Vol 45 No.3 – May/June 2008 Print Post Approved No. PP 340929/0021
OFFICIAL JOURNAL: AUSTRALIAN INSTITUTE FOR NON-DESTRUCTIVE TESTING
Print Post Approved No. PP 340929/0021
Vol. 43 No.4 – July/August 2006
Radiography — Electromagnetic — Penetrant — Eddy Current — Ultrasonic
NON-DESTRUCTIVE TESTING Australia
contents
EDITORIAL COMMITTEE: Editor: C.M. Hockings Technical Paper Editor: John Norman BRANCH EDITORIAL OFFICERS: N.S.W. Colin Hockings C/- QS&RM, SAB2/8, Qantas Airways, Mascot, NSW 2020 Mob: 0434 074 987 E:
[email protected] VIC: Dave Mullet, Lectromax Australia, 13 Brougham Street, Eltham,Vic. 3095 P: (03) 9431 1041 F: (03) 9431 2405 W.A.: Brett Gribble 2 Diamantina Way Henderson, WA 6166 P: (08) 9437 1068 F: (08) 9437 1069
[email protected] SA: Kathryn Varney 32 Myall Road, Para Hills, SA, 5096 P: (08) 8348 7010 F: (08) 8438 7001 E:
[email protected] QLD: Shayne Flynn 7 Madden Street, Silkstone, Ipswich, Qld. 4034 P: (07) 5461 1664 (W) NEW ZEALAND EDITOR: Christine Thomson NZNDTA 69 King George Avenue, Epsom, Auckland P: 64 9441 8507 F: 64 9441 4314 JOURNAL SUB-COMMITTEES: Certification Board News: Peter Sheedy Federal Council News: Dale Piddick Book Reviews: G.G. Martin Industry News: C.M. Hockings AINDT PO Box 52, Parkville Vic 3052 P: (03) 9326 7550 F: (03) 9326 7272 Website: www.aindt.com.au Email:
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July-August issue — 15 June September-October issue — 15 August November-December issue — 15 October INSTRUCTIONS TO AUTHORS OF TECHNICAL ARTICLES Manuscripts should be in electronic form: 1 in Word 2 typed with single spacing 3 with figures as tif or jpg files at better than 300dpi Manuscripts should include: 1 symbols and abbreviations conforming to recognised standards; metric units (SI) 2 references listed, after the text, in the order in which they occur in the paper 3 references indicated in the text by Arabic numerals in square brackets 4 tables and figures numbered separately but consecutively with arabic numerals and brief, descriptive titles 5 a reference in the text to all tables and figures 6 graphs and diagrams made with lines of sufficient thickness to reproduce well 7 titles and address of authors. Procedure for submission of manuscripts: 1. Copy of articles should be sent to: Colin Hockings, C/- QS&RM, SAB2/8, Qantas Airways, Mascot NSW 2020 Or email:
[email protected] 2. Manuscripts will be submitted to referees who will remain anonymous. 3. Five reprints of each paper will be supplied free to each author.
Vol. 45 No. 3 – May/June 2008
FRONT COVER: This picture is provided by NDT Equipment Sales and shows a modern isotope camera.This issue has some important information about changes to the local supply of industrial isotopes.
Regular Departments President’s Message
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Editorial
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Institute News
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Industry News
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Products and Services
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Special Features NANDTB News
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NATA News
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ICNDT News
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Interview — Arthur Harvey
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Condition Monitoring
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Industrial Isotope Contacts
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Technical Articles Wall thickness measurement sensor for pipeline inspection using EMAT technology in combination with pulsed eddy current and MFL
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G Dobmann, F Niese, H Willems and A Yashan
Portable phased array applications
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M Moles
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Published by: T he Australian Institute for Non-Destructive Testing, PO Box 52, Parkville, Vic 3052, Australia.
ISSN 0157-6461 Non-Destructive Testing Vol 45 No. 3
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COMPANY MEMBERS
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o summarize briefly, the aims and objects of the Australian Institute for Non-Destructive Testing are to promote co-operation between companies, government bodies and individuals in the study and development of non-destructive testing methods and techniques by means of lectures, demonstrations and symposia. In addition, the Institute takes an active interest in education for non-destructive testing and operates an NDT personnel qualification scheme. Firms, government departments or instrumentalities are invited to become Company members of any Branch of the Institute, Membership application forms or further information may be obtained from the Honorary Secretaries of the various Branches listed under Federal and Branch Officers. The main financial support for the Australian Institute for Non-Destructive Testing comes from the Company Members. The Institute is proud to list below these N.D.T. manufacturers, users and suppliers who support it. VICTORIA BRANCH ABEN Technical Services AeroStructures NDT Pty Ltd ATTAR Australian NDT Services Australian Paper Bureau Veritas AIRS Australia Pty Ltd CEM International Pty Ltd D.R.May Inspections Pty Ltd DSTO Air Platforms Division ETRS E.P.M & C Pty Ltd GE Inspection Technologies Geopave (Vic Roads) Holden Ltd Lavender International NDT Consultant Services (UK) Lectromax Australia Pty Ltd Metlabs NATA NDTEK Pty Ltd Olympus Australia Pty Ltd Prompt Industries Qantas Airways Limited Qenos, Olefins Manufacturing Sinclair X-Ray Inspection Services Pty Ltd Stainless Tanks & Pressure Vessel P/L
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AINDT website
Access information on Branch activity, Federal contacts, Certification, Membership, Conferences, Library, News, NDT ‘Links’, Job search and more. www.aindt.com.au
FEDERAL AND BRANCH OFFICE BEARERS FEDERAL EXECUTIVE OFFICERS NEW SOUTH WALES VICTORIAN BRANCH WEST AUSTRALIAN QUEENSLAND President: Mr Shayne Flynn BRANCH President: Mr M Lloyd-Diviny BRANCH BRANCH Treasurer: Mr Vince Wilcox Vice President: Mr Martin Lloyd-Diviny Membership Registrar: Mr David Mullett Secretary: Mr Dale Piddick Immediate Past President: Mr Bret Butler Federal Secretariat: Materials Australia Chief Executive Officer: Mr David Barnett Official Address: P.O. Box 52 PARKVILLE,VIC 3052 Phone: 03 9326 7550 Fax: 03 9326 7272 Email:
[email protected]
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President: Mr James Hobbs Hon Secretary: Mr Frank Edwards Official Address: P.O. Box 962 Balgowlah. NSW 2093 Email:
[email protected]
INSTITUTE
President: Mr John Norman Secretary: Mr Brett Gribble Treasurer: SOUTH AUSTRALIAN Mr Sean Burke Official Address: BRANCH 2 Diamantina Way President: Mr Tom Foerster Secretary: Ms Kathryn Varney Henderson, WA 6166 Email: Official Address:
[email protected] P.O. Box 3735 Secretary: Mr Graham Kidd Official Address: 71-73 Flemington Road North Melbourne Vic 3051 Email:
[email protected]
President: Mr Ian Hogarth Secretary: Mr Barry Cooper Official Address: P.O. Box 78 Amberley QLD 4306 Email:
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Port Adelaide SA 5015
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Certification Board Secretariat: Phone: 02 9949 8572 Fax: 02 9949 7573
Non-Destructive Testing Vol 45 No. 3
president’s message With the year slipping away the challenge becomes greater to ensure that we meet target dates set last year for Institute initiatives. Branch Councils are working hard to meet their commitments, so any assistance that you feel could be helpful would be appreciated I am sure. By the time this article has been published the Victorian Branch will have participated in a Careers Expo in Melbourne and the Queensland Branch a symposium on NDT Plant and Equipment Monitoring in the Sugar Industry at Townsville. I look forward to reporting on the outcomes of these initiatives in my next article. Activities within other Branch Councils are ongoing and I am sure they will be successful. I attended a National Aerospace Non Destructive Testing Board (NANDTB) meeting in Brisbane on the 27th March 2008. This Board has made good progress on policies and support processes that will serve the Aviation sector of our industry well. The Board has been in place for two years and is now in a position to provide guidance and advice in most facets within the aviation world. A draft strategic alliance will be put before the AINDT Federal Council for acceptance in September this year. As the NANDTB is independent to AINDT it was perceived essential that a strategic alliance be put in place. To date, the AINDT has had a limited representation in the Australian Aerospace sector due mostly to the administrative variations in the qualification and approval standards
Editorial No letters to the editor in this issue. But the point has been made and is restated again, that a divergence of views is healthy in any organisation, including the AINDT. Someone taking the time to express an opinion in the journal is important and a great stimulus for other interested members to consider the issue, whatever it is. And whilst not necessarily agreeing with any of the opinions expressed, it should help the reader to explore the subject and come to a better understanding of it. The correspondence between Lou Carro and Dave Barnett will not settle the issue of comparative certification costs. There are many variables affecting the total cost of certification not just the examination fees. Whether it be a personal expense or a company expense, it will be the aggregation of individual costs which need to be taken into account. Recognising also that some costs may be very real but difficult to show
Non-Destructive Testing Vol 45 No. 3
which apply to aerospace, and those which apply to other industries. This agreement brings to the AINDT a higher profile in the aerospace sector through its involvement in some of the Board’s activities, and brings to the NANDTB a professional network with international standing, operating throughout Australia. The NANDTB is internationally recognised as a full member of the European Forum of National Aerospace NDT Boards. It should be noted that neither organisation is subordinate to the other. Through such collaboration it is hoped that we gain an appreciation for the differences in cultural applications across many sectors. By striving for better understanding and awareness we can build on our skills in professional aptitude for complete harmonisation. If successful with such endeavours we can demonstrate through lead by example in support of the International Committee Non Destructive Testing (ICNDT) initiatives for Global Harmonisation. Shayne Flynn Federal President
EDITORIAL as a dollar value. Never the less, it is sound advice for those undertaking certification that they need to be fully aware of all the factors which combine to produce a final cost. Lou is to be thanked for bringing a topical and important subject to member’s attention. This issue has more Branch Institute news and Condition Monitoring news than usual, along with all the regular features. An excellent paper by Michael Moles from Olympus describes the basics and applications of phased array ultrasonic technology. It makes for a good introduction to the subject. The Aerospace Board reports from their Brisbane meeting hosted by Helitech, and there is a report on changes to the local supply of radioactive isotopes. Enjoy! Editor
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EDITORIAL Notes from the Desk The year 2008 looms large in the eyes of many people. Not only is it a leap year but it also serves as the traditional time in which the Olympic Games and the World Conference for Non-destructive Testing are held. This year, as we are aware, China will host both these significant events for the sporting world at large, and also for the more specific interests of the NDT community, and those that are associated with it. Ranking in importance the 24th Olympiad takes centre stage and will be held in Beijing from the 8–24 August 2008, during the two weeks before the 17th WCNDT is held in Shanghai, from 26–30 August 2008. The organising authorities for the WCNDT have therefore arranged these dates so that it would be possible for participants in the World Conference to participate in both of these world ranked events if they so wish. Notwithstanding this, the choice of Shanghai is perhaps the most fitting venue for the WCNDT, since it is, without doubt, the most dynamic of all cities in China. It offers much, not only to the tourist, but also to those concerned with science and technology. Shanghai is the headquarters of the Chinese Society of Non-Destructive Testing as well as being the home of the Shanghai Institute for Materials, which is one of the leading institute’s in the world when it comes to research and development into new NDT methods and techniques. Shanghai is an extraordinary city in its own right with its modernistic buildings contrasting with the old, more traditional styles of Chinese architecture. So, it is with great anticipation that AINDT’s two delegates will attend the conference and also the associated meetings of the International Committee for Non-Destructive Testing which determine the
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true course that NDT will follow over the next four years. For one of Australia’s delegates, Tony Sonneveld, who needs no introduction, the conference will have bitter-sweet memories since this will be the last meeting that he will attend as AINDT’s principal voting delegate. Having participated in ICNDT activities on the Institute’s behalf for something like twenty-five years it is worth reflecting on Tony’s involvement over all these years: • Attended every WCNDT since 1979 – a total of 7 world conferences – Shanghai will be his eighth. • Became Australia’s non-voting delegate in 1985 and voting delegate in 1992. • Elected as Chairman of ICNDT’s Membership Committee in 2004. In addition to this, Tony has been an independent member of one of ICNDT’s most influential committees, the Policy and General Purpose (PGP) committee for two successive terms and has served AINDT well in making positive contributions in this and all of his other roles. In many senses the 17th WCNDT will be the end of an era when Tony finally retires from his role as AINDT’s voting delegate to ICNDT. In doing so, an equally effective delegate will take his place, John Maccarone of the Queensland Branch. In writing this column, I would like to give thanks to Tony on behalf of AINDT for the outstanding work he has done on the international scene. There is no doubt that the work Tony will be doing next, for prostate cancer awareness, will be met with the same degree of enthusiasm and determination. We wish you every success in these endeavors. Dave Barnett Executive Officer
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INSTITUTE NEWS NSW Branch News
Security of Radioactive Sources
ANSTO – Reactor Redirection As a result of ANSTO’s decommissioning of the Hifar reactor and the new Opal reactor coming on line their business strategy has changed dramatically which greatly affects once customers of industrial isotopes. Lucas Heights operations have been supplying industrial isotopes such as Ir192 and Co60 for many years. ANSTO showed consideration of their customer base by arranging a radiography industry information session at Lucas Heights – Sydney. The session facilitated by ANSTO’s Celia Hacker was well represented by the NDT fraternity. It gave opportunity for its customers to obtain the necessary vendor contacts that can offer a supply and disposal service previously provided by ANSTO. The outcome for the customers is that they will have a choice of a registered isotope supplier that can provide a range of industrial radioisotopes. ANSTO will continue to supply a Safety Radiation Service comprising training, accreditations, calibration and consultancy services. Attendees at the information session were distributed with a detailed contact list for supplying, loading and disposal of sources both in Australia & Internationally. This is reproduced on page 80 of this issue. Suppliers stated that they are able to accommodate customers in delivery of a product as per ARPANSA regulations, handling all the necessary clearances, certificates & authorisations within the shortest delivery time possible. The presentation culminated with a hearty lunch and refreshments, giving the opportunity for customers, suppliers and ANSTO staff to intermingle and discuss options & future arrangements. Our thanks to Angela Donald, Celia Hacker, Athena Pribb and other speakers for their time and efforts to assist in the phase out of the supply of industrial isotopes. For any further information please contact Angela Donald or Natalie Chapman at ANSTO. James Hobbs
As noted in the last journal, Peter Ellis from ARPANSA was to discuss the preparation of the new Code for the security of radioactive sources. Sixteen members and guests joined Peter in Sydney to hear his presentation. The background to the work done by his group as part of the wider consideration of potential threats posed by chemical, biological and radiological was explained. He then discussed the structure and relationships between ARPANSA and the various jurisdictions which will apply this and other codes prepared by ARPANSA. Industrial radiography sources will fall into Category 2 which requires certain safety and security considerations appropriate to their potential threat. Category 1 is the most dangerous and would include high activity irradiators and the like. The aim of Peter’s group is that the code and its guidance documents are outcome based rather than prescriptive. This means that whilst offering suggestions on how to comply with the Code’s requirements, these suggestions are not the only way to comply. Each operator is free to develop and institute plans and procedures which are suited to his/her situation but show that the Code is met. ARPANSA is working closely with the US Department of Energy and the exchange of information in both directions. It will, as part of the implementation of the Code, be conducting training on developing safety and security plans. The details of this training are not finalised but will be offered around the country. The underlying premise of the work to be done will be based on the risk assessment of industrial radiography sources. To this end, Peter suggested that his aim is for a very practical and workable approach to addressing the security of these sources. Comments and questions were offered by those present, and while he is hopeful of finalising much of the material by end of April, those interested may download a copy of the code (RPS No. 11) from the ARPANSA web site and send any suggestions to Peter or one of his other staff, Julie Murray using the email sourcesecurity@ arpansa.gov.au
GE Inspection Technology Awards Congratulations to the winners of the 2007 GE Inspection Technology awards for radiography and ultrasonic testing. For radiographic testing; William Bate from Applus RTD Western Australia For ultrasonic testing; Luke Machell from Pearl Street Metlabs Victoria
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INSTITUTE NEWS WA Branch News March has been a busy month for the WA Branch. First we had our inaugural river cruise, followed up a few days later by a technical evening. The river cruise was a great success. While numbers were not quite what we would have liked, it was a great social event and we hope to build it up in the future. It represents the first real project for the new branch committee and things went pretty well getting the event organized. The MV River Bells left Barrack Street jetty and cruised up river towards Guilford. Things started quietly, with some civilized drinking and talking. Lunch was served on board, and there was a chance to get off the boat at a riverside vineyard and do a bit of sampling. Things get pretty lively on the return leg of the trip, and the photograph shows Lou Carro cutting up the dance floor in a pretty spectacular fashion. Everyone who attended agreed that this was one of the best WA branch social events ever, and that we should do it again. So, the branch is looking to make the river cruise an
annual event. We hope to eventually be able to combine the river cruise with an on shore BBQ and make the day an event suitable for branch members with young families, and well as the AINDT party set. The branch was also involved with a technical presentation involving Rod Martin of NDT Equipment Sales and Ashley Jolley from Plant Integrity Ltd. The meeting was held at the Windsor Hotel and was well attended. Rod talked about the Vidisco Digital Radiography system. This is an Israeli developed system and has some impressive capabilities, being able to distinguish organic from inorganic materials. It was originally developed as a security screening system and now the developers are expanding its capability into industrial NDT. Ashley talked about the latest developments in guided wave ultrasonics as applied to pipe inspection. The Teletest system is now able to focus on points around the circumference of pipes, providing some ability for circumferential location of defects. He went on to cover various case studies using the Teletest system, and then gave an explanation of how he ended up with the job he has. It turns out that TWI in London has its own bar, and Ashley used to drink in the bar and talked to people and finally ended up with his job. Easy.
