Download - Automation of Eddy Current Processes for NDT
Agenda
• Industry observation and call for change
• Philosophy of our technical approach
• Introduction of our solution
• The foundation of technology
• Field Implementation
• Benefits & Summary
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• 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
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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
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• 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
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Analysis
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The Customer Perspective
• Inspection schedules
• Staffing challenges
• Accuracy of results
• Control of process
• Cost of inspection
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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
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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
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RevospECT PRO
Industry’s first to include:Commercially availableHigh poweredAdaptabilityScalabilityEnd user controlEasy to implement
Automated eddy current analysis software
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Distributed Processing
Distributed Processing Farm
Analysis Workstations
Scheduler
ResultsDatabase
• Scalable architecture
• Process orientated
• Centralized control
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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
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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
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Final Acceptance
DetectMeasureClassify
ReportingType
DetectMeasureClassify
DetectMeasureClassify
DetectMeasureClassify
CustomConfiguration
Capsule B
Capsule C
AnalysisCapsule
Capsule A
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Analysis Capsules
DistributedProcessing
Final Acceptance
Capsule A
Capsule B
Capsule C
CustomConfiguration
Results
EC Data
Reporting
RevospECT Pro Software
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• 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
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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
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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
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Final Acceptance
• Automation provides performance regardless of production volume
• Final Acceptance logic provides consistency in the results
• Human performance variations are minimized
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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
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Change Analysis
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CurrentHistory
Baseline
• Processed correlation of data
• Supports multiple outages
• Provides clear visualization of signal morphology
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Change Analysis
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Current
Baseline Delta• Processed correlation of data
• Supports multiple outages
• Provides clear visualization of signal morphology
• Two channel subtraction creates Delta Channel
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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
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The RevospECT Solution
• Improves overall detection
• Analysis is close to acquisition
• Requires fewer resources
• Provides focus on the critical flaw
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RevospECT Implementation
• Architecture provides application to multiple inspection modes
• Seven years experience in Steam Generators
• Experienced team of configuration support analysts
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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
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RevospECT Engineered to Order
• Applied to RCCA inspection application
• Applied to condenser tubing
• Looking at RFT, surface eddy current, and UT applications
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Summary
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Commercially availableHigh poweredAdaptabilityScalabilityEnd user controlEasy to implement
Cost ManagementOutage ExcellenceOperational ExcellenceOperational ExcellenceOperational ExcellenceCost Management
RevospECT PRO AUTOMATED ANALYSIS SOFTWARE
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