TC5700 TUBE INSPECTION SYSTEM

Transcription

1 TC5700 TUBE INSPECTION SYSTEM Eddy Current Remote Field Magnetic Flux Leakage Ultrasound Fast: 2 m/s multichannel, multifrequency ET Multichannel, dual-frequency RFT with voltage plane analysis IRIS with real-time C-scan recording Analysis and report buildup concurrent with inspection

2 TC5700 BETTER, FASTER, AND MORE RELIABLE INSPECTIONS No single inspection technique is adequate for all types of materials and a single-technology system may only be used for a narrow range of applications. Eddy current (ET) is commonly used to inspect nonferromagnetic materials, remote field (RFT) or magnetic flux leakage (MFL) for that of carbon steel and ferritic materials. Ultrasonics (UT) may be used for accurate thickness measurements of either type of materials. The TC5700 may be configured to include any combination of ET, RFT/MFL, and UT. The combination of technologies makes the TC5700 an ideal instrument for use in the wide range of applications typically encountered by NDT inspection providers. Combining two or more technologies increases inspection reliability and provides a more accurate evaluation of flaws. For instance, carbon steel wear hidden under a support plate is very difficult to size using RFT or MFL, while a UT C-scan provides a clear and accurate measurement. The TC5700 is modular and may be configured as a low-cost, single-technology, entry-level system. Other technologies may be added later as the need arises. Applications Eddy Current Remote Field Magnetic Flux IRIS Multichannel UT (Bobbin) Leakage (Ultrasound) (up to 16x1) Nonferromagnetic heat exchanger tubes Steam generator tubes Air conditioner tubes Ferritic and carbon steel tubes Carbon steel tube, wear under support Aluminum finned carbon steel tubes Boiler tubes Water pipes, buried pipes Steel plate corrosion mapping Tube Inspections Condenser and nonferromagnetic heat exchanger tubes are inspected using the eddy current option of the TC5700, achieving multifrequency inspection speeds of 2 meters per second. Ferromagnetic heat exchanger tubes may be inspected using either RFT, MFL, or IRIS. High-resolution rotating UT probe, IRIS probe, or high-speed multielement UT probes are available for both ferromagnetic and nonferromagnetic tubes, providing accurate wall thickness measurements. The TC5700 interfaces directly to R/D Tech s probe pusher. A remote control feature and automatic probe pusher control allow one-man inspections to be carried out. Boiler Tube Inspections Remote field and IRIS are both suitable techniques for inspecting boiler tubes in the generating bank. RFT has significant advantages over IRIS because the RFT boiler probes can easily inspect the bend area and maintain an inspection speed of up to 0.5 m/s (1.5 ft/s). IRIS would be recommended as a backup technique for sizing defects found by RFT. IRIS is also very effective for near drum inspection. Corrosion Mapping and Surface Inspections Steel plates, pressure vessels, or pipes can be inspected with multichannel UT, multichannel MFL, or a combination of both methods, ensuring 100% coverage regardless of the damage mechanism. The TC5700 may also be interfaced to XY scanners for ET surface inspections of reactor vessels and other critical surfaces. The TC5700 provides a simple, easy to interpret real-time color C-scan display of the inspection with a comprehensive inspection report. IRIS inspection. RFT boiler tube inspection.

3 TC5700 SYSTEM OVERVIEW The TC5700 interfaces to standard Pentium PCs allowing easy selection and upgrade of memory size, disk drives, and other storage media, and printing on any PC printer. TC5700 Choose any module: Eddy current (ET) Remote field (RFT) / magnetic flux leakage (MFL) Ultrasound (UT) One or more modules (up to three) can be installed in the same instrument at any time. Remote 16-channel UT pulser/receiver Direct interface to scanners R/D Tech s MultiView analysis software ensures efficient generation and management of inspection lists. Inspection planning may be performed directly from user-defined tube sheet diagrams. The comprehensive analysis and reporting software allows quick, PC Standard Pentium PC with Windows NT Standard Ethernet link Supports local language keyboard and operating system Data storage on any PC drive (removable hard disks, magneto-optical, or DAT) Standard PC printers multichannel analysis with phase-todepth and voltage-to-depth sizing curves. Analysis and reporting may be performed during inspection or offsite. Both tabular and graphical reports are available. Reports Comprehensive reporting features: Inspection summary Tabular report (spreadsheet-compatible) Heat exchanger database Screen printouts, tube sheet maps Editing and sorting tools ET module 4-ch. UT module RFT/MFL module Probe Pusher Optional position encoder for constant sampling regardless of probe speed Direct start/stop and forward/reverse control from PC Remote control capability for one-man inspections Automatic end-of-tube detection Pneumatic probe pusher (Airgun) Interface to R/D Tech s pipe scanners for inspection of critical surfaces Probes Compatibility with a wide range of probes, including: ET, RFT, MFL, and UT probes, from R/D Tech or other manufacturers MRPC probes and ET array probes R/D Tech custom-made hybrid probes combining two or more technologies Software Windows software with uniform user interface for all techniques Creation and management of inspection list Phase-to-depth sizing curves for ET and RFT data. Computer-assisted analysis of ET and RFT data Ultrasonic C-scans Setup wizard for easy configuration

