automation of eddy current processes for ndt

Automation of Eddy Current Processes for NDT Inspections

1© Zetec Inc. – All rights reserved

Agenda

• Industry observation and call for change

• Philosophy of our technical approach

• Introduction of our solution

• The foundation of technology

• Field Implementation

• Benefits & Summary

© Zetec Inc. – All rights reserved

• Inspections are benefiting from advancements in technologies, providing better performance with higher capabilities than even ever before

– Improved sensors with more elements

– Faster instrumentation with more channels

– Improved signal to noise ratio for better detection

– Higher portability and reliability

The State of Inspections


The Impact on Data Analysis

• Zetec saw a convergence of events indicating a need for technology in the analysis of data

– Aging of the analyst workforce shrinking availability

– Advanced sensors and instrumentation are delivering more data at faster rates

– Improved signal quality is driving analysis to lower levels

– Economic pressures on asset owners to reduce costs and schedules while improving inspection performance


• Project managers are struggling to assemble analysis teams

• Inspections windows have shortened

• Analysts are scanning more data than ever

Attention span per flaw has dropped

The Impact on Data Analysis

5

Analysis


The Customer Perspective

• Inspection schedules

• Staffing challenges

• Accuracy of results

• Control of process

• Cost of inspection


The Solution Goals

• Harness technology to automate the analysis process

• Address inconsistencies in the human component

• Answer the challenge of increased data and acquisition speeds

• Provide transparency and control of the automated analysis process

• Develop an architecture of flexibility to address near and future needs


RevospECT PRO AUTOMATED ANALYSIS SOFTWARE

POWER YOUCONTROL


Voice of the Customer

• Need a software solution high in capability but low in complexity

• Need commercial availability with flexible deployment options

• Need control points for reliability but easy to adjust through process


RevospECT PRO

Industry’s first to include:Commercially availableHigh poweredAdaptabilityScalabilityEnd user controlEasy to implement

Automated eddy current analysis software


Distributed Processing

Distributed Processing Farm

Analysis Workstations

Scheduler

ResultsDatabase

• Scalable architecture

• Process orientated

• Centralized control


Distributed Processing

• Provides performance regardless of the complexity of analysis techniques applied

• Handles bolting on future technologies without performance penalties

• Supports auto re-evaluation post inspection


Analysis Capsules• Analyzers detect and classify signals

• Often multiple analyzers are required for a specific reporting type

• A capsule is a logical grouping of analyzers based on reporting type

• Multiple capsules are grouped into a configuration to meet analysis guidelines

13

Final Acceptance

DetectMeasureClassify

ReportingType




CustomConfiguration

Capsule B

Capsule C

AnalysisCapsule

Capsule A


Analysis Capsules

DistributedProcessing

Final Acceptance

Capsule A

Capsule B

Capsule C

CustomConfiguration

Results

EC Data

Reporting

RevospECT Pro Software

14

• Configurations are loaded into the RevospECT Pro system

• Processing of analysis combines available ECT data with configurations and schedules for processing

• Analysis results flow to Final Acceptance for rationalization and reporting


Analysis Capsules

• Capsules provide a logical grouping of multiple analysis methods

• User adjustments are available to modify thresholds to meet reporting objectives

• Additional capsules can be added to extend the value of the configuration


Final Acceptance

• Multiplicity in analysis creates multiple results

• We developed a logic engine for processing volume of signals detected

• Clear logic rules are applied to rationalize to a final answer

• Final results are saved to the final report


Final Acceptance

• Automation provides performance regardless of production volume

• Final Acceptance logic provides consistency in the results

• Human performance variations are minimized


Augment traditional degradation analysis with full-tube automated change analysis using Historic Data Compare (HDCTM)

• HDCTM has been site qualified for full-tube degradation detection– Passed site SSPD exam for free span and structure regions

• Structure wear at supports• Loose part wear at free span• Tube to tube wear in free span• Loose part detection in free span

Change Analysis


Change Analysis

19

CurrentHistory

Baseline

• Processed correlation of data

• Supports multiple outages

• Provides clear visualization of signal morphology


Change Analysis

20

Current

Baseline Delta• Processed correlation of data

• Supports multiple outages

• Provides clear visualization of signal morphology

• Two channel subtraction creates Delta Channel


Change Analysis

• Powerful visualization improves flaw analysis

• Automated delta channel analysis is an independent and complementary analysis method

• Multiple outage evaluation provides for auto addressing of history


The RevospECT Solution

• Improves overall detection

• Analysis is close to acquisition

• Requires fewer resources

• Provides focus on the critical flaw


RevospECT Implementation

• Architecture provides application to multiple inspection modes

• Seven years experience in Steam Generators

• Experienced team of configuration support analysts


973

Hours

Proven Performance

Reduced byup to 83%

132 Hours

53Staff

Reduced byup to 45%

Analysis Team Analysis Schedule

• Specific Customer Results:

– 2009 to 2016


RevospECT Engineered to Order

• Applied to RCCA inspection application

• Applied to condenser tubing

• Looking at RFT, surface eddy current, and UT applications


Summary

26

Commercially availableHigh poweredAdaptabilityScalabilityEnd user controlEasy to implement

Cost ManagementOutage ExcellenceOperational ExcellenceOperational ExcellenceOperational ExcellenceCost Management

RevospECT PRO AUTOMATED ANALYSIS SOFTWARE


Thank You!

Learn more at: www.zetec.com/revospect-pro/

automation of eddy current processes for ndt

Data & Analytics