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Weld inspection goes digital

 

USM Vision - a total ultrasonic solution to increase productivity in new process pipework

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USM Vision offers a complete digital inspection workflow, from the inspection plan creation to the data sharing that can be done wirelessly.
USM Vision has been developed to meet the market need to transition from radiographic to ultrasonic weld 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 Weld Inspection System Virtual Demonstration

 

Lean Improvements

Lean improvements in manufacturing processes are achieved as weld 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.

 

Co-working activities:

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

Co-Working

 

Qualified inspection personnel are deployed to
optimum effect

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.

 

Rhythm Software Platform

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

Rhythm Software Platform

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

 

   USM vision 1.2 comes now with a new set of productivity improvement on Rhythm, reducing the number of clicks to perform tasks when analyzing set of images. Rhythm features now as well functionalities to merge different acquisitions to one set of images, simplifying the scan understanding and reporting.

Parallel tasking

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

Parallel Tasking

 

Higher productivity even with restricted access

Pipes to elbows, pipe to fitting and pipe to
flange joints do not always allow access to both
side of the weld.

new   Dual scan allows the user to perform the
two ultrasonic passes from one side of the weld
with one single physical scan.

 

Advanced Imaging

Advanced   Imaging

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.

 

1. Probe position doesn’t satisfy procedure criteria

2. Operator adjust probe position

3. Probe position now satisfies
procedure criteria.Operator can validate step and move forward

Inspection Plan Creation and Validation

Creating a Weld Inspection Plan

No ultrasonic knowledge is required to create and populate a weld 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 weld inspection according to the welding standard and code based procedure selected.


fb-f-creating-inspection-plan

Validating a Weld Inspection Plan

A technician qualified in ultrasonic testing 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 weld inspection
plan can be exported to the acquisition unit.


new   The import and export function for weld
inspection plan files is simplified so that the weld
inspection plan can be exported without forwarding the
entire database.


Ray_trace_left.jpg

 

Calibration and Data Acquisition

Calibration

As the data acquisition is 100% guided, this task doesn’t require a highly skilled operator. The technician merely selects a weld 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.


calibration

 

Acquiring the Weld Inspection Data

The inspection data, for each weld, is simply
acquired by following the weld 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 weld
inspection plan. Data can be exported, for one pass,
one weld or for the complete weld inspection plan,
for analysis and reporting at any time during the
weld inspection.

new   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.



weld inspection data

Data Analysis and Reporting


Analyzing the Weld Inspection Data

All weld inspection data is communicated to an analysis station using the Rhythm software platform. Here the suitably qualified ultrasonic inspector can review and analyze the weld 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.


analysing

 

 

Reporting

Expert interpretation of weld 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.



Reporting

Free Viewer

In addition to the report, data files can be
exported if needed with a free viewer allowing
third parties to have access to raw data.

Free Viewer Movie

Archive and Share Data


Archiving the Weld Inspection Data

The weld 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.


archiving

 

 

Sharing the Weld Inspection Data

All weld 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
weld inspection data across experts and locations
with ease!



Sharing

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 welding 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
USM Vision

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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Paralle Weld Inspection Task