Banff Pressure Vessel (1)

8/6/2019 Banff Pressure Vessel (1)

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Advanced Acoustic Emissionfor On-stream Inspection of Petroleum

Industry Vessels


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Current ApproachCurrent Approach -- MONPAC PLUSMONPAC PLUS

Evaluation of Pressure Vessels - MonPac PlusAE Technology Program Developed by MONsanto and

PhysicalAcoustics Corp.Applications

Structural Integrity Monitoring

Leak Detection

Process Monitoring

Materials Research


3/19

Sponsored by ten companies, including seven financially(Exxon/Mobil, Shell, Saudi Aramco, BP, Chevron andPetrobras) and three vendors (PAC, QSL -Plus and

Matrix) for equivalent in-kind contributions

Collaborating with NASA LRC

University Support: Dr. R. Weaver - Univ Illinois (UI), Dr.

Chon Tsai, Dr. Stan Rokhlin - Ohio State Univ (OSU), Dr.

W. Sachse - Cornell, Dr. Mandayam - Rowan

PERF 95PERF 95--11: Advanced AE for On11: Advanced AE for On--Stream InspectionStream Inspection


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Accurate Source Location

Quantitative AE/FFS Relationship

Reliable Source Discrimination

PERF-PAC AE Software & System

Recommended Practice & Guidelines

Advanced AE for OnAdvanced AE for On--stream Inspectionstream Inspection

The overall objective of this effort is to deliver reliable AE

methods for global, on-stream inspection of pressure vessels

in lieu of internal inspection incorporating advances in;


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Pre-Test Support (built into the software) for assisting in

setting up an AE Examination based on vessel

parameters, attenuation analysis, and user desired

minimum detectable crack size.

Real Time Acquisition of waveforms with improved eventdetection, event timing features, accurate source location,

source discrimination, crack size quantification, and

Fitness for Service Analysis determination without need

for follow-up NDT inspections after the test.

Advanced AE for OnAdvanced AE for On--stream Inspectionstream Inspection

The result of this work is to be a waveform based, procedure

driven, Multi-channel AE System and Software for planning

and conducting advanced AE vessel testing composed of;


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PrePre--Test AnalysisTest AnalysisAdvanced Dispersion Curve analysis Main setup menuAdvanced Dispersion Curve analysis Main setup menu

Example Source: surface

Material: 2-thick carbon steelplate

Fluid Loading: Water on oneside (hydrotest)

Source-to-sensor Dist: 0.5m

Sensor: PAC R-15Isensor

Filter: 3- 300kHz Bandpass,or100-300kHz Bandpass


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PrePre--Test Analysis SupportTest Analysis SupportWaveform Prediction from Material Properties and Dispersion CurvesWaveform Prediction from Material Properties and Dispersion Curves

Predicted waveform at sensor face Predicted waveform out of sensor


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PrePre--Test Setup & Analysis SupportTest Setup & Analysis SupportAttenuation SetupAttenuation Setup

Attenuation Setup Menu Attenuation Map on Vessel


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PrePre--Test Setup & Analysis SupportTest Setup & Analysis SupportAttenuation AnalysisAttenuation Analysis

Triangular

Attenuation

Map

Zonal

Attenuation

Map w/0dB

weld atten.

Zonal

Attenuation

Map w/4dB

weld atten.


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PrePre--Test Setup & Analysis SupportTest Setup & Analysis SupportMinimum Crack Size DeterminationMinimum Crack Size Determination

.


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Vessel is shown overlaid onlocation plot with welds andnozzles showing.

Graphs show a series of pencillead breaks along the length of thevessel.

Top graph shows the point plotscolored based on the receivedamplitude at the first hit sensor.

Bottom graph shows the PointPlots colored based on the

Source Amplitude correctedvalues, using the Attenuationgraph setup during pre-test. FFSassessment relies on the SourceAmplitude feature.

PERFPERF--PAC Acquisition and AnalysisPAC Acquisition and AnalysisLocation GraphingLocation Graphing

Location Graph with Amplitude based points

Location Graph with Source Amplitude based points


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PERFPERF--PAC Acquisition and AnalysisPAC Acquisition and AnalysisDetailed Event AnalysisDetailed Event Analysis

Any event can be accessed by Hit/Event Linking to show the waveform

composition and the event and hit data which forms the event.

Just move the

data cursor

over a point,right click and

select

Hit/Event

Linking to

show the

waveform and

event data.


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PERFPERF--PAC Acquisition and AnalysisPAC Acquisition and AnalysisDetailed Event AnalysisDetailed Event Analysis

Any event can be accessed for Fitness for Service Assessment via a

FAD Diagram (Failure Assessment Diagram) in acquisition or replay

Just move the

data cursor

over a point,

right click and

select FAD

Analysis to

show the FAD

Diagram.


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PERFPERF--PAC Acquisition and AnalysisPAC Acquisition and AnalysisSphere Location and Event AnalysisSphere Location and Event Analysis

Traditional longitude/latitude lines to help show position or actual weld lines per ASME can easily be

setup in spherical location mode. Note sensor #2 is reference 0,0 position. Note also transparencyof location dots on reverse side of sphere. Sphere can be rotated freely in acquisition or replay.


15/19

Continuing Experiments to determine AE to CrackRelationship. (Work is currently being conducted at

Rowan University on a bi-axial loading machine). Reliable Source Discrimination work is continuing at

Cornell University with assistance from Univ Illinois.

Testing of Pressure Vessels starting in September2004.

Completion of Recommended Practice & Guidelines(for PERF-PAC testing)

Continuing PERF 95Continuing PERF 95--11 Efforts11 Efforts


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Reliable Source DiscriminationReliable Source Discrimination

Identify source based on signal response

Discrimination methods evaluated

Time-frequency AnalysisNeural Network

Wavelet

Pattern Recognition

Time-Frequency Analysis and PatternRecognition are being further investigated.


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Reliable Source DiscriminationReliable Source DiscriminationStudying the Inverse ProblemStudying the Inverse Problem

Original Spectrogram of AE waveform Processed Spectrogram with actual colored

wave modes overlaid.

By performing Frequency - Time Analysis on the received AE waveform, it is possible to

extract the original wave modes as material properties are already known. Then with the

determination of source distance, one can determine the original moment tensors, leading to

a description of the source. Crack sources can then be distinguished from other sources.

However, the above example is based on theoretical wideband waveforms.


18/19

Field ExperienceField Experience

Items Tested 8 Total Tests Cooling Tower

Reactor Vessels

Horizontal Pressure Vessel Piping


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ObservationsObservations

Developments have enhanced ability to perform a moreeffective AE test

Accurate Source Location improved significantly

FFS analysis very conservative

Documents

Banff Pressure Vessel (1)