Paut Nots-krishnan.pdf

”Advances in Phased Arrays and Other NDT Technologies” 18th World Conference on NonDestructive Testing Durban, South Africa, April 16-20, 2012

Presentation Outline • • • •

Olympus - What we manufacture A brief introduction to phased arrays Olympus NDT phased array equipment Practical solutions to common inspection problems – – – – – – –

OmniScan MX2 EPOCH 1000i Eddy current array (ECA) PipeWIZARD V4 In-line inspection (pipe mill) developments Remote Video Inspection (RVI) Innov-X X-ray florescence (XRF) analyzer

Olympus Corporation Our Mission Olympus is a precision technology leader, designing and delivering innovative solutions in its core business areas:

Cameras and Audio, Industrial Testing Instruments, Life Science Imaging Systems and Medical and Surgical Products. Our focus is on enhancing people's lives every day. We are a company committed to helping people enjoy the continuum of life. Our relationship with our shareholders, customers, employees and business partners is at the center of everything we do.

Cameras & Audio Olympus continues to innovate products and technologies that the boundaries of digital photography and audio capture.

expand

This includes award-wining digital compact cameras, interchangeable lens camera systems for professional and consumer markets, and related underwater products and accessories. For additional information, visit

getolympus.com.

Life Science Imaging Systems Olympus designs and manufactures comprehensive microscope-based systems for biomedical research, diagnosis and education.

Combining this expertise

with

tomorrow’s genomic, proteomic, and internetbased technologies, Olympus is paving the way for science.

future advances in life

Medical & Surgical Olympus offers solutions in the fields of: • Gastroenterology • Gynecology • ENT • Pulmonology • Surgery • Urology

Olympus, which incorporates surgical market leader Gyrus ACMI,

solutions for healthcare professionals that help improve outcomes and enhance quality of life for their patients. By enabling less invasive procedures, develops

innovative diagnostic and therapeutic endoscopy and early stage cancer evaluation and treatments, Olympus is

.

the future of healthcare

transforming

Industrial Products Olympus provides an industry-leading portfolio of innovative test, measurement, and imaging instruments.

Innovative testing instruments are used in industrial and research applications ranging from aerospace, power generation, petrochemical, civil infrastructure and automotive to consumer products. Olympus instruments

quality of products and add to the safety of contribute to the

infrastructure and facilities.

Industrial Solution Technologies Our leading edge testing technologies include : 9 Conventional Ultrasound 9 Eddy Current and Eddy Current Array 9 High Speed Video 9 Microscope Solutions 9 Optical Metrology 9 Phased Array 9 Remote Visual 9 X-ray Fluorescence (XRF) / X-ray Diffraction (XRD)

Industrial Products Olympus testing and imaging products include: 9 Flaw Detectors 9 Integrated Inspection Systems 9 Thickness Gages 9 Advanced NDT Solutions 9 Microscope Solutions 9 Optical Metrology 9 Video Scopes, Borescopes 9 High Speed Video Cameras 9 XRF / XRD Analyzers

Industry Solutions Industries that Olympus provides solutions for include:

How Phased Arrays Work – Beam Focusing

•large range of focal depth (focusing) • adjustable each pulse.

How Phased Arrays Work – Beam Steering • large range of inspection angles (sweeping) • multiple modes with a single probe (SW, LW)

Common Probe Geometries Linear

1D linear array

2D matrix

Circular

1D annular array

2D sectorial annular

Key Concept

• Phased arrays do not change the physics of ultrasound • PA’s are merely a method of generating and receiving a signal • (and also displaying images) • If you obtain X dB using conventional UT, you should obtain the same signal amplitude using PA’s.

How Phased Arrays Work • The operator inputs the focal depth(s), inspection angle(s) and/or couplant, type of scan, plus how many and which elements are to be fired. • The operator must also input details on the array and wedge, OR the system has probe recognition (as with OmniScan). • The phased array calculator calculates what time delays to apply to each element.

Defining depth and refracted angle

Snell point

X axis or Scan axis Interface

Law scan offset

Focal point (X,Z)

Depth Angle

1. The calculator searches for the Snell point. 2. Then, the X, Z point of the focal point is determined. 3. The wedge delay is calculated and the focal law is offset accordingly.

Calculator The focal law (difference in delay to reach the focal point) for each element is then calculated. The actual path between two points taken by a beam of light (or sound) is the one that is crossed in the shortest time.