qUEENSLAND Branch News AINDT visit to Australian Aerospace Ltd
On Wednesday 26 March the Queensland Branch of the AINDT travelled to the Brisbane Airport Precinct to view the assembly of the two ‘state of the art’ helicopter models that are being delivered to the Commonwealth for use by the Army and Navy. The visit was a joint venture with the WTIA and The Royal Aeronautical Society Brisbane Branch. We started the visit at the Brownlee St. Multi Role Helicopter (MRH) Assembly Line. Mr Andy Feron welcomed us and proceeded to show us around whilst describing the helicopter and its assembly. The MRH is manufactured by NATO Helicopter Industries (NHI) whose head office is in France, however most of the helicopter is manufactured in other countries such as; Italy – transmission system and rear fuselage, Germany – centre fuselage, Netherlands – undercarriage which is retractable, and France – forward fuselage and rotor blades. Most of the structure comprises carbon fibre composites and monoliths. During production extensive NDT, mainly ultrasonics is done on these structures. Twin Rolls Royce Turbo Meca engines are fitted. This is a multi-role cargo aircraft with a capacity to carry 20 fully armed troops/paratroopers. It has an electronic warfare defence and attack systems and is the first ‘fly by wire’ military helicopter to be built. Two have been completed, in
Europe, fully test flown, and delivered to the Commonwealth. This leaves 42 to be assembled and delivered in Brisbane. Australian Aerospace is technically an extension of the French Assembly Line. After Brownlee St we proceeded to the Australian Reconnaissance Helicopter (ARH), Tiger assembly line in Pandanus Avenue. This hangar also provides the facilities for final assembly and test flying of both helicopters. We were welcomed by Mr Rob Finnigan and Mr Matt Canning who also showed us around. The Tiger is manufactured by Eurocopter France and Eurocopter Germany. France manufacture the centre fuselage, rotors, transmissions and undercarriage, while Germany manufactures the forward fuselage and tail section. Carbon Fibre construction similar to the MRH is used structurally. It has a 30mm cannon, 2.75 inch rockets, hellfire anti-tank missiles plus electronic warfare countermeasures. The weapons are activated via a roof mounted multipurpose sight operated by either crew member through a Head Up Display (HUD) on their helmet visor. The helicopter has ‘in line’ seating for the crew with the battle captain at the rear and the pilot at the front. There are 22 Tigers being manufactured for delivery to the Commonwealth. Ten have been delivered, the first 4 of which were fully assembled in France. We also toured the test flight area for both helicopters and saw them in their final delivery stage. At the completion of the night we adjourned to an outdoor entertainment area where light refreshments and supper, arranged by Barry Cooper, were enjoyed by all. During the refreshments the Chairman, Ian Hogarth thanked Australian Aerospace Ltd for hosting the tour and all members who participated.
A cross section of the visitors
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As a member of Australian Aerospace and initiator of the visit I would like to thank; Mr Rob Hunter for sanctioning the visit, Mr Graham Matthews for arranging the details, and the tour guides who gave of their time – Mr Rob Finnigan, Mr Matt Canning and Mr Andy Feron. Gavin Smith Non-Destructive Testing Vol 45 No. 3
INSTITUTE NEWS Report on the AINDT R&D sub-committee meeting Western Australian Branch President John Norman, organised a tele-conference for the AINDT R&D sub-committee (Colin Hockings, Martin Lloyd-Diviny, John Norman) on the 20th of February with several interested academics and scientists; Dr Christine Scala of DSTO, Associate Professor Martin Veidt of University of Queensland, and Associate Professor Adrian Mouritz of RMIT. Several other scientists have expressed interest but were unable to participate in the teleconference. Colin Hockings was also not available to participate on the day. John Norman summarised the background to the initiative to improve the academic standing of the AINDT journal and make it more attractive to researchers to publish the results of their work. The issues giving rise to this are; • AINDT has very little contact with and relevance to the scientific and academic communities • AINDT strategic plan requires AINDT to try to become involved in academic and scientific areas • AINDT sees benefits from improving connections between scientists and academics on the one hand with industry and business on the other. The AINDT may be well placed to bring academics and scientist working in NDT related areas together with businesses interested in developing commercial applications of NDT research. The discussion canvassed what options would be available to develop a relationship with researchers. Some of these possibilities were; a new class of AINDT membership for scientists and academics work; develop the existing journal into one that would meet requirements for academic and scientific publishing; producing a less frequent new publication aimed at the R&D interests and running a series of research conferences or seminars, separate from the current biannual conference? It was agreed by the academic and scientific participants that numbers would probably be too low for a special grade of AINDT membership, at least initially. This may be an initiative that could come later if the other proposals were successful. Christine Scala stated that her experience was that she found it very difficult to get Australian contributions to academic publications, and felt that any AINDT initiative attempting to establish a new scientific publication would face the same problem. The meeting decided that an annual review would have better chances of success, than a regular publication. It was also decided that if AINDT could join with another organization that already publishes annual research reviews in an area associated with NDT (e.g. welding, fracture mechanics, materials science, etc) and contribute an NDT stream, this would have a greater chance of success. The resultant agreement was that any effort to upgrade the existing AINDT journal for academic appeal would not be successful.
In regard to seminars and conferences, the consensus was that the best results could be achieved by the AINDT joining with a scientific society that already has NDT interests. Materials Australia, ACAM (Australian Congress on Applied Mechanics), and the Australian Fracture Group, are examples of such societies. If specialist NDT streams prove successful and popular, a specialist NDT scientific conference could be considered in the future. Since the R&D meeting some AINDT members have expressed a view that a close association with academia is not in the best interests of the Institute, and would not represent a wise use of its resources. In response to these views, and to keep members engaged in the discussions, John Norman made the following comments: “Firstly, AINDT is not, and never was, just a technician’s society. This is clear from reading the AINDT strategic plan, and is also recognized by those of us a bit long in the tooth. Years ago, members joined AINDT for technical interest and to meet other people involved in NDT, at all levels. The notion that AINDT is just for the technicians is more recent and is associated with a focus on certification. I guess we don’t expect people who join just to get cheaper examination fees to take a wider interest, but it would be great if they did develop that wider interest in all levels of NDT. If AINDT gets the scientists and academics a bit more interested, maybe some good and interesting results can start to filter down.” “Secondly, the Western Australian Branch have recently had a successful technical evening. One speaker was Ashley Jolley from Plant Integrity Ltd (part of TWI), out from England to do some work at BP Refinery using Teletest equipment. Ashley is of a similar age to many of our younger members, and he has what many would consider a “dream job” in NDT. He works for a company set up to commercialize research from TWI. He works with state of the art technology and gets to travel the world using it and showing it off to interested people. Many R&D based companies have similar jobs, but your chances of finding that type of job in NDT in Australia at the moment are about zero. With some encouragement from AINDT, maybe we can get some useful NDT R&D happening in our universities that then gets commercialized by an Australian company, which can then offer some pretty interesting work to some of our technician members.” “Thirdly, we don’t have R&D based NDT equipment manufacturers in Australia (apart from the railway inspection companies and a few others), but other countries seem to have plenty. There are a number of companies from countries like Israel, Korea, Italy, Denmark, France, Spain, Brazil, Russia, India, China, apart from the big three of the UK, USA, and Germany producing state of the art NDT equipment based on R&D.” “Finally, AINDT also has corporate members, and I feel some of our corporate members will be very interested in these initiatives.” If anyone would like to contribute or comment please contact John directly or the Federal Executive.
MARINE INSPECTION SERVICE PTY LTD
CSWIP & PCN TRAINING AND EXAMINATIONS MIS have an exclusive agreement with TWI (The Welding Institute UK) to provide internationally recognized Non Destructive Testing and Welding Inspection Training and Certification. NDT courses are available in all methods and are conducted by experienced TWI approved trainers. The courses meet the international requirements of ISO 9712 and EN 473. Internationally recognised CSWIP Welding Inspector and Senior Welding Inspector courses are regularly available and are also conducted by experienced TWI approved trainers. Courses are held several times per year and CSWIP or PCN examinations are available at any time. We can also provide renewal and resit examinations for CSWIP and PCN certification as required. For further information or bookings please contact Mark Grogan or Vicki Foster Tel: (08) 9437 6155 Fax: (08) 9437 6022 Email:
[email protected] Address: 8 Egmont Road, Henderson WA 6166
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industry NEWS Complex Geometry Inspection System Trials Midas-NDT have commenced trials on a complex geometry inspection system. The system will be supplied to an aerospace customer in England for the inspection of composite components and consists of a 6,500mm by 4,000mm by 1,850mm (scanning dimensions) jet probe system under full multi-axis computer control of all ten axes of movement. The system, designed for the precision inspection of double curved panels, specifically IFS panels for the A380 aircraft, will utilise the latest midas-ndt ultrasonic instrumentation, data will be captured and evaluated in the latest midas-ndt Zeus v3 data acquisition and evaluation package. The system has two independent towers each containing five axes of movement (length, width, height, vertical angle & horizontal angle), this combination of movement axes allows the complete inspection of all angles necessary for double curved aerospace components
New ASTM E18-07 Rockwell Hardness Standard
New technique for inspecting composite structures
The long awaited ASTM E18-07 Rockwell Hardness Standard has been released. While it is technically similar to the older version, some changes affect both users and service providers. Here is a brief summary of the major changes:
The novel technique known as SIDER (Structural Irregularity and Damage Evaluation Routine) is used to find damage in composite ship structures. Its inventors received an award from the US Navy for their work. The method can be used anywhere, eliminating the need to cut samples from the material and send them to a laboratory for evaluation. SIDER involves exciting a composite structure with a modally tuned impact ‘hammer’ and recording the vibration response using accelerometers. This information is put into a frequency analyser, where the frequency response function (FRF) is determined. Conventional NDT vibration methods use either mode shape or frequency shifts to determine whether damage exists. These methods can detect damage only when it is extensive. With SIDER, the FRF is used to obtain the operational deflection shape from which the operational curvature shape can be determined. The curvature is much more sensitive to minimal levels of damage. The other significant feature of the SIDER method is that the identified damage areas can be mapped with great precision onto an image of the structure, allowing anomalies to be located quickly. The device has also been used to inspect the composite vertical stabilizers of the F-18 Super Hornet aircraft, the twisted rudder on the DDG guided missile destroyer, and the hull of a Stiletto all-composite ship. In addition to these military platforms, SIDER has been used to inspect a composite road bridge, a composite bridge deck in and an A320 composite vertical stabiliser. Proof of concept work is continuing for a version which will work underwater.
Indenters: All indenters require certifications and serial numbers. In the case of diamond indenters, there are now three classes, each class having different tolerances. Class B diamond indenters are intended for everyday use. Class A indenters are used for standardising Class B indenters during the manufacturing process, and for troubleshooting by service technicians. Reference diamonds are used to standardise Class A Diamonds. E18-07 now requires that unless a manufacturer has a certification for a given diamond that states that it was physically measured and is compliant with the tolerances for geometry and performance outlined in E18-07, the machine cannot be certified to ASTM E18-07. Indenter balls and indenter holders also will require independent certification. Direct Verifications: In a Rockwell hardness tester direct verifications include measuring the force at preload, total force and force at elastic recovery (the reading position). Additionally, the timing and machine hysteresis must be verified. The new standard now states a direct verification (less the timing) must be performed “When adjustments, modifications or repairs are made that could affect the application of test forces, the depth measuring system or the machine hysteresis.” To comply with E18-07, if adjustments are made that affect any of these key elements, a direct verification must be done to ensure that all of these elements are in tolerance. As Found Results: E18- 07 now states that as found results must be obtained and recorded for every scale that is to be recertified.
