Safety Advance inspections with phased array
Another parameter that has a large impact on the quality of the inspection – and therefore on the probability of detection – is the number of UT elements in one transducer. Conventional UT uses one-element transducers, but advanced inspections, such as those using imaging and sectorial scans, require a so-called ‘phased array’ of elements.
Phased array transducers work by using multiple elements, each of which produces its own UT waves. By carefully controlling each element, phased array flaw detectors such as the Olympus OmniScan MX2 (figure 4) can exert better control over the UT beam, allowing more precise inspection with a higher probability of detection (figure 5).
Combining the benefits of phased array and pitch–catch inspection, dual matrix array (DMA) probes can be used to enable the most comprehensive inspection of welds (figure 6). Among the benefits of DMA probes are imaging capabilities, sectorial scans and easy coverage of a weld without moving the probe back and forth. These benefits simplify inspection for an improved probability of detection.
Figure 5: The use of multiple-element transducers for transmitting and receiving helps to reduce noise in inspecting challenging materials.
A final drawback to the use of radiography for inspection of pipelines is the time it takes to create an image with sufficient brightness and contrast. Exposure times depend highly on the material and its thickness, but can take anywhere from a few minutes up to several hours.
Utilise the power of sound waves
Ultrasound (UT) inspection is a commonly used alternative to radiography for inspecting welded components. UT works by generating high-frequency sound waves, which travel unimpeded through many uniform materials, but deflect off boundaries between different materials, such as flaws. This phenomenon makes ultrasound highly suitable for flaw detection.
There are different setups available to carry out pipeline inspection using UT, depending on the resolution and noise levels required. One of the main choices when using UT is between a pulse–echo and pitch–catch configuration. In a pulse–echo configuration, a signal is detected by the transducer that also emits UT waves; the pitch–catch technique uses two separate transducers. The pitch– catch technique, also known as the transmit–receive longitudinal (TRL) technique, produces a less noisy signal when inspecting difficult materials.
When it comes to inspecting complex welds, such as dissimilar- material welds, the accuracy and precision of phased array probes improves flaw detection. Phased array gives the operator more control over the beam and DMA probes with different frequencies can be used depending on the type of material to be inspected. For example, low-frequency 1.5 MHz probes are suitable for inspections where wave propagation is challenging, such as materials with a large grain size.
Figure 6: A DMA probe consisting of two transducers, each containing 28 elements
Faster and safer weld inspections
Ultrasonic phased array inspection for large-scale weld inspections can offer important benefits over radiography. The main benefit of ultrasound is safety: the absence of X-rays means that there is no need to clear the area around the inspection site. Not only does this improve safety for staff, it also causes less disruption to other activities in the area.
With respect to precision, ultrasound can offer superior probability of detection of certain weld defects compared to radiography. For example, when it comes to detecting lack-of- fusion defects, the orientation of the defect can be misaligned with respect to the direction of the X-ray radiation, which leads to low contrast in radiography.
The speed of inspection is also an important consideration when selecting inspection equipment. This is also an area in which ultrasound offers benefits; typical ultrasonic inspections can be completed quickly with data analysis performed on-site. The speed of radiographic inspection is highly dependent on exposure times, which can be anywhere from a few minutes up to several hours for one weld, depending on the material of the weld.
Summary
Regular inspections of pipelines improve safety for staff and prevent costly failures and the associated repairs. NDT is well suited for inspecting pipelines on a large scale. Radiography has long been the gold standard for pipeline inspection, but comes with important safety concerns – as well as problems with the detection of certain defects such as lack of fusion.
A setup using UT flaw detectors, such as OmniScan MX2, and phased array DMA probes has the capability to inspect large sections of pipelines quickly, reliably and without the use of harmful radiation. It also offers high probability of detection in hard-to-inspect locations such as dissimilar-material welds. These benefits mean that UT scans are less disruptive and improve safety in industrial pipeline inspections.
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Author Details Thierry Couturier, Senior Product and Applications Specialist – Ultrasound and Phased Array, Scientific Solutions Division, OLYMPUS EUROPA SE & CO. KG • Amsinckstraße 63, 20097 Hamburg, Germany • Tel: +49 40 23773 0 • Email:
scientificsolutions@olympus-europa.com • Web:
www.olympus-ims.com
Intrinsically Safe, Wireless Flow Totaliser Provides Field Display of Flow Rates and Totals from Flow Meters
SignalFire Wireless Telemetry introduces a new Intrinsically Safe Wireless Flow Totalizer that connects to industry-standard inductive turbine flow meters (such as the AW-Lake TW Turbine) to measure, locally display, wirelessly transmit and archive flow measurements. Data and diagnostics are available locally using the display as well as remotely from a SignalFire Gateway using Modbus standard protocol.
Enhancing new or existing turbine meters with wireless data management capabilities, the SignalFire Flow Totaliser is ideal when an operator must check flow rates or totals in addition to tracking data in a SCADA system. For example, when offloading a tank, a local technician can use the Wireless Flow Totalizer to measure before/after totals of pumped fluid. Using an external pushbutton, workers can cycle through a backlit LCD display to get appropriate readings for flow and total.
Scott Keller, Founder and General Manager of SignalFire Wireless Telemetry, notes “We designed the Wireless Flow Totaliser to easily fit on standard turbine type meters to report daily flow volumes, minimising complex programming by the system integrator.”
Featuring a built-in user-configurable, real-time clock for daily contract hour setting, the Flow Totaliser maintains an internal thirty- day log of daily flow totals for historical analysis or backup storage. Units are battery-powered for long life (5+ years) and require no external power supply. Enclosed within a weathertight, high-strength polycarbonate housing that withstands outdoor elements, the Intrinsically Safe Wireless Flow Totaliser is hazardous location classified for Class 1, Division 1 safe operation. Easy to install and maintain, units are ideal for use in the oil & gas, metals & mining, water & wastewater, chemical, power, food & beverage, pulp & paper, aerospace and pharmaceutical industries.
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PROFINET I/O Now Available for Leading Range of Electromagnetic Flowmeters
As new Industrial Ethernet communication option, PROFINET I/O is now available for Krohne’s electromagnetic flowmeters with IFC 300 signal converter. This includes all compact and field versions of the Optiflux x300 series (except Optiflux 7000), Waterflex 3300 and Tidalflux 2300.
With PROFINET I/O, all measuring, process and diagnostic information from the meters is available real-time via a single communication channel, allowing for direct and convenient integration of new meters, direct identification of defective devices as well as bidirectional communication and parameter setting. Other advantages include reduced costs for wiring and connecting hardware since PROFINET uses standardised and homogenous Ethernet infrastructure from field devices to control room.
In collaboration with Phoenix Contact, Krohne has published the whitepaper “Ethernet-Based PROFINET Integration of Field Instruments in the Water and Waste Water Industry”. The free whitepaper explains the background of PROFINET and its benefits in more detail and shows different network topologies.
ANNUAL BUYERS GUIDE 2018 •
WWW.PETRO-ONLINE.COM
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