Technical Information

VisonArray Ultrasonic Inspection System
Introduction

The VisonArray Ultrasonic Inspection System is our current state-of the-art and patent NDT technology. It not only meets today's inspection needs, but those of years to come.

What is presented here is a generalized format. It should be noted that we are able to develop special inspection systems for special needs and/or special projects, depending on our client's unique requirements.

As an original equipment manufacturer, it is our policy to use as many off-the-shelf items as possible. Reducing our manufacturing costs and providing simplified maintenance and repair for our clients is one of our major goals. An additional benefit to this approach is the documentation provided by the original manufacturer of individual components.

Having the best inspection system available, is in itself, not the sole answer in obtaining a quality inspection. We feel that the inspection system is only an extension of the person who is conducting and who is ultimately responsible for the quality of the inspection. For this reason and as part of the total package, we have incorporated an extensive training program. This insures the ultimate success of the entire program. Certified personnel will conduct the training along with an inspection supervisor who is well acquainted with the operation of the inspection system.

We will always be available, to the best of our ability, to provide ongoing support, training, personnel, technological improvements, and/or help in any area where it is felt we could be of assistance.

SECTION 1
GENERAL OVERVIEW

1.1 SIZE, LENGTH, AND WALL THICKNESS
1.2 COVERAGE
1.3.DETECTABILITY
1.4 PRODUCTION SPEEDS
1.5 ULTRASONIC TEST INSTRUMENTS
1.6 TRANSDUCERS
1.7 TRANSDUCER HEAD ASSEMBLY
1.8 SIGNAL MONITORING
1.9 SYSTEM CONTROL
1.10 OPTIONAL DIGITAL COMPUTER ENHANCEMENT PACKAGE
1.11 VISONIC™ 3D VIRTUAL IMAGING INSPECTION

1.1 SIZE, LENGTH, AND WALL THICKNESS

Technical Industries Inc., VisonArray Ultrasonic Inspection Systems are designed to inspect oilfield tubulars, ASTM, and other tubulars ranging in sizes from 1.99 inch to 30 inch OD, with couplings. Length capabilities range from 5 feet through 60 feet. Wall thickness minimums and maximums are a function of transducer frequency, shear wave angle, and pipe outside diameter. With the VisonArray inspection head design, transducers are easily interchanged with few limitations on pipe size, shear wave angle, and transducer frequency. This design allows quick changeovers to accommodate a variety of wall thickness.

1.2 COVERAGE

In the recommended standard "Full Scan" configuration, the transducers are oriented to provide 360° flaw detectability within 14 (fourteen) inches from the ends and wall thickness measurements within 2 (two) inches of the pipe ends. Variable speed controls for pipe rotation and gantry travel allow for easy and accurate control of the inspection helix.

1.3.DETECTABILITY

Transducers can be selected to produce various degrees of detectability and sensitivity. With proper transducer selection, all VisonArray systems are capable of repeatedly detecting small reflectors on both the I.D. and O.D. surfaces. These small reflectors include 1/8" diameter 5% round bottom pits and 1/2" x 0.010" x 5 % EDM notches at any orientation.

1.4 PRODUCTION SPEEDS

Production speeds are a function of numerous variables, some of which are: transducer size and frequency, material size, material length, material condition, system sensitivity settings, number and severity of flaws exceeding threshold, pipe straightness, etc. Under normal condition, using the recommended "full scan", non-stop scanning speeds average approximately 30 (thirty) seconds per inch of outside diameter.

EXAMPLE: 30 sec. x 7"=Approx. 3.5 minutes per 40 foot length.

Using the "mill scan", non-stop scanning speeds average approximately 10 (ten) seconds per inch of outside diameter.

EXAMPLE: 10 sec. x 7" =Approx. 70 seconds per 40 foot length.

For complete cycle time, using the standard loading and unloading procedures, approximately 1 (one) minute is added for loading and unloading.

1.5 ULTRASONIC TEST INSTRUMENTS

The VisonArray test systems have twenty channel flaw/thickness capability. Each channel has a maximum repetition rate of 2,000 pulses per second. This system provides a "True Systems Approach" to ultrasonic testing of oilfield tubular goods.

