NDT PV100 series
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For more on the PV100 Series: http://bit.ly/1vD0zTw The PV Series is a solution package with different configurations to meet customer’s applications The PV Series solutions include: Acquisition unit Scanner Applicable Accessories Setup and Analysis Tools View our presentation to learn how this package is easy to use and can be a great inspection tool for those in manufacturing and welding. Contact us: http://bit.ly/1rDmq94 Sign up for our newsletter: http://bit.ly/1j5FOTy
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NDT PV100 series
- 1. Olympus NDT PV100 Series Nicholas Bublitz Global Products Support Specialist
- 2. PV Series Description The PV Series is a “solution” package. Different configurations can meet customer’s applications.
- 3. PV (Pressure Vessel) Series Description The “PV” Series solutions include: – Acquisition unit – Scanner – Applicable Accessories – Setup and Analysis Tools
- 5. Applicable Customers and Codes ♦ PV100 is predominately geared towards the following two customers – Manufacturing companies utilizing AWS, API and ASME codes for weld inspection (pressure vessels, piping etc.).* – Service companies performing weld inspection to AWS and ASME and API requirements* *and other codes outside North America
- 6. Wind Tower Manufacturers ♦ Typically inspected with manual shear wave to AWS D1.1, a typical tower weld is 14-40’ in circumference taking hours to manually inspect a single weld with no record of data ♦ Radiography is often used as well. Besides disruption of production or movement of parts to a safe area, radiography does not provide depth information for repairs
- 7. Service Providers ♦ Many manufacturing weld inspection services are outsourced to an outside source. ♦ Also, many welds in oil and gas, structural and other industries require regular inspection to ensure safety. ♦ AUT systems like the PV100 series offer many unique advantages over more conventional ultrasonics and radiography.
- 9. PV100 Description ♦ PV100 is a generic description for a weld inspection package utilizing more conventional ultrasonic techniques (Shear wave, TOFD, Creeping Wave) ♦ Package tools are determined predominately by wall thickness and code conformance ♦ Although we use PV100 generically, there are actually several packages available based upon customer requirements (PV100-101-102)
- 10. PV100 Technique ♦ Technique varies on applicable code requirements and wall thickness – PV100 Wall thickness ~10-30 mm – PV101 Wall thickness ~30-160mm – PV102 Wall thickness ~150-300mm ♦ Application Example: Typical wind towers have a thickness range of 12 – 46mm. They might utilize both the PV100 and 101 techniques.
- 11. PV100 Ultrasonic Techniques ♦ PV100 incorporates TOFD for the volume and shear wave Pulse Echo for the weld cap and root (from each side) ♦ PV101 incorporates 2 channels of TOFD (volume and root) and Creeping wave for the weld cap ♦ Other configurations of these and other conventional ultrasonic methods (refracted longitudinal wave etc.) may still be referred to as PV100 generically
- 12. TOFD ♦ Uses send and receive probes ♦ The incoming wave vibrates the defect and emits energy in all directions ♦ The receiver gets one or more signals from the defect
- 13. Wave Propagation FLAW Diffracted waves Diffracted waves Incident wave Reflected wave All directions - Low energy - Independent of incidence angle
- 14. TOFD Limitations Blind areas : – Near surface Due to the width of the lateral wave as well as timing inaccuracies Can be reduced by reducing PCS, using higher frequency probes, incorporating highly dampened broadband transducers, as well as software tools (lateral wave removal). These minimize, but do not eliminate the near surface dead zone. – Back wall Large signal from reflected energy at the back wall creates a dead zone as well
- 15. Recommended Solution ♦ TOFD is a very good tool for weld inspection. ♦ However, it does have some limitations, Pulse Echo can cover these limitations. ♦ SOLUTION: Incorporate both TOFD and PE simultaneously ♦ Pulse Echo channels can be targeted on the cap and root, TOFD’s weak spot for a full volumetric inspection.
