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Current job position Click to edit Master subtitle style Provide NDT support to five BP Refineries in the USA and six overseas in the Netherlands, Germany, Spain and Australia.
BA Degree from Marshall University in general studies with a major in Nondestructive Testing and minor in Engineering. Certified ASNT NDT Level III in Radiographic Testing, Ultrasonic Testing, Liquid Penetrant Testing, Magnetic
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Purpose of Presentation
l Educate the inspector and engineer on the
benefits and challenges (pros and cons) of guided wave pipe inspection.
n
Sources
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TWI, Long Range Ultrasonic Technologies Part of Click to editthe TWIs Non-Destructive Testing Technology Master subtitle style Group broacher downloaded from website, www.twi.co.uk
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GUL website, www.guided-ultrasonics.com PetroChem Inspection Services, Inc. 1475 East Sam Houston Parkway South, Suite #100, Pasadena, Texas
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Contents
Abstract Introduction Sensitivity or Detectable Metal Loss General Restrictions Level of Inspection Difficulty GUL System Challenges and Benefits Teletest System Challenges and Benefits Conclusion
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Abstract Many inspectors and engineers do not realize there are three main commercial guided wave systems available globally and the differences in those systems This presentation will discuss two out of the three systems and provide information to help the inspector or engineer decided which guided wave system may be the best for a particular piping inspection situation. The physics or technical details will not be discussed
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Guided waves are low frequency sound waves (in tens of kilo hertz sound waves as opposed to mega hertz in conventional ultrasonic testing) generated by edit Master subtitle style Click to transducers wrapped around the pipe circumference.
The MsS system (not discussed in details in this presentation) by Southwest Research is slightly more complicated.
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These sound waves sweep the entire thickness of the pipe, the pipe acting as a wave guide where the term guided waves originated. Screen response signals are caused by reflections from pipe features like butt welds, pipe tees, supports, clamps, etc.
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Sorting or screening NDT tool will classify pipe in categories of wall loss levels.
Typically guided waves provide 100% initial pipe wall screening coverage which should not imply 100% full reliable inspection coverage.
It is impossible to get response from small discontinuities 1% and less of pipe cross-section and longitudinal cracks 3% and less pipe cross-section.
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Sensitivity or Detectable Metal Loss Guided waves do not measure wall thickness, just changes
Typical reflectors are pipe bends, circumferential welds, pipe tees, reducers, pipe supports, and of course corrosion
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General Restrictions of Guided Wave Systems At each guided wave test, the acoustic performance is situational.
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Basically if pipe butt welds can not be resolved on the screen presentation for a length of pipe, the exact inspection distance or how far the acoustic wave has travelled can not be determined.
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Level of Difficulty Considering Test Conditions The following slides detail a guide for best, intermediate and complicated conditions for Guided Wave inspection.
The guide takes consideration of many factors for internal pipe product, external surface conditions, and pipe configuration
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Note: Pipe flanges stop guided waves; pipe tees severely distort the acoustic sound; area immediately under transducer clamp and short distance on each side of test location not inspected
Level of Difficulty Considering Test Conditions Best Conditions Internal pipe product
Gas; vapor
Pipe configuration
Straight runs of pipe; simple pipe supports (minimal contact); loose bolted pipe supports; no elbows; no smaller diameter pipe branches
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Level of Difficulty Considering Test Conditions Intermediate Conditions Internal pipe product
Low viscosity liquid (minimal acoustic absorbing); medium viscosity liquid (more acoustic absorbing)
Slight corrosion pitting; thin plastic type coating; wet damaged insulation; underground sandy conditions (better); underground general soils (expect acoustic absorbing); soil-to-air interface
Pipe configuration
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Mainly straight runs of pipe Few pipe elbows; reducers; tight encompassing or clamped supports (tight bolted supports); smaller diameter pipe branches (large pipe and small diameter branches, for example 30 diameter pipe with 3/4 branch is not difficult to inspect)
Level of Difficulty Considering Test Conditions Complicated Conditions Internal pipe product
High viscosity liquid (high acoustic absorbing); waxy, paraffin, thick sludge, bottoms type liquid (severe acoustic absorbing); brine product can result in salt out and sound attenuation
Bitumen or thick plastic coating (high acoustic absorbing); moderate corrosion pitting; concrete casing tightly adhering to pipe; severe general corrosion pitting; underground compacted clay (most severe acoustic absorbing). Factory applied polyurethane coating very attenuating
Pipe configuration
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A permanent test loop was used to compare both GUL and Teletest systems The same test clamp location was used for both systems and located about midway in the 6 test loop. Each system could easily display the pipe butt welds and the larger defects or machined anomalies placed into the 6 test pipe.