Travelling with spare batteries The United States Department of Transportation has implemented new rules for travelling with batteries. Effective January 1, 2008, the following rules apply to the spare lithium batteries carried in case the battery in a device runs low. Spare batteries are the batteries carried separately from the devices they power. When batteries are installed in a device, they are not considered spare batteries. You may not pack a spare lithium battery in your checked baggage. You may bring spare lithium batteries with you in carry-on baggage Under the new rules, batteries with up to 8-gram equivalent lithium content may be brought on board an aircraft. All lithium ion batteries in cell phones are below 8 gram equivalent lithium content. Nearly all laptop computers also are below this quantity threshold. You can also bring up to two spare batteries with an total equivalent lithium content of up to 25 grams, in addition to any batteries that fall below the 8-gram threshold. For a lithium metal battery, whether installed in a device or carried as a spare, the limit on lithium content is 2 grams of lithium metal per battery. Almost all consumer-type lithium metal batteries are below 2 grams of lithium metal. But if you are unsure, contact the manufacturer! More information: www.tsa.gov/travelers/airtravel/assistant/batteries.shtm
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FLIR Systems and CEDIP Infrared combine Cedip Infrared Systems infrared camera operations will be integrated into the Thermography Division of Flir Systems and trade under the Flir brand name. Flir Systems became the majority shareholder of fellow infrared specialist Cedip Infrared Systems earlier this year. Cedip Infrared Systems and Flir Systems invest heavily in the development of both their IR camera products as well as the software. The combined operation will naturally have the same ethos ensuring a future-proof path for all customers and distributors. High-end R+D customers will however be the major beneficiaries from this move. Both companies already have a strong presence in the production of scientific grade. The fortified Flir Systems will now have the capacity to develop R+D Systems that are application specific with a greater range of cooled detector combinations. The centre of excellence of these high-end cameras will remain at the Cedip Infrared Systems base in France. The combined forces of Flir Systems Thermography Division and Cedip Infrared Systems is expected to take infrared technology into a new areas of application and development. Pierre Potet, President of Cedip Infrared Systems, commented: “Teaming up with Flir Systems Thermography Division is a great opportunity for the development of Cedip Infrared Systems high end thermography products. The combination of the international sales network and global expertise of Flir Systems together with the technology of Cedip Infrared Systems, will immediately benefit all the customers and markets we serve”. Non-Destructive Testing Vol 45 No. 3
industry NEWS Non-Destructive Testing Management Association (NDTMA) Russell Fraser Sales at the Singapore Air Show Singapore Airshow was held this year from the 19th until 24th February 2008. As Asia’s leading aerospace and defence exhibition and positioned among the top three air shows in the world, it serves as a global marketplace and networking platform for the civil aviation and military community. Russell Fraser from Russell Fraser Sales Pty Ltd had the pleasure of attending the exhibition which was held in the Changi Exhibition Centre, Singapore. The purpose for the trip was to work with the team from Lumos Technologies on their Exhibition stand. Parading some of the finest aircraft in the world, including civilian and military types from small fighters to the largest commercial aircraft, the Airbus. Not only did the exhibition allow attendees to further penetrate the market with their products, but guests were entertained by static aircraft displays in the airport pavilion, and aerobatic flying displays not to be missed. The Aerobatics was awe-inspiring, with the ‘Black Knights’, F-16 pilots from the Republic of Singapore Air Force, as well as performance from the ‘Royal Australian Air Force Roulettes’ and the daily A380 doing it’s best to impress. The A380’s size does this alone when it flies low. In the midst of all of the fun, Russell had to do some work. Demonstrating the Lumos X-Loupe portable microscopic camera was a breeze as the superior performances of both the A-Series and G-Series offering up to 300x magnification speaks for itself. Further to this, with the software now available, the camera can think for you, making the A Series system into a metrology tool. By taking various photographs of the same object, with different focal depths, the software is able to have the whole image depth range in focus in one photograph. The Lumos stand was directly opposite the Australia stand. Russ got to see the flying display while there, and above is a photo of the Lumos staff. If you would like to see more photos go to our website. Russell Fraser Sales provides the highest standard of non-destructive testing equipment throughout Australasia. The wide range of products service a wide range of industries such as Ultrasonics, Ultraviolet, Radiography, Magnetic Particle and Dye Penetrant Inspection, Eddy Current Testing, Surface Inspection and Hardness Testing. The company’s vision is to provide quality, performance, price and service to their valued customers. For more information visit www.rfsales.com.au or contact them on 02 9545 4433.
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The NDTMA (Non-destructive Testing Management Association) was formed about thirty years ago to provide a forum for the open exchange of managerial, technical, and regulatory information critical to the successful management of NDT personnel and activities. The membership is comprised of delegates from member companies involved in the use, practice, and promotion of NDT. Each member company designates one voting delegate, but there are no restrictions as to the number of employees who may participate. For the most part delegates are NDT professionals, managers, and executives involved in furnishing or using NDT services or products. The web site is www.ndtma.org The NDTMA is dedicated to the concept that NDT is a profession. On-going objectives are to help NDTMA members, as NDT professional managers, to: • Expand their business and management skills including OH&S • Promote and market NDT service both nationally and internationally • Monitor regulatory requirements and changes, and participate in the rule-making process • Participate in the development and revision of industry codes and standards • Promote and maintain high ethical standards and practices within the NDT community • Increase the quality of the NDT product and the image of the profession • Keep abreast of technical advances in NDT.
Thermoplastics for Radiation Shielding GE Plastics of Pittsfield, Massachusetts in the US has launched LNP Thermocomp, a new line of thermoplastic materials with high specific gravity, intended to replace lead in many health care applications which call for radiation shielding. Medical equipment and devices that emit radiation need to be shielded to protect operators, clinicians, patients and sensitive electronic equipment from tube leakage and room scatter. The high density compounds enable radiation shielding solutions without the use of known toxic substances, while providing design freedom, high volume, low cost manufacturing capability through the use of injections moulding.
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nandtb news The National Aerospace NDT Board held a meeting at SikorskyHelitech in Brisbane at the end of March. This represented the second anniversary of the Board and elections to the Board and to the executive were finalised. For election to the Board a web page was set up and eligible organisations could vote on line. While it was run very smoothly and promoted through CASA and AINDT channels, future use of this approach will need even greater publicity and promotion. The Board gained the expertise of Jason Maitland as a representative for the Regional Airlines. This sector of the industry did not have a nominated representative on the Board up until now. The elected executive is Chairman; Ron Quirk (Helitech), Deputy Chariman; Brian Tydeman (Timken), and Secretary: Colin Hockings (Qantas). The Board’s web site www.ndtboard.com has a host of information including its full membership.
contractors in military aviation, and the advent of military aircraft being operated as de facto civilian aircraft, he indicated that the harmonisation of ADF and civilian training and qualifications for NDT personnel will be fundamental to the success of this development. Jed Murray gave a presentation on what work the ADF is doing to standardise its NDT training within the Australian Qualification Framework. Consideration of future activities received a good deal of attention and Garry Bowden was tasked with developing a draft strategic plan, based on the discussions at this meeting. Ron Quirk emphasised the importance of having a shared vision among the Board and its stakeholders, and a strategic plan is a practical way articulate the vision and maintain the focus of the Board. The Board can be contacted through the web site and welcomes inquires and suggestions. Those attending the meeting are shown in the picture below.
The business of the meeting included an initiative to enter into a strategic alliance with the AINDT. The Board believes that there are specific benefits for both groups if closer relations are developed. The proposal will be taken to the AINDT Federal Executive by Shayne Flynn. Operational procedures continue evolve and like all existing ones, can be found on the web site. The application of the 2006 version of AS 3669 in regard to the standard for aerospace Level 3 is one such procedure which is important for the Board, CASA and the industry. CASA was encouraged to be more definite in its expectations of the Board. To this end there were two initiatives undertaken. The first was to update and formalise a Memorandum of Understanding between CASA and the Board. Secondly, CASA is to provide to the Board details of how it believes it can be most effective in its role as described in AS 3669, but also in a more general sense to educate and assist industry. One such activity is the finalisation of two separate Airworthiness Bulletins for fluorescent penetrant and magnetic particle inspection, which will be issued shortly to replace obsolete CAOs on these subjects. The ADF continues to take a keen interest in the Board through its position as observer. The newly appointed Commanding Officer of NDISL at the Amberley Base in Queensland, Squadron Leader Tony Wood, attended this meeting. With the increasing use of civilian
Standing: Sqd. Ldr.Tony Wood,W.O. Jed Murray, Gavin Smith, Peter Virtue, Ron Quirk, Gary Martin, Garry Bowden, Jason Maitland. Seated:Trevor Robinson, Brian Tydeman, Colin Hockings, Shayne Flynn.
nata news NDT Test Specimen Audits (formerly ‘Proficiency Testing’) The quality of the results obtained by a non-destructive testing facility can be assured by various quality control activities. One such control is the independent auditing of facility competency. This involves participation at least every two years in independent or externally conducted NDT competency audits, using validated test specimens. Most readers will be aware that NATA no longer conducts its own Test Specimen Audit Program (this is NATA-speak for the activity formerly known as Proficiency Testing). Instead, provision of these services throughout the various fields of testing accredited by NATA has been sought from commercial providers. The requirements for independent test specimen audits are detailed in NATA’s Technical Circular No 5, Test Specimen Audit Policy, and commercial providers are given guidance through the Provider Specification for Test Specimen Audits – NDT. Both of these documents may be down-
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loaded from NATA’s web site – www.nat.asn.au, via Publications/Field Updates/Non-destructive Testing. One commercial provider, Advanced Technology Testing and Research, (ATTAR), has indicated an interest in providing NDT test specimen audits in accordance with the above specification, and the organization’s details may also be obtained from the web site, following the same path as above. A comprehensive selection of validated specimens is available from ATTAR to hopefully suit the wide range of NDT facilities which hold NATA accreditation. NATA would welcome enquiries and expressions of interest from other organizations who would be desirous of providing independent test specimen audits. Interested parties should contact Brett Hyland, Manager, Non-destructive Testing at NATA’s Melbourne office, phone (03) 9329 1633, fax (03) 9326 5148 or e-mail:
[email protected] Non-Destructive Testing Vol 45 No. 3
ICNDT news Chairman’s Message The stage is set for the 17th WCNDT in Shanghai, China, from 27–30 August 2008 and with that comes the platform for ICNDT to move forward with the legalisation of our organisation. Over fifty years ago, the International Committee for Non-Destructive Testing, ICNDT, was given considerable independence and a broad mandate ‘to promote, encourage, support and provide a venue for international NDT societies to gather under one roof to advance the field of non-destructive testing’. On several occasions during its more than 50 years of experience, ICNDT has chosen to reassess its function and question how it can best serve the international NDT community. From those analyses came policy and structural changes designed to maintain ICNDT’s relevance, to improve its responsiveness, and to augment its effectiveness. In Montreal 2004, during the full assembly meeting, the members voted to address our business strategy and operational framework. The result would require three major activities for the Executive and Policy and General Purpose Committees to be completed by the17th WCNDT: rewriting of the terms of reference, implementing formal operating procedures and preparing the legalisation for ICNDT. This past three-and-a-half years have been dedicated to accomplishing the latest objective set by our membership in 2004. The leadership and perspectives provided by the members of the Executive and Policy and General Purpose Committee has helped to keep our goal focused and achievable. It would be remiss of me if I did not take this opportunity to thank all the members of the committee for their dedication to the betterment of our organisation.
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The final step required to implement the work done by the two standing committees mentioned above is for the ratification of the latest terms of reference, which has been disseminated to all ICNDT members through the ICNDT Secretariat and General Secretary. I now call on all members to be present in Shanghai during the 17th WCNDT to experience our next historic event with the acceptance and signing of the 2008 ICNDT Terms of Reference. On behalf of the hosts of the 17th WCNDT, the Chinese Society for Non-Destructive Testing and the International Committee for NonDestructive Testing, I look forward to seeing you in August 2008. Douglas J Marshall
Also in the latest issue of the ICNDT Journal which can be accessed at www.icndt.org are the following reports: • Upgraded ICNDT web site • Asia-Pacific NDT workshop in Japan • EFNDT Board meeting report • 10th anniversary of the Hungarian NDT Society • Reports of NDT conference in Prague • Certification conference in Germany • NDT Certification system in Mexico • News from the Brazilian Society for NDT
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INTERVIEW Interview with Arthur Harvey Where did you spend your childhood Arthur? Arthur: I’m a Queenslander I was born in Stanthorpe but very shortly after that the family moved to Grafton. My father passed away when I was five, and I left there aged seven and a half to attend the Masonic Boarding School in Baulkham Hills. My two older brothers were already there. After leaving at eighteen and a half years old I was one of the longest serving pupils of the school. Of course being the son of a deceased Mason, attendance at that school was free. My mother was ill equipped to pay the education costs of three sons. Was it Monday to Friday or were you there all the time? Arthur: We were there all the time and went home for the three school holidays, but at the shorter holidays like Easter we remained at the school, because we lived so far away. Do you remember your very first job after leaving school? Arthur: I remember vacation jobs at home in Grafton, one of which was prophetic because it was in a wine and spirit merchant. I since have gone on, as many people know, to enjoy a red wine or two, or three. My other vacation job was an attendant at a petrol station and I knew that I didn’t really like the oil industry because on the first day on the job I was overcome by the petrol fumes when I was looking too closely down the spout as I was filling up petrol tanks. I was carted off home semi-comatose from petrol fumes. After starting at the University of NSW, School of Metallurgy; no I back track, my very first job two days after leaving school in November 1968 was at Australian Iron and Steel, Port Kembla, where I joined a bunch of other potential university candidates. I was aiming for a full time scholarship and was offered a part time one, so I resigned from AIS after only about three months, early 1969. I attended university then full time with the benefit of a Commonwealth Scholarship. Sitting next to me in the interview room at AIS was a guy called Steve Gull who was awarded the full time scholarship, and he went on with me to university. Some years later we were both sent by our employers to Western Australia, and our friendship has continued up to the present day. Did you have a preferred career you wanted to follow? Arthur: As a result of the career co-ordinator or advisor at Northmead High where I went from the boarding school to the State school for our education, he suggested either a pilot training or industrial chemistry or metallurgy. I think I would have loved to be a pilot but not as a commercial pilot just flying from A to B and back again under such a strict regime of rules. So I discarded the pilot theory and thought of chemistry, because I had been good at chemistry at school. But having got the job at AIS straight after school, it changed from chemistry to metallurgy. That was a change I never once regretted. For a couple of years before Tony Sonneveld got hold of you in 1975, you were with Babcock and Wilcox. Can you tell us the pathway that led you from school to that point? Arthur: Well, in the applied science degree at UNSW you could not carry any failed subjects. You had to spend the next period to catch up that subject before you could rejoin the full time course. My maths was not a particularly strong point and I failed maths in second year, and had to repeat it before I could commence third year. In doing so I lost my Commonwealth Scholarship and I had to find another source of income, so I joined Babcock and Wilcox at Regents Park, then the New South Wales premier pressure vessel manufacturer. That was a blessing in disguise because not only was I introduced to NDT but I also came under the tutelage of Pat Cooney. He was their chief chemist and took me under his wing, and I learnt a considerable amount about NDT, chemistry and life in general during that time. Metlabs wasted no time sending you out of Australia to Singapore and later New Zealand. Do you think you were ready for that responsibility at that time, and did you appreciate what would be required of you? Arthur: That’s not an easy question to answer because I find it difficult to put myself back into that time frame. The natural answer to both questions would be no, but I think that’s probably not accurate. Metlabs had sent two or three people up to Singapore before me, so by the time I was offered the job I was fairly familiar with what was required of me. The magnitude of the task was probably a little larger than I thought,
