Future Non Destructive Testing Developments

for New Construction Pipelines

API / AGA Joint Committee on Oil & Gas Pipeline Field Welding
Practices

2012 Dallas January 26th

Jan van der Ent
Technical Authority Pipelines
Content of presentation

Today’s AUT system functionality

Why advanced AUT
Future AUT developments

Matrix Phased Array

Future 3D ultrasonic imaging
Summary / conclusions
Digital RT inspection methodology

Inspection methodology
RAYSCAN system
Why advanced 3D RT?
Future RT development, 3D tomography
Summary / conclusions
Today’s AUT system functionality

Mechanized AUT of Pipeline Girth Welds

Most systems offers Conventional
Ultrasonic probe and Phased Array
probe functionality in 1 system
Most systems offer phased array modus
:128 PA and some conventional
channels
Most systems are offering standard
functionality for pipeline inspection such
as : Pulse Echo, TOFD and Mapping
image /porosity techniques
In some cases a digital cable (Ethernet)
connection to between Main unit and
scanner/probes is used to limit /
eliminate interference
Scan speed between 40-80mm/sec

However present AUT system performance is influenced by international &

client specifications and system functionality limitations
Presently used AUT inspection principle

Zonal approach, typical

height for Cap & Root
2.0mm, Fill channels typically
3.0mm
Probe angles are selected
perpendicular to weld bevel
profile Typical 3mm in height
Assumption is made that :

Defects are positioned at
the theoretical weld Weld bevel configuration is the basis
bevel configuration for the position and orientation of
reference reflectors

Defects are present Typical 2mm in height
within the zone
L.O.I.F is not taken into
account

The weld bevel configuration is dictating the AUT inspection concept

Ultrasonic limitation of zonal concept

Sizing requires calibration whereby an unrealistic assumption of the defect

shape is made (disc, cylinder, rectangle)
Probability of detection depends on beam characteristics and geometry
(focal spot size, beam angle cap / root reinforcement) and used inspection
sensitivity
Positioning is inaccurate due to the size of zones and influence of the wall
thickness variations
Display methods AUT data interpretation requires experience (TOFD &
Mapping)

Weld configuration |5
Limitations of the current method

Presence of cap Defect orientation Probe offset

dx = 0mm

dx =
2mm

4 dB

17 dB 8.6 dB

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Ultrasonic limitation of zonal concept

Orientation of defects

Fundamental error is also achieved as
Defect
actual defects present in the welds don't in orientation
most cases have same orientation as
compared with calibration standard

Defects with skewed orientation (i.e
cracks) are having a low probability of
detection as all probe functions are
directed in axial direction only
Ultrasonic limitation of zonal concept

Effect of amplitude response due to

defect orientation
General obtained statistical performance

Present obtained statistical system performance ;

Generally achieved POD values are influence by dictated system settings and
sensitivity settings

Generally achieved sizing accuracy show significant deviation in over- and
under sizing amongst other factors caused by present dictated methodology

2,2mm @ 95% Confidence

Examples of statistical performance

Why advanced AUT

Requirements for inspection integrity are

increasing;

For the fatigue exposed constructions
in the offshore industry, such as Steel
Catenary risers

For strain based design pipelines for
the On and Offshore industry
POD and Sizing performance need to be
improved to comply with the more stringent
ECA acceptance criteria using advanced
AUT methodology

Example of ECA calculation

 Future Phased Array development

Approach  use more beam configurations:

More beams in all directions, also sideways accommodate tilt and skew
Better coverage  higher probability of detection
Improvements in data display  ‘quasi’ 3D
Use sophisticated interpretation SW (operator cannot handle complex data)

256 active elements

2D beam steering

Beam steering to compensate for

defect orientation ; tilt and skew

MPA probe contain 512

elements (64x8 )
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Matrix Phased Array

Ultrasonic beam steering and focusing capability in 2D direction

in steps of 2º

CL Top view Defect

orientation
Matrix PA probe
Compensation
for skew

512 (64x8) elements

Side view

Compensation
for Tilt

Scanning in small increments in axial,

Gate areas over full weld body radial and through wall direction
Example root defect detection
Multiple angle per zone, also in skew direction!

Highest amplitude at 56˚

This corresponds with 1mm defect
height

Crack in root (1 mm height) || 13

Proto type Matrix Phased Array system

Quasi 3D display
Quasi 3D display
Quasi 3D display
Quasi 3D display
Quasi 3D display
Quasi 3D display

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Introduction of new methodology

Objective / Design criteria

Generate a (3D) image from defects

The image must present the defects’ orientation, position and size

Straight forward result display (no strip charts)

Interpretation inspector independent and with minimal experience

Detect ability independent on defect shape and orientation
Exploring if new ways…..

Reality in medical sector, why not possibly in the NDT (industrial) sector

Well known TOFD inspection result presentation (right side)

Need experienced and certified operators…..

