Papers

Raised Face Flange Inspection
2008-05 - R. Ginzel - NDT.net

This Standard Practice describes the method used to determine the presence of deterioration on raised face (RF) flange seal faces. The extent of corrosion/erosion ingress of the flange seal face will be quantified. Currently RF flanges are visually inspected requiring the system to be purged, isolated and disassembled. This costly practice can be eliminated by using modern phased array ultrasonic inspection while the system remains assembled and in many cases while on-line.

A Qualification Process for Phased-Array UT using DNV RP-F118 Guidelines
2011-08 - E. Ginzel - NDT.net

A phased array UT procedure was qualified to permit fracture-mechanics-based acceptance criteria to be used on a specific Tee shaped weld. The process used the DNV RP-F118 [1] as a guideline for the detection and sizing assessments required. The qualification process is described and the results are summarised along with modelling confirmation examples.

Modeling in the development of complex NDE solutions for AECL NRU reactor

2012-09 - Brent Zeller - NDT Canada

In May of 2009, the NRU (National Research Universal) reactor was forced to shut down after a small heavy water leak. In 2009-2010 repairs were performed in order to restart medical isotope production mid-August 2010. Since the NRU vessel?s return to service, a series of periodic inspections is required to ensure the safe operation of the reactor. Eclipse Scientific was mandated to develop the NDE procedures and robotic manipulator for the In-Service Inspection program of the NRU vessel. This included the development and implementation of phased array ultrasonic inspection techniques and eddy current array technology techniques to be used with unique material characteristics, property and physical state changes. The inspection mandates were required in a short time frame and environmental conditions represented very difficult delivery and inspection circumstances. This paper presents how modeling was used in the development process to achieve the inspection mandates. The modeling software used ranged from advanced ray tracing (ESBeamTool) to full UT/ET simulation (CIVA) and was key in obtaining approval of the procedures, developing good training material and obtaining excellent data from the inspections.

Remote Robotic Inspection of Irregular Surfaces on the Inner Diameter of the AECL NRU reactor
2012-09 - Brent Zeller - NDT Canada

In May of 2009, the NRU (National Research Universal) reactor was forced to shut down after a small heavy water leak. In 2009-2010 repairs were performed in order to restart medical isotope production mid-August 2010. Since the NRU vessel?s return to service, a series of periodic inspections is required to ensure the safe operation of the reactor. Eclipse Scientific in collaboration with Utex Scientific Instruments and Liburdi Automation developed the NDE inspection system for the In-Service Inspection program of the NRU vessel. In addition to the difficult environmental, delivery and inspection circumstances the inspection team were faced with the problem of doing an immersion inspection of the inside surface of the reactor vessel through a small 4.75? access port at a distance of more than 30 ft to the inspection area at the bottom of the reactor. The vessel was built over 50 years ago and the inner surface has been modified by the repair program during the forced outage, so there are no accurate drawings of the inner surface of the vessel that an automated system could rely upon. Eclipse Scientific in collaboration with Liburdi Automation developed a robotic arm that is designed to enter from the remote access port to deploy the Phased Array and Eddy Current Array inspection heads into the reactor vessel. The motion control and data acquisition system was developed in collaboration with Utex Scientific Instruments using their InspectionWare software. This paper will highlight the challenges faced in the development of an inspection system that is capable of using ultrasonic signals to learn a surface and, using this acquired surface topography, effectively and safely deploy and articulate the different inspection heads required to perform the In-Service Inspection of the NRU vessel.

Errors resulting from curved phased-array wedges
2011-08 - E. Ginzel - NDT.net

Ultrasonic operators have long struggled with the problems associated with setting sensitivity when inspecting pipe girth welds on small diameter pipe. Issues have been compounded with the introduction of S-scans used by phased-array techniques. This article describes how the solution by some technicians to calibrate using a flat wedge and then change the wedge to a contoured wedge for the actual scanning can lead to errors. Recommendation is made for a codified approach.

CIVA Modelling for Pipeline Zonal Discrimination
2011-04 - E. Ginzel - NDT.net

The technique of inspecting pipeline girth welds using zonal discrimination has been used extensively since the late 1980s. Refinements in the past decade have included the introduction of phased-array equipment, improved sizing algorithms, developments for small diameter pipe and techniques for exotic alloys, to mention a few. Until recently, inspecting pipeline girth welds using zonal discrimination has not taken advantage of modelling in the same way as other applications. Simple ray-tracing software has provided a good means for operators to calculate probe positioning and focal law limitations for coverage; however, the effects of flaw characteristics and focusing parameters has not been studied with modelling in the same way it has in the power generation applications. This paper looks at the use of the analytical modelling software called CIVA as a tool to investigate many of the issues facing pipeline AUT.

