Phased Array Presentation

AN OVERVIEW ON PHASED ARRAY TECHNOLOGY

HAROON CAJEE

PRESENTATION OVERVIEWPRESENTATION OVERVIEW

Company Introduction Brief Overview PA Method/Technology. Why should you embrace this innovation?

Oceaneerings number one ethic is the safety, health and well being of its employees, contractors, customers and the public.Safety will never be compromised.

POLICIES & STATEMENTSPOLICIES & STATEMENTS

United Kingdom

Middle East

Asia Batam, SingaporeKuala Lumpur, Perth

Africa

Americas

Dubai

OCEANEERING - GLOBALOCEANEERING - GLOBAL

UNBROKEN CONTINUOUS STERLING SERVICE TO PTMI SINCE 1993

SERVICE RANGESERVICE RANGE

ADVANCED AND CONVENTIONAL NDT - Phased Array TOFD - AUT

INDEPENDENT TRAINING SCHOOL

VENDOR & PROCUREMENT INSPECTION

MATERIALS ENGINEERING & TESTING

ROPE ACCESS

OFFSHORE & ONSHORE PIPELINES

INTEGRITY & INDEPENDENT INSPECTION AUTHORITY

Automated Phased Array Ultrasonic Systems Experienced in offshore and onshore, Sub-sea and difficult terrain Aberdeen, Indonesia and Abu Dhabi support facilities Large pool of permanent inspection personnel

PHASED ARRAY AUT - PIPELINESPHASED ARRAY AUT - PIPELINES

PORTABLE and or SEMI AUTOMATED ULTRASONIC & TOFD INSPECTION USING HAND HELD SCANNERS & PHASED ARRAY PROBES

WHY IS IT DIFFERENT FOM CONVENTIONAL UT Encoding & recording capability.

Another way to do UT No magic, only physics!

ADVANTAGES - PA facilitates speedier inspections, interpretation aids and smaller scanning devices thus increasing the application.

PORTABLE PHASED ARRAYPORTABLE PHASED ARRAY

CODE PERMITS IN LIEU OF RADIOGRAPHY

35 40 45 55 65

Delays

WELD INSPECTIONWELD INSPECTION

SOUND PROPAGATIONSOUND PROPAGATION

Multiple Crystals

Allows for larger inspection area and increased probability of detection

Beam Steering

Allows for optimal detection / sizing for traditional and complex geometries.

Full Coverage / Focusing

Allows optimal sizing of defects

Phased Array Image

X-Ray Image

TYPICAL IMAGE RT /PA

PorosityRadiography Phased Array technique

SCAN AND DEFECT SAMPLESSCAN AND DEFECT SAMPLES

InclusionRadiography Phased Array technique


Incomplete Root Penetration

TOFD technique

Radiography Phased Array technique


KEY OBJECTIVE The integration of RT activities with the production needs would require careful planning and

the use of new technologies to ensure minimal disruption at an affordable price. The NDT Scope especially RT needs to be completed in a manner that minimizes downtime of other trades and completed in a timely manner to ensure that crucial production and welder control information are relevant and that the production process in respect of hydro-test, painting, site erection and commissioning are not impeded. In this instance we have the added concerns of the proximity of existing plants and the potential impact on the nucleonic alarms

CHOICE OF TECHNIQUERT Conventional

RT SCARPA/TOFD

PRODUCTIVITY-COST EFFICIENCYINTEGRATION-SAFETY

METHODOLOGY PREMISE/DRIVERSMETHODOLOGY PREMISE/DRIVERS

INSPECTION TECHNIQUE COMPARISONINSPECTION TECHNIQUE COMPARISONMethod Pipe Crew Size

Scan / shot time

Set-up time

PRODUCTIVITY Welds per hour

Production Interruption

Safety Hazards

Record of Inspection

Auditable Results

RT2 Sch 40 2 man 5 min. 5 minutes per/weld 6 to 10 100% 100%

YES YES

12 Sch 80 2 man 30 min 5 minutes per/weld 2100% 100% YES YES

24 Standard 2 man 60 min

5 minutes per/weld 1.5

100% 100% YES YES

Manual UT

2 Sch 40 1 man 10 min. 5 minute per/weld NA 0% 0%NO NO

12 Sch 80 1 man 30 min 5 minute per/weld 20% 0% NO NO


5 minute per/weld 1.5

0% 0% NO NO

PAAUT

2 Sch 40 2 man 30 sec 3 minute per/weld 10 to 20 0% 0%YES YES

12 Sch 80 2 man 1 min3 minute per/weld 10 to 12 0% 0% YES YES


3 minute per/weld 10 to 12 0% 0% YES YES

Amounts are based on averages, results will vary.

