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AN OVERVIEW ON PHASED

ARRAY TECHNOLOGY

HAROON CAJEE

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

POLICIES
POLICIES &
& STATEMENTS
STATEMENTS

Oceaneerings number one


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

OCEANEERING
OCEANEERING -- GLOBAL
GLOBAL

Dubai

Middle East

United Kingdom

Africa

Americas

Asia
Batam, Singapore
Kuala Lumpur, Perth

UNBROKEN CONTINUOUS STERLING SERVICE TO


PTMI SINCE 1993

SERVICE
SERVICE RANGE
RANGE

ADVANCED AND CONVENTIONAL NDT


- Phased Array TOFD - AUT

INDEPENDENT TRAINING SCHOOL

VENDOR & PROCUREMENT INSPECTION

MATERIALS ENGINEERING & TESTING

ROPE ACCESS

OFFSHORE & ONSHORE PIPELINES

INTEGRITY & INDEPENDENT INSPECTION AUTHORITY

PHASED
PHASED ARRAY
ARRAY AUT
AUT -- PIPELINES
PIPELINES

Automated Phased Array Ultrasonic Systems


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

PORTABLE
PORTABLE PHASED
PHASED ARRAY
ARRAY
PORTABLE and or SEMI AUTOMATED ULTRASONIC & TOFD INSPECTION
USING HAND HELD SCANNERS & PHASED ARRAY PROBES
WHY IS IT DIFFERENT FOM CONVENTIONAL UT Encoding & recording
capability.

Another way to do UT

No magic, only physics!

ADVANTAGES - PA facilitates speedier inspections, interpretation aids and


smaller scanning devices thus increasing the application.

CODE PERMITS IN LIEU OF RADIOGRAPHY

WELD
WELD INSPECTION
INSPECTION

Delays

35

40

45

55

65

SOUND
SOUND PROPAGATION
PROPAGATION
Multiple Crystals

Allows for larger inspection area and


increased probability of detection

Beam Steering

Allows for optimal detection / sizing for


traditional and complex geometries.

Full Coverage / Focusing

Allows optimal sizing of defects

TYPICAL IMAGE RT /PA


Phased
Array
Image

X-Ray
Image

SCAN
SCAN AND
AND DEFECT
DEFECT SAMPLES
SAMPLES
Porosity
Radiography

Phased Array technique

SCAN
SCAN AND
AND DEFECT
DEFECT SAMPLES
SAMPLES
Inclusion
Radiography

Phased Array technique

SCAN
SCAN AND
AND DEFECT
DEFECT SAMPLES
SAMPLES
Incomplete Root Penetration
Radiography

TOFD technique

Phased Array technique

METHODOLOGY
METHODOLOGY PREMISE/DRIVERS
PREMISE/DRIVERS
KEY OBJECTIVE
The integration of RT activities with the production needs would require careful planning and
the use of new technologies to ensure minimal disruption at an affordable price. The NDT
Scope especially RT needs to be completed in a manner that minimizes downtime of other
trades and completed in a timely manner to ensure that crucial production and welder
control information are relevant and that the production process in respect of hydro-test,
painting, site erection and commissioning are not impeded. In this instance we have the
added concerns of the proximity of existing plants and the potential impact on the nucleonic
alarms
CHOICE OF TECHNIQUE
RT Conventional
RT SCAR

PA/TOFD

PRODUCTIVITY-COST EFFICIENCY
INTEGRATION-SAFETY

INSPECTION
INSPECTION TECHNIQUE
TECHNIQUE COMPARISON
COMPARISON
Method

RT

Manual

UT

PA
AUT

Pipe

Crew
Size

Scan / shot
time

Set-up
time

PRODUCTIVITY
Welds per hour

Production
Interruption

Safety
Hazards

Record of
Inspection

2 Sch 40

2 man

5 min.

5 minutes
per/weld

6 to 10

100%

100%

YES

12 Sch 80

2 man

30 min

5 minutes
per/weld

100%

100%

YES

24
Standard

2 man

60 min

5 minutes
per/weld

1.5

100%

100%

YES

2 Sch 40

1 man

10 min.