Automated Ultrasonic Inspection of Nozzle Welds using Phased-Array Ultrasonic Testing - Part 1 - Inside Access
2010-09 - E.Ginzel - SimNDT

Nozzle weld inspections have long been an important function carried out by ultrasonic test methods. When performed using manual techniques the plotting of defects located is a time-consuming ordeal requiring local profiles, wall thickness readings and compensation for curvature effects. The introduction of Code Case 2235 for ASME compliant vessels has allowed many welds in the vessel be inspected using ultrasonic methods. The computerisation requirement in the Code Case is easily applied to longitudinal and circumferential butt welds. However, complexities of geometry can limit the useful application of ultrasonic methods to nozzle welds unless provision is made for the mechanics to provide adequate tracking to assure full-volume beam coverage. This paper discusses the options available when phased-array techniques are used with mechanical apparatus that provides encoded motion from the inside surfaces of either the nozzle or the vessel. Modelling provides evidence of the physical parameters that must be considered for full coverage. Actual scan results are provided to indicate how well the models predict the coverage by detecting targets at the edges of the weld zones. Modelled and actual results indicate that a scan-plan made using a ray-tracing programme can provide suitable indication of required coverage. In many cases, the mechanical apparatus used to guide the probe can be designed with a minimum of complexity when scanning access is from the inside surface of either the nozzle or vessel.

Automated Ultrasonic Inspection of Nozzle Welds using Phased-Array Ultrasonic Testing - Part 2 - Outside Access
2010-09 - E. Ginzel - SimNDT

Part 1 of this series of papers on nozzle weld inspections by phased-array ultrasound options, provided several recommendations for scanning from the nozzle or vessel inner surfaces. Part 2 discusses scanning when access is available from the outer surfaces of the nozzle or vessel. Modelling provides evidence of the physical parameters that must be considered for full coverage. Actual scan results are provided to indicate how well the models predict the coverage by detecting targets at the edges of the weld zones. Modelled and actual results indicate that a scan-plan made using a ray-tracing programme can provide suitable indication of required coverage. In many cases, the mechanical apparatus used to guide the probe can be designed with a minimum of complexity when scanning access is from the outside surface of either the nozzle or vessel.

Phased Arrays for Detecting Cracking in Bolts
2008-05 - M. Moles, R. Ginzel - MENDT

Phased arrays can be used for detecting cracking (and other defects) in high tensile bolts. The technique uses a "fingerprinting" approach to the bolts. In contrast to current code procedures where an operator manually scans a normal beam probe over a bolt and interprets the results, this phased array technique uses an S-scan and a mechanized scanner. Specifically, the phased array probe is mounted in contact on the head of the bolt, and performs a small angle longitudinal wave S-scan down the bolt. The array is mounted in a mechanized and encoded jig for 360o rotation round the bolt. Signals are received from the threads, bolt geometry and from mode conversions. In essence, the S-scan gives a fingerprint of the bolt at all depths and orientations when the operator scans round the bolt collecting data. Any perturbations from defects or cracks are typically very visible. Interpretation is much simpler than with alternative bolt inspection techniques. Some examples from calibration and cracked bolts will be shown. The technique can be finetuned for different bolt dimensions and features.

Cost-effective pipeline girth weld AUT for Brazil
2007-03 - D. Cziraki, A. Danis - NDT.net

The expansion of the Brazilian Samarco Mineração S.A. mining production facility required the construction of a second iron ore slurry pipeline. This upgrade interconnects the facilities of Samarco in Mina do Germano, Minas Gerais, with Ponta Ubu in Espiritu Santo. The project involves 340.6 km of 16" and 57.8 km of 14" steel pipe, and includes several new pumping, pressure measuring, and valve stations. At full production capacity the new pipeline will convey 16.5 million tons per year, in addition to the current 13.5 million tons per year.In early April 2006, Eclipse Scientific Pipeline AUT Group and Materials Research Institute were contracted by NDT Do Brasil to act as project start-up consultants for the client's impending entry into the pipeline girth weld inspection market. NDT Do Brasil's advanced ultrasonic inspection team has been actively performing AUT with phased array and TOFD techniques for many years, and it was decided that the time had arrived to break into the growing and very competitive pipeline girth weld inspection market. Project startup consultants were engaged to assist with technical details.