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FirstMap Corrosion Mapping SystemWebinar July 18, 2013
Bob Lasser, PresidentImperium, Inc.Beltsville, MD
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• Introduction to FirstMap Corrosion Mapping• Technology Description• Application Scope• Product Demonstration• Recent Study• Q&A
Agenda
About Imperium
• Founded in 1996• Sole provider of ultrasound camera technology• Patented technology• Systems in petrochemical, aerospace, medical
fields
• Lack of trained NDT personnel• Lack of confidence in thickness readings, missed
corrosion• Need higher POD, faster device • Need areas where AUT can’t reach• Advances in imaging technology
• A picture is worth 1000 words• Time and cost pressures – Need to do more with
less
Why Industry Needs A New NDT Device
FirstMap Advantages• Images are easier to interpret • FirstMap provides an actual image of the defect including
thicknesses • Very fast• High resolution• Higher confidence than single thickness readings • Not effected by beam dispersion• Built in delay line• No extensive training required; less trained technician• Real time
B-scan to C-scan
Defect
Defect
Sound Transmitter
Array
Video
Lens
Target
Subsurface fault
Pulse Echo – 50/50 Beamsplitter
Pulse echo image of quarter
Acoustic beamsplitter
Water
Imperium’s Patented ArchitectureApplies optical imaging techniques to ultrasound
Optical Sensor (CCD) Lens
Ultrasonic Sensor (2) F1 Acoustic LensAcoustic Flashlight
Flash
Note: CCD means Charged Coupled Device
Optical Architecture:
Ultrasonic Architecture:
Imaging Array – 100 micron pixels120 rows x 120 columns = 14,400 pixels
FirstMap
• Made up of control unit, camera probe
• 3” pipes down to flat• Images through coatings• Equipped with pulse echo or
dual element transducer for thickness readings
• Battery powered• Rugged
Calibration Procedure
Dual element mounted to camera head
Remove transducer Place on thin section of wedge– Note thickness
Place on thick section of wedge– Note thickness
Workflow
ScanCalibratePower up Analyze/Review
FirstMap Scanning Speed
8” Rough Pipe Section
Top of pipe with very rough surface
Holes on bottom of same pipe
C-scan image through rough top surface
Mapping on 8” Pipe
Mapping on 8” Pipe
Pipeline Corrosion Mapping
Storage Tank Bottoms
Compare FirstMap’s easy to interpret readout
Microbiological Induced Corrosion
Black areas indicate MIC, note the veins of MIC also
Benefits to NDT Industry• Broad application base
• Pipelines, storage tanks, pressure vessels• Find smaller amounts of corrosion faster• Does not sacrifice any current data quality • Provide better information to end customer• Better tool to provide comparisons• Use Level 2 thickness inspector to generate
images, not just readings• Get to areas where current tools can’t go• Cover more area faster while capturing
better data
Advanced Corrosion Technologies
“The probability of detection is far superior to standard thickness readings. FirstMap™ is a diagnostic tool that can instantly detect subsurface corrosion down to 1 mm pits. We are now able to quickly and easily identify problem areas that could potentially lead to much bigger issues.”
-Josh Fontenot, Director of Technologies, ACTT
FirstMap Demonstration
About Study• Wanted to compare Imperium’s FirstMap Corrosion
Imaging system to Phased Array UT (PAUT)• Investigated resolution• Other factors included ease of use, cost, training
requirements• Joint study between Imperium, Inc. (Beltsville, MD)
and Advanced Corrosion Technologies & Testing (Sulphur, LA)
B-scan vs. C-scan
Phased Array
FirstMap
Resolution Study:FirstMap vs Phased Array
• Investigated axial, lateral, and elevation resolution
• Used Omniscan MX2• Both systems working at 5 MHz• Did mathematical study, then took data to
compare expected results
Omniscan PAUT System Test Settings: Probe: 5L64-NW1 (5 MHz)Wedge: SN1-0L5L64Mode: Phased arrayFocal Depth: 0.1”Focal Law: Linear sector with overlapSkew Direction: 900 (straight down mode)Scan Offset: 0Index Offset: 0Element Quantity: 8First Element: 1Last Element: 64Thickness: 0.25”Surface: Flat plate
FirstMap System
Frequency: 5 MHzNumber of Pulses: 1Gate start: 0.1”Gate width: 0.5”
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Lateral (X):ΔD = (0.44 x V) / (F x sin (θ/2))
Axial (Z):ΔZ = V x T/2
Elevation (Y):Defined by the length of the array elements, and will be on the order of several millimeters
Phased Array Theoretical Resolution
Source: Olympus NDT Manual
Resolution Summary
INSPECTIONSYSTEM
AXIAL RESOLUTION
LATERAL RESOLUTION
ELEVATION RESOLUTION
FirstMap™ 1.5 mm 0.1 mm 0.1 mm
PAUT 0.3 mm 0.34 mm > 1.0 mm
Resolution Panel
Resolution Study - Set A: 0.100” holes
Phased Array
FirstMap
Resolution Study - Set B: 0.040” holes
Phased Array
FirstMap
Resolution Study - Set C: 0.023” holes
Phased Array
FirstMap
FirstMap Omniscan: Amplitude Omniscan: TOF
Resolution Results
Comparative Study: FirstMap, X-ray, Phased Array
Reviewed different techniques for corrosion mapping Used common standards Recorded image quality Recorded time of setup, scan, training cost
Targets StudiedStepped standard
Corrosion piece
8” diameter pipesection
Stepped Standard
FirstMap
Phased Array
X-ray 192 iridium
0.25” Corroded Steel Panel
FirstMap
Phased Array
X-ray 192 iridium
8” Diameter Pipe Section
FirstMap
Phased Array
X-ray 192 iridium
Questions?
Corrosion Mapping Comparison
NDT Method FirstMap™ Phased Array with Scanner
Iridium-192 Radiography
Equipment & Related Costs
$45K $70K $100K
Daily Cost ~$800 ~$1200 ~$2000
Inspection time per square foot (includes setup)
5 minutes 15 minutes 30 minutes
Required Training
16 hours 160 hours 400 hours
Required Experience
Level I or Level II
Level II NDT Advanced
Availability of Technicians
Available Limited Very limited
Required Technicians
1 1-2 2
