UT PA PRODUCT R

UT PA PRODUCT RANGE

&

INSPECTION SOLUTIONS

1© Zetec Inc. All rights reserved

2019 February – MultiTest Ltd

• UT Products range versus Applications

• Ultravision

• Inspection Solutions

2

Agenda

© Zetec Inc. All rights reserved

PRODUCTS RANGE


4

A full family of PA UT Products

Dynaray 64/64 to 256/256 Zircon32/128Quartz

32/128 & 2x16/128 © Zetec Inc. All rights reserved

• Topaz 16/64 + 1 CV channel (PE or TOFD)

– Weld inspection PA & TOFD, Carbon Steel,

up to 50mm thick, multiple passes

– Corrosion, composite mapping

– Forging parts up to 150mm

• Topaz 16/128 + 1 CV channel (PE or TOFD)

+ Weld inspection PA & TOFD, Carbon Steel,

up to 50mm thick, single pass

5

Win7 Embedded, SSD 128GBScreen Multitouch 10.4in, 1024x768PA 75V, UT 200V (50Ω probe connected)

Gain (Analog) : 70dB (2 amplifier stages, +digital gain 48dB)

DZ 100MHz, 16 bits(beam 16E), 8192ptsAcquisition file 300/700MB (64/128)


• Topaz 32/128P + 2 CV channels (PE or TOFD)

+ Weld inspection PA & TOFD, Carbon Steel, up to 100 to 150mm thick,

+ Forging parts up to 300mm

+ Time Reversal Option: Composite inspection with real-time profiling/focal adaptation

• Topaz 32/128PR+ Weld inspection for Stainless steel and Corrosion

Resistant Alloy Steel.

1st release in 2013,

HW Updated in 2016 for higher performances

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Win7 Embedded, SSD 128GBScreen Multitouch 10.4in, 1024x768PA 75V, UT 200V (50Ω probe connected)


DZ 100MHz, 16 bits(beam 16E), 8192pts (16384 remote)

Acquisition file 2GB


• Topaz 64/64PR + 2 CV (PE or TOFD) up to+ TFM 256^2 65K pixels

• Frame 60x60mm (5MHz, LW)

• Frame 30x30mm (5MHz, SW)

• Topaz 64/128PR_TFM-HR_D+ Weld inspection PA & TOFD, Carbon Steel, up

to 200 to 250mm thick,

+ Forging parts up to 300mm

+ TFM – FMC High Resolution 1M pixels• Frame 240x249mm (5MHz, LW)

• Frame 120x120mm (5MHz, SW)

+ FMC data saving on the fly

+ Bipolar Pulser

7

Win7 Embedded, SSD 256GBScreen Multitouch 12.1in, 1024x768PA 150Vpp, UT 200V (50Ω probe connected)


DZ 100MHz, 16 bits(beam 4E), 16384ptsEncoder : 3 axisAcquisition file 2GB


• Dynaray 64/64, 125/128 or 256/256,

• Dynaray Lite 64/64.

– Weld inspection PA & TOFD, Carbon

Steel, up to 300mm and above

– Forging parts up to 3-6 meters, with a full

resolution A-Scan, 256k points vs 8k to 16k.

– High voltage PA 200V

– Low frequency probes 0.5MHz


• Zircon 32/128P

• Zircon 32/128PRInspection Very Harsh environment,

Same electronic that the Topaz32,

+ Act a UV3-Basic license

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Data Throughput 20MB/sAcquisition file: 20GB (UV3, tested up to 20GB, no

limit or limit based on MSW)


• Quartz 32/128PR or 2x16/128PR

In-Line inspection, Similar electronic that the Topaz32,

+ Parallel firing (2x16)

+ Higher voltage : 100V vs 75V

+ Probe splitter embedded

+ Higher data throughput: 30MB/s vs 10 or 20.


ULTRAVISION Versions & Key points


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A full family of PA UT Products

All products Controlled by a single Software Platform


TOUCH (Topaz or PC)

• Viewer (free)

• Basic, for Topaz 16

• Advanced, for Topaz 32, +management of Matrix Probes, +opt Time Reversal

CLASSIC (PC Win7 or Win10)

• Basic, +tools for analysis

• Advanced, +Beam Simulation, DGS calculation, Assisted analysis tools, +3D ray-tracing and Data visu on pipes and plates, +TFM FMC,

• 3D, +3D on any components

EC, (EDDY CURRENT/MIZ200) → UT / EC ACQUISITION IN //


Keys Points• Training

• A single SW platform for all instruments, Touch (simplified interface) for 1st

operators, Classic for advanced analysis and operators.

