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Real Time Corrosion Mapping System: A Comparative Study

Real Time Corrosion Mapping System: A Comparative Study. Bob Lasser, David Rich Imperium, Inc . Beltsville, MD Josh Fontenot, Tim Borel Advanced Corrosion Technologies & Training (ACTT) Sulphur , LA . About Study.

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Real Time Corrosion Mapping System: A Comparative Study

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  1. Real Time Corrosion Mapping System: A Comparative Study Bob Lasser, David Rich Imperium, Inc. Beltsville, MD Josh Fontenot, Tim Borel Advanced Corrosion Technologies & Training (ACTT) Sulphur, LA

  2. About Study • Wanted to compare Imperium’s FirstMap Corrosion Imaging system to Phased Array UT (PAUT) • Investigated resolution • Other factors included ease of use, cost, training requirements • Joint study between Imperium, Inc. (Beltsville, MD) and Advanced Corrosion Technologies & Testing (Sulphur, LA)

  3. About Imperium • Founded in 1996 • Leading developer of ultrasound camera technology • Systems in petrochemical, aerospace, medical fields About Advanced Corrosion • Founded in 2002 • Extensive experience in advanced NDT methods • Presence in several locations on Gulf Coast

  4. Why Industry Needs A New NDT Device • Lack of trained NDT personnel • Lack of confidence in thickness readings, missed corrosion • Need higher POD • Need areas where AUT can’t reach • Advances in imaging technology • A picture is worth 1000 words • Time and cost pressures – “FirstMap” diagnostic tool quickly identifies areas for further investigation

  5. FirstMap Advantages • Images are easier to interpret • FirstMap provides an actual image of the defect including thicknesses • High resolution • Higher confidence than single thickness readings • Not effected by beam dispersion • Built in delay line • No extensive training required; less trained technician • Real time

  6. Evolution of UT Methods B-scan C-scan A-scan

  7. B-scan to C-scan Defect Defect

  8. Imperium’s Patented ArchitectureApplies optical imaging techniques to ultrasound Optical Architecture: Optical Sensor (CCD) Flash Lens Ultrasonic Architecture: Acoustic Flashlight (2) F1 Acoustic Lens Ultrasonic Sensor Note: CCD means Charged Coupled Device

  9. Pulse Echo – 50/50 Beamsplitter Sound Transmitter Array Pulse echo image of quarter Subsurface fault Video Water Lens Acoustic beamsplitter Target

  10. Imaging Array – 100 micron pixels120 rows x 120 columns = 14,400 pixels

  11. PIPELINE CORROSION MAPPING

  12. SCANNING & STITCHING • Make large mosaic images from smaller ones • Capture both C-scan and thickness • Uses encoder attached to camera Tilting encoder Optical image of corrosion inside pipe Dual element transducer Scanned/stitched image of corrosion inside of pipe

  13. INSPECTING STORAGE TANK BOTTOMS WITH FIRSTMAP Compare FirstMap’s easy to interpret readout

  14. MICROBIOLOGICAL INDUCED CORROSION Black areas indicate MIC, note the veins of MIC also

  15. PIPELINE CORROSION MAPPING

  16. Benefits to NDT Industry • Broad application base • Pipelines, storage tanks, pressure vessels • Find corrosion faster • Find smaller amounts of corrosion • Does not sacrifice any current data quality • Provide better information to end customer • Better tool to provide comparisons • Use Level 2 thickness inspector to generate images, not just readings • Get to areas where current tools can’t go

  17. B-scan vs. C-scan Phased Array FirstMap

  18. Resolution Study:FirstMapvs Phased Array • Investigated axial, lateral, and elevation resolution • Used Omniscan MX2 • Both systems working at 5 MHz • Did mathematical study, then took data to compare expected results

  19. Omniscan PAUT System Test Settings: Probe: 5L64-NW1 (5 MHz) Wedge: SN1-0L5L64 Mode: Phased array Focal Depth: 0.1” Focal Law: Linear sector with overlap Skew Direction: 900(straight down mode) Scan Offset: 0 Index Offset: 0 Element Quantity: 8 First Element: 1 Last Element: 64 Thickness: 0.25” Surface: Flat plate

  20. FirstMap System Frequency: 5 MHz Number of Pulses: 1 Gate start: 0.1” Gate width: 0.5”

  21. Phased Array Theoretical Resolution Lateral (X): ΔD = (0.44 x V) / (F x sin (θ/2)) Axial(Z): ΔZ = V x T/2 Elevation(Y): Defined by the length of the array elements, and will be on the order of several millimeters Source: Olympus NDT Manual

  22. Resolution Summary

  23. Resolution Panel

  24. Resolution Study - Set A: 0.100” holes Phased Array FirstMap

  25. Resolution Study - Set B: 0.040” holes Phased Array FirstMap

  26. Resolution Study - Set C: 0.023” holes Phased Array FirstMap

  27. Resolution Results FirstMapOmniscan: Amplitude Omniscan: TOF

  28. Comparative Study: FirstMap, X-ray, Phased Array • Reviewed different techniques for corrosion mapping • Used common standards • Recorded image quality • Recorded time of setup, scan, training cost

  29. Targets Studied Stepped standard Corrosion piece 8” diameter pipe section

  30. Stepped Standard FirstMap Phased Array X-ray 192 iridium

  31. 0.25” Corroded Steel Panel FirstMap Phased Array X-ray 192 iridium

  32. 8” Diameter Pipe Section FirstMap Phased Array X-ray 192 iridium

  33. Corrosion Mapping Comparison

  34. Advanced Corrosion Technologies “The probability of detection is far superior to standard thickness readings. FirstMap™ is a diagnostic tool that can instantly detect subsurface corrosion down to 1 mm pits. We are now able to quickly and easily identify problem areas that could potentially lead to much bigger issues.” -Josh Fontenot, Director of Technologies, ACTT

  35. Imperium, Inc.5901-F Ammendale RdBeltsville, Maryland 20705 301-431-2900 / 301-431-0200 fax  www.ImperiumInc.com

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