WELD INSPECTION SOLUTION

PV-100, PV-200

Fast inspection time Elimination of hazards and site clearance downtime of RT Code compliance Instant inspection results Full data storage

920-199A-EN

Ultrasonic Weld Inspection Solutions

Olympus has created the AUT PV solutions (automated ultrasonic testing) to provide you with an affordable means to inspect welds according to code. These solutions are portable and can be put to work virtually anywhere. The perfect combination of acquisition unit, scanner, encoder, and software makes the inspection of pressure vessel welds and other welds an easy task. Fast inspection of small- and large-diameter welds 100% volumetric weld coverage Adaptable to butt welds, circumferential welds, long seams, one-sided access configuration, and most common weld profiles Inspection of wall thicknesses from 8mm to 300mm and part diameters from 100m to flat Digital archiving of inspection data Elimination of film archiving Portable for in-house and field inspections Improved productivity compared to radiography Improved probability of detection (POD) compared to radiography

Automated Ultrasonic Testing Versus Radiography Testing

Ultrasonic technology has been proven very effective for pressure vessel weld inspections and it is easily adapted to common codes such as API and ASME Sec III, V, VIII, CC2235, CC2599, and CC2600.

COMPARING THE INDICATIONS

Measurements Performed by ID Type of Defect
Toe crack

AUT
Position X, Y, and Z Length sizing Height sizing Position X, Y, and Z Length sizing Height sizing Position X, Y, and Z Length sizing Position X, Y, and Z Length sizing Height sizing

Radiography
Position X and Y Length sizing No detection

2 3
4

Centerline crack Porosity Incomplete root penetration

3 4

Position X and Y Length sizing Position X and Y Length sizing

Combining Different Techniques for Full-Weld Coverage and Improved Efficiency

1 2 3 4

PHASED ARRAY PULSE-ECHO TECHNIQUE

The phased array technique uses a mosaic of transducer elements in which the timing of the elements excitation can be individually controlled to produce a certain desired effect, such as steering the beam axis or focusing the beam.

Surface-breaking crack in a 50 mm thick weld, undetected by radiography

1 2

Analysis of the weld inspection results given by AUT and radiography shows that AUT provides both depth and height information, and is more sensitive to planar-type defects while eliminating radiation hazards.

4 3

PULSE-ECHO TECHNIQUE
The pulse echo technique is an ultrasonic test in which discontinuities are detected by the reflected echoes from defects.

Benefits of the Olympus PV Solution

PV Solution Radiation hazard No No Yes Very good Very good High precision High precision Yes Yes No Poor Good Poor Good precision Radiography Restricted area needed Ease of deployment on site Probability of detection (POD) (planar defects such as crack and lack of fusion) Inspection throughput Depth sizing capability Length sizing capability

TIME-OF-FLIGHT DIFFRACTION (TOFD) TECHNIQUE

The time-of-flight diffraction technique is an ultrasonic test that relies on the diffraction of ultrasonic beams from the corners and ends of internal structures (primarily defects) in a component being tested.

CREEPING WAVE TECHNIQUE

The creeping wave technique is an ultrasonic test in which discontinuities are detected by the return of a creeping wave that tracks the surface of the component being tested.
2

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PV-100
Pulse-Echo and TOFD Inspection Solution
The PV-100 solution is based on the proven OmniScan UT flaw detector. This advanced UT instrument uses two inspection techniques simultaneously. The combination of time-of-flight diffraction (TOFD) and the pulse-echo or creeping wave technique allows a full volumetric inspection in a single pass. Inspection results are available instantaneously providing immediate code based acceptance or rejection. This solution was specifically designed to meet the productivity requirements of construction welding in petrochemical and power-generation industries.

Combining Different Techniques for Improved Efficiency and POD

Pulse-echo channel, 60 shear wave for weld cap coverage.