2. RT: Assumes required exposures with 20 curie source.

3. Manual UT: Assumes minimum scanning requirements as per ASME.

4. Set up time is based on typical accessibility and work plan.

NOTE: Does not include time and or cost for film processing, reporting, re-shots, etc.

RADIOGRAPHY vs PHASED ARRAYRADIOGRAPHY vs PHASED ARRAY

RADIOGRAPHY

Radiation Source requires large area of clearance.

Results take time to filter through the system , films to be processed , interpretation and reports

One Dimensional view Productivity in the region of 20 welds

per RT crew per 10 hour shift in a fabrication shop environment

Productivity in the region of 10 welds per shift in situ i.e platform field welds

Re-location of spools for RT

PHASED ARRAY

Work does not require any personnel clearance

Three dimensional Images Hard Copy digital record Automated systems Immediate results in most cases Inspection can take place along side

welders , no need for re-location of spools

Immediate repairs can be carried out if needed

Productivity in the region of 75 welds per PA crew per 10 hour shift in a fabrication shop environment.

Productivity of 30 welds per PA crew per 10 hour shift in situ

YES , WITHOUT A DOUBT

RT PLACES A CEILNG ON YARD PRODUCTIVITY

INTEGRATING RT WITH EXISTING TRADES IS A MAJOR CHALLENGE

RT RESULTS IN DELAYS WHICH PARLAYS INTO FINANCIAL LOSSES

YOU CAN CREATE THE MOST EFFICIENT PROCESSESS HOWEVER YOUR OVERALL CAPABILITY AND OUTPUT WILL BE IMPEDED BY RT

THERE IS NO SAFE LEVEL OF RADIATION BUT DUE TO LITTLE ALTERNATIVES WE ACCEPT AS LOW AS REASONABLY POSSIBLE

ALARP

RT RESULTS IN BACKLOGS, MULTIPLE HANDLING OF ITEMS,CO-ORDINATION & DELAYS

RT RESULTS TAKE ON AVERAGE 24-36 hours TO CONFIRM

DOES THIS METHOD ADDRESS A NEED IN YOUR ENVIRONMENT?

DOES THIS METHOD ADDRESS A NEED IN YOUR ENVIRONMENT?

YES , IT UNDOUBTEDLY ADDRESSES A NEED IN THE MARKET

CODES AWS D1.1

ASME B31.3ASME VIII

ASME B31.1

MATERIALS RANGE Carbon Steels Stainless Steels

TitaniumInconel

THICKNESS RANGE >6MM

>3.5MM TO 6MM WITH ADDITIONAL VALIDATION AND CLIENT APPROVAL

CONFIGURATIONSAll welds with access to one side as a minimum can be inspected with PA , including nozzles , nodes , circumferential welds and Longitudinal welds

LIMITATIONS Pre-engineering required Planning is a requisite Will not cover complete

scope of welds

WHAT ARE THE PRIMARY APPLICATIONS FOR THIS METHOD?

WHAT ARE THE PRIMARY APPLICATIONS FOR THIS METHOD?

THE SIMPLE ANSWER IS NO

THE PARAMETRES AND TECHNOLOGY RELATED TO RT IS SIMILAR TO THE EDISONS BULB, NOTHING MUCH HAS CHANGED

ASIDE OF SEMI AUTO UT THERE IS NO OTHER TECHNOLOGY ON THE HORIZON

ITS EITHER RT OR PA UT

ARE THERE ANY COMPETING TECHNOLOGIES OR OTHER

OPTIONS

ARE THERE ANY COMPETING TECHNOLOGIES OR OTHER

OPTIONS

RESISTANCE TO CHANGEInternal & External factors

START UP COSTS All new and emerging technologies require high capital investment thus discouraging adoption

PRICE AS PERCEIVEDDirect price higher as generally we disregard the intangible costs. Radiography overall is a very expensive option.

WHAT ARE THE MAJOR IMPEDIMENTS THAT WE FACE IN

INTRODUCING THIS TECHNOLOGY

WHAT ARE THE MAJOR IMPEDIMENTS THAT WE FACE IN

INTRODUCING THIS TECHNOLOGY

RT HAS BEEN ADOPTED AS THE PRIMARY METHOD DUE TO COMPETENCY ASSURANCE ISSUES WITH MANUAL ULTRASONICS.

MANUAL UT Lack of hardcopy and

completely relies on the skill, competency, experience and integrity of the individual and highly influenced by the environment and location and other external issues

PHASED ARRAY UT

Validated Techniques for all operators to work to.

Recordable System which provides a digital hard copy , with encoded scans providing an accurate reference point.

All key processes are automated

Automated reporting system available

HOW DO WE ADDRESS THE COMPETENCY ASSURANCE ISSUES?

HOW DO WE ADDRESS THE COMPETENCY ASSURANCE ISSUES?

