Automated

NDT Systems

Material
Testing
Systems
 Ultrasonic Testing System
LONGITUDINALLY WELDED SAW PIPE UT INSPECTION SYSTEM

This state of the art ultramodern system consists of

multi channel ultrasonic equipment with transducers
and other associated electronics subassemblies and
test mechanics. UT Equipment type: Open
architecture PC based multi channel UT test and
evaluation system. System can be provided in
various configurations as per the customer
requirement meeting various standards like API,
Shell, EXXONMOBIL, etc. for example test
configuration can be like four I, one X, Tandem & ON
Bead (8 probes for longitudinal defect in I mode, 4
probes transverse defect in X mode, 4 probes for
Tandem and 2 probes for on bead).
Electronics: Quick Scan:
! Multi channel ultrasound system for industrial
applications.
! Parallel and multiplexed channels capability

! Up to 8 parallel channels or 32 channels in

multiplexed mode
! Channels for defect detection and dimensioning,
including OD, ID, and WT measurements
! Four gates per channel including a synchronization
gate
! Multiple-alarm capability

! Open architecture enabling the use of multiple units

when a large number of parallel or multiplexed
channels are required

SHELL INSPECTION SYSTEM

A tailor made immersion type inspection system with
3 axis manipulator was developed for forged shell
components. The system is fully automatic with
gantry type pick and place system, in feed and out
feed buffer with walking beam type conveyor system.
Multi channel PC based UT system is provided for
high speed simultaneous inspection of the forged
shell. The data is automatically generated and stored
in the computer.
SPIRAL WELD PIPE UT INSPECTION SYSTEM

This new generation system has been designed

considering the complexity of the inspection
sequence incorporating latest state of art Laser
based Weld Tracking System. This multi-channel
ultrasonic inspection system can take care of various
configurations required by the customers now a
days. This system is intended for high-speed
ultrasonic inspection of spiral welded pipe. It can be
installed for on-line inspection or off-line inspection
testing. Flaw detection meets or exceeds API Spc.5L
and 5CT, or as specified by the customer. The basic
system includes 16 channels with expansion
capacity to 32 channels for enhanced flaw detection
in heavy thickness welds. The channels for body
inspection depend on inspection coverage and
inspection specification, from 16 to 48 channels.
Electronics: Quick Scan:
! Multi channel ultrasound system for industrial
applications.
! Parallel and multiplexed channels capability
! Up to 8 parallel channels or 32 channels in
multiplexed mode
! Channels for defect detection and dimensioning,
including OD, ID, and WT measurements
! Four gates per channel including a
synchronization gate
! Multiple-alarm capability
! Open architecture enabling the use of multiple
units when a large number of parallel or
multiplexed channels are required.

IMMERSION SCANNING SYSTEM

We deliver immersion tank system for automated
inspection of forging, auto component, bars etc.
Such system provides complete inspection with
reliable results at high inspection speeds. The
generated record is stored in computer. The tanks
are equipped with multi axis scanner depending on
the requirement of the application
 Ultrasonic Testing System
UT PLATE INSPECTION SYSTEM

Fully automatic 60 to 300 Channels system

(depending on the plate width and area to be tested)
for 100% coverage of the plate width has been
developed. It is fully automatic, state of the art,
computer based system generating C-Scan type
report.
Mechanical system consists of Gantry arm, Client-
computer, Vertical drive system, Tracking structure
pneumatic system, Transducer holder & Motors. The
probes are placed in the probe holder and water for
the coupling is fed with pump. Probe holder is
designed in such as way that it ensures a small layer
of water between surface of plate and probes hence
problem of improper coupling is avoided. These
holders have a mechanical arrangement to clamp on
to the surface of the plate as soon as the plate comes
below it for testing. All these mechanics are held by
an over head boom or gantry. Vertical drive system is
used to vary the height of the probes holders
according to variations in plate thickness. The probe
holders are mounted on guided pneumatic cylinders
and these cylinders clamp on to the plate as soon as
plate moves below it. The probe holders are
connected to pneumatic cylinder via a universal joint
kind of arrangement to enable probes to get aligned
to the plate surface, the landing mechanics are
sturdy enough to avoid bending caused due to
friction between probe shoe and plate surface. The
system is complete with water reservoir pumps etc.
The system operates in complete automated cycle
after initial settings are done for a particular plate size
and the inspection is monitored by an operator in
control room.
SEAMLESS PIPE INSPECTION SYSTEM

