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The Omniscan and the Codesfor Weld Inspection
Thierry COUTURIER, OISE
Petr Dobsak, Olympus CEE
2
Example with ASME Code Case 2235
� Phased-Array
� TOFD
The OMNISCAN and the CODES
3
Example with ASME Code Case 2235
� Based on Performance Demonstration
� Requires detecting three defects (ID, OD, sub-surface)
� Requires full data collection and encoder (AUT)
� Can be TOFD, pulse-echo or combination, or Phased Array
The OMNISCAN and the CODES
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� ASME – CC2235� Has dominated for 12 years for AUT instead of RT
� Very widely used – globally
� Completed with 5 ASME Code Cases� CC 2541: Manual Phased Array with single beam
� CC 2557: Manual Phased Array with S-scans
� CC 2558: Manual Phased Array with E-scans (Linear Scans)
� CC 2599: Encoded (AUT) Phased Array with E-scans (Linear Scans)
� CC 2600: Encoded (AUT) Phased Array with S-scans (Linear Scans)
The OMNISCAN and the CODES
Example with ASME Code Case 2235
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� One Person Operation
� Portable Phased Array instrument� PA + TOFD
� Hand Scanner
� Couplant andPump
� Linear Scanning
The OMNISCAN and the CODES
Example with ASME Code Case 2235
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� Calibrate all beams - Very important
� Wedge calibration� Velocity Calibration� TCG Calibration
� Use same Focal Law for calibration as for scanning
� Develop Scan Plan to show coverage and appropriate angles
� Use two (or more) S-scans if required - Multi-Group
� Scan parallel to weld with Encoder /Full data collection at fixed distance from centerline
The OMNISCAN and the CODES
Example with ASME Code Case 2235 – Equipment requirement
7
� Ray tracing using ESBeamTool or the Omniscan Weld Overlay with sample
Bevel Incidence Angles (arrowed) calculated on 25mm wall double-V weld
� Can check if angles are “not appropriate”
The OMNISCAN and the CODES
Scan Plans (1)
Example with ASME Code Case 2235
ANGLES
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Scan Plans (2)
HAZ poorly addressed
� Note poor coverage of heat affected zone (arrowed) ▬► move array for optimization
� Again Ray tracing using ESBeamTool or the Omniscan Weld Overlay is
required
COVERAGE
The OMNISCAN and the CODES
Example with ASME Code Case 2235
9
Transmitter ReceiverLateral wave
LW
Upper tip Lower tip
Back-wall reflection
BW
The OMNISCAN and the CODES
Example with ASME Code Case 2235
10
Typical TOFD Display� Gray scale and RF for
phase information
� OD and ID visible
� Defects detectable in middle
The OMNISCAN and the CODES
Example with ASME Code Case 2235
11
� Some customers can develop their own procedures� AREVA� GDF� TOTAL� …
The OMNISCAN and the CODES
Our approach
12
The OMNISCAN and the CODES
Some existing codes
(ASME, ASTM, EN, ISO, AWS, API, DNV, …)
13
TOFD Codes
� ASME TOFD Code (Section V Article 4 Mandatory Appendix III) (2006)
� ASME TOFD Interpretation Manual (Non-mandatory App. N)
� ASTM E-2373 - Standard Practice for Use of TOFD Technique (2009)
� ASME Code Case 2235-9 - Boiler and Pressure Vessel (Oct. 2005)
� BS7706 “guideline”- Calibration and setting-up TOFD technique (1997)
� ENV 583-6 - TOFD technique as a method for defect detection and sizing
� EN14751 (supersedes EN583-6) – Used in Europe
� EN15617 - NDT of welds. TOFD technique. Acceptance levels (20 09)
� ISO 15626 - NDT of welds. TOFD technique. Acceptance levels (20 11)
The OMNISCAN and the CODES
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PA Codes - American
The OMNISCAN and the CODES
� ASME Code Case 2235-9 - Boiler and Pressure Vessel (Oct. 2005)
� ASTM E-2491-06 Recommended Practice for phased array set-up
� New E-2700 RP for Phased Array of welds.
