmental issues
More sensitive on critical defects, so higher safety
factor in welds during or after construction
Structural integrity on assets and installations

Rotoscan System

Thanks for your time!

Contact us for more information at:

Mailing Address:

Unit 19, No 39, First Lane, Behrooz

St., Mirdamad Blvd., Tehran- Iran

Tel/Fax:

+98-21-2222 3991

E-mail:

contactus@karkia-ind.com

Internet:

www.karkia-ind.com