Use of Water Immersion UT techniques to assist with data capture and analysis. Dr. N. R. Pearson (Speaker), S. Marshall, M. Kircough, W.

Transcription

1 Use of Water Immersion UT techniques to assist with data capture and analysis Dr. N. R. Pearson (Speaker), S. Marshall, M. Kircough, W. Woodhead

2 Outline Introduction assets lifecycle Data acquisition stage Reporting stage Conclusion 7 th MENDT

3 1. Introduction assets lifecycle Operation Data acquisition Define inspection requirement Modify Perform inspection Inspection Re-inspect Reporting Re-commission Analysis Generate Report Repair (if needed) 7 th MENDT

4 2. Data Acquisition: RMS Data acquisition Define inspection requirement Modify Perform inspection Available tool: Rapid motion scanner (RMS) Automated X/Y scanner Water immersion UT 7 th MENDT 5

5 2. Data Acquisition: RMS Available tool: Rapid motion scanner (RMS) Automated X/Y scanner Water imersion UT 7 th MENDT 6

6 2. Data Acquisition: RMS Available tool: Water immersion approach Periodicity of measurements (Resolution) Rapid motion scanner (RMS) Amplitude tracking Automated X/Y scanner Water imersion UT 7 th MENDT 7

7 2. Data Acquisition: RMS water immersion Immersion UT probe 7 th MENDT Probe Holder

8 2. Data Acquisition: water immersion A-Scan Electrical connector 17ms INITIAL PULSE Immersion UT probe Bubbler Probe holder body 4.2ms BWE SURFACE ECHO Water feed Bubble of water 25mm 17ms 2 ND BWE 3 RD BWE 2 ND SURFACE ECHO

9 2. Data Acquisition: water immersion A-Scan Electrical connector 17ms INITIAL Water PULSE path measurement (Near surface variation) Immersion UT probe Bubbler Probe holder body 4.2ms BWE SURFACE ECHO Water feed Material Thickness inc. paint Bubble of water 25mm 2 ND BWE Material Thickness 3 RD BWE 2 ND SURFACE ECHO Signal loss (amplitude tracking)

10 2. Data Acquisition: water immersion Example pipe

11 2. Data Acquisition: water immersion Artificial discontinuity (internal surface) Artificial discontinuities (near-surface) (i) (iii) (ii) UT Thickness measurement UT water path measurement (i) (iii) (i) (iii) (ii) (ii)

12 2. Data Acquisition: Periodicity of measurements a) 50mm X 50 mm b) 5mm X 5mm c) 2mm X 2 mm d) 1mm X 1mm So, what is the expense?

13 Time (Minutes) Smallest defect diameter (mm) Smallest defect diameter (mm) 2. Data Acquisition: resolution and efficiency trade-off Duration of scan Flat-bottom hole (Nyquist rate) 10x sampling (Recommended) th MENDT RMS Scan resolution (mm x mm) Defect Detection Defect Sizing Nyquist Recommended Scan Resolution Time (Minutes) Defect diameter (mm) Defect diameter (mm)

14 2. Data Acquisition: Amplitude tracking Un-bonded area Glue over spill area Bonded area A-Scan for un-bonded area. 2 nd, 3 rd & 4 th BWE signals are displayed Edge of glue spill over area. high attenuation due to signal scattering A-Scan for bonded area. Attenuation of 2 nd & 3 rd BWE signals due to bonded material (sound absorbed) 7 th MENDT 15

15 2. From Data Acquisition -> Reporting Advantages Disadvantages Water immersion column provides additional condition information, e.g. Surface discrimination Disbonding of internal liners Amplitude Available tool: Detailed representaitons Rapid motion scanner (RMS) Accurate periodic measurements at predefined intervals Large volumes on information about the asset Automated X/Y scanner Water imersion UT Continuous water feed Accuracy/Efficiency Trade-off from: Time available for inspeciton Smallest defect you are willing to miss. Can lead to large data sets to analyse and report 7 th MENDT 16

16 3. Reporting stage Inspection Data acquisition Reporting Operation Define inspection requirement Modify Perform inspection Analysis Generate Report Repair (if needed) Re-inspect Re-commission 7 th MENDT

17 3. Reporting stage: Quantity of data How to distil the quantity of data to make repair or fitness-for-service decisions? Low volume of data Reporting Analysis Generate Report Is it Fit for purpose (1 Bit, Yes or No) Data acquisition Define inspection requirement Modify Perform inspection Statistics of asset condition (KB s of data) Data volume triangle Areas of interest determined through analysis (100 s MB of data) Gathering measurements (GB s or TB s of data) HIGH volume of data

18 3. Acquisition to Report process Data acquisition Reporting Manual thickness measurements Pictures RMS Multiple Scans Dataset Combination of spread sheets and word processors and image manipulation tools to conduct data : management analysis CAD import Stitching and overlapping presentation manipulation merging Report Other inspection measurements: MPI MFL Phased array ToFD A time consuming process

19 What is CMAP: UT corrosion mapping More than just a stitching tool Repository for inspections Data Documents Certifications, Permits, Historical inspections Arranging scans automatically (stitching) Analysis of: Measurements (A-Scan) Defect geometry Defect profiles (B-Scan) Inspection Area analysis Comparison with historic inspections Assess trends Automated Report generation (in Word) Export complete inspection, including documents to another CMAP user. Export to CSV for further RBA Sales Meeting

20 3. Reporting stage: Gigabytes Is it Fit for purpose (1 Bit, Yes or No) Statistics of asset condition (KB s of data) Areas of interest determined through analysis (100 s MB of data) 7 th MENDT Gathering measurements (GB s or TB s of data)

21 3. Reporting stage: Megabytes Thickness map of a storage tank shell, generated from a large collection of AUT scans. Is it Fit for purpose (1 Bit, Yes or No) NFPA 704 "fire diamond" Statistics of asset condition (KB s of data) Areas of interest determined through analysis (100 s MB of data) 7 th MENDT Gathering measurements (GB s or TB s of data)

22 3. Reporting stage: Kilobytes to decision Distilling the inspection data further Find minimum and maximum thickness Measure discontinuities Is it Fit for purpose (1 Bit, Yes or No) Statistics of asset condition (KB s of data) Areas of interest determined through analysis (100 s MB of data) Gathering measurements (GB s or TB s of data) 7 th MENDT

23 Conclusion The balance of efficiency and recorded data has been addressed for two inspection stages: Data acquisition: Defined by inspection requirements Justify efficiency by determining the smallest defect you are willing to miss. Harness as much information as possible during the inspection UT immersion can provide multiple details of an asset without impacting on efficiency Reporting: Reduce the number of man hours required to filter vast quantities of data to a manageable amount (without compromising on valuable information) through: Automated data sorting, User friendly tools for risk based analysis Coming features: Real-time analysis of defects and how they relate to acceptable criteria in suitable standards of the inspection, E.g. critical zone calculations Comparison between historic and recent inspection data 7 th MENDT

24 Thank you for your attention For further demonstrations, come and join at Stand B17-B20 7 th MENDT