New Phased Array Scarf Monitoring System from GE At TUBE

Huerth, Germany – March 31, 2008.

A major feature of the GE Sensing & Inspection Technologies’ stand 6E39 at the TUBE exhibition in Dusseldorf was the company’s weld profile visualisation system using phased array technology. This new scarf monitoring system provides a real time, accurate picture, on-line, of both the ID and the OD profiles of scarfed ERW pipes, as scarfing takes place during the manufacturing process. As a result, it is possible to effect real time control of the scarfing process by identifying events such as tool drift and edging as they occur. This can achieve significant reductions in scrap.

The heart of the new system is the ultrasonic phased array transducer, which electronically simulates the scanning action required to provide the weld profile information. The resultant information is then fed into the field-proven UTxx digital flaw detection platform. This incorporates standard or phased array flaw detection channels and all the associated processing electronics, to give a complete scarf monitoring and flaw inspection package.

In operation, the transducer test head assembly is mounted such that it is directly above the weld line. The mill coolant acts as the ultrasonic coupling medium. The transducer test head then uses its phased array elements to monitor the inside and outside diameter of the weld as it is being cut, at a scanning rate of up to 300 profiles/sec.  Transducers and shoes are available to monitor tubes from 50 up to 500mm in diameter and typical coverage is ±25mm from the nominal weld centre line.

Inspection data is displayed in true-to-scale cross-sectional profile at one or multiple monitor screens and high and low limit alarms provide warning of weld profile deviation. Intelligent dynamic software averaging techniques minimize the possibility of false readings.

The weld profile visualization system features all-electronic set-up for ease of use and repeatability and it can be installed within feet of the weld station, depending on local temperature conditions. As a result, it operates both as a process control system as well as a quality control system. It can be combined with a flaw detection system and it allows inspection traceability through a built-in data logger, which records minimum and maximum thickness readings across the weld area and strip thickness.

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