920-219A-EN

Phased Array Testing Machine• FlawDetection• WeldProfiling• AutomaticWeldTracking

INDUSTRIAL NDT SYSTEMS

In-Line ERW Tube Inspection

2 www.olympus-ims.com 3

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In-line Testing MachineThe Olympus mechanical solution for ERW pipe inspection is based on an small automated bridge (gantry type) that positions the inspection head in-line or off-line when performing inspections, auto-matic calibrations, or maintenance operations.

Flaw Detection A cylindrical phased array probe is located on each side of the weld to inspect in both clockwise and coun-terclockwise directions. The UT beams are electronically steered to generate the desired refraction angle in the tube radial direction.

Weld Profiling and TrackingA cylindrical phased array probe lo-cated on the weld fires at zero degrees. The scarfing is automatically monitored and the weld is profiled to create a true side view of the weld for fast profile analysis.

Water Wedge ConceptEach inspection head is designed with a unique Water Wedge mechanical concept providing many degrees of freedom in order to follow pipe movement and maintain perfect coupling.

This versatile concept enables different types of probe holders and cylindrical PA probes to be used when inspecting different pipe sizes. Wear plates that can be attached to the inspection head are also available in different sizes to fit each pipe diameter.

Pneumatic suspension enables the inspection head to follow the pipe movement and raise the Water Wedge if there is a scarfing window or butt weld between coils. The head rotation capability allows each probe independent movement from –120 to +120 degrees.

Phased Array compared to Conventional UTConventional UT InspectionWhen two conventional UT probes are used on each side of the weld (one for ID and the other for OD inspection), only a very narrow zone in the center of the HAZ is covered at 0 dB attenuation. As such, the UT probe’s beamwidth profile shows maximum amplitude only in the center of the probe and rapidly decreases on each side. Slight mechanical movement (position-ing) can result in high variations of detection amplitude.

Phased Array InspectionUsing only one PA probe on each side of the weld provides wide sector cover-age of the HAZ with constant amplitude. This unique solution provides con-stant amplitude detection within the entire inspection area, even when there is significant mechanical movement (positioning).

Automatic CalibrationThe calibration sequence is performed by mov-ing each probe over a reference defect on the calibration tube (no tube rotation) to automati-cally compensate the gain of each beam for each detection gate. The calibration check sequence displays each calibration tube defect in an easy-to-interpret strip chart and weld-mapping view.

Calibration BenchThe Calibration Bench is an optional stand designed to per-form automatic calibration and calibration check sequences at standard inspection speeds.

Phased Array Weld Inspection ConceptWith Phased Array technology, a linear electronic scan is performed by moving the acoustic beam along the axis of the array without any mechanical movement. The beam movement is performed by time-multiplexing the active elements.

Automatic Weld TrackingUnique patented algorithm based on time-of-flight analysis perform automatic detection of the scarfing area and send feedback to the PLC to automatically adjust the inspection for each water wedge.

In-Line ERW Tube Inspection System

48 Woerd Avenue, Waltham, MA 02453, USA, Tel.: (1) 781-419-390012569 Gulf Freeway, Houston, TX 77034, USA, Tel.: (1) 281-922-9300

505, boul. du Parc-Technologique, Québec (Québec) G1P 4S9, Tel.: (1) 418-872-11551109 78 Ave, Edmonton (Alberta) T6P 1L8

www.olympus-ims.com

info@olympusNDT.com ERW_EN_201011 • Printed in Canada • Copyright © 2010 by Olympus NDT.*All specifications are subject to change without notice. All brands are trademarks or registered trademarks of their respective owners and third party entities.

isISO9001and14001certified.

UT

Advanced SoftwareAs part of the system, Olympus offers PCs fully-configured with QuickView InLine, an advanced software used for system setup, acquisition, and data management.

QuickView includes a wizard for user-friendly creation of setup files. The inspec-tion configuration and calibration param-eters for each pipe diameter are saved, and reloaded by the operator before each batch inspection. Final inspection results are merged and displayed in order to differenti-ate between accepted and rejected tubes.

Testing InstrumentationThe electronics of the phased array inspec-tion system are based on the QuickScan™ LT PA (16:256 or 32:256) unit. These electronics meet IP 55 standards and are designed for easy integration in the indus-trial environment.

Inspection System SpecificationsProduct Range and Inspection Speed

Diameter 60 mm to 245 mm (2.375 in. to 9.625 in.)

Wall Thickness 3 mm to 16 mm

Inspection Speed Up to 1.5 m/s (295 ft/m)

Inspection Coverage

Weld Sector Coverage At least 25 mm for entire product range (adjustable)

Axial Pulse Density (APD) 1 mm (adjustable)

Weld tracking capacity -90º to +90º

Data Presentation

Real-time inspection result C-scan, strip charts, and alarms

Parameter setup A-scan, B-scan

Inspection layouts 20 different user-configurable layouts

Inspection Modes*

Typical Inspection Modes45º, 60º, 70º (typical inspection configuration: 45º pulse-echo mode and 45º pitch-catch mode)

Firing Modes Pulse-echo, pitch-catch

Inspection Mode ConfigurationSeveral inspection modes can be performed simulta-neously on the same PA probe.

Detection Capabilities for Typical Reference Defects

API References

1/2 in./1 in. (12.7 mm/25.4 mm) N10 and N5, ID and OD longitudinal notches1/8 in. (3.2 mm) through drilled hole (TDH)1/16 in. (1.6 mm) TDH

Non-API References

1/32 in (0.8 mm) TDH1/8 in. (3.2 mm) half wall drilled hole1/16 in. (1.6 mm) half wall drilled hole1/32 in. (0.8 mm) half wall drilled hole

Minimum SNR 9 dB to 12 dB

RepeatabilityLID/LOD notches: ≤ 1.5 dB1/8 in. (3.2 mm) TDH: ≤ 2.0 dB1/16 in. (1.6 mm) TDH: ≤ 2.5 dB

Reporting and Data Storage

Report typesInspection, calibration, and calibration-check user-configurable reports

Storage Real-time database inspection data storage* The inspection modes mentioned are the most typical. Intermediate angles can be easily created with the Setup

Wizard.

Specific Product FeaturesWeld tracking: Automatic tracking of the weld area

Weld profiling: Real-time weld-profile visualization

Calibration: Automatic calibration sequence

Calibration check: Automatic calibration check at production line speed

Defect marking: Automatic defect marking

Intelligent data storage: Data synchronization with “flying saw”

Data communication: DCOM exchange protocol with production line level 2 software

Diagnostics: Full system diagnostics using HMI and QuickView

Safety: Automatic detection of scarfing window and butt weld between coils