Our principal Olympus NDT has developed an

innovative Full Body Inspection System dedicated to
Seamless Pipes. Based on the Water Wedge
concept holding linear Phased Array probes, the
Olympus NDT system provides a flexible technology
that can be used to meet the most stringent
requirements such as the API and the major oil
producer specifications. The Water Wedge
assembly can be implemented with a stationary
rotating conveyor associated to a mechanical portal
''gantry type'' or with a helical conveyor using a ''V
type'' mechanical support. The system contains
several Water Wedges: each Water Wedge is
dedicated to one or two inspection modes (when
oblique detection is required). A total of six inspection
modes are possible: Longitudinal, Transverse,
Oblique (multiple angles), WT, Laminations and
Coupling check. The number of Water Wedges is
optimized according to the inspection requirements
such as type of defects, productivity, etc. Each Water
Wedge is interchangeable for more flexibility and
easy maintenance operation and can hold different
probe holders housing one or two linear Phased
Array Probes. Pipe rotation and water wedge
translation are linked with encoders to ensure a
perfect defect mapping.
ERW TUBE/PIPE UT INSPECTION SYSTEM

Gantry Based UT Inspection system has been

developed for both weld and body lamination
inspection system. The system achieves very high
inspection speed of 25-30m/sec. some of the
specification for this system are as below:
! Pipe Diameter: 6-20”
! Length: 6-18m
! Scanning Speed: 25-30m/min
! Laser Seam Tracking
! 8 channels for Weld and 16-24 Channels for Body
! Qualification: API
The gantry type lay out gives the flexibility in
installations depending on customer's mill lay out.
System meets the API norms and can be adapted for
customers' specific requirement.
COIL UT INSPECTION SYSTEM:

Coil UT inspection system consists of 25-96

channels depending on percentage of the area to be
scanned and width of the coil. This system is suitable
for both spiral plant mill as well as ERW plant mill
application. The system consists of gantry type
mechanism which shifts the probe cluster form inline
position to off line calibration position. The system is
fully automatic and controlled with its own PLC which
is in turn integrated to mill's control system.
Some indicative specifications :
Coil Width: 600-2000mm
Plate Width: 600-5000mm
Testing Speed: 2-10m/min
Coverage: 25-100%
BAR UT INSPECTION SYSTEM:

The Bar UT system has been designed keeping in

view today's stringent requirements of the industry.
The system is available with both conventional and
latest Phased Array ultrasonic technology. A wide
range of configurations have been worked out
keeping customer's requirement and budget in view
of our client like system can be bar rotating type (slow
speed) or non bar rotating type (high speed),
conventional UT or Phased Array UT (for high
sensitivity), Rounds or RCS. The diameter range is
from 20-200mm depending on type of system
selected.
The system has floating head technology which
gives very high repeatable performance.

Cassettes in the frame with centering devices

Description of the Floating Head Assembly:

Floating head system

BAR UT INSPECTION SYSTEM:

Automatic closing of centering

devices on bended bars

Initial positioning adjustment

Centering devices 4points

for round and square bars

Floating Head suspension:

Used 4 spring leaded devices

This mechanic is mounted

inside the UT tank for inspecting
in total immersion

Floating frame with cassettes

Base fixed in the immersion tank

Cassettes are mounted in a floating head where the water path of the probes is adjustable depending on the
size of bars.
The frame described above is immerged in the UT tank filled with water.
The UT tank with its flexible probe holder inside is mounted on an elevating table.
BAR ECT ARRAY INSPECTION SYSTEM:

The ECA bar inspection solution is based on a mechanical concept using closing wear shoes, which allows the
inspection of the whole circumference of the products. The ECA system uses multiple layouts having several
probes. Each wear shoe comes in contact with the surface. The contact of the probe on the bar is maintained by a
moving spring-loaded system having multi-degrees of freedom. This concept of a flexible probe holder was
specifically developed by OLYMPUS in order to follow the twist of square bars and to give repeatable performance.