Subjective interpretation, introducing human errors….
Seismic Imaging

Vibrator truck Array of recorders

Original earth's crust Result of the measurement

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IWEX concept

With the IWEX ultrasonic array technology we downscaled the seismic

experiments;

Measured wave field can be extrapolated forward in space and
time: Where is the wave later in time?

The same field can be inversely extrapolated to any point in the
medium : Where does the wave comes from?
This process is called “IWEX: Inverse Wave field Extrapolation

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IWEX concept

IWEX: Inverse Wave field Extrapolation

Each sensors is listening and recording;

wave travel time, phase, velocity, direction, etc.

All sensors talk to each other and exchange
information in real time

ultrasonic array

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 IWEX concept

IWEX: Inverse Wave field EXtrapolation

Concept:
Transmit with 1st element

ultrasonic array

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IWEX concept

IWEX: Inverse Wave field EXtrapolation

Concept:
Transmit with 1st element
Receive with all elements

ultrasonic array

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 IWEX concept

IWEX: Inverse Wave field EXtrapolation

Concept:
Transmit with 1st element
Receive with all elements
Transmit with 2nd element

ultrasonic array

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IWEX concept

IWEX: Inverse Wave field EXtrapolation

Concept:
Transmit with 1st element
Receive with all elements
Transmit with 2nd element
Receive with all elements

ultrasonic array

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IWEX concept

IWEX: Inverse Wave field EXtrapolation

Concept:
Transmit with 1st element
Receive with all elements
Transmit with 2nd element
Receive with all elements
And so on until all elements have been used as a source
ultrasonic array

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IWEX concept

IWEX: Inverse Wave field EXtrapolation

Concept:
Transmit with 1st element
Receive with all elements
Transmit with 2nd element
Receive with all elements
And so on until all elements have been used as a source
Obtained data for N elements:

N sources x N receivers = N2 A-scans

DATA

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IWEX concept

IWEX: Inverse Wave field EXtrapolation

Concept:
Transmit with 1st element
Receive with all elements
Transmit with 2nd element
Receive with all elements
And so on until all elements have been used as a source
Obtained data for N elements: N sources x N receivers = N2 A-scans
Process with IWEX algorithm (based on Rayleigh integral)

DATA IWEX

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IWEX concept

IWEX: Inverse Wave field EXtrapolation

Concept:
Transmit with 1st element
Receive with all elements
Transmit with 2nd element
Receive with all elements
And so on until all elements have been used as a source
Obtained data for N elements: N sources x N receivers = N2 A-scans
Process with IWEX algorithm (based on Rayleigh integral)
Result: Cross-sectional image of inspected object

DATA IWEX

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Scan: 90° 2mm slit (2D)
Scan: 45° 2mm slit (2D)
Scan: 0° 2mm slit (2D)
Principles of IWEX imaging

Weld sample with seeded defect

3D Ultrasonic inspection result derived from an actual weld having an enclosed tungsten
fragment
No calibration block is required, defects are visualized in true dimensions, position and
orientation
Principles of IWEX imaging

Scanning block with inclined slit

Scanning block with cylindrical
hole
Artificial defect can be visualized
in 3D
Proto type system and resolution

Present proto type inspection

system is able to resolve
small bores (side drilled
holes) with spacing of 0.5 to
1.5mm at some distance
from ID surface

S
Summary / Conclusion

The presented proto type AUT developments have:

The potential to improve the Probability of Detection and Sizing accuracy

The potential to reduced or eliminate the subjective interpretation of the AUT
operator

The above factors may lead to :

More reliable AUT inspection of critical components

Relaxed acceptance criteria as inspection uncertainty is reduced

The presented new techniques/methodologies have the potential to fulfill

this requirement however need to be validated in more detail
Future Non Destructive Testing Developments
for New Construction Pipelines

API / AGA Joint Committee on Oil & Gas Pipeline Field Welding
Practices

2012 Dallas January 26th

Jan van der Ent
Technical Authority Pipelines
Contents of presentation

Introduction of Digital Radiography

Advantages of digital radiography
Digital Radiography inspection methodology
RTD RAYSCAN system

Digital detector and Image processing principle

Time delayed integration

Image Quality indicator

Software features
Practical benefits of RTD RAYSCAN
Future development, 3D tomography

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Introduction of Digital Radiography

Radiographic image = x-ray image (photography)

RTR = Real Time Radiography = direct x-ray image

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Digital RTR vs. Conventional RT

Advantages of digital vs. conventional RT:

Shorter exposure times (due to high sensitivity)

Reduced angle of radiation beam

Improved radiation safety (lower keV)

Direct on-line weld image display

No residual products lower costs

• No use of chemicals

• No film

Large dynamic range (multiple film classes covered)

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Geometric unsharpness comparison

Panoramic film Directional film RAYSCAN METHODOLOGY

External source
Detector

Crawler

IMAGE 1 IMAGE 2 IMAGE 3

Image 1 : Poor geometric un-sharpness, high radiation risk!