5 minute
per/weld

NA

0%

0%

NO

12 Sch 80

1 man

30 min

5 minute
per/weld

0%

0%

NO

24
Standard

1 man

60 min

5 minute
per/weld

1.5

0%

0%

NO

2 Sch 40

2 man

30 sec

3 minute
per/weld

10 to 20

0%

0%

YES

12 Sch 80

2 man

1 min

3 minute
per/weld

10 to 12

0%

0%

YES

24
Standard

2 man

3 min

3 minute
per/weld

10 to 12

0%

0%

YES

Amounts are based on averages, results will vary.


2. RT: Assumes required exposures with 20 curie source.
3. Manual UT: Assumes minimum scanning requirements as per ASME.
4. Set up time is based on typical accessibility and work plan.
NOTE: Does not include time and or cost for film processing, reporting, re-shots, etc.

Auditable
Results
YES
YES
YES
NO
NO
NO
YES

YES

YES

RADIOGRAPHY
RADIOGRAPHY vs
vs PHASED
PHASED ARRAY
ARRAY
PHASED ARRAY

RADIOGRAPHY

Radiation Source requires large area


of clearance.
Results take time to filter through the
system , films to be processed ,
interpretation and reports
One Dimensional view
Productivity in the region of 20 welds
per RT crew per 10 hour shift in a
fabrication shop environment
Productivity in the region of 10 welds
per shift in situ i.e platform field
welds
Re-location of spools for RT

Work does not require any personnel


clearance
Three dimensional Images
Hard Copy digital record
Automated systems
Immediate results in most cases
Inspection can take place along side
welders , no need for re-location of
spools
Immediate repairs can be carried out if
needed
Productivity in the region of 75 welds
per PA crew per 10 hour shift in a
fabrication shop environment.
Productivity of 30 welds per PA crew
per 10 hour shift in situ

DOES
DOES THIS
THIS METHOD
METHOD ADDRESS
ADDRESS
A
A NEED
NEED IN
IN YOUR
YOUR
ENVIRONMENT?
ENVIRONMENT?

YES , WITHOUT A DOUBT

RT PLACES A CEILNG ON
YARD PRODUCTIVITY

INTEGRATING RT WITH
EXISTING TRADES IS A
MAJOR CHALLENGE

THERE IS NO SAFE LEVEL


OF RADIATION BUT DUE TO
LITTLE ALTERNATIVES WE
ACCEPT AS LOW AS
REASONABLY POSSIBLE
ALARP

RT RESULTS IN
BACKLOGS, MULTIPLE
HANDLING OF ITEMS,COORDINATION & DELAYS

RT RESULTS TAKE ON
AVERAGE 24-36 hours TO
CONFIRM

RT RESULTS IN DELAYS
WHICH PARLAYS INTO
FINANCIAL LOSSES
YOU CAN CREATE THE MOST
EFFICIENT PROCESSESS
HOWEVER YOUR OVERALL
CAPABILITY AND OUTPUT
WILL BE IMPEDED BY RT

YES , IT UNDOUBTEDLY ADDRESSES A NEED IN THE MARKET

WHAT
WHAT ARE
ARE THE
THE PRIMARY
PRIMARY
APPLICATIONS
APPLICATIONS FOR
FOR THIS
THIS METHOD?
METHOD?

CODES
D1.1

AWS

ASME B31.3
ASME VIII
ASME B31.1

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

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

MATERIALS RANGE
Carbon Steels
Stainless Steels
Titanium
Inconel

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

ARE
ARE THERE
THERE ANY
ANY COMPETING
COMPETING
TECHNOLOGIES
TECHNOLOGIES OR
OR OTHER
OTHER
OPTIONS
OPTIONS

THE SIMPLE ANSWER IS NO

THE PARAMETRES AND TECHNOLOGY


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

ASIDE OF SEMI AUTO UT THERE IS NO


OTHER TECHNOLOGY ON THE HORIZON

ITS EITHER RT OR PA UT

WHAT
WHAT ARE
ARE THE
THE MAJOR
MAJOR
IMPEDIMENTS
IMPEDIMENTS THAT
THAT WE
WE FACE
FACE IN
IN
INTRODUCING
INTRODUCING THIS
THIS TECHNOLOGY
TECHNOLOGY

RESISTANCE TO CHANGE
Internal & External factors

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

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

HOW
HOW DO
DO WE
WE ADDRESS
ADDRESS THE
THE
COMPETENCY
COMPETENCY ASSURANCE
ASSURANCE ISSUES?
ISSUES?

