Ultrasonic C-Scan Video Corrosion Mapping

Corrosion Mapping
Principles of Video Corrosion Mapping
Real time colour graphic images of corrosion or erosion are produced by use of a standard 0 transducer. By using a CCD camera and the videotracking system, real time graphic images are generated by scanning a hand held probe. A Light Emitting Diode (LED) is attached to the transducer. The camera tracks this LED to obtain the positional information required by the system. Each thickness is assigned a separate colour, and a graphic contoured image is produced showing a topographical map of the internal surface condition.

Corrosion Mapping
Microplus Imaging System CCD Camera

Light Emitting Diode

A selection of software routines such as 3-D enhancements, material percentage losses, crosssectional images, is included in the map software package

Corrosion Mapping
Composite Image By Joining Scan Files

Corrosion Mapping
Key Features
As no mechanical scanners are necessary, this technique permits the ultrasonic imaging of complex geometrys such as Tees, Valves and Bends. Colour composite images may be generated by joining individual scan areas, to show the overall condition of plant. Coverage is guaranteed as non-inspected areas are highlighted On-Line analysis Automatic Report generation

Corrosion Mapping

Image showing Isolated Pits

7

Time of Flight Diffraction TOFD

Developed to accurately size and monitor the through wall height of in service flaws in the nuclear industry. Equally effective for the detection of flaws in welding, irrespective of type or orientation. Does not rely on the reflectivity of the flaw Uses the diffracted sound initiated from the flaw tips

2 Probes opposite each other. 1 transmitting and 1 receiving the signals

10

Tx
Lateral wave

Rx

Signal returned from backwall

Energy is transmitted in to the Material in short bursts The energy spreads out into an angular beam

11

Tx
Lateral wave
upper tip

Rx

Planar flaw

lower tip

Backwall

Energy is diffracted from both upper and lower flaw tips

12

Tx

Rx

upper tip

Upper flaw tip Lower flaw tip

lower tip

13

Benefits of TOFD
Real Rime Inspection Results Superior inspection reliability Reduced inspection time Accurate sizing Reliable propagation monitoring No necessity to shut down plant as inspection can be deployed "on-line" Cost effective Hard Copy Evidence Repeatable Easy Storage of data
14

TOFD for Weld root Corrosion

Top Surface Corrosion Inner Surface

15

16

17

18

Phased Array A Basic Introduction

19

Why Phased Array?

High speed electronic scanning without moving parts Improved inspection capabilities through software control of beam characteristics Inspection with multiple angles with single, electronically controlled probe Greater flexibility for inspection of complex geometries
Optimized focusing Optimized beam angle

20

Phased-Array Probe
Basically, a phased-array is a long conventional probe

cut into many elements.

21

Electronic (Linear) Scanning

22

23

Beam Steering
Is the capability to

generated by the array probe. Allows for multiple angle inspections, using a single probe Applies asymmetrical (e.g. linear) focal laws

modify the refracted angle of the beam

24

25

Combined Beam Processing

Linear combined with steering and focusing

26

Applications
In-service weld inspection including Stress Corrosion Cracking As welded defect detection Complex Geometries Nozzles, Flanges, Shafts C-Scan mapping

27

28

29

CHIME

Creeping HeadWave Inspection Method

30

CHIME
An ultrasonic technique for the efficient, rapid and complete inspection of pipe or plate called CHIME for the examination of under-clamp or under-support corrosion: Large area, single pass corrosion, pitting and crack detection Probe separation up to 1m or more 100% coverage of material between the probes Suitable for steel pipes and plate Sensitive to both internal and external surfaces

31

Applications of CHIME
Pipe Supports, saddles or sleepers Clamps Vessels/Tanks Pipe screening for internal corrosion Pipes with limited access

32

The CHIME technique

Time

Bulk Waves

Head Waves

33

CHIME on Isolated Pits

Tim e Probe movement

P1
25%

P2

100%

P3
55%

Pit depth is 25% to 100% of WT

34

CHIME for Internal Pipe Inspection

35

CHIME for Pipe Supports

Example of data collection around a pipe support

Note: Inspection can be carried out using either set up a) or b) only

36

CHIME on 6 Pipe Section

37

Wavemaker Pipe Screening System

38

Waves are sent along the pipe

10s of meters of pipe are examined from one location Difficult to inspect areas, such as roadways can be screened for defects
39

Capabilities
Can be performed at elevated temperatures without taking the pipe out of service 100% of the pipe is inspected (within the diagnostic length of a test) Pulse echo type operation provides information on feature position and approximate size Sophisticated analysis aids interpretation of results

40

Target Applications
Rapid, full coverage screening of pipes Especially cost effective in difficult to access locations
Sleeved road crossings Corrosion under insulation Wall penetrations Pipe racks Rope access

Can detect cracks and general metal loss (greater than 5% of the cross-sectional area)

41

Limitations
Highly attenuous bitumas based coatings and denso wraps. Internal concrete lining on pipes Pipe with a high level of general corrosion will reduce the effective scanning lengths. Heavy clay soils. Short, less than 5mtr, length of piping.
42

Pre-inspection Set-up
A ring of transducers is placed around the pipe No couplant is required Usually no surface preparation required

43

Small Diameter Pipes

Tested using solid rings For pipes 1 - 8 inches diameter Can be mounted in less than a minute 3 inches clearance needed around pipe
8 Ring R2F8

44

Large Diameter Pipes

Tested using inflatable ring For pipes 6 inches or greater Employ conventional foot pump to inflate 2 inches clearance needed around most of pipe