Image 2 : Multiple exposures, high radiation risk!
Image 3 : RAYSCAN system methodology
– Eliminates geometrical un-sharpness
– Eliminates multiple images
– Reduces the radiation risk
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RTR inspection methodology

Tube
DWSI technique used in
the RTR system
Pipe
Tube and detector rotate
around the pipe and the
data is processed.
After full rotation the
whole weld is captured
and processed by the
software.

Detector
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RTD RayScan system

No X ray crawler inside

Small beam: => Higher safety due to limited
DWSI = Double Wall Single Image
radiation and subsequent shielding
Fast production (3mins cycle time) source
2” to 12” range (currently)
Unique application for pipeline RT inspection

detector

The beam travels through two

walls. However, due to high
magnification of the first wall
only the second wall is sharply
visible on screen.

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The heart of the Rayscan: Digital Sensor

Rayscan uses a digital sensor

(like a digital photocamera... but
for Xrays)
The Xray-photographs are 6mm
wide and up to 220mm long
300 photographs (or frames) a
second are being made!
Software re-constructs all
photographs to a complete weld-
image
High efficiency of sensor makes it
possible to inspect large wall
thicknesses with relative low
Active radiation.
area
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Digital X-ray detector principle

Direct detection of x rays Incident

with: x-ray Field
Dielectric photons electrode

Biased semiconductor layer

Collection array
X-ray photons hit the
semiconductor
Semi-
X-ray photons generate conductor
charges in semiconductor
Field separates charges
Collection array –
Charges are processed by (signal to computer)
collection array

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Image Processing

TDI = Time Delayed Integration = Core process = stacking of x-ray

frames

Each frame is an actual x-ray with a 0,0033 second exposure.

Each frame carries a part of the required signal.

Software sorts and piles up frames.

Time Delayed Integration

Camera
frames

1 2 3 4 4 4 4 4 position
frame frames frames frames frames frames frames frames

Final image

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Moving camera & Motion unsharpness

Motion unsharpness occurs when photographing moving

objects or photographing a still object when moving
The solution:
high speed camera
RTD RayScan =
high speed x-ray
photography
300fps (1/300sec)
Smaller details
>> motion unsharp-
ness effect bigger

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RTD RayScan system performance

Minimal motion un-sharpness

No film un-sharpness
Image quality equal or better than film or other digital RT
High performance (using constant potential X-ray ) with
lower radiation, see example below;

Conventional directional X ray  300 keV x-ray radiation

Digital CP RT  160 keV x-ray radiation
Noise reduction  improved image quality

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Image Quality Indicators (IQI)

According to EN 1435, soon to be accepted ISO 17636

part 1 and 2 (DR)
IQI’s are used to measure sensitivity and spatial resolution
Single : Sensitivity
Double : Spatial resolution

Single wire IQI Double wire IQI (Rayleigh criterion >20%)

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Software: General user-interface

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Image Enhancement with RTD RayScan

Brightness

Contrast

Wall Thickness 16mm, 8” CS - 175kV, 4mA

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Digital Zoom with RTD RayScan

Source side IQI –

Cluster porosity 13th wire visible Scattered porosity

Wall Thickness 16mm, 8” CS - 175kV, 4mA

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Defect Evaluation and Marking

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Rayscan application On and Offshore

Application Off-shore
Lay-barge

Application On-shore
Cross country

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Movie Rayscan system

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Practical Benefits of RTD RayScan

Typical benefits of RTD RAYSCAN

No films or consumables, no storage cabinets required

No darkroom, no processors or chemicals (chemical waste)

No waiting time for film development

Less personnel (scanner tech + operator)

Digital enhancement tools

Lower radiation

Wide range of pipe sizes and wall thickness
However also the Digital radiographic inspection technique,
despite the mentioned benefits, is limited to the use of standard
workmanship acceptance criteria as no defect height can be
measured.

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3D Radiographic Inspection of Pipeline Girth Welds

Future development
 Why 3D Radiographic Inspection?

Defect orientation

Defects can be missed due to orientation
Position of Source relative to film

Defects can be missed due to orientation
Operator subjective interpretation

Influence of human judgment
Probability of Detection

Is negative influence by above factors
Standard Radiographic

Doesn’t offer defect height sizing
Main objectives are :
• To improve the Probability of Detection
• To introduce ECA based acceptance criteria into the RT
inspection
Inspection principle

3D testing of objects
100-1000 projections
High measurement time
 Scanning in X direction through weld

X -scan direction

Defect height visible in cross section | 58

Defect height System Data analysis

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 Thank you!

Jan van der Ent

ApplusRTD
Technical Authority Pipeline Department

What is more
in the pipeline?

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