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Phase Coherence Imaging (PCI) Based Applications

1. Early-Stage High Temperature Hydrogen Attack (HTHA) Detection
2. Early-Stage (Voiding) Creep Inspection Detection
3. Thermal Shock Crack Detection
4. Induction Hardness Depth Estimation & Material impurity testing (Quality Control)
5. Accurate Crack Morphology Imaging and Sizing (Quality Control & On-line Monitoring)

Pioneering Industrial Applications of Phase Coherence Imaging (PCI)

• ADG instrumental in leveraging Phase Coherence Imaging approaches for challenging inspections
• Major advantages for detection of small, difficult to detect flaws/microstructural damage
• Developed statistical based dynamic range setting on images to avoid false calls
• ADG authored influential paper on using statistical interpretation of PCI data to make industrial inspection practical

PCI - High Temperature Hydrogen Attack (HTHA)

• Phase Coherence essential for imaging earlier stages of HTHA
• Proven on verified samples (from Lavender International)
• PCTFM with automatically set dynamic range keeps from false calling grain noise

Deployment: PCI for HTHA Inspection

• Industry first HTHA inspections with phase coherence performed in January 2022 by Acuren/Eclipse
• Phase coherence imaging identified significant material impurities as well as region of possible HTHA

PCI: Creep Inspection

• Phase Coherence found to improve sensitivity to aligned voids, drastically improves SNR and suppress artefacts
• Proven on verified creep samples provided by EPRI

Deployment: PCI for Creep Inspection – Integrated in Acuren’s HEP Program

PCI for Thermal Shock Crack Inspection

• Thermal shock cracks are difficult to detect: tight, variable orientation
• PCI found Sensitivity to some cracks verified by destructive testing
• Field inspection performed at client site, report submitted to TSSA in support of fitness for service assessment
• Components to be monitored with phase coherence going forward

PCI for Quality Control Applications: Induction Hardened Depth Estimation

• Developed improved method to measure hardened depth on raceways for SGRE
• Grain noise contrast on PCTFM image used to automatically compute HD
• Technique also found to be sensitive to flaws in hardened zone
• Currently developing prototype for Siemens Gamesa Renewable Energy for in factory inspections (2024)

PCI for Quality Control Applications: Accurate Crack Sizing

• Long, shallow cracks in bulk plates, cannot be inspected after painting
• Eddy current array can detect but cannot depth size cracks
• Cracks tolerable up to specific depth (1.3mm), need way to measure accurately
• Cracks detected by ECA accurately depth sized via tip diffraction (not feasible with TFM)
• Depth sizing accuracy verified to be within 0.2 mm
• To be implemented by client for in-factory inspections starting in 2024

Multi-Mode Phase Coherence Imaging Algorithms

• Mutli-mode PCI method merges results from all viable modes into a single high-resolution image
• Cracks often easy to detect but hard to size, position, characterize (even with advanced methods)
• Multi-mode PCI is ideal for accurate sizing and imaging crack morphology and orientation
• Ideal for accurate monitoring of crack progression to avoid shutting down too early

Deployment: Multi-Mode PCI for Characterizing Critical Flaws in Nozzles

• Critical toe crack inspection performed for client
• Difficult to confirm if flaw is toe crack from standard FMC/TFM image, can only see corner and tip
• New multi-mode approach showed expected profile of toe cracks previously observed

Deployment: Multi-Mode PCI for Characterizing Critical Flaws in Nozzles

• Profile of toe crack observed with multi-mode approach, confirmed by destructive testing

Highlights of Projects
Phase Coherence Imaging (PCI) Based Applications Anomaly Detection UT Data Analysis Based Applications FMC/TFM Based Inspection Applications Phased Array Based Inspection Applications Wind Turbine Blade and Main Shaft Inspection Applications Software Based Solutions

For more information, email us at rad@acuren.com
or call (519) 372-1831 and ask for one of our innovation experts