• Data compatibility• 1 File format for Setup, Data, for any versions (Touch, Classic), for any

instruments, no need of data converter.

• Reads *.DAT and *.RDT examination data, back to 1992 (.RDT files before2006).

• Large file size, up to 20GB, and more with powerful PC

• 2-3 release per year with product bulletins and guidelines


ULTRAVISION Concept & some Features


Key Features & Concept

1 Software platform, From Design to Analysis,

3D Display for your setup


3D Block definition• Loading of a custom file “.SAT”

• Selection of a predefined component,

• Drawing of 3D component inside Ultravision


Adding of Indications and back Ray-tracing• LW and/or SW, any skips


Scanner Simulation• X table,

• XY Table

• Feeder Tube

• Pipe OD

• Pipe ID

• Polar Scanner

• Projected Line


Ray-Tracing from Probe• Evaluation of steering/skewing needs for a correct coverage


Side Lobe(incorrect design)

Beam Simulation• Evaluation of the beam size, risks fo sides lobes

• Statistics about the beam


Setup/PA Calculator• Conventional UT probes support

• PA TOFD support

• Multi-channel support

• Tandem configuration with single and dual probe configurations.


Acquisition• Real Time Top/Side view of the Weld (real time Merge views)

• Camera recording, synchronised on UT Data

Uncorrected View(Scan vs Angle)

Corrected View(Top view)

Weld Axis


Analysis• Fast Analysis: Volumetric Views with rebounds

Surface

BackWall

Side View

Top View

Sectorial View

End View,(Projection)

A-Scan


Analysis / 3D


Reporting



Weld (CS)

Paintbrush for Corrosion

Boiler Tube

Long Seam Weld

Weld : SS, CRA

Forging (Long UT Path)

Composite (Time Reversal)

Inspection Solution


Circular & Long Seam

Weld Inspection

Inspection Solution

Modular Scanner for Circular Weld

Flexible, adaptable solution

• Manual or motorized,

• For pipes from NPS2.5 to plates

• Ruler linked to SW for probe positionning

• Adjustable tensioning spring

• Drift control (2 independent

motors/encoders)

2 ¼”57mm



Scanner and Tools

Ray-tracing for cylindrical geometryWeld Crawler for Longitudinal Welds, pipe ≥ 6’’

Camera

Sync.

on UT


Results – OD Crack

toe crack

7.5 x 25 mm

Polar views, Detection and accurate plotting of PA UT signals from OD crack,after ½ & 1 skip

32

Customization


Weld single access, adding of an ‘’H’’ handling 2 probes

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Customization

Prototype for tests, partly 3D printed,EDF picture, extract of the presentation “Fast-track development of a TOFD inspection procedure for forges Steam Generator channels heads”, 12th ECNDT 2018



Boiler Tube Weld

Inspection

Inspection Solution

Courtesy of RWE Power Intl.Ltd

Results – Comparison with RT


Results – Comparison with RT

• Coal Generators GENSIP Programme (UK) organized Round-Robin NDT

exercise (2013 – 2014) to assess performance and reliability of PA UT

• 50 tubes with various diameters, and containing various flaw types were

inspected by 10 NDT service companies

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1st 2 companies usedZetec Equipment.• Good and trained operators• UT Signals quality (SNR)• 16 bits resolution,


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Dual Axis Scanner for Small Diameter Pipe

• Pipe Range: NPS1.5” to NPS 3.5”

• Magnetic Wheels

• Single or Dual Side

• 2 encoded axis

• Clearance 25mm

• Ultrasound Configuration

• 2x Phased Array probe

(Circumferential Indication)

• 4x Conventional probe

(Axial Indication)



Stainless Steel

Weld Inspection

Inspection Solution

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Technique Dev, SW tools and Probe

• Circumferential Flaws • Axial Flaws

UV3 UV3

UV Touch, including an PA calculator for Dual Matrix probes

Set of Probes, Wedges for covering

various thickness and materials.



Results – SS Weld with Cap

PA UT data (30° to 85°LW) from 304 SS weld (T = 25 mm) :

all flaws detected from a single side with 2.25 MHz, 10x3 matrix array (TRL)


Paintbrush

Corrosion / Composite

Inspection Solution

Manual Scanner for LW0 Inspection

• X/Y scanning, 2 encoders

• Compatible to any probes

• Compatible with Flexible Wedges

• Different wheels vs Materials for Steel, composite

• 100% Coverage


Scanning Mechanism Innovation


Tools

Ultravision Touch

• C-Scan Stitching

• Polar View

• Area under a Threshold (thickness)

• …

Ultravision Classic

• Aberrant Points Removal

• Assisted Analysis

• 3D rendering

• Color Palette Generator (in mm/in)

• ..