Mechanical frame for Mechanical frame for

square bars inspection round bars inspection
GIRTH WELD INSPECTION SYSTEM

We provide automatic girth weld UT inspection

solution based on our principal Qlympus NDT Pipe
wizard girth weld Inspection System
Automated inspection system (AUT)
Automated inspection system (AUT) MEETS OR
EXCEEDS ASTM E-1961 AND API 1104 CODES
! Fast scanning speed: 100 mm/s
! Inspection time of less than four minutes for
onshore, 36-dia pipe welds
Automated X Ray Inspection System
AUTOMATED STEERING KNUCKLE X RAY INSPECTION SYSTEM

Blue Star NDT has supplied various online

automated X ray systems for 100% inspection of
various components. The system can be designed
as per the customer's requirement. Most of the
automobile manufacturers particularly SG iron
casting are checking their components with this
system. The X Ray machines are from YXLON
Germany and robotics is designed by us.
! Excellent image quality.
! Inspection task flexibility.
! Operator convenience.
! Compact system.
! Automation capabilities.
! High Uptime
! Easy serviceability.
! Excellent after sales support.
! Inspection documentation.
! ADR capabilities.
! Good price/performance ratio.

Automated X Ray Inspection System for:

! Automobile Components (foundries)
! Aluminium Die cast components
! Pipe Inspection
! Aeronautics
! Heavy Engineering
! Defence
! Space Research
CABINET TYPE X RAY INSPECTION SYSTEM

Fully lead enclosed cabinet type X ray inspection system with multi axis manipulator to handle various jobs up to 60
Kg weight. The complete system is especially designed for aluminum die cast components manufacturers.
The system gives real time feed back to the operator to improve the process and also confirms quality of the
product.
! Cabinet on legs
! Dismountable (reduced space for transportation)
! High voltage generator and cooler are placed beneath the cabinet (reduced floor space)
! Control console with integrated control rack
! Minimal floor space required
! Easy installation
! Compact, ergonomic design
! Cabinet weight only 4,0t or 4.5t (XL)
! Cabinet size only 2500 x 2200 x 2720mm (WxDxH)
! Control console, cabinet, sample, lead glass window in line
! Ergonomic control console
! Best fit 17” monitor
- (3 times eye-screen distance/screen diagonal)
! Use of only 2 joy sticks
- Ability to concentrate on the X-ray image only
! External manipulator travel
! Fast manipulation
! Ergonomical height for loading
! Easy to use in practice

! Practical proven manipulation speed

! Up to 15m/min(49'/min), earlier systems 2-3m/ min (8'/min)
! Adaptable for each inspection position
! Increased throughput by using simple sample fixtures
! Programmable inspection sequence
! Experience of more than 100 installed systems
! Easy to maintain
! Diagram of allowed/safe travel distances
Collision protection by software & hardware greater travel distances (depending on test part size)
! Quick remote PCNC service
! plug in connection for safe, easy and quick installation
CABINET TYPE X RAY INSPECTION SYSTEM

! Large samples may be tested

! Batch test of smaller samples
! High travel speed (known weight)
! Sample still upright
! No special / strong fixture for sample needed
! No adaptation of magnification necessary
! High sample weight
Direct your enquires to: Blue Star Testing Machines Department e-mail: ndtenquiry@bluestarindia.com
Website: www.electronics.bluestarindia.com
Blue Star Limited, Testing Machines
Headquarters:
Mumbai Delhi Kolkata Chennai
Sahas, 414/2, E 44/12 Industrial Area, 7, Hare Street, No. 46, Garuda Building,
Veer Savarkar Marg, Phase II, Okhla, Kolkata - 700 001 Cathedral Road,
Prabhadevi, New Delhi - 110 020 Tel: +91-33-22134000 Chennai - 600 086
Mumbai - 400 025 Tel: +91-11-41494000 Fax: +91-33-22134102/03 Tel: +91-44-42444000
Tel: +91-22-66664000 Fax: +91-11-41494004 Fax: +91-44-42444190
Fax: +91-22-66664001