PV-100 ATTRIBUTES
Quickly detect weld defects Accurately size defects Easily characterize weld defects Easily create customized reports On site inspection without production disruption Full data collection for auditing and code compliance Wind tower construction Pressure vessel and piping construction Structural construction welding Structural welded components Production control In-service inspection of welds
Combining pulse-echo and TOFD channels offers complete coverage of the weld. Pulse-echo channel, 70 shear wave for weld root coverage. Amongst other advanced tools, TomoView analysis software offers a TOFD Manager for calibrations, lateral wave straightening, lateral wave removal, and synthetic aperture focusing technique (SAFT). In addition, the Volumetric Merge tool can merge multiple groups.

PV-100 APPLICATIONS

Standard Inclusions
Contents of the PV-100 kit are configured depending on the thickness of the parts to inspect.
TOFD channel for weld volume coverage.

Typically a PV-100 kit consists of the following: OmniScan UT acquisition unit UT probes and wedges Industrial scanner Encoder Umbilical cable Preamplifier Irrigation system

PV-100 SPECIFICATIONS
Part thickness: 8mm up to 300mm Part diameter: 100mm up to flat Part material: carbon steel

Available Scanners for PV-100 Solution

WeldROVER HSMT-X03

Manual Couplant Feed Unit

PV-100 OPTIONS
UMBILICAL CABLES
Two different umbilical cables are available: -- The closed-type umbilical offers the most rugged protection. It covers the cable with a resistant, waterproof, and dust proof conduit. -- The divisible type is composed of two split shells that protect the cables. Although not as rugged as the closed-type umbilical, it offers other advantages: the cables inside the umbilical can be changed at any time.

Closed umbilical cable

CFU03 ELECTRIC COUPLANT-FEED UNIT

The CFU03 is a portable electrical pump unit used to supply couplant to wedges during ultrasonic inspections.

HSMT-FLEX

WTR-SPRAYER-8L MANUAL COUPLANT-FEED UNIT

The manual feed unit offers a cheap and efficient way to supply couplant to wedges during automated inspections.

TRPP-5810 REMOTE PULSER/PREAMPLIFIER FOR TOFD INSPECTION

The TRPP-5810 unit is a high-performance remote pulser/preamplifier dedicated to TOFD inspections and compatible with Olympus industrial scanners.

PANAMETRICS 5682 PREAMPLIFIER FOR TOFD INSPECTION

The Panametrics 5682 ultrasonic preamplifier provides low-noise amplification of ultrasonic signals (for one probe) ranging from 500kHz to 25MHz.
HSMT-Flex 4 OmniScan UT 8 channel UT flaw detector

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PV-200
Phased Array and TOFD Inspection Solution
Olympus has developed a versatile phased array solution for weld inspections. The PV-200 solution uses a variety of techniques to achieve a productive and efficient inspection. Phased array technology allows the scanner to adapt to different weld inspections without changing the probe position. This dramatically reduces setup time and eliminates many of the mechanical components needed with conventional ultrasonic probes. Fewer mechanical parts means fewer mechanical failures. Fast setup without manual probe adjustment Easy adjustment of ultrasonic parameters Smaller, more versatile scanners easily adjust to different weld configurations. Complete weld coverage in a single pass The PV-200 solution brings together an Olympus acquisition unit, scanner, probes, and software tailored to your needs. The acquisition unit controls all the multielement-probe channels. The software is equipped with a dedicated calculator that guides you when changing beam angles, depth, and focus without moving the probe. Length and depth sizing for code acceptance /rejection is performed at the time of the inspection and results are recorded rapidly.

Combining Different Techniques for Improved Efficiency and POD

Phased array channels for full volumetric weld coverage

Combining PA and TOFD offers complete coverage of the weld.

Amongst other advanced tools, TomoView analysis software offers a TOFD Manager for calibrations, lateral wave straightening, lateral wave removal, and synthetic aperture focusing technique (SAFT). In addition a C-scan Merge tool merges interleaved C-scans based on minimum or maximum amplitude, or TOF.