FORGING

Long UT Path

Inspection Solution

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Technique Dev, SW tools and Probe

• Beam Simulation

• DGS Curves Calculation

Quad or Tri Probe,

Fexible Array



ResultsTypical A-Scan Data on Φ1.6-mm FBH of Rotor Specimen

B2S

2M8x8E16-64-QUAD


Turbine Blade Inspection

Inspection Solution


Scanner and Tools

o Scanner, for Intrados & Extrados inspection

o Ultravision 3D for inspection design

• Beam simulation in complex geometry

• 3D raytracing

• Coverage Map


Results

o Quick Analysis on the Topaz

o Ultravision 3D for inspection design

• Beam simulation in complex geometry

• 3D raytracing

• Coverage Map


Turbine Bore Inspection

UT & EC

Inspection Solution

Technic – Scanner and tools

• UT & EC acquisition in // on Ultravision

• Scanner performs axial and circular movement, transducers move following a helical pattern.

Inspection head

with centering

Probes

Shaft

Flange

Rotation

Rods

Frame

Motor Controller Unit

UT Equipment

ECT EquipmentPump for UT coupling

Ethernet link

Laptop

UltraVision® Software :

Acquisition and Analysis


Riser Bolt

Inspection

Application Solution

January 2017

55

Dedicated Manual Scanner



Results on Test Bolt

Notches 1 and 2, close to the echo from the bolt geometry, are well resolved by usingthe Linked B-Scan View; detection from A-scan only is challenging

Scan

(deg)

Depth

(inch)

Notch 10.75ʺ x 0.25ʺ (L x

d)

Notch 20.75ʺ x

0.125ʺ

Notch 30.75ʺ x

0.375ʺ

Notch 40.75ʺ x

0.325ʺ

Notch 50.75ʺ x

0.25ʺ

Notch 60.75ʺ x

0.125ʺ

Notch 70.5ʺ x

0.06ʺ


Results on Test Bolt

Notches 3, 4, 5 and 6, all in the threaded area, and with depths varying from 0.125” to 0.375”, are clearly detected and resolved from the thread signals

Scan

(deg)

Depth

(inch)

Notch 10.75ʺ x 0.25ʺ (L x

d)

Notch 20.75ʺ x

0.125ʺ

Notch 30.75ʺ x

0.375ʺ

Notch 40.75ʺ x

0.325ʺ

Notch 50.75ʺ x

0.25ʺ

Notch 60.75ʺ x

0.125ʺ

Notch 70.5ʺ x

0.06ʺ

TIME REVERSALAvailable on Topaz32, Zircon and Quartz


TIME REVERSAL is a real-time adaptive electronic process

allowing compensating probes misalignments

2 step process, perform in real time

• Profiling of the component surface (4 to 8 // shoots),

• Data recording while firing surface-adapted delay laws to

obtain LW0 over the complete component surface (50 to 60

shoots),

• Profiling and Data recording do in 1 pass

Impact on the scanning speed: 0% to 8% max (probe 64E, aperture 6E).

Time Reversal PA UT - Concept


Time Reversal PA UT - Concept

Firing Cycle 3Firing Cycle 2Firing Cycle 1


CFRP sample, manufactured for Zetec• CFRP material, typical attenuation

• Representative geometry (stringer, spar), 6 mm thick

• Contains artificial brass inserts (3 x 10 mm and 10 x 10 mm), at

various locations and depths

Test Case - Specimen


Arc-shaped Probe :

3.5 MHz, 64 elements

pitch 0.65 mm

width 8.0 mm

aperture : 8 elements

1

64

scanning along the component Optimal position

Test Case – Radius

Configuration :

Immersion tank

water column


Test Case - Radius - Misalignment

#1: misalignment ≈ 3 mm #2: rotation


Optimal alignment of specimen and arc-shaped PA probe : standard PA and Time Reversal

generate good detection results in Gate 2 (Amplitude) and Gate 3 (Position)

Standard PA

Time Reversal

Test Case – Radius – Optimal Position

Gate 2

Gate 2

Gate 2

Gate 3

Gate 3

Gate 3


Mis-alignment (≈ 3 mm) of arc-shaped probe : standard PA “missing” defects , TR allows for

compensating and still generates good detection in Gate 2 (Amplitude) and Gate 3 (Position)

