PV (Pressure Vessel) 200 Series Description
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For more on the PV200 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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PV (Pressure Vessel) 200 Series Description
- 1. Olympus NDT PV200 Series Nicholas Bublitz Global Products Support Specialist
- 2. PV Series Description The PV Series is a “Solution” package. Different configurations can be configured to meet customer’s applications
- 3. PV (Pressure Vessel) Series Description The “PV” Series solutions include: – Acquisition unit – Scanner – Applicable Accessories – Setup and Analysis Tools
- 6. PV200 Description ♦ PV200 is a generic description for a weld inspection package utilizing Phased Array and Tofd techniques. ♦ Package tools are determined predominately by wall thickness and code compliance
- 7. PV200 Technique ♦ PV200 incorporates Phased Array ultrasonics ♦ PV200 usually also incorporates Tofd ♦ In some case other techniques like Creeping waves may be required but it is less common
- 8. Technique Overview: Brief Phased Array and Tofd Theory
- 9. What is Phased Array? ♦ Advanced Ultrasonic technique used for flaw detection, sizing, and imaging. ♦ Allows for electrical manipulation of probe characteristics by introducing time shifts to sent and received signals ♦ Utilizes multi-element (array) probes for increased capabilities over conventional ultrasonics.
- 10. Advantages of Phased Array ♦ Electronic scanning (raster) possible without moving probe. (linear or E- scans scans) ♦ Increased control of beam characteristics. ♦ Simultaneous inspection with multitude of angles using one probe (sector scanning) ♦ Can better inspect complex geometries or limited access areas. ♦ Can replace costly and hazardous radiography applications.
- 11. Sector Scans Phased Array Sector Scan Channel - Defined as different focal laws (A-scans) at different angles being generated by the same group of elements on the same channel. Sector Scan Advantages Allows use of small probes and provides large coverage area from small footprint Provides higher level of detection, flaw sizing and flaw characterization Can provide full volumetric inspection in one channelone acquisition on most welds thinner than 25mm Flaw detection and sizing less dependent on orientation due to multi-angle coverage
- 12. Linear or E-scans Scans Phased Array Linear (E-Scan) Channel - Defined as the same focal law (A-scan) being multiplexed across a series of different elements resulting in the equivalent of a conventional raster scan. Linear (E-scan) Advantages 1:1 match for conventional UT raster scans and procedures. Only different in how the data is acquired. Analysis is exactly the same. Provides fast and easy set up and calibration for amplitude based inspection criteria. Easy analysis for codes that do not require flaw characterization
- 13. Encoded Phased Array ♦ Phased Array can offer a high level of detection and sizing capability and retainable data.
- 14. 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
- 15. Wave Propagation FLAW Diffracted waves Diffracted waves Incident wave Reflected wave All directions - Low energy - Independent of incidence angle
- 16. TOFD Limitations Blind areas : – Near surface The lateral wave travels below the surface, it is not a surface wave causing a small “dead zone” near the surface – Back wall Large signal from reflected energy at the back wall creates a dead zone as well
- 17. TOFD Data ♦ Side View ♦ Grey scale palette ♦ Sized with cursors Top Volume Back Wall
- 18. 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
- 20. PV200 Main Solution Components ♦ NDT Setup Builder ♦ Scan plan Design Software ♦ Setup imported directly into OmniScan
- 21. PV200 Main Solution Components ♦ OmniScan MX2 – Portable and modular – Easy to use interface – Setup Wizards – Ray tracing and weld overlays – MultiGroup capability (up to 8 Groups)
- 22. PV200 Main Solution Components ♦ Mechanical Scanner ‒ Magnetic wheel based ‒ Chain link based ‒ Semi-Automatic ‒ Fully Automatic
- 23. PV200 Main Solution Components ♦ Couplant Delivery – Water Sprayer – manually operated – CFU – automatic water flow system
- 24. Probes and Wedges ♦ Vary by customer need, thickness, material etc. ♦ Typically use IHC (irrigation ports, holes for scanner arms, carbide feet) ♦ Curved wedges required on pipes etc.
- 25. PV200 Main Solution Components ♦ Accessories (variable) – Spare parts – Umbilical/cabling – Preamplifiers – Adapters and extensions
- 26. Analysis Software Analysis can be done ‒ On board the OmniScan ‒ In OmniPC on a PC ‒ In TV Software on a PC
- 27. Reporting Reporting is usually done in a “table of indications” manner with images of indications and associated readings Similar HTML report from all analysis options Easy email able and Windows friendly Ray-Tracing, weld overlays etc. help comprehension and characterization.