- 17. TOFD Data ♦ Side View ♦ Grey scale palette ♦ Sized with cursors Top Volume Back Wall
- 18. PV100 Principles A combination of both TOFD & Pulse-echo channels, proves to cover the weld zone generously when setup correctly
- 19. PV101 Technique ♦ PV101 adds multi-zone TOFD with the addition of the creeping wave technique ♦ This is implemented to address possible poor detection and sizing with pulse echo at the top on thicker material ♦ Creeping waves are designed to cover just a few millimeters below the surface for defects.
- 20. Radiography Replacement ♦ The PV series is suitable for codes where radiography replacement by ultrasonics is allowed ♦ Some of the benefits include no radiation hazards to contend with, no need to stop other productions, and height sizing
- 21. PV100 Main Solution Components ♦ NDT Setup Builder ♦ Scan plan Design Software ♦ Setup imported directly into OmniScan
- 22. PV100 Main Solution Components ♦ OmniScan MX2 8 channel acquisition unit ♦ TomoView or OmniPC Analysis software
- 23. PV100 Main Solution Components ♦ Mechanical Scanner – HSMT-FLEX or X03 for semi-automated requirements – WeldROVER for automated requirements
- 24. PV100 Main Solution Components ♦ Couplant Delivery – Water Sprayer – manually operated – CFU – automatic water flow system
- 25. PV100 Main Solution Components ♦ Offline Analysis – Laptop or desktop computer – Latest version of OmniPC or TomoView analysis software
- 26. PV100 Main Solution Components ♦ Accessories (variable) – Probes/wedges – Spare parts – Umbilicals/cabling – Preamplifiers – Calibration and performance blocks
- 27. Reporting The Olympus NDT OmniPC and TV software offer the ability to thoroughly analyze acquisition data. In addition they also provide a full suite of reporting tools
- 28. Performance/Calibration Blocks ♦ Used to calibrate system and define performance ♦ Used to validate technique over required range ♦ Used to test and validate operators ♦ Typically contains notches and SDH in pattern displaying coverage and effective detection and sizing capabilities
- 29. For additional information or to download a product brochure please visit: http://www.olympus-ims.com/en/pv-100/ Thank you!
Editor's Notes
- The PV Series of solutions are designed to offer improved weld inspection equipment for a variety of customers from manufacturing to in service. It has been very successful in the wind tower manufacturing market and for replacement of radiography applications. It can be applied to a wide range of applicability of diameters and wall thickness as seen in this slide.
- The PV100 is a complete product offering geared toward circumferential weld scanning with encoded data. The solution is made up of an acquisition unit, a scanner, all applicable probes and wedges and other accessories, as well as setup and analysis tools. The actual components can vary by customer applicable components, codes, and other needs. The solution is either a semi-automatic (encoded but operator driven) or fully automatic solution. PV stands for pressure vessel as it was originally derived to fulfill pressure vessel oriented codes like ASME CC 2235-9.
- Olympus NDT employs several different ultrasonic techniques pictured above. The PV 100 series of techniques focuses on Pulse echo, Time of Flight Diffraction, and the use of Creeping wave transducers as required. More detail on these techniques will be shown in later slides.
- The PV100 solution is primarily geared towards two customers: Customers who manufacture new welds and service companies who inspect welds that have already been put into service. The most common codes governing these type of welds in the United States are AWS, ASME, and API. Common applications include: pressure vessels (ASME Section I/VIII Div I and II/XII), as well as structural welds like the windmill tower base shown here which is usually governed by AWS D1.1.
- Wind Mill Tower base customers usually fall into one of two categories, either the manufacturing or sub-manufacturing companies. These companies often are already inspecting the welds with conventional flaw detectors and/or radiography as well as possibly magnetic particle and liquid penetrant inspection. Manual shear wave of these very large weldments can take hours since the outside diameter of various sections typically varies from 14 to 40 feet. The typical output from manual inspection is a signed report with no auditable data. Radiography, while able to produce an auditable output, has several disadvantages including: safety, the need to clear an area or move the component and a lack of depth and height of flaw information.