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GUL System
The guided wave system is based on the piezoelectric array sensors developed by the Imperial College in the United Kingdom
GULs Wavemaker G3 Pipe Screening System uses low frequency guided ultrasonic waves to inspected difficult pipe areas such as road crossings, while in service.
The G3 model has new advances to enhance focusing capability with reportedly down to 1% sensitivity, GPS, and improved signal amplitude calibration. GUL tightly regulates its training scheme required for all users on GUL equipment
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It has the capability of utilizing longitudinal, torsional, and flexural wave modes
GUL System
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GUL Challenges
Elbow - Sound loss or distortion Soil-to-air interface/Road Crossing: 3 minimum and 8 ( optimum) of free pipe prior to the ground entrance Piping tees, flanges can not be inspected. Couplings, fittings, branches, and corrosion acoustic distortion Compacted clay deadens the acoustic sound beam. Maximum temperature generally 150F Internal liquid or sludge material will dampen signal Longitudinal cracks in the pipe will not be detected, unless they exceed 3% cross section using the torsional waves
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GUL Benefits
Rapid scanning of numerous locations in one shift Limited surface preparation. Painted surfaces good and after local insulation removal (2 to 3) hand wire brush cleaning generally satisfactory. Coal tar wrap will require removal and wire brush Avoidance of general pipe system insulation removal Long range capabilities (if conditions are right) 100% of the pipe wall inspected (screened). Internal and external pipe wall inspection Inspect insulated pipe Corrosion Under Insulation (CUI) survey with minimal insulation removal Inspect inaccessible pipe areas
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Typical Screen Response of GUL System Showing the Dead Zone and Near Field
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Teletest System
The guided wave system is based on a piezoelectric array sensors clamped around the pipe developed by the Imperial College in the United Kingdom
The guided wave system is currently part of The Welding Institute (TWI) in the United Kingdom, Long Range Ultrasonic Technology (LRUT) group, and commercially available through Plant Integrity Ltd. (Pi)
The Teletest Focus can focus the ultrasound at points around the circumference of the pipe
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Teletest Challenges Same as GUL Challenges with following changes: Many more wires to attach to the Teletest clamp than the GUL clamp Takes a minimum of 15 minutes to download all test parameters from test location on pipe. This does not include evaluation and set up time at that same location In an 8 hour shift, less test positions can be evaluated compared to the GUL system
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Teletest Benefits
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C-Scan Display Display showing both A- scan supplemented with C-scan presentation
C-scan display shows the amplitudes of the reflectors as a function of circumferential position on the pipe and distance from the transducer ring
This helps in accurately locating the flaws and proper interpretation of the discontinuity
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Conclusions
The purpose of this presentation was to provide the benefits and challenges in using ultrasonic guided waves for inspection of piping systems
Two of the major guided wave systems used through out the world was discussed to help the inspector or engineer decide which system may be the best for their particular piping situation
This presentation does not endorse any of the major commercial guided wave systems
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Globally the guided wave manufacturers systems are in almost continuous hardware upgrades and software improvements not only for piping but for other plant equipment such as storage tank floors and exchanger tubes
Questions?
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