12 Ring R2B12

45

How It Works
Guided waves are sent in each direction Reflections are analysed

46

Backward

Position of Ring

Forward

Series of Welds

Iconic representation of identified features

Decay Curves Corrosion is indicated by large red component

47

Example #1 Pipes passing through earth wall

48

Corrosion at entrance to sleeved road crossing

1.0 0.8 -F4 -F3 -F2 -F1 +F1 +F2 +F3+F4

Amp (mV)

0.6 0.4 0.2 0.0 -30.0

-20.0

-10.0

0.0

10.0

Distance (m)

Corrosion

49

Example #2 Pipes passing through concrete wall

10 inch pipe under test 8 inch pipe under test

50

Result from (corroded) 10 inch pipe

2.0 1.5 1.0 0.5 0.0 -20.0 -10.0 0.0 10.0 20.0 -F

Amp (mV)

Distance (m)

51

Typical Ranges (in each direction, using standard transducers) Ideal conditions 80m + (best recorded 220m) Typical 30 year old pipe with little internal or external corrosion 40m Typical 30 year old pipe with some general corrosion 20m Typical pipe wrapped in factory applied foam 15m Heavily corroded pipe or pipe that is bitumen wrapped 5m Six welds The first flange or the second bend or branch
Note: these ranges can be doubled by using newly available low frequency transducers although a reduction in sensitivity is also present
52

How to Most Effectively Use the System

Best used as a screening tool that is part of a more comprehensive testing strategy
Good at quickly determining which out of a series of road crossings is most heavily corroded Good at quickly locating areas of probable concern Can not determine exact sizes (only a rough classification can be given)

53

INCOTEST INsulated COmponent TEST

54

INCOTEST - Introduction
INCOTEST (INnsulated COmponent TEST) Pulsed Eddy Current - Thickness Measurement Through insulation Average Thickness over a Footprint On-Stream No Insulation Removal Detects Both Internal and External Wall Loss

55

INCOTEST Pulsed Eddy Currents Theory

Probe Housing Transmitting Coil

Receiving Coil
56

INCOTEST Theory summary

Pulsed Magnetic Field Eddy Currents are induced Measurement of Eddy Current Voltage Detect start / finish of eddy currents in material Eddy current Duration / Thickness relationship

57

INCOTEST Area of Measurement

Volumetric reading over a given area (footprint)

58

INCOTEST Area of Measurement

Reading taken over an area of 100% volume of material

59

INCOTEST Area of Measurement

Reading taken over corroded area. Reading will be the remaining volume of material as compared to the reference reading
60

INCOTEST - Restrictions
Only suitable for low alloy steels. Does not detect isolated pits. Measure the average wall thickness over a footprint. Repeatability typically +/- 2%. Limited to wall thickness up to 65mm. Limited to insulated pipe diameters over 50mm. Cannot differentiate OD from ID loss.

61

 Can work up to 5hrs on one battery pack. Probes can be up to 200mtr away from base unit.

62

 Measures through any non-magnetic material, e.g. insulation, concrete, fire retarder, refractory cement, water, timber and air

63

 Provides a

computed thickness reading within seconds.

64

INCOTEST - Display

65

Contact Measurements
Detects and measures average wall thickness through non-magnetic coatings such as paint or concrete

66

Contact Measurements
Detects and measures average corrosion or erosion in inaccessible areas

67

Contact Measurements
Measures average

remaining wall thickness on externally corroded surfaces

68

 Measures average

remaining wall through marine growth.

69

INCOTEST - Summary
No requirement to remove insulation Fast Gives average wall thickness over a footprint (does not detect isolated pitting) Detects both internal and external corrosion / erosion Suitable for contact and non-contact applications Accurate Cost effective

70

Portable Digital Radiography

71

Applications / Features / Benefits

Testing on remote and difficult to reach locations
>Refineries for wall thickness measurement and corrosion >Remote area pipelines >On board of offshore platforms, submarines, airplanes, >Railways trucks >Museum and archeological

72

 Computed Radiography employs Imaging Phosphor Storage Technology, which when irradiated, stores a latent radiographic image for an unspecified period of time Much the same fashion as classical X-ray film

73

Raw Image Contrast enhancement Zoom in in ROI Sharpening Embosswindow/level Zoom ROI by

74

Standard

Kernels
Sharp

Smooth

Emboss

75

76

Wall Thickness measurement software :

77

Summary Computed Radiography

> Portable CR system > > > Have digital images available on the spot Transports easily between sites and into remote areas

Dynamic range much higher than film or paper > no retakes by bad exposure, different thickness in one shot

>

Phosphor plates are reusable > no film or paper needed : consumable cost saving

>

No chemicals, no darkroom > cheaper infrastructure

78

Tank Floor Inspection

Mk 2 Floorscanner
79

Tank Floor Inspection

Floorscanners - How does it work?
Magnetic Floorscanners operate on the principle that localised metal loss due to corrosion pitting in magnetised floor plates produces an anomaly in the fields above the plate. Magnetisation is achieved by scanning a powerful C-Magnet over the floor plate. The flux leakage anomalies are detected by an array of sensors between the poles of the magnet

80

Conveyor Belt Laser Profile Systems

81

Example of raw data

20.5

20

19.5

19 3 5 6 7

18.5

18

17.5

17

16.5 0 50 100 150 200 250 300 350

82

Top and bottom belt profiles with overall belt thickness

83

Internal Laser Profiling Crawler

84

Camera / Video Systems

Combination UT Thickness and video probe

85

Internal Caisson Video System

86

87