- Inspection companies are also a great potential customer for the PV100 Solution.
- PV100 is a generic term used freely to represent a scanning solution utilizing the combination of conventional pulse echo shear wave techniques along with TOFD (Time of Flight Diffraction) to provide volumetric weld inspection for in-service and newly manufactured welds. Based on code and coverage requirements other techniques (Creeping wave, double zone TOFD etc.) can also be part of the total PV solution. There are actually several pre-packaged solutions to start from when examining a customer’s requirements. They are split up by the thickness of the weld to be inspected and can be tailored to fit any number of other customer requirements as needed.
- As mentioned the PV100 can vary in the exact technique employed. The main deciding factor is code requirements and part thickness. The main techniques for most thicknesses are TOFD and shear wave pulse echo. As the thickness increases we utilize other techniques like creeping wave and focused sets of Tofd to comply with the code and get sufficient coverage. Typical wall thicknesses seen for wind mill tower bases is 12-46 mm, but can vary by tower design and manufacturer.
- Tofd is used as the primary technique in the basic PV100 technique to cover the volume of the weld. Shear wave at varying angles are then used to compliment this technique to cover the uppermost and bottom most portions of the weld (Cap and Root). As the materials get thicker it may be necessary to utilize a PV101 approach of dual Tofd (volume and root) and creeping waves for the top surface. Special applications may include other ultrasonic techniques including refracted longitudinal waves which is common for austenitic material, these also may be referred to generically as PV100 packages.
- Tofd or Time of Flight Diffraction utilizes diffracted energy versus the commonly utilized reflection technique of shear wave inspection. Using a send transducer to input the sound into the material on one side of the weld and a receive transducer on the opposite side of the weld to “listen” for any sound diffracted off any weld anomalies. Because of its wide beam nature of tofd we are able to cover large areas of the weld with a single pair of Tofd transducers.
- The technique lends itself to be very sensitive to all weld anomalies regardless of orientation unlike pulse echo techniques. Once a discontinuity is struck it will vibrate and it will emit diffracted energy in all directions allowing it to be readily detected. Height and length measurements can also be more precise than reflection techniques since the TOF or time of flight is analyzed versus the amplitude of the reflected energy.
- Tofd is relatively assumed industry wide to have two weak areas because of the wave physics, one near the top surface , and one at the far surface or back wall of the component. Although these can be minimized they always exist to some extent.
- To overcome the weakness at the near and far surfaces, pulse echo shear wave transducers are focused at the cap and root areas. When we combine these techniques we arrive at the PV100 solution, full volumetric weld inspection.
- The PV100 solution follows this technique, allowing for simultaneous cap, root and volume inspection giving full coverage with a single data set. All probe positions and angles are input linking the individual channels into a single acquisition file in one scan or pass around or down the weld. When either acquired or post analyzed in TomoView software all channels are visible at one time. Here we see a typical PV100 inspection in the TV Software program.
- Side Views (B or D scans) are typically utilized for both the Tofd and shear wave channels. Once a defect is identified it would be measured with cursors for its length and thru-wall height with acceptance/rejection criteria applied.
- When employing the PV100 system, all setups can be saved into the OmniScan for recall when applicable. For probe positioning companies with common welds usually produce a setup chart to facilitate changing from one weld configuration to another. Because of the wide beam nature of Tofd a single set of probes and wedges can cover a large range of thicknesses without the need for changing out equipment. Here we can see the sections from 14 mm to 25 mm all being covered with the same type of Tofd and shear waves probes and wedge angles at different index positions (position from center of weld). Procedure development programs like NDT Setup Builder facilitate proper probe and wedge selection and placement.
- As mentioned previously, as welds get thicker we often use creeping waves to assist in code compliance and coverage. Here a scanner is shown utilizing Tofd at both the root and volume and a pair of creeping wave transducers covering the very top of the weld. The creeping wave transducers are designed and setup to cover only a few millimeters below the surface where the first zone of Tofd will have a weakness. By refocusing the second pair of Tofd lower into the volume we are able to get sufficient coverage and detection at the back wall area.