X axis or Scan axis Interface Time

Sound path (time)

Focal point (X,Z)

In wedge In materiel

Element number

Design Parameters of Phased-Array Probes A e

H

p

g

Design Parameters of Phased Array Probes

• WEDGE PARAMETERS – Velocity in wedge (vw) – Wedge angle (ω) – Height of first element (h1) – Offset first element (x1)

Wedge (vw)

inc

h1

x1

ref

Implications of Element Size on Beamforming A B

A

α d

0.41λ sin (α ) = d

 Point A is OK because all rays are within elemental beamwidth  Point B yields unexpected results because rays are outside elemental beamwidth

Angle Range for S-scan Calibration

• Check manufacturer’s angle range in catalog • For Olympus NDT, angle range is based on physics of wedge • Then calibrate; if cannot calibrate over designated range, then cannot use full range • Effective range may depend on many factors, including material • Also, “sparse” arrays possible for large numbers of elements.

Electronic Scanning • Scans the beam along one axis of an array without any mechanical movement. • The movement is performed only by time multiplexing the active element • The beam movement depends on the probe geometry

Electronic Scanning of Welds • Electronic (linear) scanning can easily emulate typical ASME-type 45 and 60o shear wave inspections • Much faster than raster scanning. • Typical weld inspection requires two or more angles. • Need to cover weld, HAZ, any position errors => significant amount of scanning

Sectorial Scanning (S-scans)

• Sectorial scanning is the ability to scan a complete sector of volume without any probe movement. • Useful for inspection of complex geometries, or those with space restrictions • Combines the advantages of a wide beam and/or multiple focused probes in a single phased array probe

Sectorial Scans on Welds • S-scanning – changing the incident angle without changing position – can be used for a variety of inspections, including welds. • Note limitations on bevel angle incidence => multiple S-scans.

Tandem Probes for Vertical Defects

TOFD using Phased Arrays Transmitter

Lateral wave

Receiver

Back-wall reflection BW

LW

Upper tip

Lower tip

Determining Defect Location

Defect Sizing using S-scans Defect tip signal – easy to identify and size Crown defect – clearly located

T1 designation shows “top” or cap

Combined Scans Give Improved POD

Array Grating Lobes n=8 p=9 n=12 p=6 n=16 p=4.5 n=20 p=3.6

Array lobe

Main lobe

Influence of pitch p (for A = fixed): – If p ↓, or n ↑ then lobe distance ↑ and lobe amplitude ↓ Solution: Design array lobes out.

All the usual ultrasonic limitations

• • • • • •

Coupling Frequency, attenuation etc. Scanning speed Digitization rates Ultrasonic wrap-around Acoustic impedance mismatch requirements • Dead zones • Etc.

…

Additional Limitations

• One scan sees it all … too simplistic • S-scan angular range (mechanics, codes, calibration) • Focusing • TOFD from PA • One array does everything • TRAINING => Overall, excellent tool for inspections.

New equipment and solutions

OmniScan MX2

• New development at Olympus NDT • Offers better screen size and visibility • Same or better operating capabilities as original MX • Same Code compatibility as MX • Touch screen capabilities • Better data handling

OmniScan MX2

OmniScan MX photos of weld inspections.

Focus LT ® •Powerful Software for Data Acquisition and Analysis •Advanced PA Calculator (1D - 2D 2D/TRL) •Flexible SDK (NDT Data Access and Remote Control)

Turbine inspection with Geometry : – Length : 19000 mm – Max. Diameter : 3500 mm - Max. Weight : 120 tons

TV

Types of defects Slag, cracks pores & segregations

- Defect size : ERS 1.0mm to 1.8mm depending on material

Turbine inspection with

TV

• Problem: – Large quantity of data (A-Scan & C-Scan) due to dimensions of the piece to be inspected – Detection of defects close to the back wall on non parallel parts (fixed gate length) – TCG implementation (DGS to TCG conversion) Solution: •Bigger file size up to 2 GB •Conditional A-Scan to reduce file size •Offline gate length modification for parts •Import/Export TCG

WeldROVER for Large Diameter Pipes Automated pipe weld scanner for diameters <100 mm Easy to operate: two buttons and automated connection to OmniScan Uses laser beam for tracking with manual adjustments

COBRA for Small Diameter Pipes Semi-automated scanner for inspecting small pipe welds From diameters of 20 mm to 110 mm and up Low profile: <12.7 mm clearance Focused probes for better defect sizing.

PA Corrosion Mapping Components ¾ OmniScan MX or MX2 16:128 or 32:128 ¾ CHAIN Scanner ¾ HD Mapper & HydroFORM

HydroFORM - A, B & C Scans Simultaneously

EPOCH 1000i Feature Introduction Olympus NDT introduces the latest feature for the EPOCH 1000i phased array flaw detector: Encoded C-scan

Weld Overlay

Encoders on the EPOCH 1000i

• Many encoders can be used • Simplest Olympus example is the MiniWheel Encoder • Requires adapter cable from EPOCH 26pin port on back of unit to OmniScan style 9-pin encoder connector

Data Review from C-scan

• Exciting enhancements to data review after C-scan acquisition. – Storage of all A-scans from C-scan means EPOCH 1000i can recreate S-scan from a selected section of the C-scan

Eddy Current Array Flexible Probe

32 Elements 3mm coils diameter 51mm of coverage Very flexible Two row of coils to improve the resolution

ECA Blade Inspections

ECA Weld Inspection

ECA Customizable profile

PipeWIZARD V4 for Pipeline Girth Welds Built upon the proven PipeWIZARD®, the PipeWIZARD V4 system offers a highly reliable solution for onshore and offshore inspections in harsh environments.