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and of course the interaction with the predominantly Chinese workforce was a bit of a surprise to me. And I was married in Singapore during that episode as well. So I was really caught between two things. Can you imagine the consternation of my new bride when her husband opted to get up in the middle of the night to go out and check on my technicians to make sure that they were doing the job properly. Oddly enough I chose to do that because that was what was required of me. When senior AMEC employees from England came out and closed the Singapore operation I took that in my stride. I was young and ready for something new. New Zealand at the time was the subject of the Maui development by Shell BP Todd. We were already the incumbent contractor there. Max Robb who was one of the founders of Metlabs in Australia and then went to New Zealand to start operations there, was at the end of his life, cut short by skin cancer. I was offered the position and once again I didn’t think I was unready for the responsibility. I put in a lot of time and effort and was well rewarded by the development of the business there. Even though we ultimately lost the SBPT contract we went on to win numerous pipeline contracts in New Zealand as natural gas was reticulated across the North Island. I think we did about seventeen of the twenty five pipelines in the next five years. Underpinning all this in regard to responsibilities, Tony Sonneveld’s name has not been mentioned, and if I was in any doubt of what was required of me then Tony would certainly set me straight. I think I rose to the challenge because the numbers and the record will show that we achieved pretty much what was required. You have already mentioned Pat Cooney, but was there any one else who was influential during your early days at Metlabs? Arthur: Tony was significant. I still have my letter of application to be an NDT technician. I am not sure I wanted to be an NDT technician when I was already a graduate metallurgist. None the less that is what the ad said and that’s what I applied for. The ad was cryptic in that it referred to the applicant’s commercial experience. I didn’t have any, but I thought I needed to put something in and I had spent two years as president of MetSoc at the university. Our activities consisted mostly of organising smokos and sporting events. I got the interview and started on the first of April 1975. For the first nine months or so I was in Tony’s office privy to all his conversations on the phone and expected to mimic that. At the same time I was an operational NDTer. These skills I picked up during my time at Babcock and Wilcox. It was through Tony that I learnt the business. Were there any other influential characters? Arthur: Most of the people were inside the business. There was Pat O’Connell for example who was the operations manger at Metlabs New South Wales. Pat was from WA and had a particular style about him that managed to get the job done. Maybe not in the smoothest or most equitable way in a sense but in the terms of the day it was relatively efficient, and that was good. One New South Wales technician, Gary Robbins, if he was still at the company today he would be the longest serving employee. I am not sure if prior to me becoming a manager he was nearly sacked, but I nearly sacked him three or four times. Gary appealed to some clients and indeed some actually wanted him on the job, so for many years it was a bit of a love hate relationship. He did earn his place in the pantheon of NDT technicians that I encountered over the years. My introduction into Singapore was facilitated by Keith Jackson, the then southern region manager of Metlabs. With Tony he helped induct me into the ways of the Asian minds in Singapore and for that I am always grateful. Later in the darkest days of the AMEC-Matthew Hall era Keith came to the fore by giving me good advice on how to weather that time. You have a reputation for understanding your staff and their needs. Do you think that is true and what do you believe is the best way to get the most from your staff? Arthur: I’m probably not the best person to answer if it is true or not. Certainly I have tried to maintain an understanding of our staff and their Non-Destructive Testing Vol 45 No. 3
INTERVIEW needs, and I guess that stems from the fact that as with most managers of NDT companies of the day, we were practitioners ourselves. Not only could I, but I did go out and take radiographs, push probes, drag magnets and carry out heat treatment jobs. So I knew exactly what was required. Particularly the problems of doing it out of hours, in overtime, in bad weather. All of those things were perfectly familiar to me. This brought me closer to what was expected of technicians and the problems they needed to have their managers solve on their behalf. More broadly than that I think there was equity across businesses and in Metlabs case we were not privately owned, but owned by large corporations. So all the managers were also employees of the company just as the most junior of the technicians were. All of us were entitled to the same equity in the way we were treated. Some may disagree but I certainly tried to achieve that, and by my own measure, by and large I did. There appears to be a shortage of technicians, why do you think that is? Arthur: The answer to that is, that the NDT companies have not put enough energy time and effort into training. So as managers we are all guilty of that. Under AMEC in 2004 we contemplated importing technicians because of the growing shortage: under Leighton our acquisition of ITS in Queensland was in part, a desire to add more people to our business. Yes, under my management at Metlabs we did not do enough to foster the development of technicians. Certainly I applaud the Pearl Street direction early on after their acquisition of Metlabs. As of the beginning of 2008 Pearl Street’s CEO, Anthony Wooles has directed the business to recruit ten percent of its staff as trainees. We have some of these on board already and we believe that the extra people will be soaked up very quickly in terms of delivering operational work to the business. How will you train these people? Arthur: There are organizations in Victoria, New South Wales and Western Australia that train via the TAFE or equivalent TAFE system, where there is a combination of on site and off site electronic training. So there are programs that Pearl Street has already availed themselves in the time immediately prior to now, and what we are doing with these extra 50 people is a development of that. So it is well and truly possible to do it. It is the corporate willingness to spend the money up front that has been lacking in the past in Metlabs and other businesses. Despite the name changes, you have been with the same company for many years. Were there opportunities to move on to other employment which you didn’t take? Arthur: Yes, it’s certainly ironic that now that Metlabs is owned by Pearl Street and Pearl Street had previously acquired ETRS from HRL. I never expected to be part of the business of ETRS. I did receive not one but two offers for employment from ETRS. These weren’t casual phone calls but fully briefed firm offers. One was from Dave Monotti and it was a very attractive offer and I did consider it. Some time later they made another offer which I also rejected. I should note that at the time of the second offer I was in WA with Geoff Williams, and I would have regarded it as an act of sacrilege to take up a job with ETRS in Western Australia in competition with Geoff. As it turned out of course Metlabs, and I don’t want to be rude about it, kicked ETRS out of WA. That was largely down to Geoff’s ability to manage Australia’s largest NDT business. Do you think the competition between Metlabs and ETRS was good for the business? Arthur: Yes it was good but it wasn’t necessarily on an even keel. The funny thing about Metlabs that we distinguished from ETRS and other organizations was the intangible things that make a person a “Metlaber”. That’s probably different things to different people. I detected it from when I first joined Metlabs in New South Wales, and not just from Tony Sonneveld, but from people as diverse as Pat O’Connell, Gary Robbins. And it has been alive and well in all the time I have been with the business. While I supported it as best I could, it is not something I have any claim to establishing. The best example I can really show is when I attended a 35th anniversary dinner for Bob Van der Linde in Melbourne with the other managers and some of Bob’s technician colleagues, and although not knowing some of the Melbourne crew all that well, it was evident that they not only had but the fervour that I will call the Metlabs spirit. I never saw any evidence that it was strong in our competitors. Non-Destructive Testing Vol 45 No. 3
I mean if the job had to be done, the technicians went and did it. There was no questions asked about whether at the end of the day Metlabs was getting a fair price for that job or whether they would be fairly treated to do it. Some of the technicians might say that they did the job and weren’t fairly treated, and that may well be the case. Believe me, the managers put a lot of effort into trying their best to reward technicians for the extra effort they put in. Not always in a pure monetary sense but sometimes in ways that created and maintained the atmosphere of employment. Like bar-b-cues, drinks after work, all the things that make up the conviviality of working with somebody that we believed was important, and formed the Metlabs spirit. Arthur, you have a lot of experience in the industry. What can be done to maximise the transfer of this knowledge to newer entrants? Arthur: A very interesting question because the old guard of NDT, particularly in radiography, jealously guarded their abilities and were quite reluctant to pass on that knowledge to their younger colleagues. Fortunately for me having come with two years experience at Babcock and Wilcox, I knew how to produce a radiograph and I did not have to rely on the senior radiographers to show me. I don’t think we’ve mastered that. I think it does come back to the more formal approach to training that we are now adopting. I see that as being very significant in making sure that the next breed of technicians will be much better equipped. Of course there has been a change across the entire industry which is coincidental with this issue, and this is the computerisation of our testing equipment. It certainly wasn’t computerised when I first started, but now all equipment, not just NDT equipment, is computerised. The good thing about it is that the education system by and large is producing people that are computer literate, and therefore better qualified to come in and accept the operation of these devices in a way that was not intuitive to us. So I don’t see it as a particular problem in transferring that knowledge as it may once have been. What advice would you offer to the AINDT Executive to improve the Institute? Arthur: Once again another difficult question. The Institute has certainly served its members and industry quite well. We have operated for many years in an environment where the client dominates our ability to supply our services. Often they dictate or have tried to dictate the way the pricing mechanism work. There is clear evidence now that the NDT companies in the context of a shortage of personnel and a buoyant market for services, that the pendulum has swung back our way so that we have more control of the pricing aspects of our business. That means that there ought to be more margin in the companies that employ NDT technicians there fore there ought to be more room for the AINDT to by virtue of its corporate membership, but not the equipment sellers, to feed back more services to those technicians. I think over the years this has been a criticism and it varies across the States. The best example I can give is in South Australia where the Metlabs business waxed and waned. Loosing our entire business there at one stage, and then winning the ASC contract and holding that for a decade or so. The technicians we employ there have wanted to become more involved in both the broad scope and the detail of the Institute activities, but thought they were stymied from doing so. Metlabs has always been a corporate member in the States we operate in, so why that is the case I am not sure. I don’t want to overemphasise the point but the equipment suppliers have a presence that outweighs the companies that employ technicians. Technicians are really the backbone of the entire membership. Somehow the executive needs to get down to the grass roots of the technician operator level NDT people and cater for their needs. Their needs can’t be categorised simply because they vary from State to State and person to person. There is some opportunity there at the moment to test the market and talk to that level of membership and find out precisely what they want the Institute to deliver, and charge the executive of the Institute to do exactly that. I say that in a broad sense but I think New South Wales and Victoria have been more successful in meeting their members’ needs. In Western Australia, well we’re just too bloody busy to worry right at the moment. I think the technicians are happy to be gainfully employed. If there’s money to be spent then I think it should be spent there. Many thanks for your time Arthur.
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CONDITION MONITORING Electrical Thermography Erik Thorup, B.Sc Mech.Eng. IR Technology Australia Pty Ltd. Associate,The University of Melbourne
Thermographic Inspections: The fuse and circuit breaker Note should be taken that this article deals with testing of electrical circuits. When working on or close to live components a full job safety/hazard analysis must be undertaken and appropriate PPE must be worn. Within the use of thermography for condition monitoring and initial fault finding in new installations, I would still anticipate that more than 80% of these tests are performed on electrical equipment, mainly historically due to the lesser capabilities of thermal imagers just 15-20 years ago, but also due to the ease of identifying electrical problems and the costly effects which an electrical fault might have. It is therefore no surprise that the little fuse and more recently the circuit breaker (CB) probably have become the most photographed items by thermographers on the planet, since these make up a great deal of the components in any electrical plant.
It is however not everything that is hot which is a fault The way a fuse works is by a resistance wire in its inner porcelain core. Since there is a resistance in the core, this will make the fuse temperature increase with more current (A) through the resistance wire, and when the current rating of the fuse is reached, the wire gets so hot that it melts and breaks the circuit. So it is part of the normal operation of a fuse to get hot. Likewise the circuit breaker (CB) has internal components (a bimetallic strip) which heats up with higher current, and eventually makes the CB trip and break the circuit. So it is part of the normal operation of a CB to get warm. The question now is: how hot is too hot when it comes to fuses and CB’s?
The Fuse When it comes to fuses, there are usually 6 or more connections at the fuse and fuse holder which may all become faulty. You could say it’s almost a Thermographers dream component. Since the fuse and fuse holder is symmetric top to bottom, you would expect a similar thermal pattern to be present at either end of the fuse holder if nothing is “wrong”. This is the case if the correct size wiring has been used in bot sides. If a smaller gauge of wire has been used in one side, this side will often have a higher resistance and warm up more when load is induced. Internally however, the fuse holder is symmetric and should cause the same resistance at the top and the bottom and therefore show similar thermal patterns. A high resistance fault internally in the fuse holder will cause a rise in temperature and since the fault rarely is the same at both ends of the fuse holder, a thermal anomaly will occur. One of these can be seen in Figure 1.
Figure 1: A fuse holder with thermal anomaly at the load side end (FAULT)
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Should an increase in temperature be seen at either end of the fuse holder, it will be necessary to ascertain the actual current (load) which is running through the fuse and compare to the rating of the fuse. The porcelain on the fuse may in some circumstances reach above 100°C and still be within its thermal rating, when the load gets close to the maximum load rating of the fuse. Performing a test of the current flow, usually using a “tong tester”, should be left to persons qualified and authorised to do so, and remember that if a warm connection has been found, the wire may actually be lose and should not be forced as it may disconnect.
The Circuit Breaker When it comes to the circuit breaker, there are usually only 2 connections to the CB and one internally in the contact of the CB which cannot be seen. Visually the CB also seem to be symmetrical from top to bottom, but the internal composition of the breaker with its bimetallic strip, is far from symmetrical. On top of this comes that different brands will have different thermal signatures in normal load conditions, so the images here cannot directly be taken as the thermal signature for other CB’s. So to confirm that a high temperature found at one end of a Circuit breaker is really a fault, there are several ways to follow: Heat starts where the fault is and therefore the hottest point must indicate the fault. Is the heat coming from the lug or the screw terminal itself then these components are the faulty ones. If however the highest temperature is at the CB (as in Fig 2), further investigation into the rating of the CB and the load on the CB should be performed. As a guideline only and in normal room temperature, for many CB’s the temperature measured at the outside of the CB when it is running a current which is as high as the rating (10A on a 10A rated CB, 20A on a 20A rated CB etc) you can expect the temperature to be between 50°C and 60°C. The Bimetallic strip has increased in temperature and is almost ready to trip the circuit. Note the temperature is very much brand dependent. But an internally high temperature may be due to load as well as a fault at the internal contact. To ensure the fault is not due to internal high resistance in the CB, the voltage drop across the CB can be measured, again by persons qualified and authorised to do so, and compared to other CB’s of similar brand. So to perform a thorough analysis using thermography on Circuit Breakers and Fuses, always add the value of knowing the load on the circuit and the resistance/voltage drop inside if at all possible.
Figure 2: A Circuit Breaker with thermal anomaly at the load side end. As the highest temperature is “internally” in the CB, the higher temperature is most likely load related. Depending on the load measured and the rating of the CB, this is PROBABLY NOT A FAULT. Non-Destructive Testing Vol 45 No. 3
CONDITION MONITORING Condition Monitoring News The latest CM and Lubrication Newsletter 04/08 has been published and includes a wide range of articles. Below are a few extracts. www.sirfrt.com.au is the web site from which you can review all the articles. If you wish to receive the newsletter directly you can contact Peter Todd at
[email protected]. The highlights are summarised below, and an edited version of the article on CM at Yallourn Power Station in Victoria follows.
Newsletter 04/08 Highlights • Skills and Practices Flyers on Alignment • Article on Vibration Data Collection Errors • CM & Lube SIRF Member Profile on Yallourn Power Station • Links to 2006 CM National Forum Presentations • Lubrication Technicians and Reliability Improvement (Editors Opinion) • 2008 CML National Forum Pre & Post Forum Workshops • 2008 CML National Forum Proposed agenda • Links to various interesting items such as on Bearings, Lubrication, Motors and Gearboxes
TRUenergy – Yallourn Power Station SIRF CM & Lube Member Profile The Yallourn power station is located in the Latrobe Valley, 150 kilometres east of Melbourne. The 1480MW station supplies approximately 22% of Victoria’s electricity needs and 8% nationally. Yallourn has long been a trendsetter in use of maintenance technologies and that includes condition monitoring & lubrication practices. Condition monitoring at Yallourn started in the mid 70’s with Ray Beebe being the early champion of the technology. The key technologies used at that time were performance monitoring and basic vibration monitoring. Yallourn brought its first vibration data collector in 1988, which was an SKF unit using Jason Tranter’s Alert software. They converted to using a CSI data collector in 1992. As well as vibration analysis, there was a lot of performance monitoring work on pumps and other equipment such as heat exchangers and Coal Mills. Organisational Structure – Pre 2001 there was a central dedicated CM Group of five full time CM technicians looking after all aspects of CM. In 1999 they were the winner of the RBM Excellence Award. In 2001 CM was changed to a decentralised structure with only 3 full time CM technicians reporting to specific area process teams. The shortfall in resources to carry out the vibration monitoring was made up by training a number of tradesmen. There are now 12 persons trained in vibration data collection.
