Corrosion Mapping with Phased Array
Ultrasonics
Presenter
Mark Carte
Olympus NDT, Business Development Manager, Petrochem and
Fabrication
For 35 years Mark Carte has focused on applying nondestructive
testing in the Petroleum and Aerospace industries.
Mark is an active member of the American Petroleum Institute
including the Sub-Committee on Inspection NDE Task Group,
co-chair for the API Inspection Summit 2011 and a member of
API Houston Texas Chapter.
He is a member of American Society of Mechanical Engineers
and serves on the Steering Committee for ASME STS Plant
Engineering and Maintenance Technical Chapter in Houston
Texas.
Reason for this Presentation
• Industry Demand
• Understanding Damage Mechanisms &
Applications
• Considerations applicable to Corrosion Mapping
• Introduction to Corrosion Mapping with Phased
Array Ultrasonics
• Applying Phased Array Ultrasonics for Corrosion
and Mid Wall Anomaly Detection & Mapping
Industry Survey: Corrosion Mapping
The survey included:
•Major oil companies.
•Providers of inspection services
•Equipment manufactures and
•Individuals that perform Fitness for Service Calculations.
Twenty four companies and more than 50 people where included in the survey.
Cumulative experience of the individuals surveyed exceeded 600 years of
corrosion mapping experience. Most of the information gathered occurred during
meetings with numerous key personnel that are directly involved with corrosion
mapping services.
Fossil fuel process industry owner operators confirmed the current and increasing
need for corrosion mapping. The driving force for corrosion mapping is the world
demand for fuel. Safety, asset integrity assurance, contractual delivery of
product, insurance requirements, compliance with government regulations and
internal directives contribute to the utilization of corrosion mapping services.
Process facilities are required to remain on-line to meet the increasing fuel
demands. Continuous operation of the equipment requires thorough integrity
assessment using inspection techniques that can be applied while the equipment
is in service. Wall thickness reduction due to corrosion and erosion are two of the
greatest detriments that compromise containment of process.
Summary of Industry Survey
Included:
• Major Oil Companies
• Inspection Service Providers
• Engineering Companies perform FFS Calculations
Tallies:
• 24 companies, 7 countries
• >50 People including management, inspectors and equipment designers
• >600 years of experience in corrosion detection and mapping
Common Problems:
• Accurately Determine Corrosion Rate
• Repeatability of AUT Scans
• Differentiate between mid wall anomalies and ID connected wall loss
• Qualified Personnel
• Lack of Industry Standard for Corrosion Mapping
Industry Demand:
Why Perform Corrosion Mapping?
•Safety
Current Condition of Equipment?
•Economics
Reduced: Inspection cost – Downtime - Vessel Entry.
• Determine Corrosion Rate
Repeatability – Rerate – Repair – Replace – On-Line Monitor
• Determine Remaining Life
How long will it operate at current process exposure
Replacement planning
Selection of material for replacement
Understanding Damage Mechanisms & Applications:
Examples of Corrosion
• ID & OD Corrosion
• Preferential Weld
Corrosion
• Microbiological
Induced Corrosion
• Isolated Corrosion Pits
Understanding Damage Mechanisms & Applications:
Mid-Wall Anomalies
• Wet H2S
Blistering
• Laminations
Understanding Damage Mechanisms & Applications:
Applications for Corrosion Mapping
Tanks, Atmospheric and Pressurized
Flare Lines
Knock Out Drums
Heater Exchanger Shells and Channel Sections
Columns, Trays and down-comers
Boots on Horizontal Drums
Clad Vessels
Nozzles
Raised Face Flanges
Piping, flow impingement, injection points, material changes
Corrosion Under Insulation
Pressure Vessel Saddle Supports
Considerations Applicable to Corrosion Mapping:
Corrosion Mapping
Considerations Applicable to Corrosion Mapping:
Data Point Density
Low Density High Density
$ $
