Anwendungen

Anmerkungen zur Anwendung

Prüfung von Rohrrundschweissnähte mit PipeWIZARD™

Meets or exceeds API 1104, DNV 2000, OS101, and ASTM E-1961 AUT codes

Proven and qualified AUT system for double and quadruple jointing at mill, as well as onshore and offshore pipeline construction
Safe system: no radiation hazard
Efficient system: no disruption of normal operation
Money-saving system: better process control of welding, giving lower reject rates
Better weld quality with unique system performance
High defect detection capability
Extra beams for key areas, such as root passes
Any weld profile: CRC-Evans, J-bevel, modified J-bevel, V,double V .
Better productivity
Wide range of pipe diameters and wall thicknesses
Fast scanning speed: 100 mm/s
Cycle time of approximately two minutes for 36-inch pipe welds
Rapid data interpretation (virtually in real-time)

PipeWIZARD phased-array automated ultrasonic inspection system (AUT).

Lack of fusion detection confirmed by macrophotography.

Ultrasonic zone discrimination is a key feature of AUT with PipeWIZARD.

System Description

Tomoscan FOCUS™ 32:128 phased-array unit
Motor drive unit
Industrial PC
Downsized probe pan containing two linear arrays
Mechanized drive clamping onto welding band
25 m umbilical cable connecting probes, encoder, power, and couplant lines to instrumentation
Instrumentation console including PC, pulsers, and motor drive
Couplant containers, pump, and reclamation unit

Probe Pan Description

Probe pan contains two linear arrays.
Extra modules are available for transverse or dedicated TOFD inspections.
Couplant is pumped water or water-methanol in cold climates.
Encoder running on welding band gives circumferential position.

Software Description
Custom PipeWIZARD™ software running on Microsoft® Windows NT® for data acquisition, analysis, and reporting
Automatic marking of indications exceeding rejection threshold to assist the operator
Inspection reports and list of defects adapted to client requirements
Automatic saving to two separate media in real time
Automated inspection sequence

PipeWIZARD
Pipe diameter	50 mm to 1424 mm (2 in. to 56 in.)
Pipe wall thickness	6 mm to 36 mm (0.25 in. to 1.5 in.) or more depending on wall thickness and addtional transducers. (Additional transducers may be required.)
Array	Two linear 7.5-MHz, 60-element, 75 mm long
Scan speed	100 mm/s (4 in./s)
Scanner size	250 mm (L) x 120 mm (W) x 75 mm (H)
Scanner weight	2 kg (4 lb)
Additional probe pan slots	Extra slots for eight conventional transducers for transverse defects or additional scans
Weld profile	All common welds: CRC-Evans, J-bevel, manual, V, double V, X, etc. (any profile in principle)
Ultrasonics
Method	Multichannel zone discrimination or custom scans as specified
Zone size	<1 mm possible using increased number of zones. (Maximum number of zones is 32 per view, and four views are available for a total of 128.) ASTM E-1961 zone size is typically 1 mm to 3 mm.
Setup	Automatic with file loading
Automated setup	From file of weld profile or from predefined weld profile and appropriate parameters
Display	1. Conventional twin-gate strip chart display or 2. Increased number of zones for improved defect sizing or 3.Multiple B-scans for improved defect characterization or 4.Customized combination of displays Coupling and circumferential position channels included TOFD recommended
Calibration and codes	ASTM E-1961, API 1104, or DNV2000-OS-F101 custom specifications
Additional modules	For transverse defects, thick walls, dedicated TODF, and customized scans
Umbilical
Umbilical length	Typically 25 m (80 ft)
Manufacture	Armored cable 5 cm (2 in.) in diameter
Contents	128 ultrasonic cables, one motor drive cable, one encoder cable, and waterline for coupling
Phased Arrays
Instrumentation	Standard Tomoscan FOCUS 32:128 system (32 simultaneous pulsers, 128 channels)
Bandwidth	1 MHz to 20 MHz
Maximum pulsing rate	20 kHz PRF
Pulser delay	Adjustable from 0 µs to 25 µs in 2-ns increments
Pulse output	Amplitude from 50 V to 200 V, width from 20 ns to 500 ns
Receiver delay	Adjustable from 0 µs to 25 µs in 2-ns increments
Receiver DAC	Up to 30 dB/µs on each element slope before summing
Input filters	Four user-selectable ranges: None 500 kHz to 5 MHz 2 MHz to 10 MHz 5 MHz to 15 MHz
Input impedance	50 W
Inspection mode	Pulse-echo, transmit-receive (programmable)
Dynamic range	56 dB/channel
Computer interface	Both RS-232 and Ethernet™ standard
Focal law storage	Up to 1024 different laws
Power requirement	85 V to 265 V, 47 Hz to 63 Hz
Operating temperature	0°C to 50°C

Products used for this application

PipeWIZARD

Das PipeWIZARD ist ein automatisches Prüfsystem (AUT) für Rundschweißnähte, dass mit Phased-Array und konventionellem Ultraschall prüft. Speziell für die Schweißnahtprüfung vor Ort unter extremen Bedingungen bestimmt, ob Offshore oder Onshore.