The use of non-dedicated data collection people has created strains & challenges. The data collection role now has to compete with all other maintenance activities for the scare resources. This has caused problems in keeping the consistency in monitoring and in maintaining some level of continuous improvement. This requires constant attention. Sue Tulau made the observation that non-dedicated CM people don’t get the ownership and enthusiasm for the technology, compared with dedicated CM Technicians. Technology – The CM and reliability technology currently used by Yallourn are Performance Monitoring, NDT, Vibration, Thermal Imaging, Leak Detection, Oil Analysis, Laser Alignment and Balancing with a number of other precision maintenance techniques used. Their vibration program covers 437 machines with 3257 measurement points. They have recently installed an on-line vibration monitoring system on a number of their fans. Payback – The effectiveness of Yallourn’s precision maintenance improvement is shown by their reduction of Average Velocity Vibration from over 1.5mm/sec in 2003 to now around 1.1mm/sec, with the corresponding expected return of longer equipment life. The highest payback or Return on Investment (ROI) from their CM activities is provided by their off-line NDT work on boiler tubes, as tube failures have such a major effect on generator availability. The second strongest payback is from Thermal Imaging being such a flexible and broadly applicable tool. The other main CM tools of Vibration, Performance Monitoring and Oil Analysis all show strong payback. Future of CM – As Yallourn’s condition monitoring systems are successful and relatively mature, the main focus for the future is not for dramatic changed but small step improvements. There are many positive signs of increasing support for asset management investments by their management. Mark Faith suggested the main challenges are routine CM backlog management, improving knowledge sharing, maintaining the focus on training, succession planning, keeping up with new technologies, a stronger focus on RCA and the continued promotion of CM to their area process teams.
Additional Workshops – 2008 CM & Lube National Forum (October 28th and 29th) The 2008 CM & Lube National Forum will have a number of related workshops. On the 27th October there will be a number of 1 day pre forum workshops and on the 30th & 31st October there will be a post forum workshop. The workshops will be held at the same Melbourne Sebel Albert Park venue. Detailed information can be downloaded from the newsletter, or from the website. Pre Forum Workshops • Introduction to Vibration Analysis – Jason Tranter • Lubrication Practices Workshop – Bernie Piovesan • Reliability Eng. for Operating Plants – Howard Witt Post Forum Workshop • Lubrication Management LM02 (Includes Contamination Control & Oil Analysis Introduction) By Wayne Dearness
Non-Destructive Testing Vol 45 No. 3
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Industrial Isotope Contacts Industrial Isotope Supply/Services - Australian Contact Details Australian Company
Contact Details
Industrial Isotope Products/Services
NDT Equipment Sales Pty Ltd (Distributor for QSA Global)
Rod Martin – General Manager Unit 23, 58 Box Road (PO Box 2383) Taren Point NSW 2229 Australia Tel: 02 9524-0558 Email:
[email protected] Website: www.ndt.com.au
Sources avail: Ir (loaded in Sentinel/Techops pigtails), sealed sources – Se, Co, Cs Services: Loading/unloading of Sentinel/Techops (460, 660, 880) Gammamat TI-F radiography projectors at NDT premises, Sydney Self-loading/unloading of Sentinel/Techops (460, 660, 880) Gammamat TI-F radiography projectors (transporters sent direct to customers) SCAR 959 Gammamat TSI-3 and Teletron projectors require transport to QSA for loading Disposal of QSA supplied sources Manufacturer and supplier of Sentinel/Techops and SCAR 959 radiography projectors
Real Time Instruments
Kathy Lawrenson – General Manager PO Box 6920 Mackay Mail Centre, QLD 4741 Tel: 07 4965 7007 Mob: 0409 268 635 Email:
[email protected]
Sources avail: Cs sealed sources Services: Unloading/loading industrial gauges up to 111 Gbq (less than 3 Ci activity) Disposal of sources
ADM Nuclear Technologies
Mr Glen Bates – Sales Director 22 Garden Blvd, Dingley Village, VIC 3172 Australia Tel: 03 9551 6922 Mob: 0412 213 370 Email:
[email protected] Website: www.admtech.com.au
Sources avail: Cs, Co, Kr, Sr, Am (sealed sources) Services: Transport of radioactive sources Disposal of supplied sources
Australian Radiation Services Pty. Ltd.
Dr Joe Young – Managing Director 22 King Street, Blackburn VIC 3130 PO Box 3103, Nunawading VIC 3131 Tel: 03 9877 4898 Mob: 0419 541 462 Email:
[email protected] Web: www.australian-radiation-services.com.au
Sources avail: Co, Cs, Am, Be, Cf, Isotrak reference and calibration sources and other sources on request. Services: Disposal of radioactive sources Load/unload radioactive sources in gauge housing dependent on activity and type of source Load/unload gauges up to 20-40GBq (0.5 -1 Ci)
EPS Australia Distributor for Eckert & Ziegler (Isotope Product Laboratories)
Warwick Thorpe – Managing Director 21 Park Street, Hyde Park, SA 5061 Australia Tel: 61 8 8373 7070 Mob: 0421 163 597 E-mail:
[email protected]
Sources avail: Ir, Co, Cs, Am, Be, Cd, Fe, Kr - supply any isotope from Am to Zn– supplied as a sealed source Services: Provide limited disposal of sources
SN Technologies
Steve Newlands – Managing Director 36 North West Arm Rd, Gymea, NSW 2227 Tel: 02 9545 3811 Mob: 0416 214 963 Email:
[email protected]
Sources avail: Cs Services: Disposal of radioactive sources
Radiation Safety Services
Barry Lewington – General Manager 69 Robinson Ave, Belmont WA 6104 Tel: 08 9475 0099 Mob: 0414 737635 Fax: 08 9475 0165 Email:
[email protected] [email protected] Web: www.radiationsafety.com.au
Sources avail: Cs137, Co60 etc – sources quoted as required Services: Disposal of radioactive sources. Loading unloading of sources into source containers/gauges housings. Supply of approved source containers/gauge housings. Servicing housings and testing for compliance. Transport of sources
KK & S Instruments
Frank Edwards or Stephen Allen 29/7 Anella Ave, Castle Hill NSW 2154 PO Box 8200, Baulkham Hills BC NSW 2153 Tel: 02 8850 3755 Toll free: 1800 557 638 Fax: 02 8850 3577 Email:
[email protected] Website: www.kks.com.au
KK&S Instruments are the Australasian representative for Teletron Nuclear GmbH Ir-192 Isotope Cameras Non-Destructive Testing Technologies
Industrial Isotope Supply/Services – International Contact Details International Company QSA Global
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Contact Details Dennis Chedraui – Director – International Sales 40 North Ave, Burlington, MA Tel: +1 (781) 505 8271 Fax: +1 (781) 564 2771
Industrial Isotope Products/Services Sources avail: Ir, Co, Cs, Se, Isotrak sources- reference and calibration sources Services: Gamma radiography sources and equipment
NTP Radioisotopes (Pty) Ltd Roland von Gogh – Marketing Manager – South Africa PO Box 582, Building 1700, Pretoria, 0001, South Africa Tel: +27 12 305 5963 Fax: +27 12 305 5680 Email:
[email protected] Web: www.ntp.co.za
Sources avail: Ir – can be supplied as a sealed sources or loaded into Sentinel/Techops/Gammamat pigtails Services: Loading/Unloading of radiography projectors
Eckert & Ziegler (Isotope Product Laboratories)
Jim Wilson 24937 Avenue Tibbitts, Valencia, CA 91355 (Main Office) Tel +1 661 309 1010 Fax +1 661 309 1042 Email:
[email protected]
Sources avail: Ir, Co, Cs, Am, Be, Cd, Fe, Kr
MDS Nordion
Australian Distributor: GAMMATEC NDT Supplies (Pty) Ltd Robin Momsen and Margaret Mckimmie 13 King Street, Duncanville, Ext. 3, Vereeniging, 1936 Republic of South Africa Ph: +27 16 454 0260 Fax: +27 16 423 3442 Email:
[email protected] Philippe Tessely – Lead Sales Manager Agiris Email:
[email protected] Tel: +32 (0)71 823535 Fax:+ 32 (0)71 823666 Mobile: +32 (0)473 521994 Web: http://www.mdsnordion.com/agiris/agirisE/indexE.html
Service: Unloading/loading of Gammamat radiography projectors and source supply Sources avail: Ir, Co, Yb, Se Services: loading/unloading of Gammamat cameras and sales
CERCA – France
AREVA - CERCA LEA Laboratory Site de Tricastin, BP 75, 26701 Pierrelatte France Joel Hakim – Australian contact Tel: +61 2 9362 9154 E-mail:
[email protected] Web: www.lea-cerca.com
Sources avail: Sealed sources
Nuclear GMBH
Babcock Noell Nuclear GmbH (BNN), Alfred-Nobel-Str. 20, Würzburg, 97080 Germany
Sources avail: Co-60 and Cs-137 sources Products: provide teletron radiography projectors Non-Destructive Testing Vol 45 No. 3
CALENDAR DATE
LOCATION
CONFERENCE
CONTACT
2008 9-10 June
St. Louis, Missouri, USA
NDE of Aerospace Materials and Structures
www.asnt.org
9-12 June
Sao Paulo, Brazil
XXVI National Congress of NDT and Inspection
www.abende.org.br
15-18 July
Edinburgh, UK
The Fifth International Conference on Condition Monitoring and Machinery Failure Prevention Technologies
www.cm2008-mfpt2008.org
26-30 August
Shanghai, China
17th World Conference on NDT
[email protected] [email protected] www.chsndt.com
6-18 September
Shrigley Hall Hotel, Cheshire UK
NDT 2008 Conference and Exhibition
www.bindt.org
8-12 September
Oakland, California, USA
NDT/NDE for Highways and Bridges
www.asnt.org
19-22 October
Adelaide, South Australia
QUALCON 2008 – QUALITY: Process, Innovation and Adaptability
www.qualcon.com.au
10-14 November
Charleston, South Carolina, USA
SNT Fall Conference and Qualoity Testing Show
www.asnt.org
9-12 December
Kyoto, Japan
19th International Acoustic Emission Symposium
[email protected]. kyoto-u.ac.jp
14-19 September
Essen, Germany
Third Quality Testing International Exhibition
www.dgzfp.de
8-13 November
Yokohama, Japan
13th Asia-Pacific Conference on NDT
www.apcndt2009.com
Moscow Russia
ECNDT Conference
[email protected]
Durban, South Africa
18th World Conference on NDT
amanda.vdwesthuizen@ andtc.com
2009
2010 7-11 June
2012 2012
This calendar of events is based on information provided by the respective organisers and from secondary sources. NDT-Australia welcomes information on meetings related to NDT. Deadline for copy is three months ahead of cover date and information should be sent to: Colin Hockings, Editor, Non-Destructive Testing – Australia, PO Box 52, Parkville, Vic, 3052, Australia The AINDT Overseas Conference Grant is available to Institute members to assist with the cost of attending conferences overseas. For further details see NDT-Australia, Vol. 42, No. 6, 2005.
For The Best Prices On:
— RADIOGRAPHIC EQUIPMENT Consumables, Safety Equipment, Processing Equipment — ULTRASONIC EQUIPMENT Probes, Cables, Couplant, Calibration Blocks — EHC-09 THICKNESS GAUGES Data Loggers, A-Scan, B-Scan, E-E, Colour Displays — VIDEO & BORESCOPES Articulating Heads, Hard Drives, Various Applications — MAGNETIC PARTICLE INSPECTION Yokes, Black lights, Consumables — DYE PENETRANT INSPECTION Consumables — EQUIPMENT HIRE
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[email protected] Non-Destructive Testing Vol 45 No. 3
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PRODUCTS & SERVICES New Technology for Tube Inspection The DEFECTOMAT CI from Forster Instruments provides state-ofthe-art data communications featuring full network integration, support of USB peripherals, XML log structure, and remote control of the settings. This new compact instrument is the successor to the globally successful Defectomat C and CP. One of the features offered is the fully optional 2-channel evaluation. This allows the simultaneous use of the differential and absolute channel. It also allows for 2-frequency applications and simultaneous signal evaluation in the eddy current and FERROMAT channel.Other features include, password-protected operating levels, unlimited settings archive, easy to read colour screen, constant display of the most important test parameters, and remote service via telephone modem or internet log-in. In tube welding lines, using the differential and absolute channels to monitor the weld quality with weld probes or segment coils. The optional absolute channel detects open seam tubes and is more sensitive with the new sector evaluation, since disturbances such as temperature fluctuations may be suppressed phase-selectively. In tube finishing lines, using a 2-frequency test for optimal detection of external and internal flaws, or using the differential channel for flaw testing and the static absolute channel to monitor the material properties, such as a simple grade verification or geometric check with respect to the same tube wall. Additional applications include bar stock finishing lines, endless wire lines and casting/rolling lines.
New Oxford Instruments Alloy Analyser Oxford Instruments (www.oxford-instruments.com) introduces the X‑MET3000TXV+, a portable X-ray fluorescence (XRF) analyzer with vacuum pump for the analysis of light metal alloys. The instrument can measure silicon and magnesium in aluminum and the aluminum in titanium alloys. The unit brings value to operators in applications where optical emission spectroscopy cannot be used because of the mark the technique leaves on the surface. The unit’s light element capability is particularly useful where aluminium and titanium alloys are used. With this system, there is no compressed gas bottle to carry, so the cost of consumables is eliminated and inspection will not stop when the gas runs out. With traditional portable XRF analyzers, alloy identification has been based on the analysis of the heavy elements because magnesium, aluminum and silicon produce low-energy X-rays that are impeded by air. The portable vacuum pump evacuates the analysis path of air, making the measurement of these elements possible. The new vacuum feature is enhanced by the high-resolution PentaPIN detector, which delivers fast analysis and lower detection limits. It is configured primarily to identify aluminum and titanium alloys, differentiated only by their concentration of silicon or magnesium. With the PentaPIN detector, a 10-second analysis produces the equivalent of a 30-second analysis made using an instrument with a standard SiPIN detector. Improved software has been implemented to process the data generated by the detector and increase the accuracy of the results obtained. For further information please contact: NDT Equipment Sales Pty Ltd T: (61-2) 9524 0558; F: (61-2) 9524 0560; E:
[email protected]; W: www.ndt.com.au
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The editorial committee of this journal is always interested in receiving information regarding new products or services related to the NDT or related industries for possible inclusion in the New Products Column. As the journal is received by all members, both individual and corporate, it offers an excellent method of informing NDT practitioners in Australasia of new and emerging specialised equipment and services.
Conductivity Measurement – SIGMASCOPE® SMP10 Measuring the electrical conductivity according to the eddy-current method is cost-effective, because it is non-destructive. From the electrical conductivity, one can make direct conclusions regarding the tensile strength of the components. This is possible because of the changes in structure and grain size brought about by the heat treatment. They have a significant influence on the electrical conductivity. Thus, measuring the electrical conductivity is a good test for the strength. Variables such as temperature will affect the accuracy of measurements. The SIGMASCOPE® SMP10 makes such measurements possible. It operates using an external temperature sensor, which allows for the temperature measurement of specimens with an accuracy of below 1°C (1 °F) within 2 to 3 seconds. This is absolutely essential because of the significant influence of the temperature on the electrical conductivity - for aluminium about 3 per mille per degree Celsius (Fahrenheit). The electrical conductivity determined using the measurement probe is then automatically converted to 20°C (+68 °F), the standard temperature that is typical for conductivity specifications. Because of this fast and accurate temperature measurement, errors due to temperature differences can be kept below 0.1 % IACS. Because the test procedure with the SIGMSCOPE® SMP10 takes only a few seconds, a 100 % quality control is now possible even for large quantity productions. An additional advantage of the SIGMASCOPE® SMP10 instrument is the selectability of the measurement frequencies of 60, 120, 240 and 480 kHz without changing the probe. Up to 100 application memories are available and can store up to 20,000 measurements.