Considerations Applicable to Corrosion Mapping: Variable Data Point Density
6 FBHs, .100” Deep
.640” x .040” / 16mm x 1mm
.040” x .040” / 1mm x 1mm
.800” x .040” / 20mm x 1mm
.080” x .040” / 2mm x 1mm
.960” x .040” / 24mm x 1mm
.160” x .040” / 4mm x 1mm
Considerations Applicable to Corrosion Mapping:
Critical Information
• Inspection Criteria • Transportation
– Anomaly to be detected – Mobilization
– Minimum size, wall – Shipping Equipment
thickness – Personnel
– Data point density • Conditions during
• Surface Preparation inspection
– Painted – Weather,
– Sand Blasted – Access
– Rusted – Utilities
• Equipment Information • Deliverables
– Material of construction – Content
– Rolled, extruded or cast – Electronic or Hard Copy
– Surface Temperature – How soon
Introduction to Corrosion Mapping with Phased Array Ultrasonics:
Basic Principles:
• Phased Array Probes
are composed of
multiple piezoelectric
elements
• Pulsing and receiving 4 Element Aperture
of the elements are 1 mm
computer controlled
• Linear Scan
Introduction to Corrosion Mapping with Phased Array Ultrasonics:
Multiple Beam Configurations
Focused
Non Focused
Angle Beam
Sectorial
Introduction to Corrosion Mapping with Phased Array Ultrasonics:
Phased Array Probe
• 7.5 MHz, 64 element
• 60 mm coverage (2.36 in)
• 1mm Pitch (.039” x .039”)
• Scan speed of 100 mm/s (4
in/s) 1mm x 1mm Data
Point Density 2.36 in coverage
• Near surface resolution 1.6
mm (.063in)
• Primary use linear scan at
0°
Introduction to Corrosion Mapping with Phased Array Ultrasonics:
Large Effective Beam
Conventional Pitch Catch Phased Array 64 element
.187” 2.36”
12 Times more coverage with phased array probe.
Introduction to Corrosion Mapping with Phased Array Ultrasonics:
Three Techniques for
PA Compression Wave
Contact: T R
Pitch Catch &
Pulse Echo
Wheel Probe:
Pulse Echo
Bubbler:
Pulse Echo
Applying Phased Array Ultrasonics for Corrosion and Mid Wall Anomaly
Detection and Mapping:
Calibration and Performance Demonstration
• Calibration
• Performance
Demonstration
• Flat Bottom
Holes
• Images
Applying Phased Array Ultrasonics for Corrosion and Mid Wall Anomaly
Detection and Mapping:
Applying Phased Array for Corrosion Mapping
• PA Probe
Orientation
• Scan Direction
• Probe Index
Applying Phased Array Ultrasonics for Corrosion and Mid Wall Anomaly
Detection and Mapping:
Scan Views:
A, B & C Scans Simultaneously
Applying Phased Array Ultrasonics for Corrosion and Mid Wall Anomaly
Detection and Mapping:
Scan Map
• View of areas scanned
• Precise measurements for repeat scans
• Location (s) of anomalies for monitoring
• Repair plans
Applying Phased Array Ultrasonics for Corrosion and Mid Wall Anomaly
Detection and Mapping:
Heat Exchanger Shell Scan
Four square feet of surface area inspected in
2.5 minutes with .080” (2mm) x .040” (1mm)
data point density.
Applying Phased Array Ultrasonics for Corrosion and Mid Wall Anomaly
Detection and Mapping:
Scan Map
Side View of Scan Map
Plot View of Scan Map
0 32” 192
56
15
113 1 2 3 4 5 6 7 8 9 10 12 13 14 16 TDC
0”
56”
Applying Phased Array Ultrasonics for Corrosion and Mid Wall Anomaly
Detection and Mapping:
Example “C” Scan Image
Wall Loss below
T Min in scan 3
at BDC.
Scan Position is
32”L X 55”C
Reference from
TDC & Flange
to Shell Weld.
Conclusion
Positive Attributes of Phased Array Ultrasonics used for Corrosion
Mapping: “TOP 3”
•Safety
Thorough and accurate assessment of remaining wall
thickness compliments certainty of equipment integrity.
Personnel Injuries Ignition Sources
Impact Damage from Scanners Falling
•Corrosion Rate
High Data Point Density improves probability of detecting wall
loss therefore enhances accuracy of calculations.
Wide effective beam optimizes repeatability of subsequent
scans and comparison of wall loss shape and size.
• Detection and Characterization
Differentiate between mid wall anomalies and ID connected
wall loss.
Questions?
Contact Information:
Mark Carte
Olympus NDT
12569 Gulf Freeway
Houston Texas 77346
Office: 281 922 9300
Cell 1: 832 633 0283
Cell 2: 281 744 3022
[email protected]
