Therefore weld quality and integrity are critical to safety in an extremely wide range of products and structures.
Welding inspection can reduce costs by detecting discontinuities in the early stages of manufacturing, reducing the cost of rework and extending the life of components by detecting and correcting flaws. Non-destructive testing (NDT) methods can identify cracking, porosity, incomplete penetration, misalignment, inclusions, lack of fusion and similar conditions, which can compromise weld strength.
Welding is an essential and key manufacturing process which spans almost every major industry. The overview below shows GE's comprehensive selection of NDT testing and inspection capabilities
for industrial welding inspection applications across the different industries.
The reliability and safe operation of oil & gas infrastructure is heavily dependent on the structural integrity of its welded joints. The quality of these joints must be assessed from the pipe mill and
fabrication yard to the end of the operating life of the pressure vessel or piping system.
GE continually strives to provide multidisciplinary welding inspection solutions, whatever the application, whether onshore or offshore, in the field or in the factory.
UPSTREAM
Directional and crawler-compatible panoramic X-ray systems for pipeline girth welds projects.
In-service welds can be examined with Electromagnetic Testing technology using the WeldScan eddy current probes and instrument.
MIDSTREAM
Inspection systems using the latest Phased Arrays ultrasonic technology at a pipe mill.
Weldstar is an automated ultrasonic inspection system for onshore or offshore pipeline girth-weld inspection using Phased Array and TOFD.
DOWNSTREAM
Ca-Zoom PTZ cameras are used for downstream checks of refinery towers and storage tanks, avoiding manned entry.
USM GoTM is a small, light and easy to use manual UT flaw detector effective for everyday use and difficult-toaccess applications.
Power Generation
In the power generation sector, reliable and accurate non-destructive testing of welds and integrity assessment of boiler tubes are both essential in order to maximize efficiency,
minimize downtime and improve productivity.
GE offers a wide portfolio of support services and solutions for inspecting pipes, tubes and vessels, in manufacture, pre-service and in-service. These solutions use a variety of technologies to ensure that
the inspection technique best matches the application, and finds application in fossil-fuel and nuclear stations as well as gas turbines, wind and hydro-electric assets.
FOSSIL FUEL
Digital Radiography for boiler pipe inspection at manufacturing stage as well as for in-service inspection.
RVI video borecope image of welding inspection and sizing in a gas turbine.
NUCLEAR
Manual Phased Arrays ultrasonic inspection of a weld using PhasorTM XS and dual Phased Array transducers.
PTZ camera and crawler for visual welding inspection on reactor head control rod guide tubes.
RENEWABLES
Semi-automated ultrasonic inspection using USM VisionTM for wind tower welding inspection.
In the aerospace industry weld quality and integrity are critical to safety. Welding inspection is therefore essential during airframe & engine manufacturing, maintenance, repair and overhaul.
AIRFRAME MANUFACTURING
Small welded tube inspection with digital X-ray flat panel.
Laser beam or friction stir welding inspection with PhasorTM XS.
ENGINE MANUFACTURING
Aircraft engine inspection using the XLG3TM video borescope, an RVI solution.
RVI of weld I.D. in fuel-supply lines.
MAINTENANCE, REPAIR & OVERHAUL
GE DXR 500 digital detector array for welding inspection.
Eddy current and eddy current Array blisk inspection (i.e. eddy current Array film for EC probe).
Automotive
In the automotive industry weld quality and integrity are critical to safety. Welding inspection is therefore essential during the manufacturing process of body shells, engines, safety parts
and drivetrains.
BODY SHELL
Ultrasonic inspection of spot welds using SpotChecker flaw detector.
Microfocus CT slice across a 1 mm (0.039”) diameter weld.
ENGINES
Visual inspection of difficult-to-access areas using video endoscopes.
Fully automatic ultrasonic inspection of bonds in pistons and valves.
SAFETY PARTS & DRIVETRAIN
Automatic 2D X-ray inspection of laser welds in safety parts.
Microfocus CT slice across a laser weld interconnecting two inconell tubes with a steel cylinder.
Rail
In the rail industry weld quality and integrity are critical to safety. Welding inspection is therefore essential during rail maintenance, locomotive and rail cars manufacturing and maintenance.
RAILS
STH 1 is an ultrasonic rail testing system used to inspect rail welds (flash butt welds, alumino thermic welds) for discontinuity perpendicular to the rail surface.
Ultrasonic inspection of butt welds using a roller probe.
LOCOMOTIVES
Inspection of draw gear butt welds using ultrasonic flaw detectors.
Digital radiography welding inspection during construction of boogies.
RAIL CARS
Internal remote visual inspection of liquid-carrying rail car.
PTZ camera image showing tank car interior details.
Ship
In the ship building industry weld quality and integrity are critical to safety. Fabshop and field welding inspection as well as welding tests on the propulsion systems are therefore essential.