4 EDDY CURRENT OPTION HIGH-SPEED MULTICHANNEL, MULTIFREQUENCY Eddy current is the best method for inspection of nonferromagnetic tubing. The technique is suitable for austenitic stainless steel such as SS304/SS316, brass, copper-nickel, titanium, copperfinned, and others. With state-of-the-art eddy current hardware and software, the TC5700 is a fully digital, multifrequency, multichannel instrument designed for high-speed tube testing with powerful reporting software. Tube inspection speeds up to 2 m/s (6 ft/s) with four simultaneous frequencies, eight-channel inputs, and two mixes can be achieved with no loss of sensitivity. Automatic channel adjustment for calibration to ASME code Simultaneous (nonmultiplexed) or time-multiplex operation with up to 8 frequencies, from 1 khz to 6 MHz Up to 6 time slots in multiplexed drivemode for up to 24 channels (48 channels with the extended ET option) 4 differential inputs (8 differential inputs with extended ET option) Electronic probe balancing No need for external reference probe Phase-to-depth and voltage-to-depth sizing curves Up to 128 real-time mixes and filters Setup wizard for quick and easy setup and calibration C-scan from eddy current array probe MRPC C-scan for detection of circumferential cracking at the tube sheet Compatible with bobbin coil, MRPC, transmit/receive, nx1 probes, and with probes from other manufacturers Analysis and report buildup concurrent with inspection CONDENSERS FEEDWATER HEATERS AIR CONDITIONERS SURFACE INSPECTION User-Friendly Software The TC5700 acquisition software features an easy-to-use graphical user interface, automatic angle and phase measurement. Multiple screen layouts are available with up to 12 strip charts and up to 16 impedance planes. Strip charts Tube list Code section Control panel Information section Nonmultiplexed Drive In addition to the conventional time-multiplexed drive mode commonly available throughout the industry, the TC5700 features a simultaneous drive mode. Instead of time-multiplexing each excitation frequency, one-by-one as shown below, the coils are driven with all frequencies superposed simultaneously. This method requires more complex signal processing but yields much superior speed. Inspections at 2 m/s Using Nonmultiplexed Drive The TC5700 is capable of 4-frequency eddy current inspections at a speed of 2 m/s. Resulting signals from an ASME standard tube Time-multiplexed drive mode Simultaneous drive mode Channel selection Phase depth overlay Vector plane Measurement Mixed channel Simultaneous at 0.5 m/s Simultaneous at 2 m/s Time-multiplexed at 2 m/s Condenser inspection at 2 m/s with the Airgun. The high-speed inspection has not caused any phase shift or amplitude change, and the signal shape has not been distorted. The right image shows the same tube, inspected at 2 m/s using time multiplex. Note the introduced distortion and the potential for error in phase measurement.

5 RFT AND MFL OPTION FOR INSPECTION OF FERRITIC/CARBON STEEL TUBING Inspection of carbon steel tubes using conventional eddy current technique is not very effective as the ferromagnetic properties of carbon steel drastically attenuate induced currents. Such tubes may, however, be inspected with the TC5700 using either remote field, magnetic flux leakage, or ultrasound. Remote Field (RFT) BOILERS FEEDWATER HEATERS AIR COOLERS BURIED PIPES CARBON STEEL HEAT EXCHANGERS Remote field is a variation of eddy current send-receive probe technique. The detector coils are separated by a distance equivalent to two or three times the tube OD. The receive coils sense the flux lines that cross the tube wall twice. Remote field has an equal sensitivity to ID and OD indications, while the phase shift is directly proportional to wall loss. RFT is also a suitable technique for detection and sizing of localized defects such as pitting. The analysis is performed in standard XY vector plane. Pit depth is evaluated with a depth curve such as used in eddy current. Detection and sizing of flaws in the vicinity of support plates may be improved by using a dual-driver probe and a dual-frequency analysis procedure. Magnetic Flux Leakage (MFL) MFL is based on the magnetization of the material to inspect using a strong magnet located inside the probe. As the probe encounters a wall reduction or a sharp discontinuity, the flux distribution varies around that area and is detected either with a Hall-effect transducer or an inductive pickup coil. A special analysis technique called the voltage plane greatly simplifies calibration, analysis, and flaw assessment. In the voltage plane, defects can be easily sized for depth and volume. Vector plane for pit sizing. Dual-frequency RFT capability with real-time mixes 4 RFT coil inputs (up to 8 with expanded RFT option) Current or voltage drive, adjustable Low frequency range starts at 20 Hz Adjustable bandwidth from 8 Hz to 200 Hz Phase-to-depth and voltage-to-depth curves for wall loss measurement Voltage plane or vector display MFL is suitable for wall loss measurement and detection of sharp defects such as pitting and grooving. MFL is effective for aluminum finned carbon steel tubes because the flux leakage field is mostly unaffected by the presence of such fins. 4-channel MFL (8 with expanded option) with adjustable gain, filters Compatible with inductive coils and/or Hall-effect sensors (matching circuit required) Strip chart or C-scan display IRIS and MFL probes for air coolers. Voltage plane with depth-sizing box. Furthermore, the voltage plane permits discrimination against nonrelevant indications. The TC5700 performs realtime voltage plane probe balancing, data acquisition, and data display. Boiler tube with defect located in the bend area. MFL inspection of an air cooler. The color C-scans show several internal pits from the same area.