Ultrasonic Inspection System – Ultraprobe 10000 The Ultraprobe 10,000 allows inspectors to perform condition analysis, record sounds, store and manage data. UE Systems Ultraprobe 10000 is a multi-level digital ultrasonic condition analysis system. The system consists of two basic components. The first is a hand-held metered pistol ultrasonic sensing instrument with on-board sound recording and on-board data logging. The second is analytical software that will convert most computers into workstations with comprehensive diagnostic functions including spectral analysis, record keeping, trending and reporting. In addition to sound recording and data logging, system features include single-digit digital frequency tuning capability, application-specific software and screen selection for such applications as: bearing inspection/trending, electrical inspection, steam trap testing, valve testing, and leak detection. Test data can be uploaded to the Ultraprobe or downloaded to a host computer. When data is uploaded, inspectors have the ability to compare current test results with baseline data on the same screen to spot any potential problems. Inspection flexibility is enhanced with 23 modes for operation that will enable users to customise the instrument functions and screens to fit specific inspection needs. Non-Destructive Testing Vol 45 No. 3
If you have an item that would be of interest to members please send details in for the New Products editors’ consideration and possible inclusion in a future issue. Articles with a brief technical description of about 250-300 words accompanied by good quality colour photographs will be given preference. Information should be forwarded to: Colin Hockings: chockings@ qantas.com.au, AINDT:
[email protected] or Research Publications:
[email protected]
PRODUCTS & SERVICES
New CT-Gage from Sonatest
Panametrics Series 35 Thickness Gauges
Making precise wall and coating thickness measurements is fast and easy using the new Sonatest CT-Gage and CT-Gage DL (data-logging) ultrasonic thickness gauges. Not only do both models measure coating and wall thickness quickly and accurately, from only one side, but they automatically measure and eliminate any coating from wall thickness measurements, allowing users to locate fine corrosion and pitting-without removing the coating. The gauges store 64 custom setups and switching into the time based B-Scan view enables a cross section view of the material. The high-speed scan function provides 50 readings per second!
The Panametrics-NDT™ Series 35 ultrasonic precision thickness gages provide easy-to-use and cost-effective solutions in applications where the opposite side of the test material is difficult or impossible to reach. These rugged, pocket-sized gages make stable, repeatable thickness measurements on most materials of varied shapes and sizes. Accurate thickness measurements are displayed in large numerals on the backlit LCD or can be viewed along with the live waveform in the optional A-scan Mode.
Five user-selected operating modes are included: Coating On, Coating Off, Thru Coat and Coating Only. All measurements are temperature compensated. Minimum coating thickness is 0.0127mm allowing the gauge to precisely measure thin coatings with it’s advanced waveform analysis technique. A large backlit graphic LCD features easy-to-read fonts, graphics and display codes which show all critical settings. CT-Gage features include: auto probe zero, auto probe recognition, auto temperature compensation, and a stand alone coating only mode. The standard pulse-echo and thru-paint echo-echo modes are standard features. The CT-Gauge Data-Logging model adds built-in memory, with an RS-232 output for transferring data. Data Files can be user-set for a “grid type” structure or a “sequential” file. In addition, each file can be set to store “data only” or “data plus B-scan” graphic. The CT-Gage DL can store 16,000+ readings, with B-Scan captures and all gauges settings and features, or turn the graphics mode off and store over 210,000 readings. For more information, please contact Russell Fraser at Russell Fraser Sales on (02) 9545 4433 or www.rfsales. com.au
35 Series Features • Velocity and Reduction Rate measurements are standard on all models • Wide thickness range from 0.0030" to 25.0" (0.08 mm to 635.0 mm) depending on instrument and material • Uses contact, delay line, and immersion transducers • Application Auto-Recall with default and custom setups • Hand-held; weighs only 8.5 oz. (0.24 kg) • Min/Max Mode • Hi-Low alarm • English and metric display (inches/mm) • Multi-language user interface • Long battery life The 35 and 35DL can use transducers ranging from 2.25 to 30 MHz, which means that these versatile gauges can solve the majority of thickness gauging applications, from very thin to very thick on a variety of materials. In general, transducers with higher frequencies and smaller diameters allow measurements of thinner or curved parts and enhance the accuracy of the measurement. Models 35HP and 35DL-HP have a very low ultrasonic frequency bandwidth and a special pulser-receiver, the HP gages are specifically designed to optimise ultrasound penetration when measuring thick, highly sound attenuating or sound scattering materials. Typically these materials cannot be measured with most other ultrasonic thickness gages.
VJ Inspection Systems Introduces New Wheel Inspection System VJ Inspection Systems (www.vjt.com) introduces the VJT W4000 X-Ray Wheel Inspection System. The system improves aluminum automotive wheel quality control management. It delivers complete high-resolution coverage of the entire wheel in a single image. The system provides operators with a single, uninterrupted wheel discontinuity picture, with multiple viewing angles, to more quickly and accurately ensure quality control and optimize manufacturing process adjustments. The incorporation of linear diode array (LDA) imaging technology, automatic defect enhancement (ADE) for manual inspection and defect recognition software (DRS) for fully or semi-automated inspection all combine to improve inspection quality while reducing operator fatigue. Database storage of inspection records allows analysis and process improvement. Real-time feedback of inspection results and ADE images to production stations enable online process control. Non-Destructive Testing Vol 45 No. 3
Additional features include an industry standard cycle rate (one 17-inch wheel every 30 seconds); multiple views from a single scan; high-resolution imaging system; 250-kilovolt source available with PC-controlled cooler; image and archival system; minimal moving parts for nominal maintenance; ability to scan wheels from 13 inches to 24 inches in diameter; programmable system controller; compliance to US 21CFR1020.40, UVV, DIN54113, VDE-0-100, CE, EUATOM 96/29 and IEC 529. For further information please contact: NDT Equipment Sales Pty Ltd T: (61-2) 9524 0558; F: (61-2) 9524 0560; E:
[email protected]; W: www.ndt.com.au
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technical paper
Wall thickness measurement sensor for pipeline inspection using EMAT technology in combination with pulsed eddy current and MFL G Dobmann, F Niese, H Willems and A Yashan
Abstract An electromagnetic acoustic transducer (EMAT) is presented for excitation and detection of linear polarized shear waves at normal incidence with the use of a horizontal magnetization of the specimen. The sound field is optimised for the measurement of the wall-thickness of steel plates and pipe walls with metal-loss and pitting due to corrosion. As an EMAT – insonifying a pipe wall from the id-surface – does not provide an incident surface echo signal, because the wave is directly excited in the material, the position of metal-loss (id- or od-surface) cannot be detected. To overcome the drawback, the EMAT is utilized also as an eddy current sensor and the transmitting pulse for UT-excitation at very early receiving times is evaluated as eddy current signal in order to detect the transducer lift-off. So far the lift-off is > 0 and simultaneously the EMAT signal can be evaluated, id-metal-loss is detected. In the case of zero lift-off, the EMAT time-of-flight information describes the wall-thickness and – if reduced – od-metal–loss. In the case of larger lift-off (> 500 µm), i.e. larger idmetal-loss, the potential of the EMAT to excite and detect ultrasound is tremendously reduced. However, in that case the pulsed eddy current feature to measure the liftoff can be evaluated up to a lift-off of 8mm to size the id-corrosion. Furthermore, the EMAT as an inductive sensor can detect the magnetic flux leakage excited by the horizontal magnetic field and produced by the metal-loss so far the speed of the inspection tool is not too low. Because of the low frequency of the flux leakage signal compared with the high frequency EC or ultrasonic signal it is possible to separate and analyse the different signal parts. Due to the combination a probe was developed and optimized. The contribution reports to the obtained state of the art and the potential for gas pipe inspection.
Keywords In-Line Pipe Inspection, Gas Pipes, EMAT, EC, MFL, Combination Transducer, Metal-Loss, Detection, and Sizing
Authors Details Gerd Dobbmann is a deputy and division director at the Fraunhofer Institute for Nondestructive Testing located in Germany. Frank Neise and Andrey Yashan are from the Fraunhofer Institute for Nondestructive Testing, IZFP in Saarbrücken, Germany. Herbert Willems is from NDT Systems & Services in Stutensee, Germany.
1
Introduction
Pipelines are often exposed to corrosion because of the environmental conditions as well as the properties of the transported media. In order to prevent pipeline damages the pipeline operators inspect the pipelines at regular intervals using in-line inspection tools also called intelligent pigs. These tools are moved with the medium while testing the pipewall with standard NDT techniques such as ultrasonics or MFL.
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In liquid pipelines ultrasonic inspections with piezoelectric transducers are readily applied as the medium is used as couplant for transmitting the ultrasonic impulses into the pipewall. By measuring the time of flight between the entrance echo at the internal surface and the back wall echo from the external surface the (remaining) wall thickness can be determined. Additionally, the location of a metal loss in the wall (internal or external) is obtained by measuring the distance between the sensor and the internal wall. However, in gas pipelines it is not possible to use the classical ultrasonic inspection techniques because of the absence of the needed liquid coupling. Here the magnetic flux leakage (MFL) technique is usually applied for metal loss inspection. The pipe wall is tangentially magnetised by permanent magnetic yokes. Between the pole shoes of the yoke Hall sensors are mounted to detect the magnetic flux leakage in case of thickness change of the pipe wall. The use of MFL has some limitations: • The detection sensitivity with regard to external corrosion is limited (especially in case of larger wall thickness). • The MFL signal depends on the material properties as well as on the wall thickness. For the determination of (remaining) wall thickness a calibration is needed. • The accuracy of depth measurement is reduced due to the indirect method as compared to the direct measurement when using ultrasonics. In this paper we present an alternative to MFL for metal loss inspection in gas pipelines which is based on the dry working EMAT technique. In a similar way as the classical ultrasonic technique the wall thickness (e.g. the wall thickness reduction by metal loss) can be determined by the timeof-flight of the back wall echo signal. As an EMAT sensor needs to be close to the surface in order to efficiently generate ultrasound, ultrasonic measurement is no longer possible if metal loss is present at the transducer-near side. In order to ensure reliable measurement for this case, the EMAT technique is combined with the eddy current (EC) technique and the magnetic flux leakage (MFL) integrated in a single sensor.
2
Sensor development and optimisation
2.1 EMAT Sensor Arrangement Common EMATs for normal incidence and wall thickness measurement use a normal magnetic field excited by a magnet unit above the coil [1]. The magnetic field provides a strong attractive force between the magnet and the specimen. Therefore the coil that is located between the magnet and the specimen is exposed to strong mechanical stress and strain. Due to the strong force acting on the sensor system heavy wear has to be taken into account in case of a dynamic inspection especially when the sensor crosses weld beads. Non-Destructive Testing Vol 45 No. 3
Wall thickness measurement sensor for pipeline inspection
The EMAT design described here avoids the wear problem because the magnetiser unit and the coil system are mechanically decoupled. The new magnetiser is designed like a u-shaped yoke similar to an MFL magnetiser that generates a horizontal magnetic field between the pole shoes. The coil system is mounted in the region between the pole shoes. A slight suspension is needed to keep the coil near to the surface of the test object. The coil that is designed as a simple air coil is no longer affected by magnetic forces. The superposition of the horizontal magnetic bias field and the electromagnetic fields excited by the coil generate an ultrasonic oscillation in the surface of the test object by magnetostrictive interaction [1, 2]. The oscillation is a source for an ultrasonic pulse travelling normal to the surface into the material. The magnetostrictive coupling mechanism is a very effective one as compared to the Lorentz mechanism used in EMAT design with normal magnetisation. Figure 1 shows the basic sensor arrangement of the new EMAT design.
Figure 3: Horizontal Magnetic Field Strength in case of Wall Thickness Reduction.The Upper Inset shows the Shape of the Test Sample Containing Three Artificial Defects.
2.1.2 Sound field
Figure 1: Sensor Arrangement
2.1.1 Magnetostrictive operation point The magnetostrictive acoustic coupling depends strongly on the applied bias magnetisation. This dependency has been examined for different pipeline steels. Figure 2 shows the behaviour for the different steel samples. In principle the shape of the curves is similar the field values of the maximum amplitudes are all in the region of 300 to 350A/cm. However, the height of the maximum amplitude varies to some extent. The optimal bias magnetisation for the generation of ultrasound is not the field value at the maximum amplitude because of the fact that thickness reductions in the pipe wall (e.g. metal loss) lead to an increase of the magnetic bias field at those positions. The effect (see Figure 3) is well known and exploited in the MFL technique. However, in case of the magnetostrictive generation of ultrasound it is undesirable, because deep wall thickness reductions increase the magnetic field strength and the efficiency of the ultrasonic generation may be considerably reduced. Therefore the operation point is chosen to about 3/4 of the maximum amplitude in the raising part of the curve. Then the signal-to-noise-ratio for the ultrasonic backwall echo is sufficient in undamaged areas as well as in damaged regions.
For a precise ultrasonic wall thickness measurement, especially in case of non-parallel and rough surfaces, it is advantageous to have a sound field distribution with a high main lobe under zero degree and only a low number of side lobes with low amplitudes. Therefore several coil types (see Figure 4, Table 1) have been examined. The best results are obtained using a circular coil with clustered wires and separated transmitter and receiver coils. A second optimization criterion is the mode purity of the ultrasonic excitation respectively the selective receiving sensitivity with regard to longitudinal or transversal waves. For a reliable determination of the wall thickness pure modes should be used in order to avoid disturbing signals. The diameters of the circular coils have been varied to optimize the mode purity. The results are shown in Figure 6. The reduction of the coil diameter reduces the longitudinal part of the ultrasonic wave. Figure 5 shows the combined transmitter and receiver sound fields parallel and normal to the bias magnetization for the optimized coil design with regard to mode purity and sound field. Table 1: Investigated coil types coil type
amplitude maximum under zero degrees
oval coil
yes
rectangular coil (1)
yes
spiral or pan cake coil
yes
butterfly coil
no
butterfly coil with angled return
no
paths rectangular coil (2)
no
2.2 Combination with Pulsed Eddy Current
Figure 2: Dependency of the Ultrasonic Amplitude and the Magnetic Field Strength in case of Magnetostrictive Coupling for Different Pipeline Steels and ST37 Non-Destructive Testing Vol 45 No. 3
If metal loss is present at the transducer-near side, it is not possible to determine the remaining wall thickness because the lift-off of the EMAT sensor caused by the wall thickness reduction may lead to a complete loss of the ultrasonic signal. In order to ensure a reliable measurement for this case, the EMAT technique is combined with the eddy current (EC) technique. The EC technique is able to detect metal loss at the transducer-near side by measuring the transducer lift-off. The EMAT excitation signal is used as a pulsed EC excitation. Thus both techniques
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Wall thickness measurement sensor for pipeline inspection
Figure 4: Investigated Coil Types: Upper Row, from Left to Right: Butterfly Coil, Oval Coil, Rectangular Coil (1); Lower Row: Butterfly Coil with Angled Return Paths, Spiral or Pan-Cake coil, Rectangular Coil (2)
component normal to the surface as an induction voltage when moving relative to the component. The integration of the induction voltage yields the value of the MFL signal. A separation of the receiving signal into an EMAT part and a MFL part is ensured by frequency filtering as the frequency range of the MFL signal is basically different from the range of the ultrasonic signal.