- It has been very popular in recent years to use AUT techniques to replace radiography applications. Ultrasound lends itself to safe deployment without interrupting work going on around it. It also offers accurate depth and thru wall height sizing which often can allow for fracture mechanics or ECA criteria to be applied. With radiography the depth and height of the discontinuity are often unknown . Shown here is a comparison of the Tofd technique and radiography technique on the same weld specimen.
- Typically the first part of an encoded PV100 examination is designing a scan plan to ensure coverage and detection capability. The part is drawn in and the applicable transducers are placed accordingly. This is usually also a code requirement to document this plan. With NDT Setup Builder this setup can then be imported into the OmniScan platform to do the acquisition.
- Typically the OmniScan platform with an 8 channel conventional ultrasound module is used for acquisition. It can be operated directly off the mainframe or driven by a laptop with the TomoView software. The main difference between choosing to use TomoView or OmniScan only for acquisition is data display while scanning. The OmniScan will offer a single channel view, while TV will allow for all acquisition channels to be viewed simultaneously while scanning. The OmniScan platform allows for further expansion into phased array Ultrasonics by changing the acquisition module while keeping the same general user interface.
- Typically only a semi-automatic scanner is required. The HTSM-Flex offers all the necessary probe holders and other capabilities to perform the PV100 technique, including space for a preamp for the Tofd channels, water manifold for Couplant delivery, magnetic wheels, and rulers for probe positioning. The HSMT-X03 is another option. It is also possible to utilize an automated scanner like the Weld Rover to perform PV100 techniques. An automated option will typically offer improved data as the acquisition speed and control of the scanner is more controlled then the manually driven semi-automatic scanners. Full details of each scanner option can be seen in the Industrial Scanner Brochure
- Water is typically utilized as Couplant to ensure adequate consistent coupling during the scanning. Regulated pumps like the CFU-03 can be used, or portable manual water sprayers can be used. In some environment additives can be added to keep the water from freezing.
- Post analysis of data can be done on the OmniScan but the use of a PC and analysis software is usually preferable. OmniPC or TomoView can be used for this purpose. OmniPC has the advantage of having the same user interface as analysis on the OmniScan itself so it is easy to use and requires little to no training. TomoView has some advanced processing tools like file merging and offline gain adjustment. These features are used often in phased array inspections but less in the typical PV100 application. A configured Industrial style laptop can be acquired with all the necessary software to analyze and report findings. Shown above is a typical data display in both OmniPC and TomoView. The shear wave channels are typically set to an amplitude response pallet, so defects reaching reject level can be easily discerned by color. Measurements can be quickly acquired by cursors and readings . The results can be reported directly out of either software into a Windows friendly format for easy distribution.
- Depending on the customer’s needs there are a lot of smaller components that typically go into a PV100 solution as well including: cabling, probes, wedges, spare parts etc. All necessary components can be identified based on the welds to be inspected so a total solution package is offered. If needs change, other accessories can be added later. Umbilical or divisible cable style wiring is typically used to group all the necessary inputs into one strand.
- Typically the length, height, amplitude and position of an indication are needed for reporting. These and other user selected readings are readily available and will be included on the report. The standard report can be customized with a variety of views and readings, or screenshots can be taken for custom reports in other software programs as needed.
- Performance and Calibration blocks are used to calibrate the velocity, wedge delay, sensitivity, as well as any material attenuation correction needed. They are also used to demonstrate that the technique is valid and to test operators ability to run the system and size defects adequately. These blocks typically cover a range of thicknesses, the number of blocks needed will depend on the welds being inspected and the procedure/code criteria. They typically use notches and Side drill holes (SDH) for calibration and demonstration capabilities. Typically one to two performance blocks will be required to cover a typical wind tower base manufacturers range of thicknesses, service companies may have to make job specific blocks as jobs are acquired. The location of calibration reflectors and other requirements of these blocks should be spelled out in the applicable procedure and codes.