INITIALLY MARGINALLY HIGHER DIRECT COSTS BUT OVERALL PA MUCH CHEAPER

EFFECTIVELY ONE OFF START UP COSTS

HUGE PRODUCTIVITY GAINS

WHAT ARE THE COMMERCIAL IMPLICATIONS?

WHAT ARE THE COMMERCIAL IMPLICATIONS?

Price dependant on volume and duration of project.

PA IS SUBSTANTIALLY CHEAPER THAN RT

TECHNICAL

Pre Planning Mandatory

Pre Engineering Required

Training and Certification of Personnel

Streamlining the process

Gaining Client Approval

OPERATIONAL Integration into the piping

workshop process Expediting NDE Requests

, PA will be carried out much earlier in the process than Radiography

Determining NDE method for all welds on each spool and control

Co-Operation of All personnel

WHAT ARE THE TECHNICAL & OPERATIONAL IMPLICATIONS ?

WHAT ARE THE TECHNICAL & OPERATIONAL IMPLICATIONS ?

PRE_PLANNING REQUIRED

Validation to date shows a slight decrease in repair rates due to the ability to size in more dimensions .

Where radiography utilizes length only for accept or rejection , PA-UT utilizes Length and height

Fully encoded scanning ensures accurate defect information is available including depth , length and circumferential location

DEFECT DETECTION AND REPAIR RATESDEFECT DETECTION AND REPAIR RATES

NO MAJOR DIFFERENCE

CODES CODES

ASME CC 2235 (CIT) allows use of UT instead of RT for wall thickness > 12.7mm

Code case 181 allows use of UT instead of RT for all thickness ranges

TOFD, PA and TOFD/PE techniques allowed

Performance Demonstration required

CODE PERMITS AND FACILITATES

27

KEY DELIVERY COMPONENTS

CAPABILITY SKILLS SETS - Critical

PA/TOFD FACILITIESPA/TOFD FACILITIES

60m perDay with 2 ops.

PA/TOFD CAPACITYPA/TOFD CAPACITY

SCANNERSSCANNERS

Oceaneering has developed its own range of scanning devices to allow rapid high quality scans on all diameter pipes and plate welds.

The results of phased array encoded inspections are very reliant on the scanners utilized and Oceaneering has invested heavily to ensure the very best of equipment is available.

Link scanners in Use

SCANNER IN USESCANNER IN USE

Special scanners designed and manufactured

PROJECT SPECIFIC SCANNERPROJECT SPECIFIC SCANNER

VALIDATIONVALIDATION

Validation is required by ASME and Oceaneering manufactures in house code case compliant validation welds

34

TRAINING FACILITY

ABSOLUTELY VITAL COMPONENT

35

TRAINING FACILITY


36

INTERNAL TRAINING


37

CLIENT TRAINING


YOU NEED TO ADOPT THE BEST PRACTICES AND METHODS AVAILABLE

LARGE ORGANIZATIONS INHERENTLY FACE INERTIA AND LACK OF AGILITY.

THIS TECHNOLOGY REDUCES AND MITIGATES THE INHERENT RISK OF RT AS THE PRIMARY METHOD

WHY SHOULD WE PROCEED WITH THIS TECHNOLOGY?

WHY SHOULD WE PROCEED WITH THIS TECHNOLOGY?

IMPROVES EFFICIENCY AND PRODUCTIVITY

ENHANCES SAFETY AND ELIMINATES RADIATION HAZARD

RADIOGRAPHY IS A VERY EXPENSIVE OPTION

THANK YOU VERY MUCH

OUR GLOBAL EXPERIENCE, LOCAL TRACK RECORD AND TECHNOLOGY WILL PROVIDE

YOU WITH A VALUABLE PARTNER TO ACHIEVE YOUR GOALS AND OBJECTIVES TO

OUR MUTUAL BENEFIT

Slide 1PRESENTATION OVERVIEWSlide 3Slide 4Slide 5Slide 6Slide 7Slide 8WELD INSPECTIONSOUND PROPAGATIONTYPICAL IMAGE RT /PASlide 12Slide 13Slide 14METHODOLOGY PREMISE/DRIVERSINSPECTION TECHNIQUE COMPARISONRADIOGRAPHY vs PHASED ARRAYSlide 18Slide 19Slide 20Slide 21Slide 22Slide 23Slide 24DEFECT DETECTION AND REPAIR RATESSlide 26KEY DELIVERY COMPONENTSPA/TOFD FACILITIESPA/TOFD CAPACITYSCANNERSSCANNER IN USEPROJECT SPECIFIC SCANNERVALIDATIONTRAINING FACILITYTRAINING FACILITYINTERNAL TRAININGCLIENT TRAININGSlide 38Slide 39

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Phased Array Presentation