Real Time Corrosion Mapping System: A Comparative Study Bob
Lasser, David Rich Imperium, Inc. Beltsville, MD Josh Fontenot, Tim
Borel Advanced Corrosion Technologies & Training (ACTT)
Sulphur, LA 1
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About Study Wanted to compare Imperiums FirstMap Corrosion
Imaging system to Phased Array UT (PAUT) Investigated resolution
Other factors included ease of use, cost, training requirements
Joint study between Imperium, Inc. (Beltsville, MD) and Advanced
Corrosion Technologies & Testing (Sulphur, LA)
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About Imperium Founded in 1996 Leading developer of ultrasound
camera technology Systems in petrochemical, aerospace, medical
fields About Advanced Corrosion Founded in 2002 Extensive
experience in advanced NDT methods Presence in several locations on
Gulf Coast
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Lack of trained NDT personnel Lack of confidence in thickness
readings, missed corrosion Need higher POD Need areas where AUT
cant reach Advances in imaging technology A picture is worth 1000
words Time and cost pressures FirstMap diagnostic tool quickly
identifies areas for further investigation Why Industry Needs A New
NDT Device
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FirstMap Advantages Images are easier to interpret FirstMap
provides an actual image of the defect including thicknesses High
resolution Higher confidence than single thickness readings Not
effected by beam dispersion Built in delay line No extensive
training required; less trained technician Real time
SCANNING & STITCHING Make large mosaic images from smaller
ones Capture both C-scan and thickness Uses encoder attached to
camera Tilting encoder Dual element transducer Optical image of
corrosion inside pipe Scanned/stitched image of corrosion inside of
pipe
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INSPECTING STORAGE TANK BOTTOMS WITH FIRSTMAP Compare FirstMaps
easy to interpret readout
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MICROBIOLOGICAL INDUCED CORROSION Black areas indicate MIC,
note the veins of MIC also
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PIPELINE CORROSION MAPPING
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Benefits to NDT Industry Broad application base Pipelines,
storage tanks, pressure vessels Find corrosion faster Find smaller
amounts of corrosion Does not sacrifice any current data quality
Provide better information to end customer Better tool to provide
comparisons Use Level 2 thickness inspector to generate images, not
just readings Get to areas where current tools cant go
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B-scan vs. C-scan Phased Array FirstMap
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Resolution Study: FirstMap vs Phased Array Investigated axial,
lateral, and elevation resolution Used Omniscan MX2 Both systems
working at 5 MHz Did mathematical study, then took data to compare
expected results
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Omniscan PAUT System Test Settings: Probe:5L64-NW1 (5 MHz)
Wedge:SN1-0L5L64 Mode:Phased array Focal Depth:0.1 Focal Law:Linear
sector with overlap Skew Direction:90 0 (straight down mode) Scan
Offset:0 Index Offset:0 Element Quantity:8 First Element:1 Last
Element:64 Thickness:0.25 Surface:Flat plate
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FirstMap System Frequency:5 MHz Number of Pulses:1 Gate
start:0.1 Gate width:0.5
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21 Lateral (X): D = (0.44 x V) / (F x sin (/2)) Axial (Z): Z =
V x T/2 Elevation (Y): Defined by the length of the array elements,
and will be on the order of several millimeters Phased Array
Theoretical Resolution Source: Olympus NDT Manual
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Resolution Summary INSPECTION SYSTEM AXIAL RESOLUTION LATERAL
RESOLUTION ELEVATION RESOLUTION FirstMap1.5 mm0.1 mm PAUT0.3 mm0.34
mm> 1.0 mm
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FirstMapOmniscan: AmplitudeOmniscan: TOF
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Comparative Study: FirstMap, X-ray, Phased Array Reviewed
different techniques for corrosion mapping Used common standards
Recorded image quality Recorded time of setup, scan, training
cost
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Targets Studied Stepped standard Corrosion piece 8 diameter
pipe section
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Stepped Standard FirstMap Phased Array X-ray 192 iridium
Advanced Corrosion Technologies The probability of detection is
far superior to standard thickness readings. FirstMap is a
diagnostic tool that can instantly detect subsurface corrosion down
to 1 mm pits. We are now able to quickly and easily identify
problem areas that could potentially lead to much bigger issues.
-Josh Fontenot, Director of Technologies, ACTT