TOFD channel for additional volumetric coverage

Standard Inclusions Available Scanners for PV-200 solution

WeldROVER HSMT-COMPACT
Contents of the PV-200 kit are configured depending on the thickness and material of the parts to inspect. Typically a PV-200 kit consists of the following: OmniScan PA acquisition unit (16:128 or 32:128) UT probes and wedges PA probes and wedges Industrial scanner Encoder Umbilical cable Preamplifier Irrigation system

PV-200 ATTRIBUTES
Inspect immediately after welding to help you monitor the welding process. Detect and size vertical defects using TOFD and tandem techniques (requires instrument with P-R option). Maximize the probability of detection (POD) with controlled focusing. Create an automatic setup procedure for any weld profile. Reduce data analysis and reporting time. Many inspection parameters such as weld profile are accommodated in software offering improved flexibility.

PV-200 APPLICATIONS
Wind tower construction Pressure vessel construction Structural construction welding In-service weld inspection Inspection of carbon steel, austenitic, and dissimilar welds Inspection of circumferential and long-seam welds

CHAIN

PV-200 SPECIFICATIONS
Part thickness: 8mm to 100mm Part diameter: 100mm up to flat Part material: carbon steel and austenitic steels
MCDC-01: one axis DC motion controller

HSMT-FLEX

OmniScan PA flaw detector

PV-200 OPTIONS
Options are identical to those of the PV-100 described on page 4: Umbilical cables CFU03 Electrical couplant-feed unit WTR-SPRAYER-8L Manual couplant-feed unit TRPP-5810 Remote pulser/preamplifier for TOFD inspections Panametrics 5682 Preamplifier for TOFD inspections

Remote control WeldROVER scanner

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Probe and Wedge Ordering Information

PHASED ARRAY PROBES
Part Number 5L16-A10 10L32-A10 5L32-A11 5L64-A12 5L60-A14 Frequency (MHz) 5.0 10.0 5.0 5.0 5.0 Number of Elements 16 32 32 64 60 Pitch (mm) 0.6 0.3 0.6 0.6 1.0 Elevation (mm) 10 7 10 10 10 Corresponding Wedge SA10 SA10 SA11 SA12 SA14 Connector Type OmniScan OmniScan OmniScan OmniScan OmniScan

PHASED ARRAY WEDGES

Part Number SA10-N55S-IHC SA11-N55S-IHC SA12-N55S-IHC SA14-N55S-IHC Type of Beam Normal Normal Normal Normal Refracted Angle () 55 55 55 55 Wave Type Shear Shear Shear Shear Wedge Option Group IHC IHC IHC IHC Probe Type A10 A11 A12 A14

TOFD AND UT PROBES

Part Number C540-SM C542-SM C543-SM C563-SM C544-SM C566-SM C567-SM C568-SM Frequency (MHz) 2.25 2.25 5.0 10.0 10.0 2.25 5.0 5.0 Element Diameter (mm) 12.5 6.0 6.0 3.0 6.0 9.5 3.0 9.5 Corresponding Wedge ST2 ST1 ST1 ST1 ST1 ST2 ST1 ST2 Connector Type Microdot Microdot Microdot Microdot Microdot Microdot Microdot Microdot

TOFD AND UT WEDGES

Part Number ST1-45L-IHC ST1-60L-IHC ST1-70L-IHC ST2-45L-IHC ST2-60L-IHC ST2-70L-IHC SPE2-45S-IHC SPE2-60S-IHC SPE2-70S-IHC Refracted Angle () 45 60 70 45 60 70 45 60 70 Wedge Option Group IHC IHC IHC IHC IHC IHC IHC IHC IHC

Optional Software Ordering Information

Part Number TV29-LITE TV29-A TV29-F TV29-FSIMU Description TomoView 2.9 LITE (Weld and Aero) TomoView 2.9 Analysis TomoView 2.9 Inspection including Advanced Calculator TomoView 2.9 Inspection including Advanced Calculator and Acoustic Field Simulation Module
is ISO 9001 certified. 5L64-A12 probe with SA12-N55S-IHC wedge

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PV_100_200_EN_201002 Printed in Canada Copyright 2009 by Olympus NDT. *All specifications are subject to change without notice. All brands are trademarks or registered trademarks of their respective owners and third party entities.