FABSHOP WELDS
Phased Array weld inspection provides improved probability of detection and productivity.
USM VisionTM weld inspection solution for new process pipework fabrication inspection which eliminates downtime resulting from X-ray methods.
FIELD WELDS
Completely light-tight, air-tight and moisture proof Pb VACUPACTM film can be used for field welding inspection.
In-service radiographic inspection with the Eresco MF4 X-ray generator.
PROPULSION
trueDGSTM probes offer increased accuracy in discontinuity sizing.
USM GoTM is a light weight and portable ultrasonic flaw detector offering ease of use to detect, position and size discontinuities in welds.
Welding inspection can be carried out using different NDT methods. GE offers multi-inspection solutions for new project construction as well as for most project maintenance.
The overview below shows GE’s comprehensive selection of NDT testing and inspection capabilities for industrial welding inspection.
ULTRASONIC TESTING
ELECTROMAGNETIC TESTING
REMOTE VISUAL INSPECTION
RADIOGRAPHIC TESTING
SOFTWARE SOLUTIONS
Ultrasonic Testing
Ultrasonic techniques have been used in NDT for over 65 years, and apply to industrial applications requiring internal defect detection and sizing, including welding.
GE develops a wide range of ultrasonic conventional flaw detectors, phased array flaw detectors, thickness gauges, transducers, testing machines and
software for industrial applications.
CONVENTIONAL FLAW DETECTORS
Portable flaw detectors and angle-beam transducers are commonly used for weld inspection and are mandated by many welding codes and procedures.
USM GoTM is a light weight and portable ultrasonic flaw detector used to detect, position and size flaws in welds.
PHASED ARRAY FLAW DETECTORS
Phased Array technology simplifies result interpretation by creating cross-sectional and top view pictures of the weld. Beam-steering and focusing capability of Phased Array are key in enhancing resolution for
challenging applications, resulting in faster weld inspections and better probability of detection.
PhasorTM displays a cross section of the weld and allows the operator to display the A-scan associated with the optimum inspection angle.
AUTOMATED GIRTH INSPECTION SYSTEM
Combining the benefits of both conventional and Phased Array ultrasonic techniques, the complete system approach offers automated ultrasonic inspection, from job setup to data archiving.
The girth-weld pipe tester Weldstar has the ability to adjust for pipe diameters as small as 150 mm (6 inches).
The USM VisionTM portable ultrasonic weld inspection system can be used in situations conventionally requiring radiography. The intuitive user interface and integration of the
RhythmTM Software platform
optimizes available skills to achieve accurate and meaningful inspection results. It now has parallel-scanning capabilities, effectively doubling productivity.
Prepare
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 set-ups required to perform TOFD and/or Phased Array inspection of the welds.
Collect
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 (Inspection Plan Creator). After each pass the software
will propose the next weld or pass to be inspected helping the operator to use the best, most productive inspection plan.
Analyze
All inspection data is communicated to an analysis station using the DICONDE-compliant Rhythm software platform. Here, the suitably qualified ultrasonic inspector can review and analyze the inspection
data, utilizing advanced analysis tools such as real time, volumecorrected imaging, as well as conventional digital tools features for image analysis, enhancement and measurement.
ULTRASONIC TESTING MACHINES
Testing machines are integrated into production lines and are used to test a wide range of tubes and pipes. From small diameter, cold finished, seamless tubes (power plants or automotive industry) to large-
diameter, heavy wall thickness, hot-rolled seamless tubes (casing and drill pipe and welded tubes for oil and gas pipelines).
Automated inspection of tubes and pipes
UT HSAW (Helical submerged-arc welded)
The base material for spiral-welded pipes is tested as strip before the forming rolls or at the tube after welding. The in-line weld testing takes place right after the welding and before pipe expansion.
The final inspection, defined by the end-user specification, is carried out after the pressure test. Different probe arrangements adjacent to the weld and on the weld bead, are used to detect longitudinal
and transverse flaws as well as lamination type flaws in the heat-affected zone (HAZ). All imperfections where the echo exceeds the adjusted threshold are processed automatically for flaw marking.
Testing results are recorded in digital format and can be transferred to any second-level computer network.
UT LSAW (Longitudinal submerged-arc welded)
The plates for longitudinally welded pipes are typically tested in the plate mill. The weld is tested first time right after the last welding step and before mechanical expansion. The final inspection, defined
by the end-user specification, is carried out after the hydrostatic test. Different probe arrangements in single probe mode or in tandem configuration are positioned adjacent to the weld or on the weld
bead to detect longitudinal, transverse and lamination-type flaws in the heat-affected zone. Flaw evaluation and data processing is the same as for HSAW pipes.