1.6 TRANSDUCERS

The VisonArray test systems utilize specially designed, custom built transducers. The crystal is set in a cylindrical housing and pre-set to a fixed, specified angle at manufacturing. Many different sizes, frequencies and angles can be utilized to accommodate most any need.

1.7 TRANSDUCER HEAD ASSEMBLY

The transducer head assemblies are uniquely designed and field-proven for ruggedness and continuous production service. Construction is of corrosion-resistant material. High-density plastic wear-shoes protect the transducers and contain the couplant to provide the desired water gap between the transducer and the pipe surface. Orientation and vertical position of the transducers are adjustable.

With the unique VisonArray head design, transducers are easily interchanged with few limitations on size, angle and frequency. This design allows for quick set-ups and/or changeovers to accommodate a variety of needs.

1.8 SIGNAL MONITORING

The VisonArray ultrasonic inspection systems incorporate visual displays, visual alarms, audio alarms, and recorded digital data to indicate suspect pipe conditions. Visual displays are of real-time digitized wave forms from all channels and digital monitoring of thickness readings. Visual alarms consist of real-time LEDs and color change on the computer screen to indicate the detection of conditions exceeding threshold levels.

Audio alarms are sounded in real-time for conditions exceeding threshold levels of ID and/or OD flaws and wall thickness measurements. All the indications can be recorded in digital format. The signal flaw channels are recorded at the proper amplitude whenever the signal exceeds threshold levels. The threshold level can be set to zero (0) for continuous monitoring of the signal.

1.9 SYSTEM CONTROL

The VisonArray ultrasonic inspection systems incorporate a programmable logic controller to facilitate in both pipe handling and the inspection process. The use of a computer generated touch screen greatly enhances the overall system capability, aesthetics, and noise immunity that is normally associated with mechanical switches. Further system modifications are made much more easily, as no system rewiring is required.

While using this advanced feature all inspection criteria is constantly monitored by the PLC to insure that no area of the inspection is left to chance. The totally automatic feature also has the added benefit of reducing operator fatigue.

1.10 OPTIONAL DIGITAL COMPUTER ENHANCEMENT PACKAGE

Real time computer enhancement of the inspection is possible using the latest in today's technology. The digital computer enhancement package available for the VisonArray inspection systems together with the computer software package, ultrasonic signals are converted into digital information and displayed on a color coded, computer-animated screen. This information is displayed accurately in both the X and Y-axis, base on the Customer's requirements, and stored on the computers internal hard drive, optical floppy drive, or the latest in compact disk technology.

When accuracy and speed are of the up most importance for prove-up of indications found during the full body inspection process, the computer generated reporting system will become an invaluable tool. Detailed information of indications that exceed threshold levels, is generated as hard copy on prove-up sheets. The detailed information includes the job number, length number, date, time, flaw number, transducer number, transducer angle, signal amplitude, ID/OD information, X position, Y position, and total tally length. An area for final classification of the length is also provided on the prove-up sheet.

Final classification is entered into the computer generated reporting system. At the completion of the job, this information is generated in hard copy as the final inspection report. Data derived from both flaw channels and the wall measurement channels is displayed on the computer screen. Audible alarms are synchronized with the real time incoming data. Data generated by the Digital Computer Enhancement Package is routed for storage in the customer's desired format.

This information can be recalled and displayed for future reference by the post inspection software package. Many other software programs are provided with the Computer Enhancement Package. All of these packages are custom designed to meet the customer's individual specifications.

1.11 VisonArrayTM VIRTUAL IMAGING INSPECION

The latest technology required to reach the world's deepest oil and gas well depth, is Technical Industries, Inc., proprietary latest innovation. Now our customers can view, (walk) the pipe from inside, outside, and as a flat plate, stop at any point and view the wall thickness, and condition of the pipe. By using the proper algorithm you can calculate the burst rate, collapse rate, and (tensile strength) pull rate of each joint, obtain a permanent record, and by comparing recent inspections to previous ones, thus enabling the client to project future life expectancy, and usage of the pipe.