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The Omniscan and the Codesfor Weld Inspection
Thierry COUTURIER, OISE Petr Dobsak, Olympus CEE
2Example with ASME Code Case 2235
Phased-Array
TOFD
The OMNISCAN and the CODES
3Example with ASME Code Case 2235
Based on Performance Demonstration
Requires detecting three defects (ID, OD, sub-surface)
Requires full data collection and encoder (AUT)
Can be TOFD, pulse-echo or combination, or Phased Array
The OMNISCAN and the CODES
4 ASME CC2235 Has dominated for 12 years for AUT instead of RT
Very widely used globally
Completed with 5 ASME Code Cases CC 2541: Manual Phased Array with single beam CC 2557: Manual Phased Array with S-scans CC 2558: Manual Phased Array with E-scans (Linear Scans) CC 2599: Encoded (AUT) Phased Array with E-scans (Linear Scans) CC 2600: Encoded (AUT) Phased Array with S-scans (Linear Scans)
The OMNISCAN and the CODESExample with ASME Code Case 2235
5 One Person Operation Portable Phased Array instrument
PA + TOFD Hand Scanner Couplant and
Pump Linear Scanning
The OMNISCAN and the CODESExample with ASME Code Case 2235
6 Calibrate all beams - Very important Wedge calibration Velocity Calibration TCG Calibration
Use same Focal Law for calibration as for scanning Develop Scan Plan to show coverage and appropriate angles Use two (or more) S-scans if required - Multi-Group Scan parallel to weld with Encoder/Full data collection at fixed distance
from centerline
The OMNISCAN and the CODESExample with ASME Code Case 2235 Equipment requirement
7 Ray tracing using ESBeamTool or the Omniscan Weld Overlay with sample Bevel Incidence Angles (arrowed) calculated on 25mm wall double-V weld
Can check if angles are not appropriate
The OMNISCAN and the CODES
Scan Plans (1)
Example with ASME Code Case 2235
ANGLES
8Scan Plans (2)HAZ poorly addressed
Note poor coverage of heat affected zone (arrowed) move array for optimization Again Ray tracing using ESBeamTool or the Omniscan Weld Overlay is
required
COVERAGE
The OMNISCAN and the CODESExample with ASME Code Case 2235
9Transmitter ReceiverLateral wave
LW
Upper tip Lower tip
Back-wall reflection
BW
The OMNISCAN and the CODESExample with ASME Code Case 2235
10
Typical TOFD Display Gray scale and RF for
phase information
OD and ID visible
Defects detectable in middle
The OMNISCAN and the CODESExample with ASME Code Case 2235
11
Some customers can develop their own procedures AREVA GDF TOTAL
The OMNISCAN and the CODESOur approach
12
The OMNISCAN and the CODES
Some existing codes
(ASME, ASTM, EN, ISO, AWS, API, DNV, )
13
TOFD Codes ASME TOFD Code (Section V Article 4 Mandatory Appendix III) (2006) ASME TOFD Interpretation Manual (Non-mandatory App. N) ASTM E-2373 - Standard Practice for Use of TOFD Technique (2009) ASME Code Case 2235-9 - Boiler and Pressure Vessel (Oct. 2005)
BS7706 guideline- Calibration and setting-up TOFD technique (1997)
ENV 583-6 - TOFD technique as a method for defect detection and sizing
EN14751 (supersedes EN583-6) Used in Europe EN15617 - NDT of welds. TOFD technique. Acceptance levels (2009)
ISO 15626 - NDT of welds. TOFD technique. Acceptance levels (2011)
The OMNISCAN and the CODES
14
PA Codes - AmericanThe OMNISCAN and the CODES
ASME Code Case 2235-9 - Boiler and Pressure Vessel (Oct. 2005)
ASTM E-2491-06 Recommended Practice for phased array set-up
New E-2700 RP for Phased Array of welds.
API 1104
AWS D1.1
15
Some companies have developed their own procedures
Still working on Phased Array code development
Equivalent of EN 12668 is coming For PA instrument For PA probes For PA systems (application)Not before 2012
The OMNISCAN and the CODESPA Codes - Europe
16
Required features
-
Available with the OMNISCAN
17
The OMNISCAN and the CODES
Scan Plan to show coverage and appropriate angles ESBeamTool was mandatory, still very usefulWeld Overlay now available
Required features Available with the OMNISCAN
18
The OMNISCAN and the CODESRequired features Available with the OMNISCAN
Calibration of all beams - 100% Calibration of the beam coverage
Has always been a strength
Wedge Delay / Velocity Sensitivity TCG Manual/Automatic
ACG angle corrected gain TCG time corrected gain
19
Use two (or more) groups if required with Multi-Group
The OMNISCAN and the CODESRequired features Available with the OMNISCAN
20
Scan parallel to weld with Encoder and full data collection at fixed distance from centerline
The OMNISCAN and the CODESRequired features Available with the OMNISCAN
21
TOFD
The OMNISCAN and the CODESRequired features Available with the OMNISCAN
22
The Omniscan MX and Omniscan MX2
have all the required features so that an
inspection procedure can fulfil most of
the codes.
23
Phased-Array is now well accepted and understood
Still explaining how Phased-Array works
Conventional UT technique still can be used
TOFD - Still some reluctant countries in Europe
The OMNISCAN and the CODES
24
More and more used all over the world
Well-used and well-developed technique
Complementary to Pulse/Echo (Conventional UT or PA)
Successful to replace RT combined with Phase-Array
The OMNISCAN and the CODESTOFD Codes
25
TOFD Codes
Customers feel very confident as no indication can be missed when combined with P/E
Well codified, primarily from Europe
No surprise invented and developed here
Not so many differences between the existing codes
The OMNISCAN and the CODES
26
TOFD Advantages
Excellent POD (Probability Of Detection) for mid-wall defects
Good detection of mis-oriented defects
Rapid and low cost inspections Cheap solution Small amount of data Small amount of data to analyze
The OMNISCAN and the CODES
27
Probability of detection(in %)
TOFD 83 %
Automated UT(Pulse / Echo) 84 %
Radiography 60 %
Manual UT 53 %
Probability of detection
The OMNISCAN and the CODESTOFD Advantages
Results of comparison test (France)
28
Industrial Manual Weld
29
Industrial Automated Weld
30
Aerospace Composite Inspection
31
Industrial Corrosion
32
The OMNISCAN and the CODES
Limitations of the Omniscanversus the codes
33
Pipe-Wizard applications and Girth Weld inspectionDNV-OS-F101API 1104DNV-OS-C401
Tandem technique is required
The OMNISCAN and the CODESLimitation of the Omniscan versus the Codes
34
Girth Weld Inspections: Onshore / OffshorePipe Wizard
35
Phased-array Pulse/Echo
Phased
-arr
ay probe
Wedge
Weld
Pipe Wizard
36
Phased-array adjustments Adjustment of emitter and receiver to hit the zone Adjustment of beam width to cover the height of the zone Adjustment of overlap in next zone
InspectionEmitter
Receiver
F1F2F3F4F5
Zones
Calibration
F5F4F3F2F1
Cap
HPLCPRoot
Zone discrimination technique with Tandem techniquePipe Wizard
37
Pipe Wizard
Focus LT +Motor Control Unit
Automated Scanner
No more the Omniscan