Figure7: EC Amplitude for Different Sensor Lift-Off Figure 5: Sound Field of the Optimised EMAT Coil, Parallel and Normal to the Horizontal Magnetic Field
3. Experimental Results The combined sensor with the optimized coil system has been tested using several specimens with machined corrosion-like defects. The results shown in Figure 8 and Figure 9 are obtained from a 10mm steel plate with calotte-shaped defects. The diameter of the calottes at the surface are 10, 15 and 30mm, the depth is 30% of the wall thickness. The principle set-up is also depicted in the figures. The sensor system is moved along the surface of the specimen, first on the defect-free side and then on the other side containing the defects. In case of external defects (Figure 8) the wall thickness can be calculated using the time-of-flight of the ultrasonic backwall echo signal. The shape of the artificial defects and the measured wall thickness fit very well. As expected, the EC technique does not show any indication.
Figure 6: Sound Field Mode Purity for Circular Coil Systems with Different Coil Diameters are operated simultaneously. The EC receiving signal can be picked up either by the EMAT receiver coil or by a separate coil. The advantage of using a separate receiving coil is that it can be optimized for EC metal loss detection. The maximum depth that can be resolved depends on the coil diameter: a larger coil diameter leads to a larger depth range.
Figure 9 shows the results when the defects are located at the internal side. In the defect areas the EMAT signal breaks down, and the ultrasonic thickness measurement is no longer possible. However, the EC technique now detects the inside defects. The depth is determined with the help of the lift-off calibration curve (Figure 7). The measured depths differ somewhat from the real values. This can be explained by the fact that the EC response represents an average value over the sensor and the defect aperture. In both cases, the MFL signals indicate the defects in the well known manner.
The evaluation of the received EC signals follows the classical EC signal analysis, separation of amplitude and phase of the signal for the analysis frequencies. Figure 7 shows the measured amplitude for several sensor lift-offs. With the current configuration, separate EC receiver coil, a determination of the sensor lift-off is possible up to approx. 8mm. At higher depths the signal is saturated.
2.3 Combination with MFL The EMAT technique is very sensitive to sensor lift-off. In case of internal metal loss the EMAT signal may be completely lost. Then, in addition to the EC signal, also the MFL signal can be used for measuring the depth. Essential hardware components are used simultaneously for both techniques: The magnetizer is used to set the magnetostrictive operation point of the ultrasonic excitation and to magnetize the component for MFL inspection. The EMAT coil is additionally able to detect the MFL
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Figure 8: Results of the Combined EMAT, EC and MFL Inspection of External Defects Non-Destructive Testing Vol 45 No. 3
Wall thickness measurement sensor for pipeline inspection
By combining the different inspection technologies the disadvantages of the individual techniques are eliminated. As a result, a sensor is now available, that allows to redundantly measure the (remaining) wall thickness of a component as well as to determine the location in the wall of a detected metal loss. Table 2 shows an overview on which information is obtained from the individual inspection techniques. A further advantage of the new sensor conception is that essential hardware components can be used in parallel. In particular, pronounced improvements in the field of metal loss inspections of gas pipelines are expected. Table 2. Defect information obtained from the individual inspection techniques Figure 9: Results of the Combined EMAT, EC and MFL Inspection of Internal Defects
4. Conclusions & Summary An electromagnetic acoustic transducer (EMAT) has been developed and optimized for excitation and detection of linear polarized shear waves at normal incidence with the use of a horizontal magnetization of the test object. The sound field has been optimized for the measurement of the wall thickness of components such as steel plates or pipe joints. Special focus is on determining the remaining wall thickness in case of metal loss (e.g. general corrosion, pitting corrosion). The sensor system and the magnetization unit are mechanical decoupled to reduce the wear of the sensors. In order to ensure reliable measurement for internal metal loss, the EMAT technique is combined with the eddy current (EC) technique and the magnetic flux leakage (MFL). The EC technique, that uses the EMAT excitation signal as a pulsed EC excitation, is able to detect metal loss at the transducer-near side by measuring the sensor lift-off simultaneously. Additionally, a MFL signal is derived by making use of the horizontal magnetization and the EMAT receiver coil as a flux leakage sensor. The MFL signal can be separated and analyzed by appropriate filtering because it contains mainly low-frequency components as compared to the high frequency EC signal respectively ultrasonic signal.
EMAT-Info (US)
EC-Info
MFL-Info
external metal loss: remaining wall thickness
direct measurement
n.a.
indirect measurement (calibration curve)
external metal loss: length
direct measurement
n.a.
(direct) measurement
internal metal loss: remaining wall thickness
n.a.
indirect measurement (calibration curve)
indirect measurement (calibration curve)
internal metal loss: length
direct measurement
direct measurement
(direct) measurement
5. References [1]. Hirao M and Ogi H, 2003. EMATS for Science and Industry (Kluwer Academic Publishers) [2]. Wilbrand A, 1990. Theoretische und experimentelle Untersuchungen zu einem quantitativen Modell für elektromag netische Ultraschall prüfköpfe, Tech nisch-Wissenschaftl icher Bericht N r. 900125-TW, IZFP Saarbrückenz
Australasian Radiation Protection Society Inc. (South Australian Branch)
Radiation Safety Officer Seminar 27 June 2008, 9am to 4pm
University of Adelaide, Seminar Room, 1st Floor, Physics Building, Room 121 Are you a radiation safety officer (RSO) with responsibility for sealed radioactive sources? Then you should attend this seminar and meet other RSO’s who have responsibility for sealed radioactive sources used in medical, industrial, mining and research applications. You will hear presentations about radiation safety from a variety of speakers, view displays of radiation protection service suppliers, and meet other RSO’s in similar industries to yours. Topics for discussion: updates on ARPANSA Codes regarding transport, security, fixed gauges and portable moisture/density probes, web resources for RSO’s, the use of older sources in SA, waste, radiation protection training, and emergencies. Speakers: representatives from the EPA, ARPANSA, and industry. Catering: Morning and afternoon tea, lunch and post seminar drinks is included in the cost. Parking: Off street car parks are located nearby on North Terrace. Parking is not available on the University of Adelaide grounds. For further information contact: Kent Gregory 0410 388 018 or
[email protected]
Non-Destructive Testing Vol 45 No. 3
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technical paper
Portable phased array applications M Moles
Abstract This presentation describes several in-service applications for portable phased arrays. OmniScan PA is new category of instrument using ultrasonic phased arrays, as well as other technologies (conventional ultrasonics, TOFD, eddy current arrays etc.). Portable phased arrays can operate in manual, semi-automated (i.e. encoded) or fully automated modes, though most of the applications to date have been manual or semi-automated. Unlike conventional ultrasonics, portable phased arrays can provide many different displays, such as TOFD, A-, B-, C-, D-, E- and S-scans, plus combined displays which significantly help imaging. Most of the new applications so far have been specials, which take advantage of one or more of the following features: special scan patterns (e.g. Sscans), imaging (e.g. corrosion mapping or weld inspections), inspection speed, and restricted space. Portable phased arrays also offer advanced reporting capability, including pre-prepared reports and automatic pasting of images into reports for archiving. • • • • • • • • • • • • • •
Sample applications for portable phased arrays include: Detection and sizing of SCC in turbine roots Small diameter austenitic pipe weld inspections In-service inspection of pipe for SCC Butt weld inspections T-weld inspections of bridge structures HIC – Hydrogen Induced Cracking Friction stir weld inspections Nozzle inspections Thread inspections Bridge bolt inspections Spindle/shaft inspections Landing gear inspections Laser weld inspections Scribe line inspections
Keywords Phased Array, Ultrasonic Testing, Cold Cracking, Stress Corrosion Cracking Authors Details
Michael Moles works in Market Development at Olympus NDT in Canada.
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INTRODUCTION
Volumetric inspections are typically performed in industry using either radiography or ultrasonics. Radiography has the disadvantages that it is a safety hazard, and is poor at detecting the more critical planar defects (cracks, lack of fusion, lack of penetration). Manual ultrasonics is much better than radiography for planar defects, but is slow, and the results are highly operator-dependent. Automated ultrasonics typically involved large, expensive and inflexible systems, though the results are reproducible. Fortunately, technology has come to the rescue – in the form of portable phased array ultrasonics. This type of equipment is highly computerized, and can be operated in manual, semi-automated (encoded, with or without a scanning aid) or fully automated (i.e. operating a scanning rig). This new generation of equipment offers many of the advantages of phased arrays: speed, flexibility, data storage, imaging, reproducibility, and limited footprint, with many of the advantages of manual ultrasonics: portability, ease of set-up and relatively low cost.
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After briefly introducing the principles of phased arrays and types of scans, this paper describes a series of portable phased array applications. As normal with new categories of equipment, many of the initial applications have been “specials”; more recently, general applications for weld inspections have become viable. Perhaps more interesting is the observation that most of the applications are either fully manual, or semi-automated. Very few portable phased array applications use the capability of fully automated inspection.
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Ultrasonic phased arrays
Ultrasonic phased arrays are a novel method of generating and receiving ultrasound. Instead of a single transducer and beam, phased arrays use multiple ultrasonic elements and electronic time delays to create beams by constructive and destructive interference. As such, phased arrays offer significant technical advantages for weld inspections over conventional ultrasonics. The phased array beams can be steered, scanned, swept and focused electronically. Beam steering permits the selected beam angles to be optimized ultrasonically by orienting them perpendicular to the predicted defects, for example Lack of Fusion in automated welds. Electronic scanning permits very rapid coverage of the components, typically an order of magnitude faster than a single transducer mechanical system. Beam steering (usually called sectorial or azimuthal scanning) can be used for mapping components at appropriate angles to optimize Probability of Detection of defects. Sectorial scanning is also useful for inspections where only a minimal footprint is possible. Electronic focusing permits optimizing the beam shape and size at the expected defect location, as well as optimizing Probability of Detection. Overall, the use of phased arrays permits optimizing defect detection while minimizing inspection time.
2.1 How phased arrays work Ultrasonic phased arrays are similar in principle to phased array radar, sonar and other wave physics applications. However, ultrasonic development is behind the other applications due to a smaller market, shorter wavelengths, mode conversions and more complex components. Several authors have reviewed applications of ultrasonic phased arrays (1-3), though industrial uses have been limited until the last few years. From a practical viewpoint, ultrasonic phased arrays are primarily a method of generating and receiving ultrasound; once the ultrasound is in the material, it is independent of generation method, whether generated by piezoelectric, electromagnetic, laser or phased arrays. Consequently, many of the details of ultrasonic inspection remain unchanged; for example, if 5 MHz is the optimum inspection frequency with conventional
Figure 1: Schematic Showing Generation of Linear and Sectorial Scans using Phased Arrays Non-Destructive Testing Vol 45 No. 3
Portable phased array applications
ultrasonics, then phased arrays would typically use the same frequency, aperture size, focal length, and incident angle. Phased arrays use an array of elements, all individually wired, pulsed and time-shifted. These elements are usually pulsed in groups from 416 elements. A typical user-friendly computerized set-up calculates the time-delays from operator-input, or uses a pre-defined file: inspection angle, focal distance, scan pattern etc (see Figure 1). The time delay values are back calculated using time-of-flight from the focal spot, and the scan assembled from individual “Focal Laws”. Time delay circuits must be accurate to a few nanoseconds to provide the accuracy required. The set-up information is electronically recorded, and only takes seconds to re-load. Modifying a prepared set-up is quick in comparison with physically adjusting conventional transducers.
2.2 Types of scans Using electronic pulsing and receiving provides significant opportunities for a variety of scan patterns (see reference 4 for a full description). The two basic patterns are electronic and sectorial scans.
2.2.1 Electronic Scans (E-scans)
Figure 2: Schematic Illustration of Electronic Scanning E-scans are performed by multiplexing along an array (see Figure 2). Typical arrays have up to 128 elements. Electronic and linear (one-axis mechanical scanning) inspections permit rapid coverage with a tight focal spot (see below). If the array is flat and linear, then the scan pattern is a simple B-scan. The data can be processed to provide a C-scan, or combined scans (e.g. “top, side, end” views or combined S-scans and A-scans).
2.2.2 Sectorial (Azimuthal) Scans Sectorial (S-)scans use the same set of elements, but alter the time delays to sweep the beam through a series of angles (see Figure 3). Again, this is a straightforward scan to program. Applications for sectorial scanning may involve a stationary array, sweeping across a relatively inaccessible component like a turbine blade root (Ciorau et al, 2000), to map out the features (and defects). Depending primarily on the array frequency and element spacing, the sweep angles can vary from ±20º up to ±80º.
Figure 4a: (left). Conventional Raster Scanning; 4b (right). Linear Scanning In contrast, phased arrays use a “linear scanning” approach (see Figure 4b). Here the probe is mechanically scanned in a line round or along the component (a weld in this example), while the array performs electronic or sectorial scanning. Linear scanning is frequently used in pipe mills and pipe lines.
3
Portable phased array instrument
Olympus NDT has introduced the OmniScan MX, a portable phased array unit with manual, semiautomated and automated capability. In practice, this is a multi-technology unit, with replaceable function modules (besides phased arrays, there are conventional ultrasonics, TOFD, eddy current and eddy current array modules available, with other technologies in development). The current phased array unit is a 16/128 (sixteen multiplexed pulsers with 128 channels), with up to 256 Focal Laws (individual beam pulses). The unit can perform electronic and sectorial scans. The unit has similar ultrasonic specifications to an upscale single channel flaw detector (frequency, filtering, TCG, gates, alarms, range etc.), and can operate as such (6). The instrument is fully digital, and can perform encoded scans. Unlike conventional manual flaw detectors, the phased array unit records full waveform data at multiple angles/positions, and can display A, B, C, D, E, S, TOFD and combined scans. This gives much increased imaging capability. The unit also has built-in reporting capability using pasted-in scans, and internal procedure capability. There is a special calibration process for phased arrays, to ensure uniform signal strength across the array and wedge. The unit weighs 4.6 kg with one battery. There are many electronic connections on this unit: three USB ports, video input and output, speaker, microphone, and Ethernet connection, CompactFlash® card, internal 32 MB DiskOnChip®, 2-axis encoder line, 2 TTL inputs, 4 digital outputs, RS-232 or RS485, on/off, three alarms, analog out. The instrument is shockproof and splashproof for industrial applications, and operates within a wide temperature and humidity range. The function keys are clear and simple, following current flaw detector designs (see Figure 5). This portable phased array unit has a “probe recognition” function, where the array is automatically detected and characterized when connected; this eliminates programming the array parameters, which is a major benefit to operators.
Figure 3: Schematic Showing Sectorial Scanning used on Turbine Rotor.
2.2.3 Linear scanning of components Manual ultrasonic inspections are performed using a single transducer, which the operator “scans” back and forth to cover the area to be covered (see Figure 4a). Many automated inspection systems use a similar approach, with a single transducer scanned back and forth for corrosion or weld inspections. This is very time consuming, since the system has dead zones at the start and finish of the raster. Non-Destructive Testing Vol 45 No. 3
Figure 5: The Portable Phased Array Unit showing a Longitudinal Wave S-Scan
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Portable phased array applications
3.1 Arrays
4.2 Small Diameter Austenitic Pipe Weld Inspections
As with all inspection systems, the probe or transducer is critically important. This is perhaps even more so with arrays, though typically a single array can perform multiple inspections, often with appropriate wedges. There are technical limits to arrays; individual element sizes are limited in practice to around 0.15 mm (0.006") and are normally <20 MHz. However, the real limitations of arrays are cost. The more advanced arrays with hundreds of elements can easily cost tens of thousands of dollars. These arrays can be matrix, circular, conical, complex.
This application involved inspection of stainless steel pipe welds of various diameters for a nuclear waste application. The welds were autogenous, made by orbital welders; as such, the weld profile was near vertical. Wall thicknesses were generally thin. Space between pipes was minimal, necessitating a manual scan or low profile scanner. Radiography was not permitted for safety reasons. Rapid and reliable inspections were required, with full data recording.
