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Benefici della tecnica Phased Array nella mappatura della corrosione.

In diversi settori come quello petrolifero, gasiero e della produzione energetica, le infrastrutture con un numero elevato di anni possono portare a manutenzioni straordinarie e problemi di sicurezza non previsti. Per aiutare le aziende a ispezionare le componenti caratterizzate da superfici regolari, relativamente a danni e corrosione interni, abbiamo creato le sonde Dual Linear Array™ (DLA) che si avvalgono della tecnica trasmissione-ricezione.

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Atti di convegni o presentazioni contenenti case history
SAVE ottobre 2018 workshop

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da Benedetta Rampini
SAVE 2018Segui aziendaSegui




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Estratto del testo
Veronafiere 17-18 ottobre 2018 Vi aspettiamo a mcT Petrolchimico Milano, 29 novembre 2018 Cogenerazione Termotecnica Industriale Pompe di Calore 27 ottobre Cogenerazione Termotecnica Industriale Pompe di Calore Alimentare Alimentare Petrolchimico Alimentare 28 ottobre Alimentare Petrolchimico Alimentare Alimentare Petrolchimico Visione e Tracciabilit 28 ottobre Luce Energia Domotica LED Luce Energia Domotica LED Petrolchimico Alimentare Petrolchimico Petr Benefici della tecnica Phased Array nella
mappatura della corrosione.
Le sfide dei controlli ad alte temperature.
Olympus Italia ' Stefano Croce, Florin Turcu, Thierry Couturier
Evonik Technology and Infrastructure Gmbh- Dirk Treppmann, Timon Jedamski Verona, 18/10/2018 Agenda 1. Corrosion ' a fundamental problem for asset integrity 2. From Ultrasonic Thickness Gaging to Phased Array Corrosion Mapping 3. In-Service Inspection ' is it necessary ' case study Chemical Industry' 4. Challenges and Solutions for in-service inspection Page 2 Corrosion ' a fundamental problem for asset integrity Page 3 KEY INDUSTRY 1 specific pictorial KEY INDUSTRY 2 specific pictorial KEY INDUSTRY 3 specific pictorial Page 4 Corrosion Inspection & Applications 2 common applications to the three industries: oil&gas, chemical, powergen: Process Piping Pressure Vessels Agenda 1. Corrosion ' a fundamental problem for asset integrity 2. In-Service Inspection ' is it necessary' ' case study Chemical Industry 3. From Ultrasonic Thickness Gaging to Phased Array Corrosion Mapping 4. Challenges and Solutions for in-service inspection Page 5 Page 6 Why In-Service Inspection' 'In-service inspection reduces downtime and
increase safety of operation'
Thousands of vessels and hundreds of km of process piping;
90% are insulated ' hard access+ high temperature (70-
150-350oC) Inspection during downtime every 5 years for 4 weeks X-ray can be done in service up to 250mm diameter Some vessels and pipes are cladded with corrosion resistant
alloys Inspection complexity due to narrow spaces
between structures Huge costs due to downtime For in-service inspection temperature can be
decreased to an acceptable level (70-150oC) Page 7 Processo agressivo di corrosione
non uniforme, imprevedibile Random Pitting
' 15 days Variazioni di Temperatura
imprevedibili Why In-Service Inspection' - Case study ' Chemical plant Agenda 1. Corrosion ' a fundamental problem for asset integrity 2. In-Service Inspection ' is it necessary' ' case study Chemical Industry 3. From Ultrasonic Thickness Gaging to Phased Array Corrosion Mapping 4. Challenges and Solutions for in-service inspection Page 8 Benefits of Phased Array in corrosion mapping 1) Immaging OLYMPUS Scientific Solutions Page 10 TX RX 'Roof angle and V-path focus sound at the base of pits ' Much of the sound is scattered away from the transducer Twin crystal Single crystal Thickness gaging Benefits of thickness gages High sensitivity --------- V-path OLYMPUS Scientific Solutions True Thickness Sample Angular Sound Path TX RX Temperature compensation High temp probes Very good Near-Surface Resolution -
transmitter/receiver configuration
High precision ' V-path Correction,
Auto Gain Control
In Phased Array we try to reproduce and
multiply Conventional transducers