PWZ-V2

PWZ-V4

PipeWIZARD V4 -

FocusLT 64:128 rackmount is based on OmniScan technology. ¾ Strong field experience : > 200 units in the field > 1.5 million welds inspected > 300 operators trained on PipeWIZARD

¾ Designed for harsh environments : Middle-East deserts, Brazil forests, Siberian colds, salty-air offshore laybarges. ¾ TomoView 2.8: Now operating on upgradeable version of software ¾ Umbilical cable has been redesigned and field tested for more than 3 years.

In-Line Inspection: Water Wedge Concept • Unique Water Wedge concept holding different type of probe holder and cylindrical PA probes (Aqualine). • Pneumatic suspension follows the pipe movement and raises the Water Wedge in case of scarfing window or joint weld between coil.

ILI: Automatic Calibration Sequence • Automatic gain compensation each aperture and detection gate; • Automated calibration sequence capability directly on the inspection head; • Calibration results presented as an amplitude bar graph for quick analysis; • Detailed calibration report about gain compensation per aperture and per detection gate.

ILI: Flaw Detection Results • Calibration on N10 notches – Detection TDH 1/8, 1/16

L-CW ID Strip Chart L-CW OD Strip Chart L-CW ID C-Scan L-CW OD C-Scan L-CCW ID Strip Chart L-CCW ID Strip Chart L-CCW ID C-Scan L-CCW ID C-Scan

ILI: Automatic Detection of Scarfing Windows ƒ Automatic systems integrated onto the ERW-In Line for protection of the inspection head against openings cut on pipes for adjusting the welding process. ƒ System based on EC encircling coil and Nortec 500 instrument integrated in an industrial enclosure and interfaced with the system’s PLC.

ILI: Phased Array Ultrasonic Concept •

Phased Array solution for Square Bar Inspection using Linear probes – Improve the detection performances (up to FBH 0.8 mm) – Minimize the uninspected area (include the corner inspection) LW Volume Inspection

BW Dead Zone 5 mm plus Corners

SW Surface Inspection

No Dead Zone except Corners

Corner Inspection

Limited Corners Dead Zone

ILI: Sample Round Bar Inspection Solution • Immersion tank round bars < 65 mm diameter

3D Videoscope and other RVI Technology

• • • •

Basic Videoscope Structure Stereo Imaging - 3D Eye Trek Microscopic 3D mapping Articulation Advances – Pneumatic Articulation – Articulating Guide Tubes – Low force direct articulation IPLEX Ultralite

Basic Videoscope Structure Olympus constantly fine tunes the basics of Videoscope Structure, with small advances to make scopes more user friendly. From power assisted True Feel Articulation to Taper Flex© Technology.

rigid TF

Competitive products flexible distal end

proximal end

Stereo Imaging • Well established • Repeatable • Provides 3D reference • Precision largely depends on distance between lens.

Stereo Imaging – 3D Eye Trek •Allowed the very first headworn 3D view of an inspected area. •Arrived before its time, inspectors had a tendency to move their head, not the scope. •New technologies can give this Olympus Innovation new uses.

High Speed Video i-SPEED 3

High Speed Video

High Speed Video Camera

Microscope 3D Mapping

RVI - Articulation Advances • Pneumatic Articulation

• Articulating Guide Tube

• Reduced Force Articulation

Olympus Innov-X: Portable X-ray Florescence Analyzer DELTA Line

Lambda

In‐Xitu Terra

X‐5000

Typical XRF Field Applications

Alloy QA/QC & PMI

Environmental

Geochemistry

Consumer  Safety

Scrap  Recycling

Mining

Forensics Historic  Conservation

General XRF NDE • Alloy Verification - not certification • Testing: Pipes, flanges, valve components, welds, general materials • Repair: Material Verification for existing components • Suppliers: Quality Control – Verified at Receiving

Summary

• Many new developments at Olympus NDT • Particularly in phased arrays on pipelines, pipe mills and standard apps with new instruments and mechanics • Also, developments in flexible eddy current arrays, remote visual inspection, and X-ray fluorescence • More developments to come!

Thank you Have a good day and enjoy the rest of the conference.