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USM Vision Weld Inspection System

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The USM Vision is a total weld inspection solution for new process pipework fabrication. It has been developed to meet the market need to transition from Radiographic to ultrasonic inspection according to the international codes and standards through:

  • Optimizing the use of specialized inspection personnel
  • Increasing productivity i.e. lean manufacturing/construction
  • Reducing the current weld inspection radiographic constraints:
        radiation, consumables and chemical waste management
  • Simplifying the ultrasonic weld inspection process
USM Vision 1.2

 

 

 

USM Vision Weld Inspection System Virtual Demonstration

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Benefits

Lean Improvements

in manufacturing processes are achieved as inspection is done on the spot, with no need to move parts to be inspected to dedicated areas and the flexibility to inspect at times to suit workforce availability.

Lean Improvements in Weld Inspection

Co-working activities:

other tasks, such as welding and repair, can be carried out in the immediate vicinity of ultrasonic USM Vision inspections, unlike radiographic inspections, which require the immediate inspection area to be shielded.

Co-working Weld Inspection

Qualified inspection personnel are deployed to optimum effect

as USM Vision brings a unique task-sharing capability to weld inspection. This allows non-ultrasonic specialists to create ultrasonic inspection workflows and to perform weld inspection, simply by following menu-directed instructions. Qualified ultrasonic inspectors are required only to assess original inspection plans and inspection results.

Qualified Weld Inspection

Parallel tasking

allows qualified inspectors to make optimum use of their time, as time not spent collecting data can be used validating inspection plans for future tasks and analyzing inspection data.

Paralle Weld Inspection Task

Advanced Imaging

Advanced Weld Inspection

Real-time volume corrected images

Secured operation

This allows non-ultrasonic specialists to create ultrasonic inspection workflows and to perform weld inspection, simply by following menu-directed instructions.

 

Secured Weld Inspection Operation

The inspection data generated by USM Vision is acquired, reviewed, shared and archived by the Rhythm software platform

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Digital Radiography images and UT TOFD data analyzed on the same software

Features

Creating an Inspection Plan

No ultrasonic knowledge is required to create and populate an inspection plan. All that is required is to describe the inspection task, and enter the basic information such as site location, number of welds, pipe diameter, thickness and material, weld preparation, procedure and method to be used. The software will then calculate and generate all the UT setups required to perform TOFD and/or Phased Array inspection of the specified welds. These set-ups include:

  • Selection of the correct probes and wedges from a database
  • Positioning of the probe
  • Positioning of the required UT parameters to perform an efficient inspection according to the standard and code based procedure selected.
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Validating an Inspection Plan

A technician qualified in ultrasonics must then validate the setups. Each weld is split in one or several passes with TOFD or PA technique. The UT specialists have to validate these passes by using a Raytracing tool. They also have the ability to modify them by selecting another probe from the data base, adjusting the probe(s) position(s). When all the passes are validated, the inspection plan can be exported to the acquisition unit. The import and export function for inspection plan files is simplified so that the inspection plan can be exported without forwarding the entire database. new 

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Calibration

As the data acquisition is 100% guided, this task doesn’t require a highly skilled operator. The technician merely selects an inspection plan, and is then guided through a step-by-step process from the probe and wedge validation, UT calibration (PCS and sensitivity calibration for TOFD, element and wedge check, DAC / TCG curve recording for PA), scanner settings and calibration and is then guided.

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Acquiring the Inspection Data

The inspection data, for each weld, is simply acquired by following the inspection plan and the different TOFD and PA passes calculated by the IPC. After each pass the software will propose the next weld or pass to inspect to help the operator to use the best, more productive way in the inspection plan. Data can be exported, for one pass, one weld or for the complete inspection plan, for analysis and reporting at any time during the inspection. For Phased Array, the system can inspect the two sides of the weld with one physical scan which effectively doubles productivity. The instrument can now perform inspection with linear Phased Array scans as recommended in some codes. USM Vision 1.2 can handle probes up to 128 elements which means that pipes of greater wall thickness can be inspected with linear scans. new 

Analyzing the Inspection Data

All inspection data is communicated to an analysis station using the Rhythm software platform. Here the suitably qualified ultrasonic inspector can review and analyze the inspection data, using advanced analysis tools such as real time, volume-corrected imaging, as well as conventional digital tools features for image analysis, enhancement and measurement. In addition, a variety of measurement and viewing tools is contained within the analysis software.