OLYMPUS Scientific Solutions Page 13 Dual Linear Array Reproduces a twin crystal probe ' in Phased Array V-path can be corrected on exported data Pitch-catch technique produces very little interface echo for
improved near surface resolution: 1 mm (0.04 in.) Beam coverage width up to 32 mm (1.26 in.) Imaging = higher POD V-path Immaging
(POD)
Same benefits as thickness
gages
+
Imaging and POD
Large Effective Beam 60 mm (2.36 in.) 4.7 mm (.187 in.) Conventional pitch-catch Phased array 64 elements 12 more coverage with a phased array probe Data Point Density Low Density High Density Added value inspection $$$ Greater probability of detection Missed Detected Views while Scanning C-scan B-scan D-scan A-scan Pahsed Array Visual : Phased Array Visual: C-scan B-scan D-scan Other benefits of PA Export C-scan (thickness values) Page 19 Page 20 LESS WHITE Areas
(less loss of backwall= better
reflectivity)
Hydroform DLA- V-path Other benefits of PA: compare P/E with T/R Other benefits of PA Multi-group and angle beams Page 21 -10deg +10deg 0deg Merged data Pitting Other benefits of PA Multi-group and angle beams Page 22 -10deg +10deg 0deg Merged data Pitting Before After Saturation Loss of
BW Echo NO
Saturation No More
Loss of
BW Echo Value Proposition ' Pipes and Pipe Elbows Page 23 Magnetic wheels hold on to the part and fol ows the elbow radius for easy operation Less fatigue with lightweight frame Cost effective flexible phased array probe and adaptative frame covers the entire diameter range Fast 2D mapping with smart indexer clicker system High quality data and easy to interpret imaging using OmniScan instruments Wide range of diameters Fast, Easy and Complete Coverage 4.5in OD and up with the same probe and scanner Cost effective Page 24 Covers 100% of the elbow surface Can fit intrados (concave) as wel as extrados (convex) Reduced prep and inspection time Fast, Easy and Complete Coverage No need for drawing grids Large beam width beam width ensure fast inspection Page 25 Increased probability of detection (POD) High Quality Data Up to 1 1 mm scan resolution data points Acquired and saved within the same file Smart indexer clicker button pauses the
acquisition while the scanner is moved to
the next scan line, preventing overwriting
data Page 26 Other benefits of PA In-Service High Temperature Corrosion Mapping Page 27 Replaceable wedges al ow for slow heat transmission What are the challenges' 1. Operator Safety and Comfort Page 28 ' Safety First ' wear protective equipment ' probe casing might heat up ' Protect from hot liquid couplant ' Explosion risks due to pipe wal loss' ' implosion is less dangerous ' Physical Comfort of Operator: lack of comfort due to high temperature from surrounding environment affects inspection quality and POD 2. Couplant Page 29 ' Water based couplants wil evaporate quickly ' Eltilene glycol, glicerine, ceramic paste, oil could stand up to 150o ' Needs to be environmental friendly ' Couplant must not contaminate the surrounding areas ' Contact with operator of hot liquid couplant must be avoided 3. Inspection methodology Page 30 ' Calibration: velocity and wedge delay ' Velocity of sound in steel changes with about 1% every 55oC ' Velocity in the delay line changes about 10 times faster ' Calibration must be done on block at same temperature ' Wedge delay more difficult: the wedge heats up continuously during scanning ' Repeat the wedge delay calibration more often ' Reduce the duty cycle 4. Scanner Page 31 ' Mechanical scanners (chain) can work up to 150. ' encoder with plastic wheel ' Magnetic wheels wil loose magnetic properties when heated above 60 deg or more depending on contact with hot material Conclusions Page 32 - Solutions exist for phased array screening in service in chemical or petrochemical industry - Benefits include: - Very high probability of detection - Reduction of inspection time during turn-around = more time dedicated to maintenance - Less unpredictable accidents with high economical impact Phased Array UT
Instrument Scanner High Temp Probe OLYMPUS Scientific Solutions OLYMPUS Scientific Solution With NEW Epoch 6LT


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