Flexible PAUT for Corrosion Mapping

How can we benefit - Where can we benefit

Sieger Terpstra
PTE - MMI Inspection and Inspection Technology
(Input from: Maaroof Ali, Huidong Gao, Wilmer Bustillos,
Michael Post

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Content

◼ Objective this session

◼ Introduction Flexoform
◼ STCH experiences – May 2019 (link to presentation)
◼ NAM/Bilfinger experiences (preliminary results in this presentation only)
◼ Future opportunities
◼ Generate group Feedback:
◼ Where to use
◼ Type of benefit
◼ What is needed for support
◼ How to progress? Actions?

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 Traditional
Objective of this session
inspection
methods: Grid- UT
◼ Introduce new corrosion mapping technology: Thickness
◼ Large product range launched by Olympus for measurement
Flexoform & Hydroform flexible array scanning
for Corrosion Mapping on piping
◼ Scanning on bends down to OD 1.3” (33 mm)
◼ All: Identify/maximize benefits FlexoForm

◼ Where are the opportunities applied to bend

◼ What do we need to do to gain benefits

(Olympus video,
see link)

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 First field experiences - STCH

1
Wilmer Bustillos – presented in NDE Global Meeting March 2019
- What is FlexoForm?
- Overview of probes and scanners (see also Olympus website)
- Examples from field measurements
- Conclusions

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What makes FlexoFORM special? Contact Mode Immersion Mode

◼ Works with slight standoff, coupling via water Couplant Water

column
◼ Higher quality data
◼ Phased Array probe is a flexible foil that fits
different holders
◼ Suitable for wide range of pipe diameters, 33
mm and up
◼ Fast electronic scan along the array, and fast
scanning along the pipe
◼ Powerful data imaging with PAUT apparatus
(Omniscan or other brands)

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Elbow C-scan scanning and mapping

◼ Datum halfway elbow, origin (0,0) at extrados x

◼ Scanner records axial scan position
◼ Scanner measures circumferential shift

Scan direction
(0,0)
(0,0)

Index direction
Intrados

Extrados

Intrados

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Shell Carson Terminal - Contact Water (link)

◼ Inspection approach:
◼ Guided Wave Testing 6-8 Inches
Flow

(GWT) W3

◼ Phased Array Ultrasonic Deep pit, more than ¾ is corroded

Testing (PAUT) – ◼ Oxygen corrosion - at 4-8 o’clock position

FlexoForm T Min: 0.025"

(0.64 mm)

◼ Three (3) locations with

significant loss of OD

thickness were detected

ID

and repaired avoiding

potential LOPC’s Remaining thickness verified using thickness gauging
2 45° Elbows

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Extrados Scan-1
Conclusions D-Scan
C-Scan

Benefits:
◼ Increases of POD due to full coverage
◼ High resolution, data collection up to 1mm x 1 mm
◼ Multiple views available: Real time of the elbow’s
condition and data interpretation fast and easy.
B-Scan A-Scan
◼ Limitations:
◼ No coverage weld or HAZ.
◼ Death zone from scanner 1/2” to 3/4”
◼ Near surface resolution 0.08” (2 mm)
◼ 8” (200 mm) minimum clearance to the fit scanner
(between pipes and pipe-ground)

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 Technique comparison

2
(2” Schedule 80 straight pipe)
NAM-Bilfinger trials April 2019 (Arjan Nijboer – NAM)

Needed improvement to detect very local pitting in 2” piping, after

recurring leaks

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Inspection for local defects
2” Line W304

V-105

V-104
◼ Water-Condensate lines with history of leaks
2” Line W300 / W302
(2” Sched 80 pipes)

2” Line W302

◼ Compare and test 3 techniques:

◼ SLOFEC followed by Manual UT (MUT)
T-12
◼ Radiography followed by MUT Water/cond
Storage Tank

◼ Flexoform

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FlexoForm Test setup - 2”-sched80 pipes from service

Testing access bends:

Examination 25 mm from
weld possible
Testing clearance: Examination extrados/sides
Min. clearance between pipes 80 mm
elbows possible.
Coupling:
Water (flooding probe shoe);
additional wetting of pipe surface with
couplant (UCA-2M Video of scanning

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2” SCH80 WACO-line W302 DAL-9 Testpiece B28
PAUT Test Bilfinger Salamis Groningen 23-4-2019 / 25-4-2019

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Conclusion from NAM-Bilfinger 3-technique comparison

Qualitative observations:
◼ Screening followed by sizing is tedious (either SLOFEC followed by MUT or RT)
◼ Sometimes difficult to even re-detect a defect with MUT
◼ PAUT combines screening and sizing
◼ PAUT provides fast scanning, and quick (preliminary) result
Quantitative observations (preliminary):
◼ POD:
◼ SLOFEC: 36-54% => POOR
◼ RT: 72% => reasonable (missed 3 defects: 0.9, 1.1, 1.0, mm deep, viz 2x4, 2x5, 3x6 mm wide)
◼ PAUT: 90-100% => GOOD
◼ PAUT scan facilitates coating correction (tedious with MUT)

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 Identifying opportunities

3
Group discussion – feedback session

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Possible applications

◼ Scan bends (Tee’s)

◼ Scan piping on local defects
◼ UT in lieu of RT, including small bore
(>1.3”/33mm)
◼ Monitoring: FlexoForm in lieu of grid measurement
◼ Base metal HTHA detection 6” both side of the
welds. In progress (Wilmer Bustillos)

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What if (we could fully automate the data processing)
-
◼ Imagine the following:

= * *
D-Scan
Automated trending
C-Scan

of repeat measurements
Stream into
Digital Twin
Geo-tag to object
B-Scan A-Scan

Automated C-scan map

Collecting data

◼ What would be the value?

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Group discussion - Identify opportunities and value

Opportunities Value

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 Questions and Answers

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Elbow scanner System
(Evaluation by Wilmer Bustillos, Houston)
ELScan (Wesdyne) FlexoForm (Olympus) SFA-1 System (Olympus)

Specification Comparison https://www.youtube.com/watch?v=Qy1MMzJ_6XI

Diameter Range
Radial
Technique: Thickness Temp. Range
System Probe Inf. 4” to Flat Scan Resolution Coverag
PAUT 1” to 4” Range °F
“Companies performed demo on own test samples (elbows) showing 100% coverage” e

No Yet
Partial 64 Elements 2.4”
ELScan Full Up to
Immersion Lineal Array 0.08”- 1.5” 32 to 120
Only extrados Coverage 0.04” x 0.04”
FlexoForm Water column 7.5 MHz 2.0”

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