� API 1104
� AWS D1.1
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� Some companies have developed their own procedures
� Still working on Phased Array code development
� Equivalent of “EN 12668” is coming
� For PA instrument� For PA probes� For PA systems (application)Not before 2012
The OMNISCAN and the CODES
PA Codes - Europe
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Required features
-
Available with the OMNISCAN
17
The OMNISCAN and the CODES
� Scan Plan to show coverage and appropriate angles� ESBeamTool was mandatory, still very useful
�Weld Overlay now available
Required features – Available with the OMNISCAN
18
The OMNISCAN and the CODES
Required features – Available with the OMNISCAN
� Calibration of all beams - 100% Calibration of the beam coverage
� Has always been a strength
� Wedge Delay / Velocity
� Sensitivity
� TCG – Manual/Automatic� ACG “angle corrected gain”� TCG “time corrected gain”
19
� Use two (or more) groups if required with Multi-Group
The OMNISCAN and the CODES
Required features – Available with the OMNISCAN
20
� Scan parallel to weld with Encoder and full data collection at fixed
distance from centerline
The OMNISCAN and the CODES
Required features – Available with the OMNISCAN
21
� TOFD
The OMNISCAN and the CODES
Required features – Available with the OMNISCAN
22
The Omniscan MX and Omniscan MX2
have all the required features so that an
inspection procedure can fulfil most of
the codes.
23
� Phased-Array is now well accepted and understood
� Still explaining how Phased-Array works
� Conventional UT technique still can be used
� TOFD - Still some reluctant countries in Europe
The OMNISCAN and the CODES
24
� More and more used all over the world
� Well-used and well-developed technique
� Complementary to Pulse/Echo (Conventional UT or PA)
� Successful to replace RT combined with Phase-Array
The OMNISCAN and the CODES
TOFD Codes
25
TOFD Codes
� Customers feel very confident as no indication can be missed when combined with P/E
� Well “codified”, primarily from Europe
� No surprise – “invented” and “developed” here
� Not so many differences between the existing codes
The OMNISCAN and the CODES
26
TOFD Advantages
� Excellent POD (Probability Of Detection) for mid-wall defects
� Good detection of mis-oriented defects
� Rapid and low cost inspections� Cheap solution� Small amount of data� Small amount of data to analyze
The OMNISCAN and the CODES
27
Probability of detection(in %)
TOFD 83 %
Automated UT(Pulse / Echo)
84 %
Radiography 60 %
Manual UT 53 %
Probability of detection
The OMNISCAN and the CODES
TOFD Advantages
Results of comparison test (France)
28
Industrial – Manual Weld
29
Industrial – Automated Weld
30
Aerospace – Composite Inspection
31
Industrial – Corrosion
32
The OMNISCAN and the CODES
Limitations of the Omniscanversus the codes
33
�Pipe-Wizard applications and Girth Weld inspection�DNV-OS-F101
�API 1104
�DNV-OS-C401
�Tandem technique is required
The OMNISCAN and the CODES
Limitation of the Omniscan versus the Codes
34
Girth Weld Inspections: Onshore / Offshore
Pipe Wizard
35
Phased-array Pulse/Echo
Phased-array probe
Wedge
Weld
Pipe Wizard
36
�Phased-array adjustments �Adjustment of emitter and receiver to hit the zone
� Adjustment of beam width to cover the height of the zone
� Adjustment of overlap in next zone
InspectionEmitter
Receiver
F1
F2
F3
F4
F5
Zones
Calibration
F5F4F3F2F1
Cap
HPLCPRoot
Zone discrimination technique with Tandem technique
Pipe Wizard
37
Pipe Wizard
Focus LT +Motor Control Unit
Automated Scanner
No more the Omniscan