- 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. Applicable Customers and Codes ♦ PV200 is predominately geared towards the following two customers – Manufacturing companies utilizing AWS and ASME and API codes for weld inspection* – Service companies performing weld inspection to AWS and ASME and API requirements* *and other codes outside North America
- 30. For additional information or to download a product brochure please visit our website: 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 inspection. It has a wide range of applicability to various diameters and wall thickness as seen in this slide. It has been a very useful solution for replacing conventional ultrasonic methods as well as radiography inspections.
- The PV100 is a complete product offering geared toward 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.
- Olympus NDT employs several different ultrasonic techniques pictured here. The PV 200 series of techniques focuses on Phased Array and Time of Flight Diffraction and can include the use of Creeping wave transducers as required. More detail on these techniques will be shown in later slides.
- PV200 is a generic term used freely to represent a scanning solution utilizing the combination of phased array and Tofd techniques (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 etc.) can also be part of the total PV200 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.
- For many application phased array alone can provide sufficient coverage and detection capabilities. Tofd is often added as an additional tool or for precise sizing. The additional of Tofd does not add much initial cost to the system and does not negatively affect scan speeds as it is a single beam wide coverage technique.
- Phased Array is an advanced ultrasonic technique utilizing intelligent software and multi-element transducers which allow for advanced beam forming compared to traditional ultrasonics with fixed single angle transducers.
- Some of the advantages of phased array are shown here. Typically E-scans and/or Sector scans can be used to cover the entire weld with a high level of detection capability. Because there is no dangerous radiation with ultrasonic techniques it is becoming popular to use encoded phased array and Tofd in lieu of Radiography.
- Sector scans are simply put multi-angle inspections (ex: 35-70 degrees) out of the same transducer, allowing a wider coverage area and better detection and sizing capabilities.
- E-scans are simply the same angle being repeated across a series of elements electronically which mimics a conventional angle beam transducer manual being rastering in and out from the weld center.
- Sectorial and linear scans can be combined into the same inspection for a very high level of detection and sizing capability (OmniScan can acquire up to 8 groups of different types of scans simultaneously). Images are displayed typically in top down (C-scan) or side views (S-scan).
- 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 the 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 near surface or lateral wave, and one at the far surface or back wall of the component. These can be reduced by adjusting some parameters but never eliminated completely
- 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.
- 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. Shown here is a comparison of the Tofd technique and radiography technique on the same weld specimen.
- Typically the first part of an encoded PV200 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.
- Depending on the applications that need to be inspected, various modules from 1664 to 32128 are available for the OmniScan MX2 portable platform. The first number will control how many elements can be used for a single beam and the second number how many total phased array elements can be utilized for the inspection. A 16:128 could utilize a single 128 element transducer or 2 64 element transducers. For thinner welds requiring only single sector scans a 16:64 is common, for more diverse and thicker inspections 16:128 or 32:128 are more common as they allow more flexibility in coverage, the full use of E-scans etc.
- Typically only a semi-automatic scanner is required. Many of the Olympus NDT scanners allow for both Tofd and phased array to be assembled on them simultaneously. The choice of scanners will depend on the application range of diameters, thicknesses, etc. and the number of probes needed to be affixed to the scanner. For general weld inspections the HSMT line of scanners are very common including the Flex scanner. For specialized applications like small diameter piping Olympus offers specific scanners like the Cobra scanner pictured. For fully automated inspections the WeldROVER is a common choice. Please see the Industrial Scanner catalog for all options and discuss your needs with a Technical Representative.
- 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. Water is usually fed directly from the pump through a manifold on the scanner and to the individual wedges.
- The selection of probes and wedges will vary based on the diameters, wall thickness, material type etc. Most use built in or removable “IHC” features which are irrigation ports to connect to the pump, holes to fit scanner arms and adjustable carbide feet which helps to prolong wedge life and provide uniform coupling.
- Depending on the customer’s needs there are a lot of smaller components that typically go into a PV200 solution as well including: cabling, 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.
- All analysis can be done directly on the OmniScan if desired. Many prefer offline or PC analysis. Olympus NDT offers OmniPC (offering the same user interface as OmniScan means reduced learning curve) or TomoView software. TomoView has some advanced features like volumetric merging and post gain adjustment. Please see technical representative or software brochures for details.
- HTML reports are typically made by entering indications with chosen sizing and other readings associated with them. Images are captured as the user prefers to include for each indication.
- 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 for calibration and demonstration capabilities. The location of calibration reflectors and other requirements of these blocks should be spelled out in the applicable procedure or by the code.
- The PV200 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), API piping, as well as structural welds which is usually governed by AWS D1.1.