6 INTERNAL ROTATING INSPECTION SYSTEM HIGH-SPEED ULTRASOUND OPTION The TC5700 features a unique 4-channel ultrasonic option, expandable to 16 channels. This option is suitable for tube profilometry or crack detection using IRIS, motorized, or multielement UT probes. It is also suitable for steel plate corrosion mapping using a linear array of transducers. IRIS NONFERROUS HEAT EXCHANGERS NEAR-DRUM AIR COOLERS BOILERS CARBON STEEL HEAT EXCHANGERS The UT option was designed to use the IRIS probe. IRIS is an ultrasonic technique well suited for petrochemical and BOP tube inspections. The technique uses an ultrasonic beam to scan the tube ID surface in a helicoidal pattern ensuring that the tube full length is tested. The TC5700 monitors the frontwall and the backwall echoes in order to measure the tube wall thickness. The TC5700 display provides the analyst with extensive information for decision making. When a defective area is observed, the acquisition process can be suspended and analysis performed on a composite display. This display is made of a color C-scan and a B-scan with real-time animated cross sections and a D-scan to show the profile of the tube. Real-time C-scan eliminates missed defects due to operator fatigue. Tube (or plate) profiles for ID, OD, or wall thickness are provided for offline analysis. Profiles allow quick and easy flaw detection. Data can be recorded to RAM for online analysis, or the full tube length may be recorded to disk for offline analysis and reporting. Real-time B-scan provides cross section view and is used for flaw sizing. Measurement cursors for precise flaw sizing. Tube statistics: average, maximum, and minimum values for ID, OD, and wall thickness. In the setup mode, the user makes adjustments with visual feedback of the waveform on an A-scan display. This permits optimizing the settings and assisting in troubleshooting probes and cables. In acquisition mode, a color C-scan (wall thickness map) and a B-scan (IRIS oscilloscope-like display) are displayed simultaneously in real time. After every rotation of the turbine, the B-scan is updated and a line is added to the C- scan. The C-scan scrolling can be continuous or synchronized with an encoder. Applications IRIS tube profilometry Boiler tube inspection (IRIS or multichannel) Near drum inspection (crack or corrosion) High-resolution motorized probe tube inspection Tube inspection using 8- or 16-channel nonrotating high-speed probes Steel plate corrosion mapping (4 or 16 channels recommended) IRIS probe and corroded boiler tube. IRIS boiler tube inspection.

7 SOFTWARE AND PROBES ACQUISITION, ANALYSIS, AND REPORTING SOFTWARE MultiView Software C-Scan and ET Array Software Option MultiView acquisition software is supplied as a standard item with the TC5700 and includes the following features: Setup, calibration, and acquisition software Storage of unlimited number of inspection setups Creation and management of inspection list (tube lists) Impedance plane and strip chart presentations of ET and RFT data Amplitude and phase measurement of ET and RFT data Up to 128 real-time mixes Automatic data recording synchronized with tube list Screen printouts This option provides C-scans and associated measurement tools for inspections using MRPC and array probes (1 to 48 coils). This option, when used with dual-axis encoders, provides C- scans proportional to the inspected surface. Tube Analysis Software Option Automatic detection of landmarks (support plates and tube sheet) from ET and RFT data Phase-to-depth sizing curves for ET and RFT data Depth sizing curves from peak-to-peak volts or vertical volts Computer-assisted analysis of ET and RFT data Tabular report entries and report generation RFT Voltage Plane Analysis Software Option Voltage plane theoretical curve and circumferential sizing overlay Voltage plane flaw sizing Voltage plane balance Dual-driver software control Inspection Planning and Tube Sheet Report Option (CARTO) Database management of exchangers, reports, and tube sheet maps Graphical tools for creation of tube sheet maps and inspection lists Storage of all reports and tube sheet maps in a database Display results from single or multiple reports R/D Tech manufactures a wide range of ET, RFT, MFL, and UT probes. R/D Tech eddy current probes feature replaceable cables, to maximize the life of the probes themselves. This also allows the use of multiple probe heads of various diameters with a single cable. The TC5700 is also compatible with probes from other manufacturers. Special multitechnology probes (RFT + ET, RFT + MFL, and UT + ET) are also available on request. ET, RFT, MFL, AND UT PROBES