Standard PA

Time Reversal

Test Case – Radius – #1 Misalignment

Gate 2

Gate 2

Gate 2

Gate 3

Gate 3

Gate 3


Standard PA

Time Reversal

Test Case – Radius – #2 Rotation

Gate 2

Gate 2

Gate 2

Gate 3

Gate 3

Gate 3

Mis-alignment by rotation of arc-shaped probe : standard PA completely useless; TR allows

for compensating and still generates detection in Gate 2 (Amplitude) and Gate 3 (Position)


Inspection System - Example

UltraVision®

PC workstation for Data Acquisition

1 64

1

32

1

32

Splitter Box

2 x 64 channels

1 x 64 channels

4 x 32 channels


Collaboration with 3rd Parties

Structural Integrity - Lattitude


A non-mechanized position encoding

technology for NDE data acquisition

Conventional AUT Technology

Mechanized Scanners Supporting Equipment

1. Probes2. Probe Carriage3. Track4. Scanner Arm5. Motors6. Cameras7. Couplant

Delivery System8. Water & Power

Source

1. PAUT Equipment

2. Computer3. Monitors4. Motion

Controllers5. Network Rack6. CCTV7. Cable Bundles8. Power Source


Introduction to LATITUDE™

• Revolutionary, non-mechanized position encoding technology that enables

encoding, digitization, and recording of NDE data

• Facilitates offline review and data archiving of manually applied NDE sensors

• Portable, lightweight, and battery-powered

• Enables substantial time and cost savings over automated systems

Receiver Collar2

ZETEC TOPAZ™

4Transmitter Attachment

3

LATITUDE™ Electronics

1


Video deployment


LATITUDE Components

• Integrated with Zetec’s TOPAZ PAUT instrument

• Latitude controlled directly from the TOPAZ interface

• Encode data directly on the TOPAZ

• Latitude electronics can be attached to TOPAZ system with quick release clip for portability.

• Sealed fanless enclosure

• 2 batteries: ~10hr of use

• Connects to Latitude

collar, transmitter, and

PAUT electronics

• Attaches to rear of PAUT

electronics

• No exposed wiring, fully enclosed

• Conformable and self-aligning

• Modular design

• Compact and lightweight for transportation

• Flexible sensor spacing

Electronics

Collar

PAUT Equipment

Attaches to UT probe/wedge

Enables tracking of x- and y- position and probe skew (rotation)

Integrated button for data acquisition control

Transmitter Attachment


Possible Applications

• Weld Pre-Service and In-Service Exams

• Similar metal welds

• Dissimilar metal welds

• Corrosion mapping

• Microbiologically Induced Corrosion (MIC)

• Flow accelerated corrosion (FAC)

• General corrosion

• UT in lieu of RT

• ASME B31.1

• ASME Code applications

• Weld Overlays


• LATITUDE data set (left) and AUT data set (right) acquired on same DMW practice sample using same PAUT probe model.

• AUT data was collected by an independent party.

• LATITUDE approach requires significantly fewer lines (less scanning)

• SNR of LATITUDE data is superior, primarily due to more consistent probe contact/coupling

SI recently qualified an innovative ultrasonic testing (UT) procedure for use in examining dissimilar metal welds using LATITUDE that uses a detection-only approach.

Application: DM Welds

Circ. Flaw 1(77%)

Circ. Flaw 3(21%)

Circ. Flaw 1(77%)

Circ. Flaw 3(21%)

AUT Data34 LINES

Scan Increment = 0.040”Index Increment = 0.150”

LATITUDE™ Data13 LINES

Scan Increment = 0.080”Index Increment = 0.40”


Application: Corrosion Mapping

• Internal corrosion of a carbon steel service water pipe from a nuclear power plant

• Pipe was removed from service due to internal pitting

• Very small pit sizes require a high-resolution scanning technique

• Encoded UT data provides a high-resolution digital map of the internal surface

• But deploying robotic scanning systems can be complicated and costly

Acquired in ~2 minutes of scanning w/ Dual Matrix Array

Probe


Root Crack

Top View (looking down on weld crown)

Side View (looking in direction of flow)

Weld Area

Flaw: Root Crack

0.091”

Length: 0.306”

Nominal 16” OD1.25” WT

Application: UT in lieu of RT

• ASME code cases• Section III and XI• B31.1 and B31.3

• Specify the use of equipment that is capable of recording the UT data, including the scanning positions.

• Therefore, AUT systems have typically been deployed for these examinations.


THANKS


UT PA PRODUCT R

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