Inspection of Boiler Tubes

and Boiler Tube Welds:

Overview of NDT Techniques
Gerry Sieben Oct. 28,2015

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 Safety Moment!!

Mostaccidentshappenaway
fromwork!
AVOIDING DISASTER.
Overview of Presentation:

Considerations when choosing inspection methods

Ultrasonic Inspection
Shearwave (UTSW) Manual Scanning
Phased Array (PAUT) Semi Automated
Use of Scanners/Encoders
Displayed Examples of Flaw Indications
Comparison of Radiography and PAUT
Digital Image Radiography
Computer Radiography
Digital Radiography
Case Study
Recovery Boiler Wall Rebuild
RTR Real time radiography
 Many Considerations Exist When Selecting
an NDT Method
NDT method considerations
Probability of detection (POD)
Reflectivity, absorption,
attenuation
Accuracy of sizing
Access, environment, service
Operator dependence
Cost
Many tradeoffs exist
Sensitivity vs. penetration
Speed of inspection
(screening) vs. accuracy
(quantitative measurement)
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 Basic Ultrasonic Techniques

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 Scanning Comparison

Ultrasonic Shearwave (UTSW) Phased Array Ultrasonics (PAUT)

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 PAUT Provides Speed Advantage Versus
Manual Scanning
Conventional Rastering Phased Array Scanning

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 Use of Scanners/Encoders Improve
Consistency & Ease of Use

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 Phased Array Provides a Better Visual
Representation of the Indication

Ultrasonic Shearwave Phased Array

Flaw indication (A-scan) Crack indication (sector-scan)
Single shear wave beams Multiple shear wave beams
Time intensive for volumetric Three-dimensional view of defect
measurement

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 Example of Surface Crack Indications

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 Example of PAUT Scans of Surface Crack
Indications

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 PAUT Data Displays of Weld Indications

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 Typical Weld Defects

1
2

3
4
5

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 Porosity Conventional RT vs. PAUT

RT

Phased
Array

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 Inclusion Conventional RT vs. PAUT

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 Lack of Fusion Conventional RT vs.
PAUT

RT Phased Array

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 Basic Radiography Techniques

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 CR vs. DR: Whats the Difference?
Computed Radiography (CR) use
of phosphor imaging plate in lieu of
film
Imaging plate must be
processed through laser
scanner to convert stored energy
http://www.ndt.net/article/ecndt02/414/414.htm to digital image
Digital Radiography (DR) utilizes
Digital Detector Arrays (DDAs) in
place of film or phosphor imaging
plates
Records the radiographic image and
makes it available as a digital file
without an intermediate processing
step
Wired or wireless setup
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 Sample DR Images

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Profile Images of Superheaters
Zip Cut Welded Over.
 Digital Information Can Be Transmitted
Offsite for Additional Analysis and QA

All DR images and Phased Array data can be transmitted for offsite
analysis. The operating systems can be configured with a secured VPN
which allows the seamless transfer of data back to dedicated analysis
centers for review and reporting.
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 DR Case Study: Recovery Boiler Water
Wall Rebuild

Challenge:
Inspection of 1700 welds (A/B shot = 3400 images) as part
of Recovery Boiler wall replacement
2.5 to 3 tubes composite stainless over carbon
Needed quality of film with production of CR
Film / CR would require more shot windows, longer shot windows
and all other trades to stop production
Minimize boiler downtime
Solution
Use of AcuView solution (low-energy radiography paired
with Digital Radiography)
Utilized Baby SCAR system (13Ci Se75)
Reduced exclusion zone to ~13 inside boiler and 17 outside boiler
3 - 15 second exposures per image (13 days total for project)
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 DR Case Study: Recovery Boiler Water Wall
Rebuild Continued
Benefits
No disruption to welders using low-
energy radiography allowed Acuren
crews to work alongside
Boilermakers
Elimination of shot windows shortened
overall duration of project by ~7 days
No lag time between inspection
and identification of problem
Identified porosity issue (53% reject
rate) in first 4 hours of inspection due to
liquid argon being drawn into tig rigs
Switched to gas, project reject rate
<4%
DR saved ~one day of welding (~300
welds) from having to be redone

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 Factors to Consider

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 Safety
Ultrasonics Radiography
Ultrasonics does not pose a Radiography has stringent safety
significant safety problem requirements involving area
No radiation = no exclusion zones evacuation, perimeter watch,
No impact on other trades security, and proper handling of
the radioactive source
No chemicals
ALARA (As Low As Reasonably
Achievable)
Impact on other trades can be
mitigated with use of low-energy
radiography

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 Productivity

Ultrasonics Radiography
Generally: PAUT w/ scanner Generally: Digital Radiography
faster than manual PAUT which is faster than Computed
faster than UTSW, however Radiography which is faster than
productivity depends on the Conventional Radiography
application Unlike conventional and computer
Factors affecting productivity: radiography, DR does not involve
Access to test areas (project any offline image development
management, work permits and The image obtained is ready for
weld preparation) instant review at the point of
Number of defects found inspection, thus eliminating the
Welds pipe size, schedule and possibility of reshoots and
weld specification (PAUT requires increasing on productivity
setup time for each case)

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 Other
Ultrasonics Radiography
Temperature More sensitive to volumetric
Single weld per scan defects
Access limitations (minimum 3 on 2-3 tube welds per image
each side of weld plus spaced for No surface preparation
scanner) Film storage* vs image size (CR:
Surface preparation 20-30 MB vs DR: 3-5MB)
More sensitive to linear defects *Film can easily be digitized

Technician Availability CR: Flexible vs. DR: Flat Panel

Flat panel can lead to longer set-up
(PAUT UTSW UT Thickness) times. Both CR/DR Chemical issues.
PAUT allows for encoded data Image resolution (DR CR)
capture
(DR CR Conventional RT)
Cost per hour (DR CR RT)
Cost per weld (DR CR RT)

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RTR Real Time Radiography

Inspection of hidden damage to insulated piping systems.

Live video display of object

Corrosionunderinsulation

Evaluateheattracingunderinsulation

Locateweldsforfurtherexamination
Recent Project

RTRImagethroughinsulation
DR Image
View of Item
Image of Valve
View of Small Dia. Piping system.
Inspection Considerations:

Safety concerns

Cost

Service Benefit or Code Requirement

Downtime required

Access

Effect on other trade work

Effect on Environment
Wrap Up

Manyoptionsforweldinspection
UltrasonicTesting:

UTSW UltrasonicTestingShearWave
PAUT PhasedArrayUltrasonicTesting

RadiographicTesting:

FilmRadiography
CR ComputerRadiography
DR DigitalRadiography

InServiceInspectionofpipingsystems:

RTR RealTimeRadiography
Taking on Risk!!
Our Options
BCSafetyAuthority
WorkSafe BC
Courts
 Thanks for your time!

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