RT HAS BEEN ADOPTED AS


THE PRIMARY METHOD DUE
TO COMPETENCY
ASSURANCE ISSUES WITH
MANUAL ULTRASONICS.

Validated Techniques for all


operators to work to.

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

Recordable System which


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

All key processes are


automated

Automated reporting
system available

PHASED ARRAY UT

WHAT
WHATARE
ARE THE
THE COMMERCIAL
COMMERCIAL
IMPLICATIONS?
IMPLICATIONS?

INITIALLY
MARGINALLY
HIGHER DIRECT
COSTS BUT
OVERALL PA MUCH
CHEAPER

EFFECTIVELY ONE
OFF START UP
COSTS

HUGE
PRODUCTIVITY
GAINS

Price dependant on
volume and duration of
project.

PA IS SUBSTANTIALLY
CHEAPER THAN RT

WHAT
WHAT ARE
ARE THE
THE TECHNICAL
TECHNICAL &
&
OPERATIONAL
OPERATIONAL IMPLICATIONS
IMPLICATIONS ??
TECHNICAL

Pre Planning
Mandatory
Pre Engineering
Required
Training and
Certification of
Personnel
Streamlining the
process
Gaining Client
Approval

OPERATIONAL
Integration into the piping
workshop process
Expediting NDE Requests
, PA will be carried out
much earlier in the
process than
Radiography
Determining NDE method
for all welds on each
spool and control
Co-Operation of All
personnel

PRE_PLANNING REQUIRED

DEFECT
DEFECT DETECTION
DETECTION AND
AND
REPAIR
REPAIR RATES
RATES
Validation to date shows a slight decrease in repair rates
due to the ability to size in more dimensions .
Where radiography utilizes length only for accept or
rejection , PA-UT utilizes Length and height

Fully encoded scanning ensures accurate defect


information is available including depth , length and
circumferential location

NO MAJOR DIFFERENCE

CODES
CODES
ASME CC 2235 (CIT) allows use of UT
instead of RT for wall thickness > 12.7mm
Code case 181 allows use of UT instead of
RT for all thickness ranges
TOFD, PA and TOFD/PE techniques
allowed

Performance Demonstration req


uired
CODE PERMITS AND FACILITATES

KEY DELIVERY COMPONENTS

27
CAPABILITY SKILLS SETS - Critical

PA/TOFD
PA/TOFD FACILITIES
FACILITIES

PA/TOFD
PA/TOFD CAPACITY
CAPACITY

60m per
Day
with 2
ops.

SCANNERS
SCANNERS
Oceaneering has developed its own range
of scanning devices to allow rapid high
quality scans on all diameter pipes and
plate welds.
The results of phased array encoded
inspections are very reliant on the
scanners utilized and Oceaneering has
invested heavily to ensure the very best of
equipment is available.

SCANNER
SCANNER IN
IN USE
USE
Link scanners in Use

PROJECT
PROJECT SPECIFIC
SPECIFIC SCANNER
SCANNER
Special scanners designed and
manufactured

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

TRAINING FACILITY

34

ABSOLUTELY VITAL COMPONENT

TRAINING FACILITY

35

ABSOLUTELY VITAL COMPONENT

INTERNAL TRAINING

36

ABSOLUTELY VITAL COMPONENT

CLIENT TRAINING

37

ABSOLUTELY VITAL COMPONENT

WHY
WHY SHOULD
SHOULD WE
WE PROCEED
PROCEED WITH
WITH
THIS
THIS TECHNOLOGY?
TECHNOLOGY?

YOU NEED TO ADOPT


THE BEST PRACTICES
AND METHODS
AVAILABLE

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

LARGE
ORGANIZATIONS
INHERENTLY FACE
INERTIA AND LACK OF
AGILITY.

IMPROVES EFFICIENCY AND


PRODUCTIVITY
ENHANCES SAFETY AND
ELIMINATES RADIATION
HAZARD
RADIOGRAPHY IS A VERY
EXPENSIVE OPTION

THANK YOU VERY


MUCH
OUR GLOBAL EXPERIENCE, LOCAL TRACK
RECORD AND TECHNOLOGY WILL PROVIDE
YOU WITH A VALUABLE PARTNER TO
ACHIEVE YOUR GOALS AND OBJECTIVES TO
OUR MUTUAL BENEFIT

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