To reduce costs, Olympus NDT has set-up automated manufacturing of a standard series of linear arrays. Needless to say, there will always be “specials”, as normal in NDE. Olympus NDT has a standard nomenclature for arrays and wedges for convenience. With the arrival of portable phased arrays, the market is requiring lower cost, standardized, quick delivery, easy-to-use (i.e. probe recognition) arrays.
4
The portable phased array solution used two arrays generating shear waves, one on either side of the weld with a splitter cable. Linear scanning around the weld and a low profile scanner with a small MiniME® encoder was used for data collection. S-scans were used, with the data displayed as C-scans. Figure 7 shows a photo of the scanner and display.
Applications
This section lists a dozen portable phased array unit applications. This list is far from exhaustive, and new applications are arriving regularly. However, this should give a cross-section of typical uses, and covers a wide variety of industries: nuclear, petrochemical, defence, industrial, aerospace.
4.1 Detection and Sizing of Stress Corrosion Cracking in Turbine Roots This application has a large number of components and high downtime costs, plus limited access (see Figure 7) in a nuclear reactor. False calls must be minimized due to outage costs, and small defects (1 mm high and as little as 3 mm long) must be detected. Defect range and location varies. The phased array solution was to model the application to optimize array design, ray tracing to optimize the inspection, use relatively high frequency (6-12 MHz) and to plot the scans on a component overlay. (In practice, being a nuclear application, multiple units and multiplexed scans were used; however, this does not alter the application principles). Uncorrected S-scans were used, with minimal probe movement.
Figure 8: Phased array detection of SCC in feeder pipes. Left, Scanning Set-Up; right, Crack Detection
4.3 In-service Inspection of Pipe for SCC This nuclear application is for detecting axial stress corrosion cracking in CANDU reactor feeder pipes. These pipes are ferritic steel, with very limited access between pipes. Radiation fields are high, so inspections must be quick. Crack heights are less 1 mm and wall thicknesses typically ~ 10 mm. The portable phased array solution is to use a small 10 MHz, 16 element array with miniature wheel encoder attached (see Figure 8). Once detected, defects could be sized accurately using TOFD (now available with the unit).
4.4 Butt Weld Inspections In contrast to the nuclear applications above, butt weld inspections represent a huge and varied application. Typically, these inspections are performed according to an established code and approved procedure
Figure: 6a (left). Schematic of Turbine Root; 6b (right). S-Scan Display showing Defects
Figure 7a (left).Twin SW Wedges with Low Profile Scanner for Weld Inspections; 7b (right).Typical A-scan, S-scan and C-scan display showing 1.5mm calibration hole
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Figure 9:Typical S-scan of butt weld, showing lack of fusion defects at OD and ID Non-Destructive Testing Vol 45 No. 3
Portable phased array applications
and technique. Olympus NDT has been working with Eclipse Scientific Products and other companies to develop generic weld inspection techniques, and has ASMEcompliant butt weld inspection procedures up to 25 mm wall (7). Typical inspection criteria for practical applications include performing cost-effective, rapid and reliable inspection of butt welds in plate or tube, storing the data for reference, and imaging defects for optimum sizing. The portable phased array solution uses an array on a wedge (for wear and optimum angles) to generate shear waves as usual. S-scans or electronic scans are performed using a linear scan along the weld. The data is stored and displayed as S-scans or “top, side, end” views (see Figure 9).
The portable phased array solution is to use normal beam electronic manual S-scans to rapidly detect HIC. To determine if SOHIC is present, a second set-up file is loaded to perform using ±30º S-scans. The AutoTrack function is used to display the A-scan angle with the highest amplitude waveform. The array is skewed back and forth to optimize signals. Typically the beam is focused at midwall since most HIC and SOHIC occurs at 1/3 to 2/3 depth. The operator looks for additional signals between HIC reflections to identify SOHIC (see Figures 11a and b).
4.5 T-Weld Inspections of Bridge Structures These weld inspections are similar to butt weld inspections, but can be more challenging due to geometry. Typically, these applications involve thicknesses of 10-16 mm, and reliable detection of planar defects (cracks, lack of fusion, lack of penetration) is essential. Probe movement is limited, multiple inspection angles are necessary, and a cost-effective solution is required. The portable phased array solution is to use an encoded hand scan with a small linear 5 MHz, 16 element array. S-scans are performed between 40º and 70º using shear waves, and the results displayed as a combination of A-scans and S-scans. Other scanning and display options are possible. Figure 10 shows the T-joint geometry and an inspection in action.
Figure 10: Inspecting T-welds using portable phased arrays with an encoded array. Top: inspection geometry and procedure; Bottom: field inspection
4.6 Hydrogen Induced Cracking (HIC) HIC involves the diffusion of hydrogen into steels, where it typically forms lamellar blisters at inclusions. Standard HIC is benign and easily detected by ultrasonics, but stepwise cracking can occur between blisters, which is structurally undesirable. This SOHIC (stress-oriented hydrogen induced cracking, or stepwise cracking) is more difficult to characterize using conventional ultrasonics. While HIC forms lamellar reflectors parallel to surface, SOHIC forms as cracking between HIC blisters, at an angle to the surface. The objective is to reliably determine if SOHIC exists amongst HIC. The inspection must be rapid and comparatively low cost. Data storage is desirable. Non-Destructive Testing Vol 45 No. 3
Figure 11a: HIC with no Stepwise Cracking Visible (no SOHIC)
Figure 11b: HIC with SOHIC Visible
4.7 Friction stir weld inspections Friction stir welding (FSW) is an advanced solid-state joining process which has major advantages in terms of bond strength, weight and weld control; however, FSW can still produce defects. FSW can be used for butt welds and lap welds, normally in aluminium in the aerospace industry. Portable phased arrays can be used for detecting defects like lack of penetration, galling and worm holes. A standard array is used with a local waterbath, as shown in Figure 12.
Figure 12: Photograph of Commercial Array with Local Waterbath for Coupling
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Portable phased array applications
4.9 Thread Inspections The requirement is to rapidly and reliably inspect threads on many munitions shafts to determine if they are correctly threaded or doublethreaded (see Figures 15a and 15b). The output display should be “easy to interpret”. All data must be stored.
Figure 13: Lack of penetration defect visible on A-, B- and C-scans
Figure 15a: Drawing showing Munitions Tail and Mock-up of Probe on Custom Wedge
Figure 13 shows typical results on a lack of penetration defect 80 mm long. The defect is clearly visible using several different images.
4.8 Nozzle Inspection The requirement is to detect and measure erosion-corrosion on a 17.5 cm (7") nozzle inside surface. The inspection must be performed rapidly in-service, and must be cost-effective. The portable phased arrays solution is to use a 32-element, 10 MHz linear array, and perform Sscans using L-waves from 0º to 70º (see Figures 15a and 15b). The nozzle is imaged as a volume corrected (true depth) S-scan. Erosion-corrosion is measured from the image (see Figure 14c). The image can be zoomed, if required.
Figure 15b: Cross-Section Through Shaft Showing DoubleThreading The portable phased array solution uses a linear array with a custom wedge to fit the shaft. Focused ultrasonic beams are used for resolution, and a B-scan display to show correct or bad threading (see Figure 15c). The operator can readily distinguish between good and a double threading by interpreting the B-scan patterns (8).
Figure 14a: Photo showing 175 mm calibration block and bevel end
Figure 14b: S-Scan of Nozzle, showing Bottom Surface, Corner and Smooth End Surface
Figure 14c: S-Scans showing Eroded Corner. Right, Zoomed Image
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Figure 15c: B-Scan of Threads showing Correct Threading with Automated Accept/Reject
4.10 Spindle/shaft inspections The NDE required inspecting down a long spindle for cracking (see Figure 16a). A rapid and reliable inspection was required, which should both detect and size any defects. The main concern was that data interpretation could be difficult due to multiple reflections. This type of inspection is required for bridge pins, vehicle shafts and similar applications. The portable phased array solution used a single array rotating on the top of the spindle (see Figure 16a), performing a narrow-angle Sscan to sweep from the centerline to the edge of spindle. The results were displayed as a corrected S-scan, and known features (e.g. lands) were used to determine the locations of reflectors. Calibration used machined notches. Non-Destructive Testing Vol 45 No. 3
Portable phased array applications
Figure 17b: A-Scan and S-Scan Image from Typical Bolt, showing Threads, Reference Notch and Backwall
4.12 Landing Gear Inspections Figure 16a:Top: Spindle and True Depth (or volume-corrected) S-Scan Display with known Reflectors. Bottom,Typical Location of Cracking in Spindle
Figure 16b: Photo showing Portable Phased Array Unit, Array and Inspection Technique for Spindles
4.11 Inspection of Bridge Bolts Bolts hold bridges together, and undergo significant fatigue cycles. The bolts are large (~22 cm long), and fatigue-susceptible areas are typically hidden (see Figure 18a). Normal ultrasonic inspections do not have the multitude of inspection angles required, nor data storage and imaging. Inspections must be rapid, reproducible and convenient. The portable phased array solution is to perform a 0º-15º L-wave S-scan, focused at 100 mm (4"). This was a manual scan (no encoder) with the operator manipulating the array to get full volumetric coverage. The imaging makes interpretation much easier and more reproducible (see Figure 17b), and inspections were much faster than with conventional UT. It would be possible to include DAC or TCG.
Figure 17a: Photo showing Typical Bolt with Two Reference Notches and Array on Accessible Area Non-Destructive Testing Vol 45 No. 3
Aircraft landing gear undergo considerable stress on landing and take-off, and are potentially susceptible to fatigue cracking. The area to be inspected has three different diameters, which makes a conventional ultrasonic inspection difficult. The portable phased array solution is to use an S-scan to generate 40o to 65o shear waves inside the component, with a wedge specifically contoured to the cylinder outer diameter. This permits a single pass inspection of the cylinder, with full data collection. Though there are several different cylinder outer diameters, and multiple diameters within each, electronic set-ups make this inspection straightforward. The imaging permits defect identification (see Figure 18). Figure 18: Portable Phased Array System used for Landing Gear Inspection
4.13 Laser Weld Inspections This is an aerospace inspection for laser weld construction. The component has a complex geometry, rapid inspection is required, and full data storage is needed. The portable phased array solution is to use a linear array with a water box for coupling (see Figure 19). A 10 m long linear scan manual inspection is performed, using an encoder at 25 mm/sec. The array performs a normal beam raster inspection (E-scan), giving a realtime C-scan display. All the data is stored.
Figure 19: Normal Beam Scan of Aluminium Laser Weld with Water Box
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4.14 Scribe Mark Inspection Damage has been reported along fuselage skin lap joints, butt joints, and other areas on several commercial aircraft; this damage was caused by the use of sharp tools used during paint and sealant removal. If undetected, these lines scribed in the pressurized skin can result in cracks and possibly lead to widespread fatigue damage. All commercial aircraft that went through a repaint and sealant removal process are susceptible to scribe mark damage. Figure 20 shows the location of this damage.
for a number of inspections. While it is too early to cost weld inspections using portable phased arrays, early evidence shows that weld inspections are approximately five times faster than with conventional manual inspections. Besides the major labor savings, evidence also suggests that portable phased array weld inspections are significantly more reliable than manual inspections; the operator’s interpretation of a waveform is no longer such a key factor. Once the set-up is prepared, the same results are repeatedly obtained. We look forward to the first weld inspection trials using portable phased arrays. The arrival of portable phased arrays should have one other major impact on the NDE industry: significantly increased productivity could offset the upcoming shortage of qualified inspectors.
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Conclusions
1. Portable phased arrays are commercially and technically viable for a wide range of inspections. 2. Portable phased arrays have major advantages for: Figure 20: Schematic showing Location of Scribe Mark Damage Phased arrays offer a simple and easy-to-interpret solution for detecting scribe mark damage. There is no paint removal, which gives huge time savings. S-scan imaging works well, and the smallest configuration of the unit (OmniScan PA 16:16) is adequate. Figure 21 (left and right) show S-scan images of scribe mark damage and of a fastener respectively.
a. High speed inspections; b. Set-up flexibility; c. Multiple inspection angles and wave modes; and d. Limited access inspections. 3. Portable phased arrays should be cost-effective for a number of standard applications, e.g. welds. 4. Standard code-compliant procedures should significantly increase the application of portable phased arrays. 5. Expect more portable phased array applications in the near future!
7 Figure 21: (left) Scribe Mark Damage; (right) Fastener
5
Discussion
The applications listed above show that portable phased arrays can perform many different types of inspections, from generic weld inspections to “specials”. All these applications have one or more of the following advantages: • Speed: scanning with phased arrays is an order of magnitude faster than single transducer conventional mechanical systems, with better coverage and focusing; • Flexibility: set-ups can be changed in a few minutes, and typically a lot more component dimensional flexibility is available; • Inspection angles: a wide variety of inspection angles and wave modes can be used, depending on the requirements and the array; • Imaging: S-scans, B-scans and C-scans offer much better data interpretation than simple Ascans; • Small footprint: small matrix arrays can give significantly more flexibility for inspecting restricted areas than conventional transducers. As mentioned earlier, most of the listed applications are specials, largely because this is how most new NDE products make it onto the market place. These specials will continue, and diversify into applications not currently thought of. Some may even use the full automated scanning capability. Most important, portable phased arrays now appear cost-competitive
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Acknowledgements
Many people in Olympus NDT have assisted in the development of this instrument and applications. In particular, Pierre Langlois, who spearheaded the development, and Chris Magruder, Philippe Cyr, Simon Labbé and others who have worked on various applications. Also, several external companies have assisted with one or more of the examples here, including Eclipse Scientific Products, OPG, Materials Research Institute, Washington Group International, and Northwest Airlines.
8. References [1]. Clay A.C., S-C. Wooh, L. Azar and J-Y. Wang, “Experimental Study of Phased Array Beam Characteristics”, Journal of NDE, vol 18, no. 2, June 1999, page 59. [2]. Wüstenberg H, A. Erhard and G. Shenk, “Some Characteristic Parameters of Ultrasonic Phased Array Probes and Equipments”, NDT.net, vol 4, no. 4, http://www.ndt.net/article/v04n04/wuesten/ wsuesten.htm [3]. Lafontaine G. and F. Cancre, “Potential of Ultrasonic Phased Arrays for Faster, Better and Cheaper Inspections”, NDT.net, vol 5, no. 10, October 2000 http://www.ndt.net/article/v05n10/lafont2/lafont2.htm [4]. R/D Tech, “Introduction to Phased Array Technology Applications”, published 2004 by R/D Tech. [5]. Ciorau P., D. MacGillivray, T. Hazelton, L.Gilham, D. Craig and J.Poguet, “In-situ examination of ABB l-0 blade roots and rotor steeple of low-pressure steam turbine, using phased array technology”, 15th World Conference on NDT, Rome, Italy, October 11-15, 2000. [6]. See www.olympusndt.com/en.html for details. [7]. R.K. Ginzel, E.A. Ginzel, J. Mark Davis, S. Labbé and M. Moles, “Qualification Of Portable Phased Arrays To ASME Section V”, Proceedings of ASME Pressure Vessel and Piping Conference 2006, July 23-27, 2006;Vancouver, B.C., Canada, Paper No. PVP2006ICPVT11-93566. [8]. S. Labbé, “Signal Analysis For Automated ‘Go - No Go’ Inspection Of Complex Geometries Using Ultrasonic Phased Arrays”, 16 World Conference on NDT, Montréal, Canada, August 30-September 3, 2004. Non-Destructive Testing Vol 45 No. 3