UT Phased Array
Phased Array technology can be applied for all kinds of seamless and welded pipes (HSAW, LSAW, ERW). Single-crystal probes are replaced by multi-element probes with corresponding electronics.
Phased Array technology supports a better probability of detection (POD) and an easier probe adjustment as a precondition for repeatability of testing results. By applying the ultrasonic Phased Array
technology, different testing zones and angles can be created by electronic parameter setting. It is also possible that one Phased Array probe is used instead of multiple probe arrangements with complex
mechanics.
UT/EC ERW (Electrical Resistance Welded)
The base material for ERW pipes is tested as strip before the forming stands. In a later phase the complete pipe body is tested similarly to a seamless pipe testing. The weld is tested in-line and after the
welder or after the sizing stands because the pipe geometry can have an influence on the inspection. Typically probes are positioned adjacent to the weld for testing of longitudinal flaw orientations.
The number of probes used depends on the thickness. In a later phase the complete pipe body is tested similarly to a seamless pipe.
Electromagnetic Testing (EM)
Eddy current testing is a cost-effective, versatile and flexible NDT method. It has many advantages over other forms of inspection, including exceptional sensitivity to flaws at or near the surface,
real-time results, documentation, elimination of the need to use chemicals, and additional environmental, health and safety (EHS) benefits .
GE offers a wide range of eddy current portable flaw detectors, eddy current probes and eddy current array probes,
automated systems and software.
PORTABLE FLAW DETECTORS
The portability of the Phasec family combined with the sensitivity and durability of WeldScan probes enables performing weld inspection in difficult applications.
Portable Electromagnetic Testing instruments are ideally suited for in-situ weld inspection. These compact, durable instruments can be used to inspect a variety of welded products with GE’s WeldScan probes.
This inspection method is used to inspect oil platforms, cranes, ships and amusement park rides for weld cracking caused by cyclic fatigue, and can be accomplished through multiple layers of paint or coatings.
Rope Access Inspectors find the equipment is extremely portable, cutting the costs of erecting access platforms. The inspection of welds is covered by Standard BS EN 1711-2000.
PROBES
Weld inspection probes offer a cost-effective alternative to magnetic particle inspection for in-service inspection of welded steel structures. They can detect surface-breaking fatigue cracks through
2mm (0.078”) of surface coating material and are less expensive and quicker to use than any other method.
WeldScan probes can detect surface breaking defects through non-conductive coatings up to 2 mm (0.078”).
ARRAY PROBES
Electromagnetic Testing array technology can be an extremely useful tool for increasing productivity and detection capabilities for large surface areas including complex geometries.
Typical surface inspection methods such as Dye Penetrant, require chemicals and processing time, whereas an Electromagnetic Testing technique can be done cleanly and nearly instantly.
New probe technology makes flexible arrays easier and more cost-effective to use, and Eddy Current systems and software easier to apply to new testing requirements.
Remote Visual Inspection (RVI)
RVI is a cost-effective inspection technique used to capture real-time views and images and can be a complementary technique to other NDT disciplines in welding inspection.
GE offers a comprehensive selection of remote visual inspection (RVI) equipment - from video borescopes, pan-tilt-zoom (PTZ) camera systems and advanced measurement & imaging software.
VIDEO BORESCOPES
The use of video borescopes speeds up inspection time and provides sharp, clear illumination of surface-breaking weld attributes and defects. These instruments allow for the inspection of incomplete
penetration of new welds inside a pipe and existing welds inside assembled components.
Menu Directed Inspection (MDI) is software that runs on the video probe to guide an inspector through the inspection process. It standardizes the inspection workflow, saves time, reduces error,
and creates consistent quality.
ADVANCED MEASUREMENT & IMAGING
3D Phase Measurement provides accurate 3 dimensional surface scans allowing measurement of all aspects of surface indications. Inspectors can view and measure a defect using a single probe tip,
eliminating the extra steps required to back out, change the tip and then relocate the defect. 3D Phase Measurement provides accurate measurement “on-demand” while simplifying the inspection process.
Cross-section of a weld showing the bead height.
PAN-TILT-ZOOM (PTZ) CAMERAS
Industrial PTZ cameras can ideally be used for remote viewing in large areas. These system feature a color zoom camera module, high-intensity lighting, pan-and-tilt mechanism and industrial waterproof
packaging for protection from extreme environments.
Ca-Zoom PTZ cameras are used for downstream checks of in-service welds in refinery towers and storage tanks, avoiding manned entry.
Radiographic Testing (RT)
Radiography is a proven and reliable NDT method. One of the main areas for the application of radiography is welding inspection.
GE has invested in all forms of radiographic imaging processes: film radiography, digital imaging including Computed Radiography (CR) and Direct Radiography (DR), industrial X-ray tubes and generators and 3D
Computed Tomography (CT).