Reporting

Expert interpretation of inspection results can be provided immediately and reports can be printed off in real time. This offers a very fast assessment of the weld status as feedback for weld repairs.

 

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Archiving the Inspection Data

The inspection data are saved in the Rhythm Archive software, allowing to save the raw data with necessary tags. Input and retrieval of information is quick and easy. This accepts data from any number of LAN-connected, remote Rhythm Review workstations and stores them using various compression techniques to save storage space without sacrificing data quality.

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Sharing the Inspection Data

All inspection data can be shared with other interested parties, either as enhanced imagery or as raw data. It can be transmitted to other Rhythm Review stations for third party
verification.

Turning information into intelligence and sharing inspection data across experts and
locations with ease!

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Applications

USM Vision - A Total Weld Inspection Solution

The USM Vision has been developed to simplify and to democratize the Ultrasonic
Inspection according to the international codes and standards through:

  • Optimizing the use of specialized inspection personnel
  • Increase productivity
  • Reducing the current weld inspection radiographic constraints
  • Reducing the ultrasonic weld inspection complexity

USM Vision is especially dedicated to:

  • Energy construction industry
  • Carbon steel and Stainless steel pipes
  • Covers the Normalized Pipe Size (NPS) in automatic setup
      - Diameters from 73mm (2.875") up to 1219mm (48")
      - Thicknesses from 6mm (1/4") up to 50mm (2")
  • Higher thickness and diameter in manual setting
  • Circumferential welds
  • Short exit point wedges and short scanner arms available for pipe to elbow and pipe to flange
  • Single or dual access depending on geometric restrictions
  • Other type of welds and indications will be available

Specifications

The USM Vision is supplied as a complete weld inspection solution, consisting of:

  • IPC software for creation of the inspection plan and automatic generation of the UT set-ups. Integrate a database with procedures based on international codes and standards and ray tracing functionality for the validation of the UT parameters.
  • The USM Vision hand-held flaw detector, featuring:
    • Conventional channel, TOFD, 16/64 or 16/128 Phased Array, Real Time Volume Corrected Images, A-scan saving
    • Unique user interface to operate a pointing device by two trackballs
    • Ease of use for untrained operators
    • 26,5 cm (10.4”) color touch screen with 1024 x 768 resolution
    • Weighs only 4 kg (8.8 lb)
    • Hot swap battery exchange for continuous operation
    • Robust, rubber housing, IP 54
    • Dimensions: Length top: 367 mm (144.4”) Length bottom: 310 mm (122”) Width: 250 mm (98.4”) Heigth: varying from 60 to 100 mm (23.6” to 39.3”)
    • Modern PC interfaces including USB, Ethernet, wireless connection (WiFi)
    • IPC and analysis software can be operated from the USM Vision
    • Transport case
  • An encoder-scanner, designed for TOFD and Phased Array manual acquisition including:
    • Manual handle cart with magnetic wheels
    • Optional chain for the inspection of pipes
    • Arm with probe and center line pointer holders, forks for TOFD and PA wedges
    • Transport case
  • Set of probes and wedges relating to the specified pipe ranges and inspection codes
  • Rhythm Review 4.2 software for the analysis and reporting – Windows 7
  • Optional Rhythm modules for archiving, sharing and advance reporting functionalities

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USM Vision Asset Owner Brochure acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader
USM Vision Brochure acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader
USM Vision Piping Fabricator Brochure acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader
USM Vision Service Company Brochure acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader acrobat-reader


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Paralle Weld Inspection Task