Film systems are widely used for checking the integrity of welds and the circumstances in which these inspections take place are often very demanding.
VACUPACTM packed film is protected by a synthetic foil ensuring trouble free usage under dirty and damp conditions. ROLLPACTM film in precut format, is ideal for pipeline
projects with many pipes of the same diameter.
ROLLPACTM film packaging is completely light-tight and resistant to moisture and grease.
COMPUTED RADIOGRAPHY
Although conventional film is still superior compared to the Computed Radiography technique, standards permit CR in several cases because it can provide sufficient image quality for welding
inspection. Computed Radiography systems provide an overall imaging solution including imaging plates in specific weld sizes, scanners and weld inspection software.
CRxFLEXTM computed radiography scanner can be used in office, lab or field environments allowing imaging plates in various weld sizes to be scanned.
DIRECT RADIOGRAPHY
At stationary locations the high performance Digital Detector Array (DDA) panels can image large numbers of components in a very short time due to the low dose requirements, coupled with
automation or robotics. For field applications large format portable detectors bring significant image quality advantages coupled with their low dose requirements, especially important for control of
radiation safety.
160-300 kV portable and 160-450 kV stationary equipment with directional or panoramic tubes and different combinations of focal-spot sizes find application throughout the industrial spectrum of
weld inspection.
Field-portable ERESCO X-ray generators are used for a wide variety of film, CR and DR welding inspection applications.
3D COMPUTED TOMOGRAPHY (CT)
Process control and optimization of laser and friction welding technologies require defect detection in the micron range. Additionally, for turbine or weld-seam inspection in tubes, a large variety of rod anodes
for its microfocus X-ray tubes exist. Another important advantage of 3D Computed Tomography is that it shows the exact location, shape, orientation and size of the defect inside the sample.
Phoenix v|tome|x L 300 allows samples of up to 50 kg (110 lbs) and up to 600 mm (23.6 in) length / 500 mm (19.6 in) diameter to be scanned.
RHYTHM SOFTWARE
RhythmTM can acquire image data from CR and DR sources or from film digitizers. This data can be displayed on the monitor of a standard PC. RhythmTM offers standardized
reporting capability in easy-to-understand formats, with DICONDE-tagged images. This allows fast historical and meaningful comparison of reports from different inspections.
Flash! FiltersTM provide the sharpest view of weld inspection images.
Software Solutions
GE offers welding inspection image review tools which enables smarter and quicker decisions in the field, factory floor or in the office. We offer software for all NDT applications and methods,
including software for data input, analysis, measurement, enhancement, review, documentation, data management, remote collaboration, and storage.
FLASH! FILTERSTMIMAGE ENHANCEMENT
Flash! FiltersTM provide sharp views of weld images. As a plug-in module for the RhythmTM Review software, the clarity of the images significantly increases flaw detection
while minimizing image analysis time. Flash! FiltersTM is able to quickly edgeenhance and improve digital images into film-like images.
No Windows leveling
Streamlined workflow
Sharper images
Improved probability of detection with advanced image enhancement Flash! FiltersTM software tool.
REPORTING AND ADVANCED REPORTING
The automated report generator tools allow creation of customized report of findings. Users are able to create their own unlimited number of report formats and can automatically populate them with
DICONDE data.
The reporting tool allows customized report templates and generates reports to meet specific needs.
RHYTHM ENTERPRISE ARCHIVE
RhythmTM Enterprise Archive delivers a complete, scalable and flexible central archiving DICONDE* (the industry accepted protocol) solution for non-destructive testing images and
information. One platform to use to centrally store all data (Visual, Electromagnetic, Radiographic, and Ultrasonic). Advanced data sharing and fast retrieving capabilities allow significant improvements
in productivity and enable faster identification of quality problems.
Improving data sharing and providing a central, safe, long term information repository with RhythmTM Enterprise Archive.
RHYTHM REVIEW
RhythmTM Review accepts data from Rhythm Acquire, other RhythmTM Review workstations, and removable media, such as CDs and DVDs. It provides application tools
for analysis, enhancement, measurement, reporting and storage of received data.
Remote expert review and analysis, as information can be shared between networked Review workstations with no limit to file size.
RHYTHM ENTERPRISE WEB
RhythmTM Enterprise Web provides on-demand access to NDT inspection data maintained in a central RhythmTM Enterprise Archive server with just a web browser and
login information.
RhythmTM Enterprise Web brings DICONDE viewing capabilities to the internet and provides a convenient distribution engine with web-based functionality.
RhythmTM Web allows for optimal delivery of multi-disciplinary NDT images and reports to all users.
The overview below shows the most commonly used weld types. When performing welding inspection, it is important to understand the materials, applications, typical locations, advantages, limitations,
typical discontinuities types and the NDT methods for each different weld type.
